Carbon Buildup

[7builder]

Hi Guys I really need some serious help and advice here as I am not sure how to resolve an ongoing problem I have with lack of power when towing my caravan. I have posted a few things about this in the past as I was convinced the autobox was on its way out but having spoken to a few specialists this wouldn't seem to be the case.
Today I took the car to a highly recommended BMW Indie near me for a diagnostic check and it came back with no errors (apart from a few bulb out type codes). So the good news is no faults were found but the bad news is there were no faults found. The technician checked turbo and vacuum pipes and all was ok but he said that he was able to see the inlet manifold had a carbon build up. He was able to see this from peering into the inlet but now they want the car back to remove the manifold to check how bad it is. The problem I have is that this seems to be an open cheque book way of diagnosing and fixing the problem which could end up costly.
The inference here is that there is a carbon build up/blockage that is preventing the engine breathing properly causing it to bog down under heavy load and chuck plumes of black smoke out the rear.
Before I hand it over to a specialist to figure it out and rape me and my minuscule bank balance are there any things I can do myself? I am not willing to take the inlet manifold off having seen the procedure explained on here but what about some sort of foam cleaner? Also is it feasible to remove the dreaded EGR valve or will it fail an MoT if I do?
Any advice would be greatly received as this really needs to be sorted out now as it has taken the shine off of my X5 ownership experience and I know there is a great motor there somewhere. 

[X5-D-Sport]

7Builder....

I've had similar issues with my facelift diesel as you..

and - if you had an inlet manifold WITHOUT some carbon build up in it... then you are alone in this case...

they all have some build up due to EGR gasses & Crank Case emissions.... and all this goo burns onto & fuses well to the inlet manifold walls... it is NORMAL to a greater or lesser degree.

Re open cheque-book.... damned right, you will simple spend money and achieve nothing other than paying more tax than you already do !

1****Firstly . . check to see if you have a VORTEX crank gasses/oil cleaner device....
It is located on top of the 3.0.D engine at the rear left up against the bulkhead.
The Air filter & engine cover need to be removed & the injector wiring plastic rail loosened to access it. Held on by 4 or 6 E-Torx screws and take 25 minutes to do - easily. Get the E-Torx sockets off e-bay for a fiver.

There are several postings on this VORTEX UNIT in the GENERAL heading of the E53 column about 7/8 weeks ago.
This is an ESSENTIAL piece of kit to make sure you have it fitted either way... costs about £35 from Cotswold BMW dealer find them here on this site for a small discount as a member.

The Vortex replacement over the paper filter/separator item will significantly reduce the amount of oil vapour & crank splatter entering the engine.

2****
Remove the EGR device & fit a straight thru unit (ebay about £23/£30), and possibly a blanker to totally do away with the pipe from the exhaust manifold.
The electrical disconnection will not throw a failure notice on the instrument cluster, you will get marginally more power & cleaner running, and marginally more MPG.
**Ensure you plug the EGR Vacuum tube with an 8mm bolt or some thing too...

As a direct result, your oil contaminants in the inlet manifold will cease... and you can remove the manifold and clean it if you really must, but personally speaking.... if it isn't leaking - leave it alone all together.

There will be zero effect on the emissions of any consequence.
You can clean up the cat' converter by running some injector/fuel system cleaner thru the engine that will also help scrub the cat converter & possibly make it a little more free flowing.

The key issue is to ensure no oily goo enters the engines combustion cycle....

For MORE power...
firstly, dump the standard card air filter & replace with a K&N unit for easier engine breathing.. e-bay again...

Secondly, there is a reputable engine re-mapper on this site.... You will find him in the main index..
Chiptune - Jason I think... this guy will hoof another 30% more power out of an engine if any one can.... and his reputation is excellent - only ever heard good things about this guy & his skills.
Whatever advice he gives you - take it as the Gospel Truth... What he does not know about BMW Engine tuning is not worth knowing..

Hope this helps.
Regards
Grant B

problem solved

[7builder]

Thanks for the advice D-Sport I will look into the VORTEX device when I get home tonight. Would it be better to remove the EGR completely and fit a blanking device or just disable the EGR in-situ and block off the vacuum pipe? I'm sure I have read somewhere that removal is an MoT failure now but could be mistaken.

[X5-D-Sport]

Remove the complete EGR device.
Leaving it there is an air restriction in its self, if you peep into it, the valve is a sodding great lump in itself... and often a huge clog of carbon gungs it up also.

When you remove it, lay an old flannel under it to catch the screws that you will likely lose otherwise.

MOTs dont care whether its there or not... only care what the emissions are.

These engines are pretty good and would have to totally knackered to fail on emissions.

As per my mail earlier, its worth putting a good fuel system cleaner thru the system too.

