[netherborn]

Hi,

I've gone down a rabbit hole with my 2007 BMW E91 335D SE (M57 Engine).

Some context..

I purchased the car about 1 year ago from a mechanic who had it for 7 years. He looked after the car very well, he was unfortunately diagnosed with cancer and sold it to me, he sadly passed away earlier this year.

The car has 155,000 miles on it with the following engine modifications...

- Swirl Flap Delete
- DPF Delete
- Stage 2 remap (370bhp)

He did warn me that the car would soot up if driven a lot on short journeys, however I didn't realise to the extent this could happen.

About 3 months ago I started experiencing heavy black smoke under hard acceleration (3000 revs and above). Black smoke, to the extent of James Bond level smoke screen in Goldfinger.

I have tried the following ..

1 - Cleaned the injectors with STP - no difference
2 - Changed air filter - no difference
3 - Changed the MAF - no difference
4 - Changed the EGR - made things worse*

From my research black smoke is normally an over-fuelling issue so I considered it was probably the air intake that was the problem, (I cleaned the injectors anyway)

After trying the first 3 items, I took the inlet manifold off for a deep clean,
following this video ..

there was a horrendous amount of carbon deposits, which I took off about 90% with a pressure washer and a lot of elbow grease.

The EGR valve was pretty black and clogged up, so I just replaced it with a new one rather than spend time cleaning it up.

I reassembled everything, reconnected the battery and now the car runs like a real dog..new problems include ...

- Engine sound is very rough
- no real power under acceleration
- white smoke from exhaust at low speeds
- engine shuddering and jerking in low revs
- difficult to get above 2000 revs

I took the car for a drive about 30 miles distance, first at low speeds local and then onto a dual carriageway and got it up to a speed of 60 miles to check if there were carbon deposits fallen into the inlet manifold that needed burning off, but no joy, the white smoke continues and all the symptoms persist with a check engine light coming on.

I've reached the limit of my capabilities, any help would be appreciated.

[lnxguy]

You need to pull codes before you do anything else.

Your original problem sounded like a simple boost leak. Did you check the IC connections for leaks?

[RL18]

You have the dpf deleted but your still running the egr cooler?

[netherborn]

Originally Posted by lnxguy

You need to pull codes before you do anything else.

Your original problem sounded like a simple boost leak. Did you check the IC connections for leaks?

On a break in Wales this week, I'll post more details including codes, photos and video when I get back to London on the weekend
The original diagnostic codes were signaling faulty MAF sensor. I used a simple OBD2 bluetooth scanner and app to pull codes, a friend who had a pro scanner found the same codes before I took the inlet manifold off

[netherborn]

Couple of videos of my 335D with the engine running, just blipping the throttle.

When I started up after 5 days of the car being parked up, there was a lot of black smoke, when I got the camera in position and tried again seems to have died down a little.

The engine on idle after startup

Running like a dog in lower revs, hesitant, juddering, kangerooing at low speeds

[netherborn]

Here are the OBDII codes



I know the first one (42DE) is Glow Plugs.
(3FF1) is related to MAF and coked up inlet manifold. The MAF I have replaced and the manifold I took off and did a good clean, so not sure why thats still erroring.
3F25 not sure about

[netherborn]

Originally Posted by lnxguy

You need to pull codes before you do anything else.

Your original problem sounded like a simple boost leak. Did you check the IC connections for leaks?

Added some more information

[netherborn]

Originally Posted by lnxguy

You need to pull codes before you do anything else.

Your original problem sounded like a simple boost leak. Did you check the IC connections for leaks?

Added some more information, cars gone into the local mechanics this am.

[Scubudo]

Is there a reason you have not deleted the EGR? Let us know what the mechanic finds.

The following is more of a mental exercise on my part...so I would be interested in whether the problem ends up being one of the things in the following breakdown:
In general...black smoke = unburnt fuel...which would mean either too much fuel or not enough air.
I can think of several causes for insufficient air: Restriction (filter, stuck ASV, carbon build-up, boost leak, bad turbo). Boost leaks could occur at any of the boot connections, a ruptured boot or intercooler, cracked intake manifold, or at any of the multiple seals for the air intake.
The only causes for over fueling that comes to mind would be bad injector/s, a fault somewhere in computer/sensor system, and entry of alternative fuel source (i.e. engine oil). VCG and stuck injector I think would be most the most likely culprits.
As for the computer/sensor part of the equation...if the computer acts like it is working but can't diagnose itself with a code, I wouldn't know where to even start...other than to reboot it and pray.

