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E60 (2004 - 2010)
BMW 5-Series (E60 chassis) was first seen in the Unites States in the fall of 2003 with a 2004 Model Year designation. The E60 is now available as a 528i, 528xi, 535i, 535xi, 550i and a 535xi sports wagon! -- View the E60 Wiki

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  #1  
Old 12-02-2012, 10:55 AM
schpenxel schpenxel is offline
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Location: Greensboro, NC
 
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Posts: 3,275
Mein Auto: 2004 545i
Question Increased emissions? gah.

So, my car is a 2004 545i with 182K miles

Most mornings where it's cold outside (under 40*F or so) the idle is a bit erratic and it seems to run a little rough at first (but starts fine), but after I get out of the driveway and give it some gas it does just fine, and is fine for the rest of the day after that and throws no error codes, except for two times where I've gotten some errors.

First time was maybe a month ago where I can't even remember all of the codes that came up, but I remember it running and sounding horrible. From what I remember reading after it happened, the car had switched away from using valvetronic and was using the regular throttle body it had so many errors. This happened as I was pulling out of the driveway, and when I accelerated to leave it was very weak and sounded like an old tractor or something it was so bad. I pulled over maybe half a mile down the road, turned the car off, re-started it and all errors were gone and that hasn't happened again.

Fast forward to today and as I was pulling out I got an increased emissions warning message. It still ran fine, but I tried pulling over/turning the car off anyways, but the message was still there when I restarted.

I drove to my parents house about an hour away to drop the dog off with no other issues in driveability, and pulled all the codes in INPA. I've attached a printout from that, but basically it's the following:

27A0 (ebox fan, this one has been there forever--I just need to order a new one and replace it)
274E (Misfire detection, Checksum failure)
2747 (misfire detection cyl. 3)
2748 (misfire detection cyl. 7)
2742 (misfire detection cyl. 1)
2743 (misfire detection cyl. 5)
2744 (misfire detection cyl. 4)

Any ideas on what to replace? I remember seeing a service bulletin about some of the valvetronic components being out of spec one time but I can't remember if all the symptoms were the same or not. I'm not sure why it only does it when it's cold and is fine the rest of the time.

Oh, spark plugs were changed a few months back so those are all new.

I have already ordered CCV rebuild kits prior to this, so I'm going to make sure those are working properly but I'm not sure what else to do. I keep reading about the DISA valve, but I can't find anything about that on the V8's, only on the V6's. Is this something I have or no?

Thanks for any help!!
Attached Files
File Type: pdf engine error (12-2-2012).pdf (16.2 KB, 216 views)
File Type: pdf 12-2-2012 error memory.pdf (12.2 KB, 163 views)
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  #2  
Old 02-04-2013, 06:28 PM
Frenchyrider267 Frenchyrider267 is offline
Frenchy
Location: Hawaii
 
Join Date: Sep 2012
Posts: 149
Mein Auto: 2004 525i
Did you ever figure out what needed to be changed? I have the same error message. I was told that my MAF sensor may be the culprit. I would just hate to buy a new $200 MAF sensor just to find that the error doesn't go away.

I connected my scan tool, and some of the errors that it pulled are:

27C3 Thermal Oil-level Sensor (don't think this is related)
276D Function check, Tank Ventilation
2882 Fuel Trim, Bank 1
2883 Fuel Trim, Bank 2
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  #3  
Old 02-04-2013, 06:29 PM
schpenxel schpenxel is offline
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Location: Greensboro, NC
 
Join Date: Nov 2009
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Mein Auto: 2004 545i
Are those the only codes? I have never seen a fuel trim error on mine.

I would think fuel trim errors would be related to vacuum leak(s) and/or O2 sensor issues.

I never did figure out what mine is caused by--the weird thing is it runs PERFECT if it's under somewhere around 25*F outside. It's only when it's right around freezing that it goes all crazy. Above somewhere around 40* it doesn't do it either. Very strange

I have cleaned my MAF but haven't tried replacing it. I know there is some sort of switchover that the valvetronics system does the first 90 seconds it's running. If I understand it correctly, the valves are actually opening all the way (like a normal engine) when it's first started and the computer uses the throttle body to control RPM. Then it makes the switch over from throttle body to valvetronics.

