N47 - intermittently significant loss of power
Vehicles affected
E series
E60 E61 E81 E82 E83
E87 E88 E90 E91 E92
E93 Engine
N47 Body
Complaint
The customer complains about an
intermittent, severe lack of power.
In some cases, the
engine warning lamp lights up and the following fault code memory entries are stored in the DDE (fault location) individually or as a combination.
-4CD0 Charge pressure actuator
-4521 Charge pressure control deviation
-4530 Charge pressure control deviation
-40E9 Exhaust gas recirculation regulator, position control
-4C9E Exhaust gas recirculation valve, plausibility.
-3FF0 Air mass meter (would cause the warning lamp to light up)
--------------------------------------------------------------------------------
Cause
Stiff connection between the charge pressure regulator and exhaust turbocharger
The fault code memory entry 4CD0 exactly describes the cause. The repair kit must be fitted, except on vehicles with part no. 11 65 7808478. F
or vehicles with a Progman version earlier than V29 (regardless of production date), the fault message 4CD0 is not present because of an unfavourable DDE application.
The two fault code memory entries:
- 4521 Charge pressure control deviation or
- 4530 Charge pressure control deviation
are however an unequivocal indication that the target charge pressure could not be controlled and that output deviations
are occurring as a result.
The remaining fault entries are mostly secondary faults.
--------------------------------------------------------------------------------
Measure
The measure is subdivided for vehicles with a production date before/after (approx.) 31.10.2007
CAUTION: a clear determination is only possible via the part number. This must be observed, because
the repair kits are not interchangable!
For vehicles with the part number 11 65 7 808 478, the measure must no longer be applied.
For vehicles since 01.11.2007 (CAUTION: part number 11 65 4 727 470):
Work through the test modules for the fault entries (except 4CD0) and if the result according to
diagnostics does not display a cause of the fault, then proceed as follows.
Remove the connecting lever between the exhaust turbocharger and the electronic actuator by first removing the two circlips.
Order parts set 11 65 7 823 724 through Parts Service. (see picture 6)
Grease the connecting lever from parts kit 11 65 7 823 724 using the assembly paste, ensuring full coverage in the locating bores and in the bearing for the ball socket. (see picture 7)
Grease the locating pins on the exhaust turbocharger for the connecting lever, ensuring full coverage, and fit the connecting lever.
The ball joint must be mounted on the pin of the electronic actuator and the connecting lever fitted in such a way that the large flange on the turbine housing pin points toward the turbine housing. (see picture 8)
Refit the circlips using the assembly aid and then turn them so that the
openings in the circlips are facing each other.
(for reimbursement refer to the description for vehicles up to 31.10.2007)
For vehicles up to 31.10.2007 (CAUTION: part number 11 65 7 797 781 and - 782):
The individual fault codes are to be considered separately.
The two fault code memory entries:
-4521 Charge pressure control deviation
-4530 Charge pressure control deviation
are an unequivocal indication that the exhaust turbocharger charge pressure could not be controlled and that output deviations
are occurring as a result.
This usually points to stiffness in the linkage between the charge pressure regulator and
exhaust turbocharger.
The remaining fault code memory entries:
-40E9 Exhaust gas recirculation regulator, position control
-4C9E Exhaust gas recirculation valve, plausibility.
-3FF0 Air mass meter
are usually consequential faults attributable to the stiffness in the linkage. The EGR valve and the EGR vacuum canister do not usually have to be replaced. Parts of the EGR system or the
air mass meter should not be replaced on the grounds of this complaint unless a component can
definitely be identified as being defective.
Caution: to carry out the repair, you must wait for the engine/turbocharger to have cooled down and
you must wear safety goggles.
Procedure:
if, after working through the test module, no clear cause can be diagnosed for the fault in the components, proceed as follows:
1.
Order repair kit (BMW part number 11 65 4 728 402 turbocharger repair kits).
2. Remove the connecting lever between the exhaust turbocharger and charge pressure regulator by first removing the two circlips.
3. Using the assembly paste in the injector, copiously grease the connecting levers from repair kit
11 65 4 728 402, ensuring full coverage in the locating bores and in the bearing for the ball socket (see picture 1).
4. Grease the locating pins on the exhaust turbocharger for the connecting lever, ensuring full
coverage (see picture 2), and place the connecting lever on top. Please note that the ball joint must have been fitted on the pin of the charge pressure
regulator. Replace/insert circlips with assembly aid no. 110350 (see pictures 3 and
4) and then turn them in such a way that the openings on the circlips are facing each other (see picture 5).
Note: it is essential that the procedure for implementing the measure be strictly observed.
It is not necessary to program the vehicle.
Note: the assembly aid is supplied automatically, and is not invoiced.
--------------------------------------------------------------------------------
pic 1
pic2
pic3
pic4
pic5
pic6
pic7
pic8