2004 320D Auto Engine Trouble

[Guest]

Hi all, had a bit of a disaster yesterday on the A1. Just to give a bit of background info, the car ingested a swirl flap last year, and I had one of the pistons replaced and the head skimmed. It ran well at cruising speed, but a little lumpy at idle. It has probably covered 20,000 miles since then, mostly motorway.

I had driven about 100 miles on motorways yesterday, when I tried to overtake a wagon whilst i was doing 60 mph. The engine would not kick down, and seemed reluctant to accelerate, but gradually built up to about 70 mph. I then noticed white smoke behind me.

I pulled over and stopped. Not surprisingly, the engine was really hot (it was a scorching day). I waited a few minutes and checked the oil, which was fine. No water in it. There were no dashboard warning lights on. I opened the oil filler cap, and plumes of white smoke came out, which disappeared after a few minutes.

I called the breakdown firm, who turned up a couple of hours later.... The guy asked me to turn the engine over. I did, but it was very rough. he asked me to blip the throttle, but before I had a chance to do it, a big plume of white smoke came from the exhaust, so we shut it off. The mechanic ran his finger round the inside of the exhaust, and said it was very sooty, but no oil.

At the moment it is on a recovery truck somewhere in Lincoln, and I expect it back sometime this weekend. I can have a look at the OBD when it returns, and see if that can shed any light on it.

My first thought was a broken turbo, but the breakdown guy didn't seem totally convinced.

Can anyone shed any light on what might be the problem

Cheers folks

John

OK, so car is back, and I've ran INPA. Here are the results if anyone can help interpret them for me.

E
R R O R M E M O R Y

---------------------------------------

Date: 18.07.2014 18:04:37

ECU: D50M47A

JobStatus: OKAY

Variant: D50M47A

-------------------------------------------------------------

RESULT: 9 error in error memory !

-------------------------------------------------------------

4222 4222 Glow plug zylinder 2

Error counter: 255

Logistic counter: 40

1. Umweltsatz

Mileage 170020 km

average engine rotational speed 0.00 rpm

coolant temperature 20.01 deg C

maximum common-rail-pressure of last 10ms 31.51 bar injection volume setpoint
without volume offset 31.51 mg/cyc intaken air mass per cylinder 0.00 mg/Hub

charge pressure value 984.61 hPa

linearised APP1 0.00 %

Battery Voltage 10101.43 mV

Vehicle speed 0.00 km/h

status glow scale 0.00 –

2. Umweltsatz

Mileage 181240 km

average engine rotational speed 799.89 rpm

coolant temperature 26.03 deg C

maximum common-rail-pressure of last 10ms 315.08 bar injection volume setpoint
without volume offset 10.24 mg/cyc intaken air mass per cylinder 466.32 mg/Hub
charge pressure value 984.61 hPa

linearised APP1 0.00 %

Battery Voltage 11730.69 mV

Vehicle speed 0.00 km/h

status glow scale 0.00 -

No signal or value

Test conditions fulfilled

Error not present now, but already stored

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 42 22 24 06 00 00 FF 28 42 6A 00 46 04 50 00 64 00 3E 00 00 46 CC
1D 4C 28 1A 4A 64 00 48 00 00 -------------------------------------------------------------


4203 4203 glow control unit

Error counter: 255

Logistic counter: 40

1. Umweltsatz

Mileage 170030 km

average engine rotational speed 744.72 rpm

coolant temperature 49.12 deg C

maximum common-rail-pressure of last 10ms 322.96 bar injection volume setpoint
without volume offset 10.63 mg/cyc intaken air mass per cylinder 472.62 mg/Hub
charge pressure value 1063.38 hPa linearised APP1 0.00 %

Battery Voltage 14011.66 mV

Vehicle speed 10.86 km/h

status glow scale 0.00 –

2. Umweltsatz

Mileage 181090 km

average engine rotational speed 689.56 rpm

coolant temperature 99.32 deg C

maximum common-rail-pressure of last 10ms 315.08 bar injection volume setpoint
without volume offset 10.24 mg/cyc intaken air mass per cylinder 422.21 mg/Hub
charge pressure value 1004.30 hPa

linearised APP1 0.00 %

Battery Voltage 11730.69 mV

Vehicle speed 0.00 km/h

status glow scale 0.00 -

Implausible signal or value

Test conditions fulfilled

Error not present now, but already stored

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 42 03 28 06 00 00 FF 28 42 6B 1B 63 29 1B 4B 6C 00 56 0B 00 46 BD
19 95 28 1A 43 66 00 48 00 00 -------------------------------------------------------------