I need to do some more googling and make sure that's correct and how it actually does it, but I feel that mine is related to something in that process, I'm just not sure what exactly..

Last edited by schpenxel; 02-04-2013 at 06:33 PM.
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  #4  
Old 02-04-2013, 06:55 PM
Frenchyrider267 Frenchyrider267 is offline
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Location: Hawaii
 
Join Date: Sep 2012
Posts: 149
Mein Auto: 2004 525i
Well that's the only codes that came up in the DDE (Diesel Electronics)and DME(Digital Motor Electronics) scanner menu. There were other codes that I found, but I don't think they are related to it. Here are the other codes:

-276D Function Check, Tank Ventilation

****IHKA (Intergrated Automatic heating/AC control) and IHKA2 (Interfrated Automatic heating/AC

-9C54 AUC (probably need to buy a new AUC sensor on fan shroud- PN:64116933052)
-9C77 Refrigerant compressor (*** i think it could be low on freon****)

INSTR(Intrument Cluster)

-00,01,A5,57 No Found!
-A3B9 Dynamic Stability Control, Comunication Fault
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  #5  
Old 02-04-2013, 07:09 PM
schpenxel schpenxel is offline
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Location: Greensboro, NC
 
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Gotcha.. mine matches the description in the service bulletin below, but I'm outside of the date range they have listed, I think anyways. Mine was a December 2003 build, but I think it was early December and this says it doesn't apply to anything that early.

However, I wonder if the high mileage on mine has worn something in the valvetronics system to the point that it's basically doing the same thing? I'm at 187K now

edit: I just checked the build date on mine, and I'm at 12/16/03. I have a hard time buying their hard cut off of the last two days for 2003 though. I work in the automotive industry and it just sounds like a supplier had to give a cut off date of when they could have and couldn't have shipped bad parts, so that is the date they went with, wrong or right. The symptoms are dead on though otherwise.

