You might find this interesting - 330d Perplexities

SandmanEnters

New member
Hey guys

I'd like to hear your opinions on this one. (Might be a long post again):

I have been having a error code problem (0120 - pedal position potentiometer) for a while now. Thought I had gotten to the bottom of it a few times, but it seems to re-appear everytime with the same symptoms a few days later.. Here is the link to the post about this for details: https://www.bmwfanatics.co.za/showthread.php?tid=58270

Continuing from the end of that post, the problem returned a day later. At this point I had also installed my new Racechip Pro 2 (which is flippin awesome btw, but I'll get round to a review on that at a later stage).
I went over to netercol to run diagnostics, at his gracious invitation. He was happy with all my pressure readings, but the pedal reading did indeed deviate between the actual position (driver's wish) and where the Ecu thinks it is. The low pressure fuel pump was on 4.1 bar if I remember correctly, which seemed a little low, but not enough to be overly concerned about. Quite relieved, I proceeded to replace the pedal the next day with one that I got from Bemow Spares.

This immediately solved all issues. Car was running exceptionally well.

Not even two days later the symptoms were back though. :argh: The car had noticeable hesitation, this happened intermittently in multiple driving situations and at random rpm's. The only consistently strong (push-you-back-in-the-seat) pull has been when accelerating past 120km/h in 4th and 5th. I have left the racechip in, as I tested it by removing it and determined it had no the no effect on the symptoms. It simply made the car a lot more driveable.

The engine cut out/brick wall problem still happened at full throttle as well. I have now noticed that the car gets to full throttle (with kickdown switch depressed) without issues, but if any incremental amount of weight gets added onto the pedal when already fully depressed, the fuel supply gets cut off and the rpm's drop to idle speed. Lifting off the throttle a tiny bit then brings the fuel supply (and consequently the engine) back to life, but with a vengeance.

Then yesterday I was pulling away at a robot and the car went into limp mode. I had a mini freak out for a few moments because the last time this happened my gearbox had fused a few gears onto each other. When I calmed down I returned to intense research regarding all (or any) of my symptoms associated with limp mode. At this point I had driven home (about 1.5km) in limp mode and left the car in my garage as I had to get back to work.

I have since then started to genuinely appreciate the immense effort that went into building this engine and how complex it truly is. There are a variety of things that have all been documented on the interwebs that relate to these symptoms in some way or another. I have found these symptoms in posts from the petrol guys who have similar pedal resonse problems with the 528, as well as 330 problems with crankshaft sensors, wheel speed sensors, bad wiring harnesses, minute vacuum pipe splits, lift off pumps and pressure regulators, among others. I started to get that sinking feeling that I will never escape from this pit. (Keep in mind, it did occur to me that the secondhand pedal might also have gone bad, but this seemed highly unlikely, as the chances of one failing are very small. So both failing seemed a bit of a stretch.)

I then decided to clean the MAF again, as its involvement in limp mode seems popular. No signs of dirt/filth were apparent when I had a proper look at the sensor itself, but sprayed it down with MAF cleaner anyway. I also cleaned the plug connectors of the pressure regulator sensor, cam sensor, and the one on the MAF itself. Put everything back and started her up. Limp mode was now gone. I didn't put too much stock in this, as the battery had been disconnected as well, which could simply have reset the ecu out of limp mode.

On my hunch about the low pressure pump being a bit too low, I got a new one and installed it. I did this a few months back for the first time, but I got a proper one this time, as previous one was the cheaper version of the two. New one runs much quieter than the cheapy, and the car did drive and idle a bit better. (The overall driving experience at this stage was not at all terrible, most people I know would have been happy - I was not.) All the symptoms were still present. The hesitation seemed to be less obvious when driving in Sport mode and especially if I reset the pedal adaptation before driving off. To feel an improvement, I had to do the reset every second or third time I started the car though. (Procedure: key on pos. 2, engine off -> kickdown switch depressed for 10sec -> foot off pedal -> key back to pos. 0 -> start engine)

I went for a drive earlier tonight to open her up a bit, and once again i chose a stupid time off day for this. Traffic on the R28. In the opposite direction the highway was much clearer, so I turned back. As I was nailing it a bit on the on-ramp onto the highway, the car shifted very hard from 3rd to 4th - almost felt like I had hit something. I massive cloud of black smoke shot out of the exhaust at the same moment as the hard shift. Immediately thereafter: THE CAR WAS ABSOLUTELY BRILLIANT???

