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E61 Poor mpg and emissions light

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richd View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote richd Quote  Post ReplyReply Direct Link To This Post Topic: E61 Poor mpg and emissions light
    Posted: 08 Jul 2015 at 9:59am
I have a 2004 E61 530D, 140k on the clock. Last year I had a few emissions issues, and I ended up replacing the EGR valve, the MAF sensor, the EGR vacuum converter valve and its vacuum piping. That cured the emissions warnings, and gave me an average 32-34mpg.
 
Just before last Christmas I had a local garage fit a new starter motor, straight afterwards I noticed a drop in mpg down to 26.6. and I also started getting the odd emissions message. I gathered that the inlet manifold had to come off to fit the starter.
 
It was suggested that in fitting the starter, either a vacuum hose was damaged, or the vacuum converter
was damaged, so I bit the bullet and took the manifold off - what a palaver........!! The upshot was that I could find nothing visually wrong with the vacuum valve, and the hoses looked OK too, though as a precaution I replaced the hoses. I had intended replacing the vacuum valve at the same time, but sadly I had bought the wrong valve! So that was left in place.
 
I have tried running the engine and checking for vacuum at the EGR end of the blue hose, with the engine at idle, and also at 1500 rpm, there did not appear to be any vacuum in either case - I think I am right in saying that the EGR should be open at idle?
 
Any way, to me this does suggest the vacuum valve is kaput, but as it is less than 12 months old, and it does look in perfect condition, is there anything else that could cause lack of vacuum? There is no sign of any hissing noise, and from the way the engine runs, the turbo vanes are working as they should. I am trying to avoid taking the manifold off again if possible, so can anyone suggest anything else that could be at fault?
 
I should add that the mpg has remained at 26.6 -26.9 ever since the starter was fitted, even towing a caravan!!
 
Thanks!
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Brian4 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian4 Quote  Post ReplyReply Direct Link To This Post Posted: 08 Jul 2015 at 7:31pm
One thing the 3.0 diesels suffer from is failed thermostats either the EGR one or Main stat and the engine then runs at  mid 70c rather that 90c. With the engine running cool the ECU will still think it is cold and overfuel so could be some of your emissions issue. Best to get it too a specialist with diagnostics and they will look at any engine codes.

There is a way of accessing the engine temperature via the 'hidden menu' on the dash. 
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issus View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote issus Quote  Post ReplyReply Direct Link To This Post Posted: 08 Jul 2015 at 10:41pm
Richard
 
Before you spend anymore money/time please get a diagnosis done on your car! You could do this yourself if you bought the right type of kit. Avoid at all costs the cheap Bluetooth adaptors so beloved on Ebay and Amazon. If you take yr car to BMW Franchise expect to pay approx. £75.00 for a diagnostic check. Indies are about £20 to £50.00 depending on who you know. Not sure about your local garage as to replace the EGR valve is pretty rare and they rarely fail. Try Redish Automotive near Bristol(in the mag too!) they appear to be pretty good.
 
Please keep the forum informed how you get on.
 
See chart below; Forza West  - have heard good things about them:
 
South West
Specialists Name Town/City Contact Number Postcode Website Comments
Clayton Cars Bristol 0117 963 1699 BS3 2AW BMWRepairsBristol.co.uk
Forza West Chepstow 01291 624 563 NP16 5QZ forzawest.com Knows his stuff
Fritzs Bits Greenham 01823 674459 TA21 0LY www.fritzsbits.co.uk Specialist in older BMWs, very good knowledge base and service
Westbury IBM Westbury 01373 858826 BA13 4QT http://www.ibmautomotive.co.uk/ Excellent work. Diagnostics for most makes, too
Paddocks Fenny Bridges (Nr. Exeter) 01404 851021 EX14 3BG http://www.thepaddockgarage.co.uk/ Excellent indie BMW garage, always professional and very reasonable labour charges
JMW Autotechnic Grampound Road nr Truro 01726 883 984 TR2 4TB http://www.jmwautotechnic.co.uk Superb service, low prices, proper diagnostics kit
PC Autocare Swindon 01793 772542 SN5 3LW http://www.pcautocare.co.uk BMW Specialists, well priced E46 M3 servicing
Infinity Automotive Unit 2 Cheney Manor Ind Est Swindon 07766540918 Sn2 2qn http://www.infinityautomotive.co.uk 15 Years experience, BMW Specialists, Well priced, Full dealer diagnostic, All makes and models
Grants of Wellington Unit 5 Blackdown Business Park, Sylvan Road, Wellington, Somerset 01823 662067 Fax.01823 667314 TA21 8ST www.grantsofwellington.co.uk
Steve Rowley BMW Malmesbury Rd, Kingsditch Trading Estate, Cheltenham 01242 222 232 GL51 9PL http://bmwsaabmerc.co.uk/wordpress/?page_id=24 BMW specialists offering good value servicing on all models
E46 320d Sport Myst Blue 054 reg - probably the best BMW ever
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richd View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote richd Quote  Post ReplyReply Direct Link To This Post Posted: 09 Jul 2015 at 11:27am
I already know all about the thermostats - I keep a careful check on that to avoid DPF issues. Both stats on mine are working normally. So they are at least ruled out!
 
When the car was last in the garage, (a BMW indy) a check showed the EGR system to be the problem, but didn't specify what part in particular. As it all seemed OK up until the starter was fitted, something was clearly disturbed/damaged/broken during that fitment, as the mpg dropped straight afterwards. Unfortunately it was not possible to take the car back to the garage that did the starter at the time for them to look at, and as they were just a general garage, I felt a BMW specialist would be a better bet.
 
I do have one of the C110 scanners, that also flags up EGR, and as the rough and ready test I did showed, there does not appear to be any vacuum at the EGR from the pipe, which indicates to me that the pressure converter is faulty. I just wanted to be 100% sure there was definitely nothing else that could cause the EGR not to work, before undertaking the laborious task of taking the manifold off again.
If in doubt and all else fails - read the instructions!
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