[7builder]

I removed and cleaned the EGR valve last summer and that didn't make a difference so it looks like I will remove it completely. I remember the EGR being really gummed up with carbon so I guess the inlet manifold will be the same. With that being the case I think the best course of action will be a) EGR removal, b) remove plastic inlet manifold and give it a good dose of Mr Muscle, c) vortex engine breather update.
I'm hoping this will open up the airways and get the old bus breathing again.

[X5-D-Sport]

can only help...

And you answered the question of your problem with the last posting....

EGR valve gunked up.... and it then sends the whole bloody lot into the manifold lol...

Get rid of the EGR valve.... and PLEASE check/replace the crank breather for a vortex unit if not already fitted...

Another thing...
Be VERY gentle with the manifold, as is not unheard of for them to become a little brittle with heat & stress... and they can potentially crack on removal or re-assembly.

Also ensure you got a set of O-Ring gaskets to replace, as the old ones will be knackered for sure.

[7builder]

Thanks D-Sport

[7builder]

Today I removed the EGR valve and the inlet manifold to try and get to the bottom of what is wrong with my X5. Neither were coked up with carbon so obviously not the cause of the lack of power. I also replaced the air filter and the oil breather for a upgraded vortex version.
I took it for a test drive after and it did seem more responsive but when I reversed onto the drive I deliberately positioned it so that one of the front wheels would have to drive up a kerb. So with 3 wheels on the drive and one wheel up against the kerb I pressed the throttle to the floor and nothing happened. The engine didn't rev it just bogged down and black smoke started to pump out the back. This is a 3.0L diesel 4x4 and it couldn't pull the skin off a rice pudding when it is put under load. If I was to drive up to a brick wall then accelerate it would bog down and do nothing but pump black smoke out the back. In any other 4x4 I've owned they would sit there and spin the wheels or push the wall down.
I've had BMW diagnostics done, had the turbo checked, the intercooler pipes and anything else I can think of and I am lost as to what to do next.  >:(

[X5-D-Sport]

Me thinks the next option... and again, it can do no harm...
Shovel a bottle of injector cleaner into it....

There is a variety that comes in an Ally can with a green lid & green label...
Not cheap, but good... you put it in 1/ 4 tank of diesel and run t thru.

If youre getting lots of black smoke... this is unburned diesel... hence an injector cleaner.

If I did the kerb experiment on My diesel X5 as you did to yours... mine would take off and leap ober the kerb... and ideling engine torque alone would make it climb the kerb a wheel at a time easily !

Some thing is definately wrong with your machine
.... and it will probably be an easy simple fix too.... just gotta find it !

[7builder]

Is this the stuff?
http://www.amazon.co.uk/Clean-Drive-NCL ... B00GW1U7WC

[X5Sport]

BMW Official diesel version is part no#  83 19 2 296 922.

About £10 a bottle (100ml) per tank of fuel....

[7builder]

I've just been reading about adding 2 stroke oil as an additive .......

[X5Sport]

At least everyone will know you are there........from the cloud of blue smoke ) )

Seriously though, that may work on older type systems but these cars use precision piezo injectors so putting oil through may not be a good idea and it certainly won't act as a solvent.

[X5-D-Sport]

The amazon bottle of goo is the stuff.
And it does work... and no adverse effects...
It will also strip soot out of the cat converter with can get clogged up too.
DO NOT have more than 1/4 tank of diesel when you put it in.....

Re 2stroke oil.....  Im not sure this is a good idea at all, cannot see how it can possibly help....
Most likely just add more soot to the issues you currenly have and reduce the clean burn further still.

Re your comments yesterday... lots of black smoke at the tiny exhersion of a kerb...
You gotta be VERY low on power...and the truck loads of smoke points toward a VERY poor burn...
Your motor should LEAP over kerbs as soon as the pedal is dabbed...

So i think on a budget / common sense based priority list... get the injector cleaner thru it 1st...
And in no better, then contact Jason at ChipTune for his opinions...
You will find MANY ecxellent referrals to this chap.
But 1st, as we do know that there is significant excess smoke, we need t get the crap out of the injectors & CAT before much else will have any effect...

The issue of power loss could potentiall be down to all sorts... but things need doing in order to dissprove one thing at a time onn a sensible budget to draw out the facts and eliminate one thing at a time.


If you are any where near Coventry or Birmingham we can meet and do some comparisons of vehicles & I can plug the diagnostic kit into the OBD port on your car and get the swnsor readings and see what she is telling us....
May be able to nail another potential issue....

But if you take it straight to the main dealer, they will firstly charge you a bloody fortune... and change parts willy nilly whether you need them or not... expect a bill of about £800 at least.... and most of it will be a waste of money....

[X5-D-Sport]

Talk to Jason at ChipTune... refer him to this thread conversation for his opinion.

Ive never met the guy, however have rea about his results - all good..

but he will give you the right directions to look and his opinions over power loss will be bwtter than most main dealers information