[iaknown]

Originally Posted by Yozh

I have not yet. But if there is a leak, it would be at higher PSI.

Yes but looking at that service bulletin above, that's the 1st thing listed under that code if I'm reading it right.

Do you know what rpms that deviation is occuring?

[Yozh]

What got me thinking about vacuum lines and controllers is that before I believe I was not boosting through a large turbo and swapping the controllers and some vacuum lines fixed that issue. Before I was good to about 2500rpm then no power, and now I get weird stuff way up in the rpm range. The turbine control pressure converter is swapped with the wastegate pressure converter. I'm thinking it's the pressure converter that came from the turbine control side that is toast/leaking vacuum. Have no way to check, but as soon as new one comes in, I'll eliminate that possibility.

Meanwhile, I'll log more data tonight on a drive back home.

[Yozh]

Just thought to post a bit of an update. I have not fully analyzed the collected data, but I have received a new pressure converter (pn: 11658509323) and have now fitted it to replace an old suspected faulty one. Subjectively, car drives way better. I have not pushed it yet, but I can see the difference.

[iaknown]

So are you all fixed up?

[Yozh]

Originally Posted by iaknown

So are you all fixed up?

As soon as I can drive in my car without my wife I will be able to check for sure, otherwise the audible speed/torque limiter kicks in.

So far no deviation that I have gathered form the data collected and no 4530 code thrown. And I am back at 30+ psi of boost.

[Yozh]

I thought this was a good article and also a confirmation of how important a good tuning is when deleting the alphabet soup (EGR / DPF / SCR).

http://www.autoinform.co.uk/double-trouble/

[BB_cuda]

Yozh, did you get to go put the hammer down and see if your problem is gone?

[Yozh]

Not yet. It's holidays and we are always together. She is very "torque sensitive". There should be a medical term for that

[Yozh]

Thought I would update this. Before I begin I would like to say that even though this is a frustrating process that has caused me a lot of grief and some regret, I have learned a lot and thank this forum and the kind folks that provided some of the information and ideas for this and other.

[Mark M]

Wow, great work Yozh! Sounds like you're honing in on the culprit.

What do you surmise may have caused the plugging of the SCR? Lack of DPF to burn off the particles?

[Yozh]

Oh yeah, that's what I need a DPF. lol. Well, at least if I'm spraying urea. And that was an unfortunate part of a botched Ecotune programming.

As my rolling coal thread showed, soot with urea equals some nasty black crystallized mess.

Might I add that I had this happening for over 11,000 miles (17,500 km).

I'm certain the SCR is severely blocked. The ultimate question is, how long it will last with just soot going through it.

[Yozh]

Ha, I'm all fixed-up. Car is a beast, finally. I have missed her, the way she should have been from the get go when retuned.

Did an SCR-ectomy today and now all is good. Boost is back and fast. Gotta let it run for a bit and let DDE settle and see if I'm gonna overboost. EGTs are normal now, and so is an exhaust back pressure.

For people that are running just soot though SCR I would suggest you monitor your parameters and pending codes. As soon as you see 4530 (assuming all else is normal), and EGT codes: 4C0E and 4C04, you know what is coming BTW, the 4530 does not pop-up easily or all the time, you have to stomp on it. And it had a different behaviour between an Ecotune and JRAuto remaps.

I shall post the photos of the nasty stuff that was inside an SCR.

Also, I would like to say that factory exhaust is sooooo heavy, it's insane. I really do not understand why they needed to make it 150lbs. Seriously.

Edit: also updated the Rolling Coal thread: http://www.e90post.com/forums/showthread.php?t=1061325

[Yozh]

Here we go, the SCR guts. The substrate is wrapped in some kind of a felt/fiberglass lining. Probably so it does not rattle and may be to keep it at operating temperature for efficiency.

Attachment 1154998

I can not recall if it was a 2-stage catalyst. I believe so. So we have two parts here.

Attachment 1154999

You can see how much soot/urea is in the middle

Attachment 1155000

Attachment 1155001

Attachment 1155002

This is in intake face of the second catalyst substrate

Attachment 1155003

Same, just removed out of SCR

Attachment 1155004

This is an outlet side of the second catalyst

Attachment 1155005

Inside, you can see how much it is filled

Attachment 1155006

I still have all the "rocks" if anyone needs for analysis, doubt it though.

Enjoy.

[glitdi]

Glad to see your back in shape!
I have your diesel intake cleaner on its way should be here later this week and I have Bmw Inpa, and Rheingold if you need to do some logs... Thank you to Iaknown for your help!
Also I need a ride, for future research and developments...
How does the tune feel? Hopefully your coal problem has been rectified..

