BMW X5 E70 40D N57 Engine Issues

[smartshah]

Hi Guys,

I thought i will do my part and maybe this post or thread will help many others.

I brought the car 3 years ago, for the family. It is a 7 seater.

Details of the car:-

BMW X5 E70 40D LCI 2012/2013 N57 engine.

Problems:-

- Low Power/Low boost more noticeable on Motorway/Highways
- Engine Oil Level rose to maximum
- DPF Clogging regularly
- Engine Fan kicking in on the motorway speeds
- Coolant temps exceeding 105°C
- EGR Position plausible

First issue I tried to resolve was to get the DPF Cleaned. After cleaning it still was throwing codes. 480A DPF Excessive soot/clogged or backpressure too high.

Had the DPF professionally cleaned but still issue would occur, i had to regularly request regen via ISTA.

Anyway i decided to hand the car into Jason at BW Chiptune at Hayes in the UK. He is an incredibly knowledgeable and helpful guy.

- He drove the car and also noticed the car is low on power.

I gave it to him to sort out the following issues:-

- Low boost/power
- DPF issues
- CAS Issues (stuck in programming mode)
- Engine oil Level rising

I simply asked him to remove the injectors, and the HPFP so we can send it off to PF Jones. Car was running perfectly.

However when PF Jones received the injectors, they lost the Fuel Pressure regulator and they couldnt locate my items initially.
They had the injectors for 2 days and reported that all 6 injectors were DOA. Which is absolutely nonsense, as the car was running perfectly, no injector codes whatsoever. I firmly believe they must have mishandled them or tested them in reverse polarity which killed them. But they were not going to admit that. I spoke to the manager and a few others. They admitted that this is the first time they have seen this, where all 6 injectors are dead.

Anyway asked them to send the injectors over to a guy in Gloucestershire named Jakub. They charged me the testing fee for the injectors and the HPFP. They found no issue with the HPFP at all. But they did say that they were unable to verify if the HPFP was leaking past the shaft. So i asked them to rebuild it, which they did.

Jason, at BW Chiptune received the parts a week later and fitted them in.

This resolved the issue of the oil rising. The injectors were fine they werent leaking. So it was most definitely the HPFP. Jakub was a lovely guy he sorted the injectors out and resolved the issue. Charged me £25 per injector.

- EGR, Waterpump and thermostat

So i went ahead and brought an OEM EGR, Waterpump and Thermostat, along with coolant to do a coolant flush.

This resolved the issue with the Fan blowing like a jet engine on the motorway. You can hear it kicking in at 70mph.

- DPF Issue

I had weird readings from the counter pressure test.

Test 1 was within tolerance
Test 2 was not intolerance
Test 3 was in tolerance

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So i then ordered a manometer to actually verify the pressure the sensor is reading. And it was correct.

So then i got hold of Wynns DPF cleaner off car, from amazon for £30. Shoved the whole 5 litres in there, and leave it for 7 hours.

This sorted the DPF out, the DPF at idle is now at 6 mbar at idle.

- Low Power/Low boost

This issue still remained after the above work was carried out
I was getting a code in ISTA that was pointing to the Low Pressure Turbo (Big turbo).
However I was not convinced.

- Pressure Converters were also changed along with silicone vacuum hoses. Pressure converters tested fine but still wanted to do this as a peace of mind.

I ran the various tests in ISTA to check if there was carbon build up in the intake, but that tested fine too.
Swirl Flaps were removed prior to this.

Anyway after taking it to a few other specialists, who literally said they do not know where to look etc after having the car for a day.

I decides to take the matter into my own hands.

I looked at the boost sensor, it was severly clogged. Cleaned that out. This improved my mpg significantly but did not resolve the boost issue.
Changed the boost pipe, the red one. This was a pain to fit the new one in. An absolute pain. Still did not sort the boost issue out.

I was absolutely livid at this point.

I just went out and unplugged the MAF and drove the car. All of a sudden i can feel the boost. I ordered 2nd hand MAF genuine BMW one. And swapped it out, reset the adaptatioms for the 100th time. Went on the motorway and to my amazement and relief i had boost all the way through the rev range.

I brought 2 Exhaust pressure sensors 2nd hand, intake temperature sensor 2nd hand and MAF Sensor 2nd hand all genuine BMW parts with 30 day warranty. These bits cost me £80 in total.

I never changed the Exhaust Pressure Sensors or the intake temp sensor.

But prior to the issue being resolved i did notice that the low power issue was worse when the car was warm.

Anyway will be taking it back to Jason to sort out the CAS and revisit the tuning. Get the EGR coded shut.

I hope this helps other out there.