[9mmkungfu]

I posted this up on another site's diesel forum but figured I'd post it up here as well.

SUBJECT
M57Y Diesel Fuel Injector: Zero Mass Adaption Faults
MODEL
E90 (3 Series Sedan 335d)
With M57Y engine

SITUATION
The Service Engine Soon light is on.
Possible Fault Codes stored:

4AD5 – Zero-mass adaption injector Cylinder 1
4AD6 – Zero-mass adaption injector Cylinder 1
4AE5 - Zero-mass adaption injector Cylinder 2
4AE6 - Zero-mass adaption injector Cylinder 2
4AF5 - Zero-mass adaption injector Cylinder 3
4AF6 - Zero-mass adaption injector Cylinder 3
4B05 - Zero-mass adaption injector Cylinder 4
4B06 - Zero-mass adaption injector Cylinder 4
4B15 - Zero-mass adaption injector Cylinder 5
4B16 - Zero-mass adaption injector Cylinder 5
4B25 - Zero-mass adaption injector Cylinder 6
4B26 - Zero-mass adaption injector Cylinder 6
These faults are stored after an intake carbon cleaning (B11 03 14) or an extensive engine repair.

When following the recommended test plan, ISTA incorrectly instructs the technician to replace all six fuel injectors.

However, the same fuel injector zero-mass faults can return shortly after replacing the fuel injectors.

CAUSE
The DDE fuel injector zero-mass adaption is not being calibrated correctly.
PROCEDURE
Do not replace any fuel injectors.
The test plan will be corrected with ISTA 3.46.

Submit a PuMA Case titled “M57Y Zero-mass Adaptation.”

Set the vehicle up for an IRAP session.
The IRAP team will flash the DDE with a temporary dataset and reset the zero-mass (NMK) values.
When instructed by the IRAP team: Turn KL-15 off / engine is started briefly / engine is turned off / switch to KL-0 and let the vehicle go to sleep
The vehicle must then be programmed with the latest version of ISTA/P to install the latest working DDE software.

The DDE may need to be manually added to the measures plan.

Start the engine and let it warm up (max. ten minutes). Drive the car safely and manually select gear 3 or 4. Accelerate from 1500 to 2500 rpm – release the throttle and let the vehicle coast down to idle speed. Repeat this 10 times.
Reconnect to ISTA to send FASTA and clear the fault memory.
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle/SAV Limited Warranty.
Defect Code: 13 53 22 96 00

Labor Operation: Labor Allowance: Description:
00 00 556 Refer to KSD2 Performing “vehicle test” (with vehicle diagnosis system – checking faults)
And:
61 21 528 Refer to KSD2 Connect an approved battery charger/power supply(indicated in KSD2 as “Charging battery”)
And:
61 00 730 Refer to KSD2 Programming / encoding control unit(s)
And:
13 00 003 3 FRU Checking function of the Digital Diesel Electronics (Work time to perform Procedure step #5)
And:
61 00 980 Refer to KSD2 Continue vehicle test and performing Quick delete (Procedure step #6)
And:
13 99 000 3 FRU End vehicle test and test drive to check the status of the SES light (Work time to perform Procedure step #7)
Refer to KSD2 for the corresponding flat rate unit (FRU) allowance. Enter the Chassis Number, which consists of the last 7 digits of the Vehicle Identification Number (VIN). Click on the “Search” button, and then enter the applicable flat rate labor operation in the FR code field.

Even though work time labor operation code 13 00 003 ends in “003” and 13 99 000 ends in “000,” they are not considered a Main labor operation. Also, since the “work time” FRU allowances to be claimed are specified, a separate punch time is not required.

If a vehicle control module or component was working properly and/or had no related faults stored prior to vehicle programming and it fails to program correctly and/or requires initialization, this additional work must be claimed with separate labor operations under the defect code listed above, refer to KSD2.

Repairs to address control modules and/or components with pre-existing conditions are not eligible to be claimed under the defect code listed in this bulletin.

[flmoto]

That's a lot of procedures to correctly calibrate the DDE! It's amazing these cars run at all, with all that BS!

[floydarogers]

As the injectors are quite expensive ($500 each IIRC), this is a VERY GOOD THING. Probably BMW did it because they were replacing too many under warranty, but it helps us poor out-of-warranty guys, too.

[135i_vs_]

About time they release an SIB. They should have released an SIB for it 1.5 years ago.

Whoever had to pay for expensive unnecessary injector replacements should definitely look into compensation for a few $$$ - $,$$$.

[9mmkungfu]

Originally Posted by 135i_vs_

About time they release an SIB. They should have released an SIB for it 1.5 years ago.

Whoever had to pay for expensive unnecessary injector replacements should definitely look into compensation for a few $$$ - $,$$$.

Exactly.

I just paid for an injector replacement

[taibanl]

Originally Posted by 9mmkungfu

Exactly.

I just paid for an injector replacement

Get your money back

[bdwyer]

I had both of these SIB's performed over the past week. 65k on the clock. The coding/programming the DDE took the longest. The inside of the cabin still smells like an oil burner, hopefully that subsides soon.