[Yozh]

Thanks J, Let me know when you want me to pick those up. No problem on the ride too.

Tune is great, very refined, and no more coal, even at full throttle. But that is an understatement. Next time you come by, check it out yourself, I would be interested in your conclusions. This is the JRAuto tune now, btw.

[Chief Orman]

Originally Posted by Yozh

Ha, I'm all fixed-up. Car is a beast, finally. I have missed her, the way she should have been from the get go when retuned.

Did an SCR-ectomy today and now all is good. Boost is back and fast. Gotta let it run for a bit and let DDE settle and see if I'm gonna overboost. EGTs are normal now, and so is an exhaust back pressure.

For people that are running just soot though SCR I would suggest you monitor your parameters and pending codes. As soon as you see 4530 (assuming all else is normal), and EGT codes: 4C0E and 4C04, you know what is coming BTW, the 4530 does not pop-up easily or all the time, you have to stomp on it. And it had a different behaviour between an Ecotune and JRAuto remaps.

I shall post the photos of the nasty stuff that was inside an SCR.

Also, I would like to say that factory exhaust is sooooo heavy, it's insane. I really do not understand why they needed to make it 150lbs. Seriously.

Edit: also updated the Rolling Coal thread: http://www.e90post.com/forums/showthread.php?t=1061325

So Yozh apologies because I think I lost the thread here. Of all the things that you investigated, checked and replaced (that one might mistake for the performance hit from a leaking red turbo vacuum hose) which were the most important in getting your performance back? My 335d is mostly stock except for a JBD or DTUK.

[Yozh]

My problems were a combination of several factors. The main one was a retune. If you are stock, you will not have to deal with the complexity of my issues. If you ever get this code, you mainly need to look at the functioning of the vacuum controls system and all of it's actuators.

[Chief Orman]

Originally Posted by Yozh

My problems were a combination of several factors. The main one was a retune. If you are stock, you will not have to deal with the complexity of my issues. If you ever get this code, you mainly need to look at the functioning of the vacuum controls system and all of it's actuators.

Yozh I owe you a call on this issue, but I replaced all my hoses and had my mechanic install the Forge pipe that had been in my trunk for about a year. This was prompted by taking in my car due to an oil burning smell, a vacuum leak and what appeared to be a lack of small turbo actuation. All hoses replaced. Drive it for a week and start throwing a 4530 charge air pressure code as well as 003FF0 air flow meter signal and the damn oil smell comes back. Watching the boost gauge on my Snow water meth kit, boost is not building in the low RPMs. My mechanic is sharp and has as much experience as one can have with the d without being a tuning shop. Any thoughts on specific next steps? Still have all my emissions intact but EGR is blocked.

[sukutash]

Originally Posted by BB_cuda

Yohz, this is real nice to photo all of this and the wonderful tech data too. 2 things.
1)How the heck did E90post allow all of these photos to be brought in and high def ones too? I always run into file size limit.I do a direct post from local store of files on hard disc and don't use the photo bucket method. Is the online store allowing you to somehow bypass these limits?
2) Moderator, this one is likely to need a sticky or atleast I nominate it for a sticky.

I second this motion!

[Yozh]

Originally Posted by Chief Orman

Any thoughts on specific next steps?

Swap pressure converters around (wastegate PC to Turbo Switchover PC) and then swap EUVs from EGR cooler to a turbo-bypass valve EUV. See if you will get your small turbo singing again. This will determine which one you need to replace. Oil burning smell is interesting. You mentioned it before and you said it's not a diesel smell. No turbo oil feed line leaks? Also what about the CCV feed line, is it cracked? I would be still checking diff.pressure sensor hoses, they are just friction fit, and check the integrity of the exhaust pressure sensor line.

[Chief Orman]

Problem solved with oil smell, lack of power and code 4530. First, Yozh was dead on...the EGR vacuum actuator was shot and hose leaked. $40 part and 45 min of labor. Forge charge pipe seal also leaked. Car is back to normal.

[Mark M]

Originally Posted by Chief Orman

Problem solved with oil smell, lack of power and code 4530. First, Yozh was dead on...the EGR vacuum actuator was shot and hose leaked. $40 part and 45 min of labor. Forge charge pipe seal also leaked. Car is back to normal.

Can you elaborate? Was it the EGR pressure converter, or the EGR vacuum diaphragm that is controlled by the pressure converter?