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  #1  
Old 01-14-2019, 08:15 PM
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DEF Fault Codes - P2003A or 004BAC - when tanks are pretty full

Over the last six months our 2009 X535d w/80,000mi has thrown 3 DEF fault codes when the DEF tanks were not very low.

1 - Last summer it threw P203A: It had been awhile since I added DEF so I topped up the Active tank, cleared the code and added DEF to my shopping list.

2 - Nov 11th it threw another P203A: I filled both the Active and Passive tanks and cleared the code. But was surprised that neither one took as much DEF as I expected.

3 - Jan 11th it threw 004BAC (via Carley): So I topped up the Active tank which only took a quart!

Thinking back, I noticed the last two Engine lights (DEF codes) just after turning off a main road and down a hill. Has anyone else has seen DEF codes when their DEF tanks were pretty full? If so, did the engine light come on during/after a quick turn and/or change of slope?

Funf Dreisg
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Old 01-15-2019, 02:32 AM
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I'd guess you're not putting enough DEF in. When I've received the warning, I put at least four gallons in the passive tank and around one gallon in the active tank. You mentioned quart and stuff and that's way too little unless there is something preventing the DEF from going in. I get the warning approximately every 13k miles.
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Old 01-15-2019, 03:19 AM
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what are you using to top off? fitting/valve/etc?


Wife got the 999 warning a week ago. I added 5 gal yesterday.
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Old 01-15-2019, 04:28 AM
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I read your post again. You're getting a CEL and a DTC? That's not indicative of low urea level at all. Ard and I are speaking of the Low DEF "No Start in 999 Miles" warning that comes on in the instrument cluster and on the iDrive display. The P203/04BAC DTCs specifically concerns the reductant level detection system for the active tank which means there could an issue with the level sensors.


BMW NA extended the warranty on the active tank under SI B 01-23-16 to 10 years/120,000 miles. There is also an extended warranty for several other NOx reduction system components.


I had them all replaced in 2016 when I got the 04BAC DTC and it could not be cleared due to the level sensors in the active tank being faulty.
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Old 01-15-2019, 10:11 AM
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Thanks for your replies.

Sorry I should have posted how I add the DEF….
The day we picked up our 2009 35d I purchased 2 of the half gallon “user” bottles of DEF. These small bottles have an automatic cut off valve built into the neck. The BMW parts guy suggested that once I used a bottle, I should cut a small hole in the bottom and use the auto cutoff feature to assure that I didn’t spill any DEF. It works like a charm. I just fill the user bottle from the bottom, screw it onto the DEF inlet(s), and push down to start filling the tank(s). Until recently I have only added DEF 2-3 times as part of normal maintenance (e.g oil changes). These fill ups took the expected 3-5 gallons for both tanks. But the recent 3 fill ups took less than half that amount. With the last one taking only a quart.


The problem...
I get a CEL and when I check the OBD I get a DTC of either P203 or 004BAC (depending on whether I use InCarDoc with an inexpensive OBD WiFI adapter or more recently Carly).

The first time it happened (last summer) I just added a little DEF, cleared the code and every thing was fine. When it didn’t come back, I forgot about it. But after two more CEL/DTCs, i”m worried that there is something wrong with the sensor that triggers the DEF code, even when the tank(s) are nearly full. I assumed that the DEF sensor would simply fail. But it looks like it may be still working, except in certain driving movements (e.g. tuning off a main road and heading down hill.).

I’ll check to see if our 2009 35d is still covered under the 10 yr extended warranty. Hopefully the dealer will accept the recent Carly Report as evidence of the sensor problem even if the CEL hasn’t triggered again.

Thanks again — Funf Dreisig


Edit: Thinking back…In all three recent CEL/DTC episodes I probably could have gotten the same result by simply clearing code. Adding the DEF was the equivalent of “whistling in the graveyard” — nice but not necessary.

Last edited by FunfDreisig; 01-15-2019 at 10:50 AM.
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Old 02-16-2019, 08:27 PM
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Quote:
Originally Posted by josiahg52 View Post
...BMW NA extended the warranty on the active tank under SI B 01-23-16 to 10 years/120,000 miles. There is also an extended warranty for several other NOx reduction system components.
Thanks for the heads up.

The CEL/DTC with 004BAC came back on last week. The dealer replaced the Active DEF tank under the 10yr extended warranty with no drama

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