Another X5 3.0d starting issue thread ..

[rbjtech]

E53 2003 3.0d M57 - 130K

Foxwell NT530 scanner

I've been a lurker for many years, so first of all, thanks to the many contributors to the many 3.0d E53 non-starting threads - it appears I am not alone !

Issue - Random 'no start', mostly from hot - but also have had no start from cold as well.

Engine cranks fast but will sometimes not start. A quick quirt of Brake Cleaner or Start Spray (1 seconds worth) and she springs into life every time.

If on a long crank when trying to start, 'TRANS FAILSAFE' may come up after 10+ seconds of cranking - but after spray and a start, it goes away again and drives perfectly fine - no issues with the Auto gearbox.

Runs well and purrs nicely once started, even when cold.

Injectors : I replaced 4 of the injectors following a leak down test - Now all 6 leak a small amount, it takes about a minute for the fuel to even get to the collection bottle during idle - so I'm pretty sure the injectors are now good and start pressure is good - see below.

Camshaft Sensor : Sometimes shows this code 1E25 but may be as a result of the non start ?. Replaced as cheap and easy fix but no difference to random no starts, put the original one back.

Engine Bay Fuel Filter : Replaced with new Mann Filter, fully purged and could see all the air being purged through the clear fuel lines when originally changed.

Underbody Fuel Pump : Changed about 40-50K ago, can clearly hear it and low pressure fuel reading 4 psi on reader (which I believe is good). I can activate it fine using the scanner.

High Pressure Fuel Pump : Reading is ~296 psi when cranking and same when idling. Pressure rises and falls back to ~300 psi as engine is rev'd - (you can graph it on the foxwell), so both pump and regulator appear good ?

Fuel Pump Relay : Tested fine, but swapped relay with Horn relay for good measure. Can activate via scanner without issue and can hear pump ok.

High presure Fuel pressure Sensor on Rail : Checked connection, reading appear to be OK (~300 psi on idle).

Fuel Tank : Checked power to the lines with clamp meter (~4A each) and can hear the pumps, but have not fully tested these. Same symptoms whether full or half tank.

Battery : New Bosch S5. Cranking voltage above 12v

Alternator : Charging fine ~ 14.4v

Glow Plugs : All broken/open - but I believe these a) have no impact on a hot start anyway and b) temps never get below 0 degrees. Mostly starts fine first crank even when 0 degrees - so pretty sure Glow Plugs are not the issue here even if they are all broken/open ?

EGR and Intake Manifold cleaned (yuk!) when taken off to do Injectors. Boost sensor cleaned and correctly re-installed.

Things not checked
------------------

MAF Sensor - Never cleaned
Crankshaft Sensor - probably should have replaced when the Intake Manifold was removed ..

The TRANS FAILSAFE code is the issue that is concerning me - would a transmission issue stop the car from starting ?

Cooling off the engine appears to fix the car if left - ie I can leave the bonnet up for 5 minutes and then she'll start ok.

Thanks for any help - this is a really frustrating issue as she'll be fine for days and then starts playing up again ..