Hi guys, I need some help: I have a BMW 530 d from 2004 with huge mileage. 2 weeks ago, before leaving for vacation, I diagnosed my car and checked the error codes: there was none.
Car was driving fine almost non-stop for several (~6-7) hours, until I stopped for short.
Some minutes before the stop, the fuel lamp went ON.
Just after, when I was trying to accelerate to enter the highway, the engine lost its power, like car's computer was blocking the turbo charger. The engine RPM-s where not going above ~2500.

I also noticed that the fuel consumption in last months went up by a litre (to ~8.3 L / 100 km from ~7.3 L / 100 km).

I returned from vacation yesterday, did another diagnose. Below are the error codes I found:

1) 3F57 (Charging pressure valve)
2) 4521 (Boost pressure control circuit; negative deviation)
3) A55708 (unknown fault code)
4) A3B1 (Message (cycle indicator control lights 0x1F6) incorrectly, receiver COMBI, transmitter LM
5) 4203 (Glowplug pre-operation)
6) 4222 (Glow plug cylinder 2, activation)
7) 4212 (Glow plug cylinder 1, activation)

I deleted all the error codes, drove aggressively for ~ 50 min. Car was driving without any problems. Re-did the car-diagnose: NO ERROR CODES. But because I do not understand the reason why it appeared, I am afraid that this error can come back at the most unexpected moment. Guys, what could have caused these errors? Could you please explain me what they mean (last 3 are clear to me, although they can be connected to the above errors???) ?
I do not think that a little low fuel level can cause this. Could it be that my DPF is getting clogged?

Thank you!

 

It came out that in other forums I am not ignored as here...

Apparently I was told that the mode my car went is called: Limp mode, a mode car goes to protect turbo charger and engine when he noticed an error.
Most probable reason was the Turbos waste gate actuator was failing. That would mean the ECU gets dodgy pressure readings for the expected actuator position, giving the Deviation error.

Very probably the last 3 error codes are independent. Last 2 are keeping appearing, so I will replace the glow plugs anyway.

 

Thanks for coming back with the diagnosis - your participation will help make it a more vibrant community. Usually when people don't reply it's due to having no experience with the problem you're having. NA cars didn't see the diesels, but I'd love a 535d were it available here. Cheers from Chestermere AB.

 

Good morning from Basel. I drove more than 1000 km from the last diagnose now. I did another diagnose today: just the last 2 error codes with burned glow-plugs are there. I just hope that the glow plugs burned while I tried to accelerate to high-way and triggered all other error-codes... Is this anyway possible?

Lets see, I will keep an eye on this and write updates here...

 

What little I know of diesels, aren't glow plugs only operated when the engine is starting cold?

 

No. As far as I know, in "modern" cars they operate always until the engine coolant reaches ~75 deg C. This improves the fuel consumption.
I think at cold temperatures they operate at full power, then less.

To support my knowledge. I did car diagnose before i left to vacation. From that moment on the weather was never below 25 deg C. And glow-plugs burned. So they have been used...

 

Interesting, and good to know. Have you confirmed your main thermostat is working properly to permit the engine to reach normal operating temperature quickly?

 

Yes, sure, both of the thermostats were replaced recently and checked later...

 

Hey Tigr,
What diagnostics tool have you used? I suggest using ISTA (rheingold) as it's the most accure diagnostics for e6x.
First few codes could appear because of short term under or over voltage. Check Your battery and alternator voltage.

The glowplug codes... glowplugs are pretty cheap, but in a high mileage diesel e60 is mostly problem with glowplug relay, You can buy new one or repair existing one (Most of the time, the (+) cables inside of the Glowplug module break). You shold also change (+) cable to the glowplug module, it will be probably burnt. If you would use ISTA, and all of the glowplugs wold throw error on you, then the Glowplug module is 100%bad.

If the DPF would clog up, then You would get an Check engine light and iDrive message (Emissions fault), you can check the state of health of your DPF using ISTA backpressure test.

 

Hi Pietro. Thank you very much for your reply. Yes, I should by better diagnose tool, I have a DELPHI...

Battery and alternator voltages are correct. But you just "confirmed" my theory: 2 Glow-plugs burned, which caused a short under or over voltage, which triggered the first few diagnose error codes. (I deleted all of them, drove already more than 1000 km, and only 2 glow-plug errors are coming back.)

Glow-plug relay was exchanged 2 years ago. At that time, as you said, the error codes of all 6 glow-plugs were always there.

I agree with you now: it is not the DPF... But I do not agree with you that the Check engine light will definitely go on. I really have a lot of mileages on my car (~500.000 km), so the DPF was already clogged once. No Check engine light came up. I just lost the power, was able to drive max 80 km/h. I was on high-way, pressing the accelerator pedal was actually acting vice versa.

But anyway, thank you very much for your replay!
Tigran