Engine Controls - Hard Start/Low Power/MIL ON/DTC's
SI B 12 55 06Engine Electrical Systems
June 2009
Technical Service
This Service Information bulletin supersedes SI B12 55 06 dated June 2009.
[NEW] designates changes to this revision
SUBJECT
N54 - Diagnosis for DME FC 29DC/2FBF
MODEL
E90, E92 with N54 produced from 06/06
E93, E60, E61 with N54 produced from 03/07
E82, E88 with N54 from start of production
E71; X6 with N54 from start of production
E89; Z4 with N54 from start of production
SITUATION I
The customer may complain of:
^ Excessive cranking time before the engine starts (5-6 seconds) on a cold start or after a hot soak.
^ In most cases, diagnosis shows fault code 2FBF stored with SES lamp illumination.
SITUATION II
The customer may complain of the following:
^ "Vehicle loses power while driving" or "Vehicle runs poorly".
^ The Service Engine Soon lamp may be illuminated.
^ Diagnosis shows fault code 29DC (Cylinder injection cut-out, pressure too low in high-pressure system) and/or 2FBF (Fuel pressure on-release injection, pressure too low), and in some cases, also in conjunction with 29F1 (Fuel high-pressure, plausibility) and 29F2 (Fuel high-pressure, fuel pressure undershot).
^ In some cases, misfire faults for various cylinders (e.g., FC 20D1, 29CF, 29D2, 29CE, 29D0, 29CC) are also stored in MSD80.
Important:
If fault codes 29F1/29F2 are only stored in the DME, refer to SI B12 16 06 (November 2006).
CAUSE
Possible causes may include:
^ Sensitivity of injection pump (HDP) diagnostic software
^ Internal failure of a High-pressure Injection Pump (HDP)
^ Failure of an electric fuel pump or a clogged fuel filter
^ Failure of the low or high-pressure sensors
^ Defective fuel pressure check - valve/fuel pressure regulator
^ Failure of a volume control valve
^ Defective fuel injector
^ Intermittent electrical connection problem (wire and/or connector) in the fuel delivery system.
CORRECTION
When the fault codes listed above are stored in the DME memory:
On E90 and E92 vehicles
1. Check the vehicle's integration level.
2. If the integration level is found to be "E089-06-09-540" or lower, then reprogram and/or recode the complete vehicle using current ISTA/P (target integration level "E089-06-12-510" or higher introduced in PROGMAN V24.02).
3. Test-drive the vehicle after programming to verify the effectiveness of the repair.
CORRECTION FOR SITUATION I
For E93, E60, E61, E82, E88, E89 and E71 vehicles or on E90 and E92 vehicles with integration E089-06-12-510 or higher, where the customer complains of "Long Cranking Time", fault code 2FBF is stored in the DME with the SES illuminated; proceed as follows:
1. Use the current ISTA diagnosis software.
2. Prior to performing all applicable high/low-pressure pump ISTA test plans, IT IS NECESSARY TO CHECK the residual pressure in the fuel low-pressure system.
The test module "Pressure Retention Test on the Low Pressure Fuel System" will be incorporated into ISTA 2.14, and is planned for release together with the measurement interface IMIB in July of 2009.
Until ISTA 2.14 is available, use the procedure described below to test the residual pressure in the low pressure fuel system
3. The engine must be cooled down before the test (coolant temperature below 40° C).
4. Access the quick-disconnect coupling in the fuel feed line. On E82, E88, E89, E90, E92 and E93 vehicles, it is located underneath the car, at the bottom of the driver's side wheel housing. On E60, E61 and E71 vehicles, the coupling is located in the engine compartment, on the driver's side next to the B+ terminal.
5. [NEW] Disconnect the fuel supply line and install special fuel line plug tool 135 161 (P/N 83 30 0 496 565), item # 1, into the fuel hose from the high-pressure side of the system.
6. Install three-way adapter tool 135 270 (P/N 83 30 0 491 310), item # 2, into the supply line from the fuel tank side.
7. Connect the 25 bar pressure transducer (1) to the GT1 with MIB. (Remember that the displayed pressure value includes 1 bar of atmospheric pressure always deduct 1 bar to obtain a correct fuel pressure reading.)