Quote:
SI B 11 02 05
Engine
January 2006
Technical Service
This Service Information bulletin supersedes S.I. B11 02 05 dated May 2005.
designates changes to this revision
SUBJECT
62 Engine - Rough Idle, Misfire Faults after Cold Start
MODEL
E53 (X5 4.4 i/4.8is); E60, E63/64, E65/66 with N62 from 06/04 up to 02/05 production
SITUATION
Customer may complain of erratic engine idle speed lasting for approximately 20 seconds after a cold start.
Check Engine Soon light may be illuminated and misfire faults for various cylinders (e.g. FC 2742, 2743, 2744,
2745, 2746, 2748, 2749, 274E) may be stored in the DME.
CAUSE
Incorrect tolerances and geometry of Valvetronic intermediate levers are causing uneven cylinder filling during
the transitional cold start period (60 seconds after the engine has been started) when the Valvetronic system is
switching from the initial 6 mm to a minimum 0.3/0.8 mm valve lift.
CORRECTION
On a customer complaint basis, and after performing diagnostic procedure described below, replace the
Valvetronic intermediate levers.
PROCEDURE
Perform basic engine diagnosis (compression, ignition, fuel pressure, etc) to rule out other potential
causes.
1.
Allow 2. the engine to cool down.
Connect GT1/DIS loaded with CD 44.0, or higher, to a cold vehicle (coolant temperature below 30
deg C) and from the Function Selection select: "Service Functions", "Drive", "Engine management
ME9", "Test runs" and then "Tolerance test, intermediate lever".
3.
4. Start the engine and follow-up the test plan.
Observe rough running values when idle speed stabilizes. If values are in excess of +/- 2.5 accompanied
with noticeable engine vibration (and sometimes Check Engine Soon flashing), then remove valve covers
on both banks.
5.
Look for the intermediate lever production date (stamped on the lever, next to the smaller roller
contacting the eccentric shaft).
6.
If the production date is in the range between "04 180" and "04 324" (e.g. day 324 of the year 2004),
then the whole set of intermediate levers (16) has to be replaced. The same classification of levers must
be used when ordering the intermediate levers (classification number is stamped below production date).
There are 5 classifications of levers used in the N62 engine.
7.
ote: In an individual cylinder head, all levers must have the same classification, but two different
classification of intermediate levers may be used in one engine (e.g. bank 1: classification 2, bank 2:
1 of 3
classification 3).
Important: The lower production range of the affected intermediate levers is only an approximation. It is
possible that levers produced prior to "04 180" (but not earlier then "03 363") may have certain deviations in
tolerances.
For Valvetronic intermediate lever replacement procedure, refer to RA 11 37 012 (bank 1) and RA 11 37
014 (bank 2), found in BMW TIS.
8.
IMPORTAT:
Improved intermediate levers are currently available from 1. our Parts Department.
In the event of a reproducible customer complaint proceed with the diagnostic and repair procedure.
There is no need to contact Technical Hotline.
2.
PARTS INFORMATION
Part umber Description Quantity
11 37 7 516 895 Intermediate levers class 1 Maximum 16
11 37 7 514 012 Intermediate levers class 2 Maximum 16
11 37 7 514 013 Intermediate levers class 3 Maximum 16
11 37 7 514 014 Intermediate levers class 4 Maximum 16
11 37 7 514 015 Intermediate levers class 5 Maximum 16
11 12 7 513 194 Valve cover gasket bank 1 1
11 12 7 513 195 Valve cover gasket bank 2 1
11 31 7 507 432 Tensioner sealing ring 2
07 11 9 903 596 Valvetronic motor spacer ring 2
11 14 7 506 424 Timing chain cover, u-shape metal gasket, bank 1 1
11 14 7 506 425 Timing chain cover, u-shape metal gasket, bank 2 1
11 36 7 513 222 Vanos solenoid O-ring 4
11 36 7 546 379 Vanos solenoid O-ring 4
11 36 7 501 423 Vanos unit bolts 4
12 14 1 748 398 Cam sensor o-rings 4
11 12 7 518 420 Eccentric shaft sensor o-ring 2
NOTE:
It is not necessary to replace spark plugs tubes during a course of this repair.
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
Defect Code 11 37 91 42 00
2 of 3
Labor Operation: Labor Allowance:
Main work: 00 55 453 93 FRU E53 X5 4.4i/4.8is
91 FRU E65/66
102 FRU E60, E63/64
+Associated work: 00 55 793 91 FRU E53 X5 4.4i/4.8is
90 FRU E65/66
100 FRU E60, E63/64
Note: The following explanations will spell out the correct use of the work times.
Main Work:
Use this labor operation number when the only repair performed is the
listed warranty repair.
OR
+Associated
Work:
Use this labor operation number when other repairs or services are
performed along with the listed warranty repair.
Under no circumstances should both labor operation numbers be claimed.
Attempts to claim both times will result in an unnecessary delay in claim
processing and payment.
[ Copyright 2006 BMW of North America, LLC ]
3 of 3

Last edited by schpenxel; 02-04-2013 at 07:13 PM.
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  #6  
Old 02-04-2013, 11:10 PM
Frenchyrider267 Frenchyrider267 is offline
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Location: Hawaii
 
Join Date: Sep 2012
Posts: 149
Mein Auto: 2004 525i
I have under 110k on my 2004 525i which has a production date of 11/2003. I'm sure if I went in with this bulletin they would find a way NOT to have to do this without first requiring me to pay a $250 diagnostics fee to see if there are any other underlying issues. Nice to have an older Bimmer eh?
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  #7  
Old 02-05-2013, 05:07 PM
schpenxel schpenxel is offline
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Location: Greensboro, NC
 
Join Date: Nov 2009
Posts: 3,275
Mein Auto: 2004 545i
Quote:
Originally Posted by Frenchyrider267 View Post
I have under 110k on my 2004 525i which has a production date of 11/2003. I'm sure if I went in with this bulletin they would find a way NOT to have to do this without first requiring me to pay a $250 diagnostics fee to see if there are any other underlying issues. Nice to have an older Bimmer eh?
Tis lovely, lol

I left my laptop in the car last night so I could at least try to get some information on what was going on this morning when I started it, but of course I was running late for work and didn't get the laptop booted up until I was out of the parking lot, then the battery died on the laptop, so I didn't really get any new info, gah

Before it died I did see something about the air density that was completely off the charts, so I need to investigate that more. It may have been completely normal but it was definitely off of the scale that INPA had