[lnxguy]

You really need to use a tool like TestO and do some logging. All anyone here is doing is guessing (Me included) based upon what you've told us. We need some hard data in order to help you further. You'll be able to rule out a whole bunch of things with proper logs.

[Tambohamilton]

Originally Posted by netherborn

Here are the OBDII codes



I know the first one (42DE) is Glow Plugs.
(3FF1) is related to MAF and coked up inlet manifold. The MAF I have replaced and the manifold I took off and did a good clean, so not sure why thats still erroring.
3F25 not sure about

Did you also clean the cylinder head/valve cover? Did you replace with an OE MAF?

[netherborn]

Just came back from the mechanic, he did a smoke test and discovered two issues.

The first issue was caused by myself, I didn't secure the hose back onto the throttle body after replacing the EGR valve which is why the engine got worse, he sorted that out. my bad!!

The second issue which may have been the problem all along is where the mechanic detected a leak in the Charge air line, see in the video below


https://youtube.com/shorts/pYsK-mF6Tkw?feature=share

Zoomed in, you can see an aftermarket hose which has been botched on with a jubilee clip which has come away causing the leak.

This is the OEM part (see red arrow)




https://www.online-parts.co.uk/bmw-s...7&month=01#sub


Aftermarket

https://www.ebay.co.uk/itm/314307533...3ABFBMwLCu7IBi

OEM

https://www.ebay.co.uk/itm/174795887...3ABFBMtLbM7YBi

[lnxguy]

Yes.. That would be a boost leak.

[Scubudo]

I looked at the parts diagram that was posted this morning and thought to myself that it looked nothing like my vehicle...and concluded that it must be different because they put your steering wheel on the wrong side.

Now that you corrected that error, I can concur that it is the charge air line (aka turbo to intercooler boot). If it is only leaking at the connector, you may just require a new o'ring (Part # 11617801974).

Because of the oil entering the intake via the CCV, a boost leak in that location also tends to leak oil.

My understanding is that BMW at one point upgraded that boot (or possibly just the seal), but I am of the impression that most people on this forum upgrade the boot to products from ATM and Forge.

[netherborn]

Originally Posted by Scubudo

I looked at the parts diagram that was posted this morning and thought to myself that it looked nothing like my vehicle...and concluded that it must be different because they put your steering wheel on the wrong side.

Now that you corrected that error, I can concur that it is the charge air line (aka turbo to intercooler boot). If it is only leaking at the connector, you may just require a new o'ring (Part # 11617801974).

Because of the oil entering the intake via the CCV, a boost leak in that location also tends to leak oil.

My understanding is that BMW at one point upgraded that boot (or possibly just the seal), but I am of the impression that most people on this forum upgrade the boot to products from ATM and Forge.

Yep, easy mistake. In the UK we drive on the correct side of the road, hence steering wheel on the right.
I think the hose does need replacing looks like the connector is splitting off, I'm going to get the OEM hose and O rings from BMW for my mechanic, with the labour charges in London I don't want to take any chances with aftermarket fitments

[lnxguy]

O-rings are a good idea if you're not going to upgrade the entire hose itself. They do tend to wear out.

[Scubudo]

While I realize this is off topic...
Since I was recently working within the rather confined space of the right hand side of the engine where the DPF and Turbos are located...on right hand drive versions, how do they manage to get the steering linkage through all that mess?

[netherborn]

I'm having a helluva time trying to change the daylight running bulb on the passenger side (RHD) of my 335D 2007 E91 pre-lci.

I have looked at numerous YouTube videos, none of them look like the bulb casing I have.
I was spraying the callipers, so had the wheel off anyway and now have stripped of some of the wheel arch protectors. Underneath, I can now get to a case in which I think the bulbs are located but no idea how to get the casing off, it's stuck on solid. Any tips or better way to approach this task.

My casing looks like item (7) in the diagram ..
https://www.online-parts.co.uk/bmw-s...7&month=01#sub

Photo of my headlight casing


YouTube video of my 335D

[lnxguy]

[netherborn]

Thanks for the video ..

This is the light that is out, any idea what bulb is required ?

[lnxguy]

Isn't that a highbeam? Pull the bulb out and check or do a Google search.

[BB_cuda]

On N/A version, access to that area (cornering light) is a triangular shaped door up top in the forward area of housing. You lens in that area is clear (vs frosted white on North American version) so might be different.