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Old 11-06-2023, 12:46 AM
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Join Date: Aug 2021
Location: Portland, Oregon, USA
Posts: 3
Chips is on a distinguished road
LF help diagnosing code 4530 underboost on 35D

Bought this 2012 X5 35d (US) wholesale from a dealer after it had gone through 2 BMW dealer service departments and failed to make it to a front lot. Last one claimed was a failed small turbo. Really not sure what to try next I've already put enough time into it and I'm an amateur so roast away my order of operations. Been chasing this for months!

Only thing that stands out to me was the electric valve on the EGR cooler, brand VEMO, German made, stamped 2021, had failed due to leaking vacuum. Replaced valve gets really hot with just current flowing (key position 1) but no codes is this normal?

Used all new BMW/OE parts less silicone vac & CCV hose. Verified no vac lines kinked. Only original code was 4530 and it still persists: Charging pressure control, high pressure stage, control deviation:charging pressure too low / positive control deviation.

Here are all my notes and the latest test drive fault read. Latest drive had most number of faults and at highest frequency after replacing the failed electric valve on EGR which I'm not sure if I missed it earlier or if it just failed.

Factory 4530 Service Measures & Results/Notes
1. Check air mass system for leaks. - - replaced CCV hose, every rubber vac line, air intake seal
2. Check exhaust system before turbines for leaks
(Internal leaks possible at joint between large exhaust turbocharger and exhaust manifold at seal for turbine control flap.) - - n/a (no smoke machine available)
3. Check EGR valve.- - CBU removed, no leaks
4. Check throttle valve (fault entry) - - CBU removed, no leaks
5. Check turbine control flap - - moves freely, opens with proper vacuum, no leaks
6. Check charging pressure actuator, high-pressure stage - - joints move freely, opens with proper vacuum, no leaks
7. Check high pressure stage of exhaust turbocharger for damage on compressor wheel and turbine wheel - - replaced high pressure turbo/gasket, all turbo oil lines (no cokeing on old lines)
8. Check wastegate valve - - moves freely, opens with proper vacuum, no leaks
9. Check intake ports and intake valves for sooting
(Excessive oil entry from the crankcase ventilation can cause sooting, especially in the event of short-distance driving - - ports/valves clean (borecope inspected), intake manifold/swirl flap/EGR/throttle CBU removed, replaced all gaskets

Also replaced trying to fix 4530: x3 electric switchover valves, x3 pressure converters, EGR/intake/throttle gaskets. Replaced too the thermostat, air filters & heater water valve (non-functional). Dealer replaced last 2 years/10k miles: SCR active reservoir, up/downstream NOx sensors, MAF sensor.


Last edited by Chips; 11-06-2023 at 01:17 PM. Reason: pics
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35d, 4530, turbo, underboost


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