43F1 43F1 elect. spare heater

Error counter: 4

Logistic counter: 9

1. Umweltsatz

Mileage 171050 km

average engine rotational speed 882.64 rpm

coolant temperature 70.20 deg C

maximum common-rail-pressure of last 10ms 330.84 bar injection volume setpoint
without volume offset 3.94 mg/cyc intaken air mass per cylinder 289.87 mg/Hub
charge pressure value 994.46 hPa

linearised APP1 0.00 %

Battery Voltage 14011.66 mV

Vehicle speed 47.37 km/h

measuring point of adjusted duty cycle de 92.95 %

2. Umweltsatz

Mileage 175620 km

average engine rotational speed 717.14 rpm

coolant temperature 73.21 deg C

maximum common-rail-pressure of last 10ms 315.08 bar injection volume setpoint
without volume offset 8.27 mg/cyc intaken air mass per cylinder 270.97 mg/Hub
charge pressure value 1014.15 hPa

linearised APP1 0.00 %

Battery Voltage 14011.66 mV

Vehicle speed 4.93 km/h

measuring point of adjusted duty cycle de 92.95 %

Signal or value below threshold

Test conditions fulfilled

Error not occurred yet

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 43 F1 02 06 00 00 04 09 42 D1 20 78 2A
0A 2E 65 00 56 30 76 44 9A 1A 7B 28 15 2B 67 00 56 05 76
-------------------------------------------------------------

4AB2 4AB2 elect. spare heater

Error counter: 4

Logistic counter: 9

1. Umweltsatz

Mileage 171050 km

average engine rotational speed 1544.61 rpm

coolant temperature 70.20 deg C

maximum common-rail-pressure of last 10ms 582.91 bar injection volume setpoint
without volume offset 16.15 mg/cyc intaken air mass per cylinder 384.40 mg/Hub
charge pressure value 1043.69 hPa

linearised APP1 18.90 %

Battery Voltage 14011.66 mV

Vehicle speed 43.43 km/h

measuring point of adjusted duty cycle de 49.63 %

2. Umweltsatz

Mileage 175620 km

average engine rotational speed 717.14 rpm

coolant temperature 73.21 deg C

maximum common-rail-pressure of last 10ms 315.08 bar injection volume setpoint
without volume offset 8.27 mg/cyc intaken air mass per cylinder 277.27 mg/Hub
charge pressure value 1014.15 hPa

linearised APP1 0.00 %

Battery Voltage 13848.74 mV

Vehicle speed 0.00 km/h

measuring point of adjusted duty cycle de 49.63 %

No signal or value

Test conditions fulfilled

Error not occurred yet

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 4A B2 04 06 00 00 04 09 42 D1 38 78 4A 29 3D 6A 18 56 2C 3F 44 9A
1A 7B 28 15 2C 67 00 55 00 3F
-------------------------------------------------------------

4212 4212 Glow plug zylinder 1

Error counter: 255

Logistic counter: 40

1. Umweltsatz

Mileage 172190 km

average engine rotational speed 1020.55 rpm

coolant temperature 64.18 deg C

maximum common-rail-pressure of last 10ms 401.73 bar injection volume setpoint
without volume offset 3.94 mg/cyc intaken air mass per cylinder 441.11 mg/Hub
charge pressure value 1151.99 hPa

linearised APP1 0.00 %

Battery Voltage 14174.59 mV

Vehicle speed 39.48 km/h

status glow scale 0.00 -

2. Umweltsatz

Mileage 181240 km

average engine rotational speed 799.89 rpm

coolant temperature 26.03 deg C

maximum common-rail-pressure of last 10ms 315.08 bar injection volume setpoint
without volume offset 10.24 mg/cyc intaken air mass per cylinder 466.32 mg/Hub
charge pressure value 984.61 hPa

linearised APP1 0.00 %

Battery Voltage 11730.69 mV

Vehicle speed 0.00 km/h

status glow scale 0.00 -

No signal or value

Test conditions fulfilled

Error not present now, but already stored

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 42 12 24 06 00 00 FF 28 43 43 25 72 33 0A 46 75 00 57 28 00 46 CC
1D 4C 28 1A 4A 64 00 48 00 00
-------------------------------------------------------------

