4501 (0401) Abgasrueckfuehr-Regelung

[wpoll]

Don't you just love the German error messages....

This little pretty popped up while I was goofing around trying to get DIS connecting to my '5 (which could be a whole 'nother thread by itself - and may yet be one...) and I was checking INPA operation after changing some OBD/EDIABAS settings.

The error and error data translate as: -

4501 Exhaust Gas Recirculation

Negative control deviation / air mass too high
Test conditions not yet fulfilled
Error not yet occurred
Error would cause a warning lamp to light up
Error in debouncing phase

Normally I would be diving in to check the EGR and all the vacuum lines and vacuum modulators (and I'll probably go over them soon) but in this case I'm pretty sure that this error will be related to the growing exhaust manifold crack(s) I have. I'm still waiting on parts from Latvia so haven't sorted it yet.

While I have things apart, I'll be cleaning out the EGR - I had planned to do that before I got these codes - and will attend to any frayed vacuum hoses etc, check the vacuum operation of the EGR and I'll even clean out the little filters in the vacuum modulators.

A full error description reads: -

4501 - P0401

Information saved in
DDE

Fault code
4501 - P0401

Fault text
DDE: Exhaust-gas recirculation, control deviation: Air mass
too high/negative control deviation

Fault description
The diagnostic trouble code is logged in the ECU when the
exhaust-gas recirculation system's negative control deviation
falls below a limit defined based on the operating point.

Condition for fault identification
Test condition:
The test runs every 20 ms when the exhaust-gas
recirculation control system is activated, the monitoring
system is enabled and no other system fault is present.
Voltage condition:
The test runs every 20 ms when the exhaust-gas
recirculation control system is activated, the monitoring
system is enabled and no other system fault is present.

Condition for fault memory entry
Debounce (7500 ms)

Action in service
Check the following potential problem sources:
Leaks in mass airflow system on engine side of compressor
Leaks in exhaust system on engine side of turbine (combined with mass airflow plausibility errors).
Throttle valve defect (in combination with throttle valve faults).
Defective EGR valve (in combination with EGR valve errors).
Defective turbocharger (in combination with turbocharger faults).
Severe EGR cooler soot accumulation. Applies to engines with single-stage boost: Conduct mass
airflow system test.

Fault effect and breakdown warning
It is possible to continue driving the vehicle, emissions deteriorate.
Proceed to the nearest BMW Service facility.

Driver information
Warning light:
MIL

Service instruction
Note collateral effects on boost-pressure control (faults in
the exhaust-gas recirculation system can affect the boost-
pressure control system).
Check diagnostic trouble codes for the named components.

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Oh, the fun of it...

[yes_its_neil]

Diagnostics has come a long way from 'start her up... I'll have a listen'

[wpoll]

Originally Posted by yes_its_neil

Diagnostics has come a long way from 'start her up... I'll have a listen'

Hasn't it just...

Along with the error code, INPA provided this data...

Mileage 220000 km
Engine speed 2316.92 rpm
Coolant temperature 91.28 deg C maximum
Rail pressure of the last 10ms 913.75 bar
Injection quantity setpoint without
Quantity compensation control 36.23 mg / cyc
Aspirated Air mass per cylinder 926.33 mg / stroke
Charge pressure value 2008.61 hPa
Linearized APP1 60.63%
Duty Cycle - Exhaust Gas Recirculation 79.56%
Duty cycle - boost pressure plate 52.78%
Atmospheric pressure 974.76 hPa

Love the mileage value - the '5 is trying to tell me something...

[yes_its_neil]

It's run in now, years of driving pleasure ahead.

[wpoll]

Originally Posted by yes_its_neil

It's run in now, years of driving pleasure ahead.

There had better be - given the money I'm pouring into this thing!

Just added new glow plugs and a glow plug controller to the to do list - I've ordered a full set from the UK.

I've had two intermittent glow plugs for the last three years but just recently that fault list has grown to four permanently missing. I suspect the fine wires in the controller are failing but I'm not going to attempt repairing it (given that it's "potted") as a new Behr unit isn't too costly. The glow plugs themselves are a dead cert for replacement at this mileage.

I'll do these when I do the exhaust manifold - gonna be a BIG weekend, that one. Of course, taking off the inlet manifold puts me perilously close to removing the valve cover (making the exhaust manifold job MUCH easier) but I'm still not planning to do that - or at least unless I really have to.

