35d - continual P0401 "insufficient EGR flow"
 

I have a '13 35d that we bought last April. Since then, nearly every time the temperature drops below freezing, we get the CEL light on and when I use a code scanner, the P0401 code is there. The X5 has less than 12k miles on it and is now in the shop for the 8th time on this (the code has been logged more than 30 times).

So far, the MAF sensor has been replaced, the air temp sensor has been replaced (3x), new air filter, replaced the EGR, all turbo related tubes have been checked and resealed (twice now)... I don't think the ODBII exhaust sensors have been checked yet (I'm assuming a 35d has those). This is getting beyond a bit annoying. If it was just a light that would clear, then I wouldn't mind as much, but the performance of the car is definitely impacted as well as the fuel mileage.

Has anyone else been having this issue and or can point me to information I can use to discuss with the service department?

I've searched on here quite a bit and can find the occasional thread with the P0401 in it, but all I have found have shown other codes etc and what has already been done has seemed to address the issue.

why not just lemon it?

Have they opened a PUMA case yet? If not, that is absolutely your next move.

I had to look up what a PUMA case was - I don't know if one has been opened, but will ask. Thank you.

I'll admit this is only the third vehicle I've ever bought new or from a dealer, but I've never had to worry about how to take care of issues with a vehicle before. My '02 F250 diesel and '02 Saturn SL2 went 12 yrs and >150k miles with only one trip to service (beyond standard maintenance) the entire time.
I'm not a novice with vehicles as I've been working on and building vehicles for over 35yrs now. Not even my race vehicles have needed this much attention.

^^ PUMA **will** get to the issue.

Dealers- who often times can only do "What the computer tells me"- can sometimes waste time on these odd/new diesel issues... indeed, BMWNA told dealers in the past "ANY diesel engine codes MUST be a PUMA case"..I think this was some time ago, prior to the major recalls they had.

Sorry to hear- I had a 2010 that I lemoned and a 2012 replacement that was (is) flawless. A true lemon.

Actually, once PUMA got done with the 2010 I was convinced they had fixed it, but financially I made out like a bandit by doing the lemon.

Do also keep in mind that BMW traps much more detailed codes that the OBD stuff you read. You should be asking for these in writing with every visit-

Finally, check out the diesel subforum-

GL, keep us posted

A

Well, a PUMA case was opened on it and since I have gotten it back, it has been running without the CEL at all. We have had several sub 20F nights and mornings, so it appears they at least addressed part of it. This time around they cleaned the entire intake, resealed the turbo fittings, replaced the air temp sensor (again), replaced the MAF (again), and replaced the air filter (again). There is also a line for PCM update, but it doesn't list any details.

However, it feels like they detuned the car. Driving in and around town in D feels like a standard run of the mill car and DS feels like D used to feel like. Once on the highway and over 45mph, the car feels lively again (like a BMW should). I've tried resetting the transmission and it didn't seem like much difference. The throttle response from a stand still is extremely laggy as well where it used to have very little lag. Service is asking me to give it a couple more weeks before I bring it back in...

The 2014 X5 35d that I had as a loaner (and nearly identical options), was a completely different car as far as throttle response and performance. So we shall see..