The pedal was softer and immensely more responsive, the gearshifts were completely smooth, and the power was REDONCOULOUS. I had to stop myself from driving 180km/h every few seconds - it seems I have gotten used to much more depressed pedal at highway speeds than is normal.

I proceeded to test the engine cut off problem. Instead of cutting off, the engine just did a little shudder and promptly went on with it's business. Tried this a few times, but only got the shudder.

Another thing that has never happened before while driving in sport: If I lifted my foot from the pedal to decelerate without braking, the car shifted down from 5th to 4th if the rpm's got a bit low. I assume this is the way it is supposed to be, but usually the car stayed in 5th if I did this.

Basically the car was an absolute pleasure to drive, and a monster when applying foot.

I do not know what to make of this, maybe a carbon deposit stuck somewhere important that burned off? I thought you chaps might have something to say, or at the very least find it interesting reading.

I am very happy right now, but past behavior indicates that it wont last. Should I just leave everything alone for the moment and see what happens?

Thank you for your time, as always comments are welcomed and advice is appreciated.

Cheers
 

DieselFan

Honorary ///Member
Maybe a blocked cat that opened up?

Anyway hopefully it's sorted now.

Time for the racechip review!!!
 

SandmanEnters

New member
DieselFan said:
Maybe a blocked cat that opened up?

Anyway hopefully it's sorted now.

Time for the racechip review!!!

Hey bud, thanks for the reply. Car has been decatted completely - as far as I know there is only 3 of them? I have had 3 taken out, I assumed it was all of them.

I will definitely do the review, just want to make sure she's stable so I can find my optimum settings on the racechip and do the dyno :=):
 

DieselFan

Honorary ///Member
Ah well that rules that out. Yes there would of only been 3.

Maybe EGR was blocked and a lump of carbon flew inside the engine? Maybe just take off the boost pipe and have a peep inside. Very easy to do. Other than that maybe buildup in the valves? If so have carbon doctor do a clean. Well that's all I can think of if it was carbon buildup...
 

SandmanEnters

New member
DieselFan said:
Ah well that rules that out. Yes there would of only been 3.

Maybe EGR was blocked and a lump of carbon flew inside the engine? Maybe just take off the boost pipe and have a peep inside. Very easy to do. Other than that maybe buildup in the valves? If so have carbon doctor do a clean. Well that's all I can think of if it was carbon buildup...

Haha did that one as well, sorry bud I guess I should have stated these things earlier. I do have a list of mods/repairs in another post, I go get it and paste in here quickly:

Mods/Maintenance so far:

EGR cleaned and blanked.
Decat performed - 1 knocked out and other 2 replaced with straight pipes.
Cleaned MAF
Replaced low pressure pump(twice), fuel filter (twice) and both thermostats.
Service done 4 weeks ago - filters, belts, motor and gearbox oil changed, removed debris from behind intercooler, checked turbo for boost leaks.
Autobox has aircooled unit fitted behind the radiator
Replaced two stuffed engine mounts - solved so many issues.

I haven't looked at the valves yet - will do that as well. I understand the manifold can be deep cleaned also, will look into that.
 

DieselFan

Honorary ///Member
Maybe a blockage in the fuel line at some point? Only other thing I could think of? Or a slight blockage. The car adjusted to running slightly leaner. Opened up was "over fueling" and then adjusted back to normal, which would account for the cloud of smoke? Shit I dunno. I'm just brainstorming here.

Make sure you blank off the swirl flaps too.
 

SandmanEnters

New member
DieselFan said:
Maybe a blockage in the fuel line at some point? Only other thing I could think of? Or a slight blockage. The car adjusted to running slightly leaner. Opened up was "over fueling" and then adjusted back to normal, which would account for the cloud of smoke? Shit I dunno. I'm just brainstorming here.

That does sound very plausible in my (knowledge limited) opinion. She did take a very long time to prime when I fitted the low pressure pump yesterday. Battery actually died before she was done. Blocked fuel line could cause this as well I think? Seems we might be getting somewhere.

