[ahale2772]

Hi all, new owner from Boston Ma, 82k mile m sport in space grey, light grey interior with NOx sensor faukts after 400 miles . Took the car to the dealer last night to have it looked over with a friend, and the upstream NOx sensor was reading 1650ppm (normal range 4-7ppm). Looking at the service history of this car, the head has been off at least twice for cbu, egr issues at least 4 times, injectors twice.

I love this car already, but I'm at the point of either fighting lemon law because I can't get it inspected , or deleting it on my own dime. I'd certainly rather go the second route, but with the current climate around BPC and the EPA I'm wondering how soon I can get that done. I've emailed Jarek, no reply yet.

Is there any sense for me to order an eBay downpipe and egr delete to start on the work? As with many here, it seems like I'm confident with the mechanical work for the delete, but no so much with what's needed for the ECM to stay happy.

Thanks,
-Alex

[rulonger]

Nice car. Welcome to the gang.

There are solutions and it looks like you are on the right path. You probably know that anything you install (EGR blocks, down pipe, race pipe) will throw CELs unless you have a tune. You can surely source the parts, but wait until you have the tune lined up before putting it under the knife.

Best of luck.

[ahale2772]

Originally Posted by rulonger

Nice car. Welcome to the gang.

There are solutions and it looks like you are on the right path. You probably know that anything you install (EGR blocks, down pipe, race pipe) will throw CELs unless you have a tune. You can surely source the parts, but wait until you have the tune lined up before putting it under the knife.

Best of luck.

Yup, I get that thanks. That is my biggest concern, the tune, and what that will do to having the car in an inspectable state.

I've allready been pointed in the direction of some good delete info threads. Very helpfull stuff so far!

I need to check and see if AC belt issues are common. I know harmonic balancer are prone to failure (need to buy a fix for that), but right now it looks like the AC belt is contaminated with an oil leak from somewhere, and hence it has begun to squeak.

[kbsilver]

I have almost the exact same car minus the M-sport option, same mileage too! At the beginning they were taking of the heads to deal with CBU. Since development of blasting wands and the cleaning process (last 2-3 years?) the head should not be removed unless truly an internal engine problem, which is very rare.

Also early on they were replacing lots of injectors due to injector codes. However in most cases they were replacing perfectly good injectors, it either needed a DDE progam update or full DDE replacement.

NOx sensors seem to fail more often than O2 sensors (I had one go under warranty). Unfortunately they are also MUCH more expensive than O2 sensors.

You did not mention the common DEF tank failure issue (usually temp sensor). If you do the all the deletes, no longer a concern.

You car may not be as in desperate shape as you think. I'm still 100% stock and at 84K miles emission system wise; one CBU cleaning (at 54K), one NOx sensor, and a new DEF tank at 82K miles (all covered under platinum extended warranty). That's it.

My warranty will soon be over and will roll the dice hoping no more than a CBU cleaning and maybe one more NOx sensor down the road.

[ahale2772]

It did have an SCR tank replaced, and the nozzle cleaned twice, the rap sheet on this thing is a mile long!

After looking the car over it seems like I have a better understanding of how the systems work, and interact.

I'm working to get a good time slot to get the ECU sent out, and start working on the mechanical side of the delete.

the plan:
JR tune
EGR delete pipe
swirl valve deletes
downpipe
replace the harmonic balancer
transmission fluid flush
Change the STOCK fuel filter

drive car.

[Greck]

what is wrong with fuel filter?

I also did a brake fluid flash and steering fluid flush

[ahale2772]

Its original at 82K miles

[Greck]

I replaced fuel filter on my car too, I thought that you would like to use some racing filter and was curious about that...

[ahale2772]

finally bought some parts...

2.5 "race" tune by JR
Buzzken Downpipe
Swirl flap deletes
EGR delete
New harmonic balancer

Still need...

Auto trans flush kit
Belts
any gaskets I need to replace when I do the swirl flap deletes.

Excited to delete the car. I hate driving it thinking i'm on borrowed time before the next sensor or Urea screw up.

I'll post as much info on the delete process as I can.

[Greck]

Originally Posted by ahale2772

any gaskets I need to replace when I do the swirl flap deletes.

Yep, basically there are about dozen small gaskets on the intake...

numbers 2,3,7

http://parts.bmwofbridgewater.com/sh...=0&modelYear=0

[ahale2772]

thanks^

[BB_cuda]

Not shown in the link greck provided, there are these orange shims that I would go ahead and buy (7). See pictures. They are used in between the larger rectangular ports. I pulled intake 2 times and some of these seem to fall off as your bringing it up. MAKE SURE that all 7 are accounted for if some aren't still attached to it. Point being if you can't find some, you need to make sure they didn't fall into one of the rectangular ports!! I suggested buy 7 as I have seen them get damaged too whether that be broken rubber or distorted where top and bottom aren't parallel anymore. You won't necessarily need to change them all if they look good. Keep in mind, these don't seal but that are in the load path of the upper side nuts that go between the rectangular ports. The left over ones will be handy for a future intake removal of glow plugs or whatever else might bring the need to remove intake. Hope this helps.

[ahale2772]

it does! thanks

Can somneone explain why the intake has two runners? one to the head and one to the valve cover? is this some kind of PCV system?

[335dlci]

Originally Posted by ahale2772

it does! thanks

Can somneone explain why the intake has two runners? one to the head and one to the valve cover? is this some kind of PCV system?

long tube and short tube intake manifold runner kind of set up.

[Greck]

https://en.wikipedia.org/wiki/Variab...ntake_manifold

[BB_cuda]

When swirl flaps are closed, the large rectangular runners don't flow. The smaller round ports are called tangential ports. The idea is the swirl flaps are closed at low rpm and when perhaps cold. the flow through round ports is said to flow into cylinders in a helical or swirling manner to not create as much emissions. Somehow the swirl flow there translated into the name swirl flaps for the other ports. I guess the flaps cause swirl flow so thus the name.

The newer N57 engine has a much simpler intake manifold (photo attached). The two ports are side by side and I presume one is a swirl and other isn't.

[ahale2772]

thanks for the explanation, do both ports share the same valve? I looked for a head cutaway, very cool tech

[Mark M]

Originally Posted by ahale2772

thanks for the explanation, do both ports share the same valve? I looked for a head cutaway, very cool tech

Our head is 24 valve. Each intake port serves its own intake valve.

[BB_cuda]

I thought the two ports on the head came into a common pocket/volume where both valves are exposed. Wouldn't you want that big rectangular runner to be able to "see" both intake valves?

[Mark M]

Originally Posted by BB_cuda

I thought the two ports on the head came into a common pocket/volume where both valves are exposed. Wouldn't you want that big rectangular runner to be able to "see" both intake valves?

Cuda, your comment has me rethinking it.

Below are a few pics of my head from when CBU was taken care of. But I can't tell.

[Mark M]

Originally Posted by Mark M

Cuda, your comment has me rethinking it.

Below are a few pics of my head from when CBU was taken care of. But I can't tell.

Pics of cyl head. (Pics won't load from my iPhone). :/

[ahale2772]

Sent my ECU to the guys at FixmyVW this morning. Excited to have it back by the end of the week.

I do not have the downpipe yet, I'm hoping I didnt jump the gun on getting the tune done before the DPF is out.

two questions about that... can I drive it at all with the DPF still in, and tuned? even if i go really easy? Also, I keep hearing about a gasket for the DPF flange, is it something I should be ordering?

I'm almost excited about finishing off the rest of these pilot super sports in the rear of the 335