[Roadrunner143]

I have been reading about this issue and decided I should contribute by reporting my story. Car is 2009 BMW 335d with Sport Package purchased at 75,000km in December 2012 with BMW Certified 6yr/160,000km warranty from the dealer. First 55,000km/18months of ownership were spotless with only regular maintenance at recommended specified intervals.

June 2014 – 130,000km: First symptoms… Loss of power on highway with cruise control engaged for a half second at a time (not continuous, similar to a misfire). It was like someone was tapping the brakes randomly… not fun! And then engine shutoff twice in one month while stopped on D (drive).

August 2014 – 140,000km: I finally get my usb-OBDII cable to work with BMWLogger-2 to see some shadow codes: 4592 and 4593. These codes are cleared and they keep coming back every few days. For a few weeks I logged the clearing/reappearing codes to report to dealership. Momentary loss of power now happens every 2 weeks or less.

September 3, 2014 – 142,367km: loss of power now happens once a week. Decided to bring it to the dealer and sent my investigation of the codes (exported code lists from BMWLogger-2). Result: two injectors #3 and #4 are replaced. Car is at 142,367km and still under certified warranty until 160,000km. Cost to me: 50$ deductible.

September 4, 2014: On my way back home from the dealer I feel again the momentary loss of power after only 30km. Scan when I get home, same code 4592 reappeared. Set new appointment at dealer for carbon cleanup as it seems to be the “next step”. SI B 11 03 14 doesn’t apply here in Canada apparently and my cost is estimated at 1000$ + tx for the cleanup. I decided to go ahead and do it so that problems after cleanup happen before the 160,000km warranty expires…

September 8, 2014 – 142,788km: Car is in for carbon buildup cleaning.

September 16, 2014: Car is out from carbon buildup cleaning. 7 working days and 17 hours later it is clean. They had to send the intake to be cleaned somewhere else. This process involved “ultrasounds” and took 3 days to be done. Dealer absorbed the extra hours/work required to do the cleaning. Long road test was performed at the end (I understood they made sure to count one by one the 265hp and 425lb-ft under the hood … all there they said!) My cost: 1,128.10$.

September 21, 2014 – 143,100km: Check Engine Light (CEL) is on. Code 4B06 which points to injector #4 but this injector was replaced on September 3, 2014…

September 22, 2014: Call the dealer to report the code. I propose to clear the code and see if it comes back since this is what they would do at first. They accept. Code cleared. 30km later, CEL is on and code 4B06 is back.

September 23, 2014: Car is in for CEL with code 4B06 (cylinder 4 injector zero quantity adaptation). 4 injectors are to be replaced. Parts are ordered...

To be continued…

TLDR: 335d, injector issues, carbon buildup, injector issues...

Update September 26, 2014: Got the car back yesterday. 4 injectors changed (since 2 are two weeks old). All 6 injectors tested before putting back in the car. Long road test (showed 35km on the odometer). 150km later, no codes so far. Cost to me: 0$

Update October 14, 2014: Car was in October 6th, out October 10th from the dealer. Injection system calibrations done remotely by BMW Canada and 2 full days to do road tests. Apparently the dealer doesn't have the software to do this. Cost to me: 20$ because they ran out of diesel... the 20$ is in the tank so I didn't complain! Currently at 145,000km and fuel consumption is quite better now!

[GottaBeKD]

DDE is next on the list of things to change.

[Nushibo]

Im on the exact same story. Injector number 4 has a lot of issues lol. All injectors replaced 1 month later CBU cleaning. 1 week later shadow code injector number 4. Took it in reset code and gave it back to me. Same day injector number 4 code. Its in there now so i will be awaiting a verdict. 54k with gold warranty 7/100k.

[335D Alpha Pappa]

is injector 4 nearest the turbo? could it be a heat induced failure?

[Pierre Louis]

My money is on the DDE programming, would check the serial number of the DDE to see if it is up-to-date.

PL

[135i_vs_]

Can't believe BMW Engineering still hasn't sent a big poster to every dealer about the 335d DDE requiring replacement.

Well the good thing is, enjoy your brand new expensive injectors.

[TorqueAddict]

They should have covered the carbon build up cleaning service. :/

[Roadrunner143]

Thanks for the DDE info. I did see this item in the vehicle history report from BMW:

Date: 03/08/2011
Mileage: 38,745km
Defect Code: 0013890100
Defect Description: E70 E90 M57Y (US Diesel) Programming control modules (DDE data status)
Labour Code: 0059521
Description: Programming/encoding control units (with programming CAS)

Is this it? Or is the DDE to be replaced you mean?