I would love to hear netercol's opinion on this one, I hope he sees the post. The gentleman does seem to know his stuff:praise:

I was wondering about the swirl flaps - I have heard mixed opinions. One guy who's opinion I trust reckoned that the problem was a lot more prevalent in the 320d's because the flaps opened and closed a lot more often than they do on the 330d? But I quess it's probably worth doing anyway, considering the cost if the engine does eat one.
 

netercol

New member
wow.. this car really seems intent on leading you down the garden path.. :rollsmile:

on the plus side i am really glad that it was not your gearbox giving up the ghost again..

all the symptoms you are having seems to contradict each other dont they. all i can think of right now is that the vnt vanes in the turbo might have been sticky..

ps. sorry, see i missed your call last night.


ok just had a brain wave.. on the auto the engine and gearbox ecu's are closely linked, in a nutshell the gearbox ecu tells the engine ecu where and when to limit torque to protect the gearbox.

since you have a recon gearbox in it means the box has been in and out, its possible that a connection to the gearbox might be intermittant or faulty, or even a sensor on the box itself might be faulty.. i regret not running diagnostics on the gearbox, might have been illuminating..

might be worth a try cleaning the connectors to the gearbox if the problem returns?
 

SandmanEnters

New member
netercol said:
wow.. this car really seems intent on leading you down the garden path.. :rollsmile:

on the plus side i am really glad that it was not your gearbox giving up the ghost again..

all the symptoms you are having seems to contradict each other dont they. all i can think of right now is that the vnt vanes in the turbo might have been sticky..

ps. sorry, see i missed your call last night.


ok just had a brain wave.. on the auto the engine and gearbox ecu's are closely linked, in a nutshell the gearbox ecu tells the engine ecu where and when to limit torque to protect the gearbox.

since you have a recon gearbox in it means the box has been in and out, its possible that a connection to the gearbox might be intermittant or faulty, or even a sensor on the box itself might be faulty.. i regret not running diagnostics on the gearbox, might have been illuminating..

might be worth a try cleaning the connectors to the gearbox if the problem returns?



No problem man, I assumed you were busy. I just wanted to share the good news! The ECU theory makes sense, as the gear shifts are definitely smoother now as well. I will keep that in mind, thank you good sir.

Another thing that i forgot to mention, there used to be a sucking/whisteling sound coming from (what sounded like) the middle of the car when the turbo was boosting. I naturally assumed a boost leak, which I then had checked. Couldn't find any leaks, so I figured it might just be due to the CAT's being removed causing the sound from the turbo to come through a bit louder. Bothered me a bit though, I was planning to have it checked again soon. I first noticed it right after the decat and had Noise Boys check for leaks on the exhaust.
This sound is also gone now. Car runs much quieter on idle as well. When boosting I can now hear only the normal turbo whistle one would expect, and the engine almost hums like a V8 Mustang when driving causually.

I don't know if this sound could lend credit towards your gearbox/ECU theory as well?

I will put some injector cleaner in as soon as I fill up again just in case.

Big thanks to all of you guys for the help and advice I really appreciate it.

Have a good weekend!

Cheers,
 

SandmanEnters

New member
Quick update: I have just upped the settings on the racechip by two increments/notches on the first switch. Went from D-2 to F-2 (base setting was B-1)

(There are two switches on the chip that can be adjusted to driver's preferance. First one controls the amount of power added to the engine, 1.5% per notch, the second switch controls the range of the rpm at which the power is applied. I will look for and post a link that explains this more effectively
)

The point I actually wanted to make is that I now believe that my car has transformed into a completely different car. One from the future. Where WarpDrive technology has been mastered and applied to the internal combustion engine :rollsmile:

I have never felt torque like this on any vehicle that I have driven. I don't actually have words.

I am going to play around a bit more, then I'll make a plan to get her on the dyno. The racechip comes with a blind plug, so it's easy to revert back to OEM settings. I will do comparisons between this and my personal optimized setting. I shall then share the results with you good people. This might only happen next month though.

You guys are welcome to contact me if you would like to take a test drive.
 

SandmanEnters

New member
carelvos said:
Where does the racechip plug into?