4232 4232 Glow plug zylinder 3

Error counter: 222

Logistic counter: 40

1. Umweltsatz

Mileage 175660 km

average engine rotational speed 717.14 rpm

coolant temperature 62.17 deg C

maximum common-rail-pressure of last 10ms 291.45 bar injection volume setpoint
without volume offset 13.00 mg/cyc intaken air mass per cylinder 466.32 mg/Hub
charge pressure value 1063.38 hPa

linearised APP1 0.00 %

Battery Voltage 13685.81 mV

Vehicle speed 3.95 km/h

status glow scale 0.00 -

2. Umweltsatz

Mileage 181240 km

average engine rotational speed 799.89 rpm

coolant temperature 26.03 deg C

maximum common-rail-pressure of last 10ms 315.08 bar injection volume setpoint
without volume offset 10.24 mg/cyc intaken air mass per cylinder 466.32 mg/Hub
charge pressure value 984.61 hPa

linearised APP1 0.00 %

Battery Voltage 11730.69 mV

Vehicle speed 0.00 km/h

status glow scale 0.00 -

No signal or value

Test conditions fulfilled

Error not present now, but already stored

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 42 32 24 06 00 00 DE 28 44 9E 1A 70 25 21 4A 6C 00 54 04 00 46 CC
1D 4C 28 1A 4A 64 00 48 00 00
-------------------------------------------------------------

41F2 41F2 elec. fan

Error counter: 1

Logistic counter: 26

Mileage 179040 km

average engine rotational speed 330.99 rpm

coolant temperature 43.10 deg C

maximum common-rail-pressure of last 10ms 322.96 bar injection volume setpoint
without volume offset 29.93 mg/cyc intaken air mass per cylinder 333.98 mg/Hub
charge pressure value 994.46 hPa

linearised APP1 0.00 %

Battery Voltage 10590.21 mV

Vehicle speed 0.00 km/h

dutycycle Ubatt-corrected 4.73 %

No signal or value

Test conditions fulfilled

Error not occurred yet

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 41 F2 04 02 00 00 01 1A 45 F0 0C 5D 29 4C 35 65 00 41 00 06

-------------------------------------------------------------

4507 4507 (0402) control of exhaust re-circulation

Error counter: 13

Logistic counter: 40

1. Umweltsatz

Mileage 181180 km

average engine rotational speed 2068.68 rpm

coolant temperature 94.30 deg C

maximum common-rail-pressure of last 10ms 724.69 bar injection volume setpoint
without volume offset 21.66 mg/cyc intaken air mass per cylinder 447.41 mg/Hub
charge pressure value 1004.30 hPa

linearised APP1 48.82 %

Tastverhältnis zür Endstufenansteuerung 0.00 %

Tastverhältnis zür Endstufenansteuerung 70.11 %

Atmospheric-pressure 1014.15 hPa

2. Umweltsatz

Mileage 181240 km

average engine rotational speed 2179.01 rpm

coolant temperature 90.28 deg C

maximum common-rail-pressure of last 10ms 732.57 bar injection volume setpoint
without volume offset 19.30 mg/cyc intaken air mass per cylinder 415.91 mg/Hub
charge pressure value 974.76 hPa

linearised APP1 46.46 %

Tastverhältnis zür Endstufenansteuerung 0.00 %

Tastverhältnis zür Endstufenansteuerung 54.35 %

Atmospheric-pressure 1004.30 hPa

Signal or value above threshold

Test conditions not yet fulfilled

Error not occurred yet

Error would cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 45 07 91 06 00 00 0D 28 46 C6 4B 90 5C 37 47 66 3E 00 59 67 46 CC
4F 8C 5D 31 42 63 3B 00 45 66

