E60 M57N TU 525d EGR issues

Discussion in '5 Series' started by ssd, Aug 1, 2020.

  1. ssd
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    ssd

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    I have a E60 525d with the M57N TU engine that has had an increased emissions warning and reduced power warning but when the engine gets to 60 degrees the reduced power warning goes out. Increased emission warning stays. Reduced power warning comes back on when re-started from cold but not when still warm/hot.

    Pulled the codes using INPA 4212, 4222, 4232, 4242, 4252, 4262, 4501 and 93BD, D68E

    I have checked the the glow plugs and replaced two faulty ones (from an earlier code 4222, 4252) Checked electrical power at GP module. I have tried two replacement GP controllers (both BMW but not new - known to be working) EGR cooler, throttle body, EGR valve cleaned.

    It does have strong smell of diesel fumes wafting outside (know what this smells like as the stainless steel one was cracked and it smelt the same but since then I have put in cast iron manifold on)

    Need help on this one.
     
  2. bishbosh
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    bishbosh WARLORD Site Supporter

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    Has the cat/dpf been gutted at all? That could account for the smell of fumes.

    If not, then I would check the engine bay for a leak somewhere, should be evident with soot showing.

    The stainless steel 'what' was cracked?
     
  3. ssd
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    ssd

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    Hi bishbosh, thanks for the reply,

    The cat not been gutted and is the original done 215k miles and there a straight through pipe fitted instead of dpf. Sorry I meant stainless steel exhaust manifold was cracked so I changed it for a cast iron one.

    Had a look around the turbo pipes looked ok - will check with a mirror the exhaust manifold The flexi after the cat is worn but no obvious signs of soot.

    Wonder why the reduced power goes off exactly after temp gets to 60c??
     
    Last edited: Aug 2, 2020
  4. Jonnyg123
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    Jonnyg123 Site Supporter

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    Where are you based ?
     
  5. ssd
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    ssd

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    Birmingham Solihull area


    Sent from my iPhone using Tapatalk
     
  6. Jonnyg123
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    Jonnyg123 Site Supporter

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    Same there’s a good Indy here in mcr
     
  7. ssd
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    ssd

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    Yeah that would have been useful mate, but never mind - haven’t had chance to see if the pipes are leaking as trying to find a way of testing for leaks from the turbo side via the pipe through the inter cooler to the egr side.

    Anyone know done this; apart from the visual aspect?
     

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