It comes with a cable harness that plugs into the common rail pressure sensor. So it intercepts and modifies the signal between the pressure regulator and the pressure sensor, if I understand correctly. The thing that makes it stand out seems to be the advanced processor it uses, as it reads and modifies the signal many times more per second than a normal piggyback system would. Someone please correct me if I'm wrong I'm speaking from memory now.
 

DieselFan

Honorary ///Member
SandmanEnters said:
carelvos said:
Where does the racechip plug into?

It comes with a cable harness that plugs into the common rail pressure sensor. So it intercepts and modifies the signal between the pressure regulator and the pressure sensor, if I understand correctly. The thing that makes it stand out seems to be the advanced processor it uses, as it reads and modifies the signal many times more per second than a normal piggyback system would. Someone please correct me if I'm wrong I'm speaking from memory now.
It must tap into boost somehow to. There see two connectors.

Depends which chip you're comparing too some don't even have processors. This guy was trying to tell me today that my racechip will break my engine because it's just a bunch of transistors connected together. Had to inform him there actually a processor etc.
 

SandmanEnters

New member
DieselFan said:
SandmanEnters said:
carelvos said:
Where does the racechip plug into?

It comes with a cable harness that plugs into the common rail pressure sensor. So it intercepts and modifies the signal between the pressure regulator and the pressure sensor, if I understand correctly. The thing that makes it stand out seems to be the advanced processor it uses, as it reads and modifies the signal many times more per second than a normal piggyback system would. Someone please correct me if I'm wrong I'm speaking from memory now.
It must tap into boost somehow to. There see two connectors.

Depends which chip you're comparing too some don't even have processors. This guy was trying to tell me today that my racechip will break my engine because it's just a bunch of transistors connected together. Had to inform him there actually a processor etc.

The reason for the two connectors is that it essentially creates a bridge by plugging one connector into the rail pressure sensor, and then the plug that usually goes into that sensor gets plugged into the second connector. So it's adding a component in the communication line between the fuel sensor and (fuel regulator?).

Regarding the boost, I believe that if the injectors are providing more fuel, a signal is also sent to the (pressure converter/boost regulator?) to increase the amount of boost. I'm not sure if i'm following the chain of events correctly, but as I understand it, if the ecu reads a higher fuel pressure, it will automatically increase the boost.

I am speaking from limited knowledge and mostly logical deduction of coarse, but netercol might be able to shed more light on this?

@DieselFan: Which racechip do you currently have on your car? How is it working out for you?
 

SandmanEnters

New member
Howzit gents

Just a quick update... I recently realized that somebody in the past had decided it was a good idea to remove the vacuum reservoir completely from the vacuum system on my car. So basically I've been driving around with the turbo's vacuum feed connecting straight onto the Pressure Converter via vacuum hose, and then from the PC to the actuator on the turbo. It should be: Main Vacuum Line -> Vacuum reservoir -> Pressure Converter -> Turbo Actuator. I can't quote any figures on the effect that this has, but I suspect it would significantly decrease the size of the vacuum that can be created. This could certainly explain why my car only boosts properly from 3000rpm.

I have reattached all relevant components. My dad recently went to Germany and brought me some goodies. New PC for turbo and braided vacuum hose to replace the old ones. They seemed very worn, but I couldn't really detect any leaks when blowing into one end with the other end blocked off. Replaced them anyway. Also got a new vacuum reservoir from the stealers, not a bad price - R400.

I fitted everything, but I couldn't really feel a significantly stronger boost. Very Strange. (hell of a PITA getting to the PC and reservoir under the exhaust manifold btw)
To be clear, the car does boost from 1500rpm, just not the "pushed back in your seat" kind of torque you would expect. That only comes on at around 3000rpm.

Also, it should be noted, between the time that I last posted on this thread up until I replaced the vacuum parts, there were a few small things i found that made a decent performance improvement, so there are a few uncontrolled variables that could mess with the findings:
- I found the main vacuum hose was not properly seated into the brake servo unit, so that eliminated a big leak.
- I also discovered that PC's have tiny membrane-like air filters inside the little black box on the the PC. These get very filthy, and when I cleaned it with carb cleaner there was a massive increase in boost strengh, but still only boosting properly from 3000rpm.