-------------------------------------------------------------

4530 4530 (1297) air charge control

Error counter: 1

Logistic counter: 40

Mileage 181170 km

average engine rotational speed 2206.59 rpm

coolant temperature 87.27 deg C

maximum common-rail-pressure of last 10ms 819.22 bar

injection volume setpoint without volume offset 26.78 mg/cyc

intaken air mass per cylinder 541.94 mg/Hub

charge pressure value 1181.53 hPa

linearised APP1 60.63 %

Tastverhältnis zür Endstufenansteuerung 0.00 %

Tastverhältnis zür Endstufenansteuerung 66.96 %

Atmospheric-pressure 1014.15 hPa

Signal or value above threshold

Test conditions not yet fulfilled

Error present now, but not yet stored (debouncing phase)

Error would not cause a warning lamp to light up

Fehler in Entprellphase

Fehler in Entprellphase

Fehler in Entprellphase

Error code: 45 30 51 02 00 00 01 28 46 C5 50 89 68 44 56 78

4D 00 55 67

=============================================================

[mickl3008]

Turbo/oil is usually blue smoke, head gasket is white. You need to clear the codes and restart the engine and then re use the code reader and then start looking. Without actually seeing the car, I would guesstimate a head gasket. How was the temp before it blew?

[Guest]

Temp was normal, straight down the middle on the gauge, all journey. Checked the coolant level and still all there. Took off the EGR hose, and a bit of oil on the bottom of the unit. Not sure if that is relevant or not? Head gasket was changed last year when the piston was replaced.

I'll clear the codes tomorrow and have another go. Funnily enough, all of the INPA diagnostics with the engine running looked OK. All of the cylinders were similar in their results.

Appreciate the reply.

[Guest]

Just an update. I cleared the fault codes and only 4 came up, 3 glow plugs and one rough controller. However, the car has now deposited a load of oil through the exhaust onto the floor :-(.

Is this symptomatic of turbo failure or cylinder head problems? Still white smoke from the exhaust.

thanks

John

[Guest DazH]

To eliminate the head gasket, you could do a compression test. I believe most good kits will accommodate a diesel, mine claims to and came with an extra long screw doodah.

Daz

[Guest]

Hi Daz; I'll let the garage take care of that. I'm hoping it is turbo, as running the INPA diagnostics with the engine turning over, everything looked OK on the bar graphs as it was running. No one cylinder seemed different to the others, and the readouts looked ok.

Cheers mate

John

[mickl3008]

If there is oil in the exhaust its normally a turbo, when i say blue smoke its just a tinge of blue mixed with white. EGR valves always have a black sludge deposit. it is a stupid design. An alternative to a compression test is a sniff test, most garages will have the equipment, a lot cheaper and quicker than taking out glow plugs.

[Guest]

Looks about right with the smoke, and a puddle of diesel/oil on the floor :( .

Garage are supposed to be collecting the car today or tomorrow to investigate. Hopefully not more than the turbo gone.

Cheers

John

[GaryWebb101]

It's not blown head gasket is it?

[Guest]

Hi Gary, I don't think so. There was no water in the oil, and the coolant was still ok in the radiator. Garage initial thought is turbo - they are stripping it down as I speak. Will report back with the outcome!

Thanks for the reply.

[GaryWebb101]

Hi Gary, I don't think so. There was no water in the oil, and the coolant was still ok in the radiator. Garage initial thought is turbo - they are stripping it down as I speak. Will report back with the outcome!

Thanks for the reply.

How did it go?

[Guest]

Hi Gary, the garage have finally got around to working on it. The turbo was completely knackered, so they now have a new recon unit to fit.

The mechanic reckons that there is about 2 litres of oil sitting in the exhaust, and needs to take it off and stand it up for about 3 days to let the oil drain out of it, otherwise I will look like one of the Red Arrows with all the white smoke it will produce :-).

Fingers crossed I will get it back early next week. Seems I've been unfortunate with the classic 320D common faults - swirl flaps, mass damper and now turbo have all caused me grief, not to say a stack of money :-(.

Thanks for asking mate.