8. Plug the open end of the three-way adapter tool (2) using special tool 135 162 (P/N 83 30 0 496 565) item # 2 on the previous illustration. In this configuration, the low and high-pressure fuel systems are separated and sealed. The residual pressure measurement will be performed only on the low-pressure side.
[NEW] Alternative Tool Solution:
9. In case the GT1/MIB is not1/MIB is not available, you can use a properly calibrated mechanical gauge (e.g., P/N 83 30 0 491 260 - a pressure gauge from K-L-Jetronic special tool kit P/N 83 30 0 491 259) connected into three-way adapter tool 135 270 as follows:
# 1. - Three-way adapter tool 135 270
# 2. - Plug tool 135 162
# 3. - Pressure gauge P/N 83 30 0 491 260
# 4. - Plug tool 135 161 (into the hose to the HDP)
IMPORTANT NOTE:
[NEW] The three-way adapter tool 135 270 (P/N 83 30 0 491 310 - M62 fuel pressure adapter hose) and the coupling plugs P/N 83 30 0 495 565 (SI B04 16 09) were previously sent via the Automatic Tool Shipment Program.
10. While observing the fuel pressure, activate the electric fuel pump for 20 seconds using ISTA and the component activation function (after the vehicle test, select: Control unit tree; then DME; Call ECU functions; Component activation; and Fuel pump). When using the GT1/MIB, select Measurement System and then make the following selections: Measurement Function Pressure bar; Test Connection Pressure sensor; Measuring range - 0-25 bars. To activate the fuel pump for 20 seconds, select Control Module Functions; DME; Component activation; and Fuel pump.
11. Immediately after electric pump activation, the pressure must reach at least 4.75 bars. The residual fuel pressure, 10 minutes after the fuel pump was deactivated, must be above 3.75 bars.
12. In case the minimum threshold of 4.75 bars was not reached, further diagnose the low-pressure system using test module B1214_DI6KNDR, Low Pressure Fuel System (possibly defective electric fuel pump or fuel filter/pressure regulator).
13. If the minimum threshold system pressure exceeds 4.75 bars and the residual pressure exceeds 3.75 bars after 10 minutes, proceed to step number 15.
14. If the minimum threshold of 4.75 bars was exceeded, but the residual pressure test failed (pressure dropped below 3.75 bars after 10 minutes), then the fuel pressure regulator or the pressure check valve may be defective.
In such a case, the following components need to be replaced:
E82, E88, E90, E92, E93 Left-hand side Fuel filter with pressure regulator (P/N 16 11 7 163 295)
E89 (Z4) Right-hand side fuel supply unit (P/N 16 11 7 210 635) and Fuel filter/pressure regulator kit (P/N 16 11 7 168 284)
E60, E61 - Right-hand side fuel supply unit (P/N 16 14 7 174 893) and Fuel filter/pressure regulator kit (P/N 16 14 7 174 895)
E71 (X6) - Left-hand side fuel supply unit with fuel sensor (P/N 16 11 7 212 588).
15. In case the residual low-pressure system test did not clearly indicate a root cause, proceed with test module B1214_DI6KNDR (Low Pressure Fuel System).
This test module may be accessed in ISTA using the following path: Activities; Function Structure; Drive; Motor Electronics; Low pressure system; Low pressure control; Low pressure fuel sensor; and Search. Select B1214_DI6KNDR from the list.
16. Prior to execution of the Low Pressure test module, install a calibrated manual fuel pressure gauge (e.g., P/N 83 30 0 491 260 pressure gauge, from the K-LJetronic special tool kit P/N 83 30 0 491 259) connected with the three-way adapter tool 135 270, into the low-pressure fuel supply line, as follows:
# 1. - Three-way adapter tool (135 270)
# 2. - Pressure gauge P/N 83 30 0 491 260
17. Perform all applicable steps of the Low Pressure Fuel test module B1214_DI6KNDR. Pay attention to all questions displayed during diagnosis and answer them correctly.
After completion of all diagnostic steps, end the test module and enter the "fault feedback" screen. Enter the result of a diagnosis process into the Diagnosis Code dialog box and obtain a "Diagnostic Code". In
case no failure can be currently detected in the low-pressure fuel system, enter the last option "No fault found" into the dialog box. The obtained Diagnostic Code should be included in the comment section of the warranty claim.