Last edited by schpenxel; 02-05-2013 at 05:08 PM.
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  #8  
Old 02-06-2013, 05:51 AM
Stephen Max Stephen Max is offline
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Location: Austin, TX
 
Join Date: Jul 2010
Posts: 63
Mein Auto: 1998 M3, 2004 545i
Quote:
Originally Posted by Frenchyrider267 View Post
I have under 110k on my 2004 525i which has a production date of 11/2003. I'm sure if I went in with this bulletin they would find a way NOT to have to do this without first requiring me to pay a $250 diagnostics fee to see if there are any other underlying issues. Nice to have an older Bimmer eh?
This SIB really only has to do with the N62 engine.
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  #9  
Old 02-06-2013, 09:51 AM
schpenxel schpenxel is offline
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Location: Greensboro, NC
 
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Mein Auto: 2004 545i
For anyone reading, someone else suggested changing the minimum valve opening to 0.8mm instead of the factory setting of I believe 0.3mm. Mine was already changed to 0.8mm for whatever reason, so I was not able to change that

Hopefully that helps someone else though in the future.
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  #10  
Old 04-16-2014, 07:02 AM
thorster thorster is offline
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Location: Reykjavik, Iceland
 
Join Date: May 2013
Posts: 9
Mein Auto: e60 545i
Any updates on this situation?

I have the exact same problems as original poster mentions AND my 545i is built in Dec 2003!
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  #11  
Old 04-16-2014, 10:57 AM
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Jaystyles Jaystyles is online now
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Mein Auto: 545i Sport
i've been battling this code since Nov 2013... I have 2004 545i(July 2004) I change my maf, coolant temp sensor, thermostat sensor, and thermostat...A lot of my misfire codes cleared however Im still getting an air temp error...My indy said it cold be clogged intake with carbon due to fact im burning a little oil...I have to do my valve stems eventually. Trying to get them done for under $2,500. An indy i saw out in Long Island Tony said it could be my engine harness(oh no!). Nonetheless, im still chasing the issue.
Schp please keeps us updated as I will everyone.

Thanks!
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  #12  
Old 04-16-2014, 02:54 PM
schpenxel schpenxel is offline
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Location: Greensboro, NC
 
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Quote:
Originally Posted by thorster View Post
Any updates on this situation?

I have the exact same problems as original poster mentions AND my 545i is built in Dec 2003!
It's most likely intermediate levers being worn/out of spec

Disconnect a VANOS solenoid to disable the valvetronics system on a morning you'd expect to have the problem and see what happens.
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  #13  
Old 04-16-2014, 02:55 PM
schpenxel schpenxel is offline
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Location: Greensboro, NC
 
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Mein Auto: 2004 545i
Quote:
Originally Posted by Jaystyles View Post
i've been battling this code since Nov 2013... I have 2004 545i(July 2004) I change my maf, coolant temp sensor, thermostat sensor, and thermostat...A lot of my misfire codes cleared however Im still getting an air temp error...My indy said it cold be clogged intake with carbon due to fact im burning a little oil...I have to do my valve stems eventually. Trying to get them done for under $2,500. An indy i saw out in Long Island Tony said it could be my engine harness(oh no!). Nonetheless, im still chasing the issue.
Schp please keeps us updated as I will everyone.

Thanks!
Intermediate levers. You're wasting time/money replacing all those parts.

Try what I suggested in previous post with the VANOS solenoids
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  #14  
Old 04-16-2014, 09:50 PM
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Jaystyles Jaystyles is online now
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ok. Will try thanks!
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  #15  
Old 04-18-2014, 12:45 AM
Frenchyrider267 Frenchyrider267 is offline
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Location: Hawaii
 
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Mein Auto: 2004 525i
Quote:
Originally Posted by thorster View Post
Any updates on this situation?

I have the exact same problems as original poster mentions AND my 545i is built in Dec 2003!

Being in Kosovo now everything is so cheap. It only costed me like 25 to have a full diagnostic check on my car, and try told me that the only thing it could be that they can tell is the vacuum lines under the manifold. They would have to take the manifold off and clear all the lines to be certain. But that's just my situation. They basically said its in the intake portion


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