Regarding the potentiometer situation on the pedal: It has been clearly identified as a wiring issue (short to B+), and subsequently found to be a corroded connection on the ABS/ASC unit.The wiring from the pedal goes straight up through the firewall and into the ABS/ASC unit (next to the brake servo unit) in the engine compartment.

The good news is that this short on the pedal (logged as fault code 0120) can l lead to injection limitation, deactivation of boost control, cruise control deactivation, immediate limp mode on fully depressed pedal and even aircon compressor limitation. According to WDS diagrams. All of these symptoms have been present on my car.

So, I believe the culprit has been found. :joy:

I have not had a chance to test it though, as the corrosion was found by my mechanic while the car was (and still is) at his place for some other frightening things that I couldn't (and shouldn't) handle myself.

The frightening things I refer to: I found some grey coloured motor oil inside my expansion tank on Monday:cry:

I immediately thought that my head gasket had blown. Luckily, it seems like it was only the Engine Oil Cooler. No water in oil when I checked the dipstick, only oil in water in expansion tank. VERY relieved. It's still unnecessarily expensive, but probably only about 25% of what the head could have cost.
I've heard from a lot of guys that have been building cars for years that once a head has blown, a new one is likely to blow within 15000km again. So I would have had to sell my car. I don't want to sell my car. I ******* love my car.

Anyway, the new cooler arrived today, should have her back by Monday and will update from there.

P.S. On an unrelated subject, if anybody's pusher fan isn't coming on by itself, but the fan is still fine, check the ambient air temp sensor. Oh, and if the sensor is missing, and you buy a new one that doesnt seem to fit in the connector, you are probably trying to connect it to the horn's connector. The sensor one is usually turqoise and grey. The horn one if I remember correctly is black and (orange/green?).
They look very similar and the ambient air temp one fits onto the horn, but not the other way around. You see where I'm going with this. Don't ask me how I came upon this little nugget :bangdesk:

Hope this can help someone in the future.

Cheers guys and GO BOKKE
 

DieselFan

Honorary ///Member
Sorry I didn't get back to your last question. I have a racechip pro2. It's still not on. My car is not boosting at the moment. This should be fixed on monday :D .

The vacuum reservoir shouldnt sit under the manifold. It should sit on the shock tower. The pressure converter is a real pain in the ass to get to. I changed mine on Thursday. I found it easiest to take the two nuts that hold the bracket onto the turbo off and drop the bracket with the PC with it. Then just unplugged it. Took the two buts off the PC that hold it to the bracket and then replaced it.
 

SandmanEnters

New member
DieselFan said:
Sorry I didn't get back to your last question. I have a racechip pro2. It's still not on. My car is not boosting at the moment. This should be fixed on monday :D .

The vacuum reservoir shouldnt sit under the manifold. It should sit on the shock tower. The pressure converter is a real pain in the ass to get to. I changed mine on Thursday. I found it easiest to take the two nuts that hold the bracket onto the turbo off and drop the bracket with the PC with it. Then just unplugged it. Took the two buts off the PC that hold it to the bracket and then replaced it.

Hey bud, no worries. You're gonna enjoy that chip, I guarantee it! For some reason my reservoir is mounted on the same bracket that holds the pressure converter. The bracket is definitely designed to hold both, but I have seen photos where they are located on the shock tower. I tried to rectify this, but the bracket's fixing holes are about 10mm to close together to get it to fit onto the threads on the suspension housing.
I ended up taking off the charged air pipes going to the intercooler to get better access. Helped a lot, but added some time. Also took off the EGR to get better access to the vacuum manifold on the main vacuum line. Also a major pain in the ass - even with the EGR removed. But there was no way I was gonna attempt my first intake removal by myself on a week night. Ha, ended up not getting any sleep in anyway, finished just in time for a shower and then off to the cotton fields I went!
 

SandmanEnters

New member
Hi guys

I don't have a lot to update on, but luckily the oil in water situation has indeed proven to only be a failed oil cooler. Been driving around without any serious issues for about two weeks now.

Unfortunately I still have the damned short circuit/cut out problem with my accelerator pedal. Turned out it wasn't the previously mentioned dirty connection on the ASC/ABS unit. I will try to get it sorted out through an Auto Electrician in this week - hopefully. Can anybody recommend a good Auto Electrician who is comfortable with BMW's in Pretoria?

Thanks gents, cheers
 
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