Originally Posted by TorqueAddict

They should have covered the carbon build up cleaning service. :/

I feel the same. I brought the BMW NA service bulletin to BMW Canada's attention and got a truck load of b*** s*** reasons why it is not covered... "It is part of maintenance sir, not an issue with the engine" I guess we just have to wait and hopefully the Canadian carbon cleanup will be retroactive and will allow them to reimburse us.

[Pierre Louis]

Originally Posted by Roadrunner143

Thanks for the DDE info. I did see this item in the vehicle history report from BMW:

Date: 03/08/2011
Mileage: 38,745km
Defect Code: 0013890100
Defect Description: E70 E90 M57Y (US Diesel) Programming control modules (DDE data status)
Labour Code: 0059521
Description: Programming/encoding control units (with programming CAS)

Is this it? Or is the DDE to be replaced you mean?

As I recall, the DDE programming had further changes since 03/08/2011. You might be well off to check it at the dealer.

PL

[taibanl]

Originally Posted by Roadrunner143

Thanks for the DDE info. I did see this item in the vehicle history report from BMW:

Date: 03/08/2011
Mileage: 38,745km
Defect Code: 0013890100
Defect Description: E70 E90 M57Y (US Diesel) Programming control modules (DDE data status)
Labour Code: 0059521
Description: Programming/encoding control units (with programming CAS)

Is this it? Or is the DDE to be replaced you mean?

I feel the same. I brought the BMW NA service bulletin to BMW Canada's attention and got a truck load of b*** s*** reasons why it is not covered... "It is part of maintenance sir, not an issue with the engine" I guess we just have to wait and hopefully the Canadian carbon cleanup will be retroactive and will allow them to reimburse us.

It says right on the bulletin, COVERED under warranty.

[335D Alpha Pappa]

Yes, if you have the SIB 11 03 14, it states under the warranty section that it is "Covered under the terms of the BMW New Vehicle/SAV Limited Warranty or the BMW Certified Pre-Owned Program."

There are a listing of labor codes, including one if the dealer has to sub-let the cleaning.

You should contact BMW NA if the dealership is giving you problems.

[Roadrunner143]

SIB 11 03 14 is issued by BMW of North America. BMW Canada has it's "own SIB's" and this one is not part of it... yet. I discussed this with the dealer and with BMW Canada. That's why I hope we get it someday and similar to the SIB 11 03 14 it should be retroactive for us that already had it done at our own expense.

[335D Alpha Pappa]

So BMW does not consider Canada to be a part of North America?

Who knew?

[Roadrunner143]

Here's the official email responses from BMW Canada. I also discussed this issue by phone with them and got the same message.

We were sorry to read of the issue you are experiencing with your vehicle. Regretfully, we are unable to comment on a service bulletin offered by another country. Carbon cleaning is considered to be a maintenance item, not a manufacturer's defect, therefore, it is not covered by your vehicle's warranty. We apologize for any disappointment this may cause.

Carbon cleaning is not included in the maintenance schedule because not all vehicles will require a cleaning. Please note that BMW of North America only oversees the United States market. BMW Canada is a separate entity with our own recalls, bulletins and warranties. We trust that this information provides clarification to your concerns.

They are polite at least... but they don't make any sense IMO. I did ask why Canada is not part of North America to get the second reponse...

[Pierre Louis]

One reason for me to hold back on purchasing an extended warranty. Cases of people using it notwithstanding.

PL

[335D Alpha Pappa]

This is unfortunate since all the diesels are manufactured in germany and shipped here. There is no difference between your car, expect for the speedo with the wrong numbers, and the US cars. Luck of the draw.

Maybe you and the other canucks should get together and file a class action lawsuit. Include the gassers to increase the number of victims. It sounds like it will be the only way BMW Canada will change its policy. File a complaint with your consumer protection agency.

CBU is a problem only here in north america. The M57 engine has been in production for over ten years but the 335d was in limited production here - 2009-2011. Same engine in the X5d but I don't hear any issues with CBU.

[taibanl]

Originally Posted by Roadrunner143

Here's the official email responses from BMW Canada. I also discussed this issue by phone with them and got the same message.