In case the diagnosis of the low-pressure system did not clearly indicate a root cause, proceed with test module B1214_DI6KHDR (High Pressure Fuel System).
This test module may be accessed in ISTA using the following path: Activities; Function Structure; Drive; Motor Electronics; High pressure system; High pressure control; and Search. Select B1214_DI6KHDR from the list.
CORRECTION FOR SITUATION II
For E93, E60, E61, E82, E88, E89 and E71 vehicles or on E90 and E92 vehicles with integration E089-06-12-510 or higher, where the customer complains of "Losing power when driving", fault codes 29DC/2FBF and/or 29F1/29F2 are stored in the DME with the SES illuminated; proceed as
follows:
1. Use the current ISTA diagnosis software. Perform test module B1214_DI6KHDR (High Pressure Fuel System).
2. Prior to execution of the High Pressure test module, install a calibrated manual fuel pressure gauge (e.g., P/N 83 30 0 491 260 pressure gauge from the K-LJetronic special tool kit P/N 83 30 0 491 259), connected with the three-way adapter tool 135 270, into the low-pressure fuel supply line as follows:
# 1. - Three-way adapter tool (135 270)
# 2. - Pressure gauge P/N 83 30 0 491 260
3. Perform all applicable steps of the High-pressure Fuel test module B1214_DI6KHDR. Pay attention to all questions being displayed during diagnosis and answer them correctly.
Important Note:
When comparing the measured fuel pressure with the engine running at idle speed, make sure to let the fuel pressure stabilize for approximately 60 seconds prior to the final reading. Otherwise, an implausible value (around 150 bars) is going to be entered into the test, resulting in inaccurate diagnosis (defective high-pressure pump).
4. After completion of all diagnostic steps, end the test module and enter the "fault feedback" screen. Enter the result of a diagnosis process into the Diagnostic Code dialog box and obtain a "Diagnostic Code". In case no failure can be currently detected in the high-pressure fuel system, enter the last option "No fault found" into the dialog box. The obtained Diagnostic Code should be included in the comment section of the warranty claim.
IMPORTANT DIAGNOSTIC HINT:
In certain cases, the HDP fault may be reproduced only when the engine is under load. In order to replicate the complaint, it may be necessary to road-test vehicle with the manual fuel pressure gauge installed. The excessive low-pressure fuel fluctuation (between 50 and 70 bars) would indicate incorrect operation of the fuel delivery system.
5. Make sure that FASTA data is transmitted after the completion of all appropriate test modules.
6. In case the High-pressure Fuel Pump needs to be replaced, use the updated part P/N 13 51 7 592 881, which incorporates the latest improvements to internal sealing. For the pump replacement procedure, refer to RA 13 51 017, found in BMW TIS.
7. After replacement, clear the adaptation values of the high-pressure flow control valve in the DME by selecting the path:
^ Activities / Service Functions
^ Drive
^ Motor Electronics
^ Adjustment Programs
^ Delete Adaptations / variants, and then Test plan
^ Reset adaptive values.
PARTS INFORMATION
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
IMPORTANT:
As a commitment to our customers and to demonstrate confidence in our product, BMW will extend the emissions warranty of the High-pressure Fuel Pump (HDP) of MY 2007/2008 E60, E61, E90, E92, E93, and MY 2008 E82 and E88 vehicles equipped with the N54 engine from 4 years or 50,000 miles to 10 years or 120,000 miles, whichever comes first (refer to SI B13 03 09).
The emissions warranty extension for this component applies to the above-listed models only, and is transferable to any subsequent purchaser of these models. This extended emissions warranty is applicable to vehicles registered in all 50 states. Warranty coverage for all other parts is not affected.
BMW will inform all affected owners of the above-listed models of their extended High-pressure Fuel Pump warranty.
The Warranty information should be used if the High-pressure Fuel Pump (HDP) replacement becomes necessary on MY '07 or MY'08 E90/E92/E93/E60/E61/E82 or E88 vehicle equipped with N54 vehicle as outlined above:
The Warranty information should be used if the High-pressure Fuel Pump (HDP) replacement becomes necessary on E71 (X6) or MY2009 (or later) E90, E92, E93, E60,E61, E82, E88 or E89 vehicles equipped with the N54 engine, as outlined above:
Disclaimer