Oh, and I now have DIS running... so I have INPS, DIS and BMW Scanner (on two different laptops - the drivers for my INPA/DIS OBD-II cable clash with the drivers for the BMW Scanner cable!). With access to DIS, the xDrive transfer case oil change is now on the list too... NZ$96 per litre for the unicorn juice...

[yes_its_neil]

Yes, that is a fair list now. I had 6 glowplug errors and thought it was likely to be the controller. After replacing it, I was rewarded with 5 error messages. Seems I had a faulty controller and 5 faulty glowplugs. I ordered the glowplugs and inlet manifold gaskets, but I traded the vehicle before I did the work. I haven't investigated to see if they are the same as used in my X3, probably not. I could have sent the new Bosch glowplugs across to you.

You will likely be greeted with a similar view as shown in my photos. I did some reconnaissance and took these photos, with the intention to do some thorough cleaning when I did the glowplugs.

Good luck when you come to do the job, any long weekends coming up in NZ before Xmas?

[wpoll]

Thanks for the pictures, Neil. Doesn't look too clogged up (I've seen pictures of WAY worse...) - what mileage was this at?

Re. the intake parts fitting your X3, don't you have the same M57N engine? Parts should be the same, for pretty much any BMW fitted with the M57, M57N, M57N2 etc.

I haven't ordered the intake gaskets. I want to replace them but OEM are insanely expensive, sets ex China are insanely cheap (and shipping is too slow) and likely to be worse than old OEM, so I'm planning on re-using the old ones initially. I'll clean them up and give them a quick soak in ATP AT205 to restore some level of elasticity. I have all new gaskets for the EGR and turbo pipework etc.

Where did you get your gasket set from?

Holiday? Nah, just Labour Day in late October - I'll have this all done long before then. A normal weekend will do though. Drive home on Friday night, have some dinner, then whip out all the plastic, the inlet manifold and the glow plugs (while the engine is warm). Saturday will be the manifold - should have it all back together later that day.

Ha..! We'll see....

[Ohsoslow]

Mine has 5 glow plug errors, (lucky number 4 cylinder not faulting!) and glow plug controller, but still starts mint, so haven’t bothered with trying to replace them yet. When I pulled my intake manifold off it looked similar though, was able to clean it all out relatively easy, The head not so much. And I did just re use the old gaskets. Surprisingly quick to remove intake manifold too. Should have it sorted in an evening no worries!

[yes_its_neil]

Hi Wayne, these are links to the bits I bought at the time. I'd say my vehicle was around 235K at the time I ordered the parts and took the photos.

https://www.ebay.com.au/itm/Intake-M...cAAOSwepZXRgVo

https://www.ebay.com.au/itm/BOSCH-Gl...UAAOSw08pauOvn

My controller was a Behr as well, I can't see the link, but the eBay seller was alexander_igh

I reckon you are right with the bits being interchangeable with my M57N2, I had a quick look this morning on a chart and they had the same part number.

I haven't seen any errors on the DDE for my X3 since I've had it, hopefully that continues for some time....

Have a great Father's Day.

Cheers....

[wpoll]

Originally Posted by Ohsoslow

Mine has 5 glow plug errors, (lucky number 4 cylinder not faulting!) and glow plug controller, but still starts mint, so haven’t bothered with trying to replace them yet. When I pulled my intake manifold off it looked similar though, was able to clean it all out relatively easy, The head not so much. And I did just re use the old gaskets. Surprisingly quick to remove intake manifold too. Should have it sorted in an evening no worries!

Mine starts fine too and I only ever see the "Pre-Heating" message in the cluster if the outside temp is lower than 0DegC. Still starts fine..

But.. The DDE5 that runs the engine management can often turn on the glow plugs to maintain cylinder temps, even once the engine is warmed up. This is for emissions control, especially when idling in traffic and long downhill sections where the engine struggles to maintain correct operating temps. On later cars with DPFs they are important for DPF regeneration too. No DPFs for us though - phew!

As the glow plugs are an important aspect of the emissions control in the DDE5, it will throw codes and eventually sulk if too many glow plugs are MIA...

While my 4501 code is not likely related to glow plugs, it IS odd that the DDE threw this code (twice) only AFTER the second that third glow plug failed. The Given the other issues (cracked manifold and dirty EGR) I'm not thinking this code is related but while I'm in there...