They are polite at least... but they don't make any sense IMO. I did ask why Canada is not part of North America to get the second reponse...

I would respond something like follows:

"While the service bulletins from BMW NA may not necessarily be applicable to BMW Canada, in this case it is proof of an engineering deficiency relating to the North American specification 335d which applies to ALL M57TU2D30 vehicles sold in the North American continent regardless of whether sold in the United States or Canada.

My reference to the service bulletin is to point out that this condition results from a known engineering defect, not to point to a particular policy of BMW NA (which I might add is also not in the business of covering ordinary maintenance items under warranty). "

[Nushibo]

I'd be pretty peeved if I heard that, what our bros in Canada are not part of North America? lol Rename BMW NA to BMW USA sheesh. Well im sure theyll try to fight this all day so just enjoy your new injectors! I know I am for the 2 days i had it XD its been in the shop about 6 times since July. I've had so many loaners and they all suck all bling no punch. Best bet is to begin saving for mods since you have the cleaning done. Thats what im doing atm.

[GottaBeKD]

Just tell him we put the North in North America.

[Pierre Louis]

Originally Posted by 335D Alpha Pappa

CBU is a problem only here in north america. The M57 engine has been in production for over ten years but the 335d was in limited production here - 2009-2011. Same engine in the X5d but I don't hear any issues with CBU.

Not really true. My nephew in France, a technically savvy ex merchant-marine captain, told me CBU occurs in Peugeot diesels that are not driven hard and mostly used for short trips.

Its anyone's guess what needs to be changed, since CBU has existed in direct injection diesels from at least the 1990's. Since many cars don't seem bothered by it, the difference might be the fuel and specific design parameters under certain circumstances, as frequently discussed. We don't have much proof that doing anything specific prevents CBU since few owners have made the modifications etc. (except perhaps removing all of the pollution control equipment) but at least they are trying. Direct injection diesels have been in heavy duty service in buses etc. for years but CBU seems to have come around during the times of stricter emission requirements on diesels.

The odd thing about having only a percentage of engines that seem to have problems from CBU, is that it likely that it occurs in every modern DI diesel and is considered a "maintenance" item to clean it.

Perhaps this is why there hasn't been a class action suit, dunno.

PL

[Quasimodem]

So in regards to the DDE. Is the bad DDE causing a problem or merely causing a false SES light where there is no problem?

This important because the former "actual problem" would have to be addressed while the latter "false positive" could be ignored (for those of us outside of warranty).

Obviously, the OP was having performance problems caused by CBU. Now that that was fixed by cleaning, all of a sudden, he has DDE problems? Is this a coincidence? Did the DDE contribute to the CBU problem because it was bad? Did the people who fixed the CBU do something which corrupted the DDE?

[Nushibo]

Originally Posted by Quasimodem

So in regards to the DDE. Is the bad DDE causing a problem or merely causing a false SES light where there is no problem?

This important because the former "actual problem" would have to be addressed while the latter "false positive" could be ignored (for those of us outside of warranty).

Obviously, the OP was having performance problems caused by CBU. Now that that was fixed by cleaning, all of a sudden, he has DDE problems? Is this a coincidence? Did the DDE contribute to the CBU problem because it was bad? Did the people who fixed the CBU do something which corrupted the DDE?

Its a factor of many things tbh. But for my case its similar to OP. I drove my car normally for 40k EGR recall, maintances and such here and there. Come around 54k Injectors 3,4 and 5? Anyways two or three of them are throwing codes. Replaced all six under warranty. Then 1 month later SES again for injector number 4. CBU cleaning applied and car runs like a beast but then 1 week later SES for cylinder number 4, cleared the code and boom same day injector 4 code and now the car is sitting in BMW now. I dont know if its the DDE but thats a rule of thumb to replace its the last solution on the list.

Its trouble shooting essentially. We dont know for sure if the DDE is the cause but it couldnt hurt to replace it since the problem is a software and control issue. Its possible they could of corrupted my installing during the injector install and reflash. Each new injector needs to be re coded to the ECU so boom there might be one cause but that wont be proven until the DDE is replaced. So ill will basically give you an update after my car gets back.

For those of you out of warranty i wouldnt worry about the DDE my car ran fine even throwing a code. Id be more concerned about cleaning the intake if its gunked. The DDE shouldnt even contribute to CBU its the EGR and CCV combining to create a gunk in the intake system.