They replaced two injectors also over the past 9 months.

[montr]

I also had this procedure done about one month ago. Previously I had 16 injectors replacement. This time, they did this procedure and cleared the fault code. I got the car 3 days later and cost me $50 (I have the BMW extended warranty).

[GottaBeKD]

This is what I had done last week. With a carbon cleaning for good measure.

[rogerdiaz]

You need a new DDE +/- new short engine. That did it for me to resolve those zero adaptation fault codes.

[Smonkey09]

I recently completed intake carbon cleaning procedure due to SES light related to MAF sensor, smoothness control, and zero adjust injector codes. This week (a few days after carbon cleaning) I received another SES light with codes related to smoothness control cylinders 2 & 4 and zero adjust injector 4.

I didn't find too much carbon in my intake - there was some build up, of course, but nothing like with other's in the forum found.

I have two questions for others.

1) Has anyone attempted to run straight Liquimoly Diesel Purge through engine (vs pouring it in tank) as others do with TDIs (easier given fuel filter is in engine compartment)? Before I consider replacing injectors I'd like to give engine purge a chance. However, I cannot find posts related to others who tried using straight diesel purge, so I don't know how challenging it may be.

2) Do you suggest that I have the DDE reflashed as per SI B13-04-14 before I try to use straight diesel purge, or after?

[9mmkungfu]

Originally Posted by Smonkey09

I recently completed intake carbon cleaning procedure due to SES light related to MAF sensor, smoothness control, and zero adjust injector codes. This week (a few days after carbon cleaning) I received another SES light with codes related to smoothness control cylinders 2 & 4 and zero adjust injector 4.

I didn't find too much carbon in my intake - there was some build up, of course, but nothing like with other's in the forum found.

I have two questions for others.

1) Has anyone attempted to run straight Liquimoly Diesel Purge through engine (vs pouring it in tank) as others do with TDIs (easier given fuel filter is in engine compartment)? Before I consider replacing injectors I'd like to give engine purge a chance. However, I cannot find posts related to others who tried using straight diesel purge, so I don't know how challenging it may be.

2) Do you suggest that I have the DDE reflashed as per SI B13-04-14 before I try to use straight diesel purge, or after?

I haven't tried the LiquiMoly product but they generally make good stuff. I wouldn't hesitate to try it, but only after the service bulletin is performed.

I would definitely have that DDE updated. Most of the 335d fixes are through DDE updates.

[gtp900]

What is approx cost of this update for out if warranty people like myself? Or is this service being offered for free from BMW? I plan to check/clean cbu as soon as it warms up a bit. I will report my findings, as I have been running a meth kit, and egr block for over 10xxx mi, so mine might not be bad enough now to cause this issue, if the meth has cleaned it up?

[Smonkey09]

I'll find out next week and post. I don't think we should pay anything for faulty engine control under the federal emissions required warranty.

[Mik325tds]

Originally Posted by gtp900

I plan to check/clean cbu as soon as it warms up a bit. I will report my findings, as I have been running a meth kit, and egr block for over 10xxx mi, so mine might not be bad enough now to cause this issue, if the meth has cleaned it up?

Yes, please do post some pictures of the intake runners and intake plenum when you check for CBU. That would be very intersting to see.

[Smonkey09]

RE my LiquiMoly diesel purge question earlier--

Last night I took the engine cover off to see if I could find what fuel lines I'd need to disconnect in order to run straight diesel purge through the fuel pump and injectors, and I simply could not find the feed and return fuel lines.

I believe the feed and return fuel lines run along the drivers side of the vehicle back to the tank. I suppose that may be the easiest place to run the lines into a small container of pure diesel purge, as per this video:

However, I'm concerned that it won't be effective given how far it will be from the engine (it will be a long way for the high-pressure pump to pull the diesel purge). Thoughts from others?

[Millakins]

Originally Posted by Smonkey09

I'll find out next week and post. I don't think we should pay anything for faulty engine control under the federal emissions required warranty.

How much did you end up having to pay? I have warranty through Carmax.. which we know can be a joke. So debating how to go about this.

[Kengineer]

Originally Posted by Milla

How much did you end up having to pay? I have warranty through Carmax.. which we know can be a joke. So debating how to go about this.

Anyone have a price for this?

[OmahaDZL]

Originally Posted by Smonkey09

RE my LiquiMoly diesel purge question earlier--

Last night I took the engine cover off to see if I could find what fuel lines I'd need to disconnect in order to run straight diesel purge through the fuel pump and injectors, and I simply could not find the feed and return fuel lines.

Find the thread on replacing the HPFP...there is a video on there how to replace it...will show you what you need to see I think

[Xerix]

I too need to have this software update (Correction: I need to see if I need the update in the first place). I just finished walnut blasting my ports and cleaning my intake last night and even though the engine is like new, when it gets near or at idle, it stumbles a little now and again with code 4B06. I'm really hoping the software update and calibration fixes it.

That being said, anyone have this SIB performed and how much did it cost if anything out of warranty?

Thanks.

[Owen81]

Did you reset the injector adaptations?

[octalon7]

Did the increment wheel adaptation SIB replace this one?