NHTSA ID Number: 10148290
Manufacturer Communication Number: BMWAPR1314
TSB/Document Date: 2018-11-13
Summary
"Diesel Intake Carbon Cleaning. The Service Engine Soon light is on and the engine may run roughly. Possible Fault Codes stored: * 3FF1 air mass sensor * 4595 rough controller Cylinder 6 * 459B rough controller Cylinder 5 * 4592 rough controller Cylinder 4 * 4596 rough controller Cylinder 3 * 4593 rough controller Cylinder 2 * 459C rough controller Cylinder 1 CAUSE Based on the above stored ""Fault Code"" profile, there is excessive carbon buildup in the intake system."
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TSB/Document ID: BMWAPR1314
Replacement Service Bulletin Number:
MFR Communication Date: 2014-04-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:DIESEL
MFR Component System:
MFR Component Subsystem:
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Page 1 of 16
SI B11 03 14
Engine
April 2014
Technical Service
SUBJECT
Diesel Intake Carbon Cleaning
MODEL
E90 (3 Series Sedan)
With M57Y engine (335d)
SITUATION
The Service Engine Soon light is on and the engine may run roughly.
Possible Fault Codes stored:
3FF1 air mass sensor
4595 rough controller Cylinder 6
459B rough controller Cylinder 5
4592 rough controller Cylinder 4
4596 rough controller Cylinder 3
4593 rough controller Cylinder 2
459C rough controller Cylinder 1
CAUSE
Based on the above stored “Fault Code” profile, there is excessive carbon buildup in the intake system.
PROCEDURE
The intake valves in both the swirl and tangential ports will be cleaned, including chemical cleaning of the intake
manifold.
See the PDF attachment B110314 Preliminary Work.pdf for removal of the intake manifold and valve cover.
Important!
Wear safety goggles and protective gloves.
When working on the oil, coolant or fuel circuit, you must protect the alternator from contamination. Cover the
alternator with suitable materials.
Failure to comply with this procedure may result in alternator malfunction.
It is essential to adhere to conditions of absolute cleanliness when carrying out repair work on the fuel system.
Do not allow any dirt particles or foreign bodies to get into the system.
Use only fluff-free cloths.
Remove all traces of dirt contamination before dismantling lines or separate components.
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Seal all fuel system openings with protective caps.
Recycling:
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.
This procedure supersedes Repair Instruction RA 1112800, “Cleaning cylinder head intake channels and intake
plenum (E90US, M57T2)” found in ISTA/D.
SPECIAL TOOLS REQUIRED
Alignment pin 11 6 080 (used for
securing cylinder 1 TDC).
Socket for crankshaft hub 01 6 480
(used for advancing the pistons/valves
to TDC).
Carbon blaster 81 29 2 208 034
For set-up and maintenance of the
carbon blaster, see attachment BMW
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Page 3 of 16
Group Carbon Blaster.pdf.
Use only 20/30 SAE or 0.45-0.80mm walnut shells which can be sourced locally or through one of the following
distributors:
MARCO® Corporate – 800 252 7848 Ext. 284 - marcousa.com/index.cfm
Trinity Tool Company - 800 587 4626 - trinco.com
McMASTER-CARR® - mcmaster.com
Vacuum adapter for tangential swirl
port:
2 356 967
Vacuum adapter for swirl port:
2 356 966
Blasting wand for tangential swirl port:
2 356 969
Blasting wands for swirl port:
2 356 970 with straight outlet
2 356 968 with lateral outlet
Reference SI B04 03 14 for specific
details on the carbon blaster
attachments for the M57Y engine.
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Page 4 of 16
Modifying wand 2 356 968 (before
first use):
Bend wand 968 (1) straight (2). This
will ensure the wand bottoms out
inside the swirl port.
Insert wand 968 into the swirl port
adapter 966 at one inch and mark off
the exposed end (1) with a paint
marker. Do not pull the wand past this
mark while cleaning!
Set of professional hooks (1)
(purchased separately)
6-piece set PN2KKV3 – Grainger
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Professional Hook Set shown as an
example
Grind down the tips of the picks (1) to
avoid scratching or gouging the
aluminum in the swirl ports.
CLEANING THE INTAKE MANIFOLD
Note:
Unless it is necessary for another reason, replacing the intake manifold is not required when performing this
procedure.
Note:
Picture shows M57T2 Europe
Release the three screws (1).
Remove the throttle valve from the
exhaust-gas recirculation valve.
Release the four screws for the
exhaust-gas recirculation valve (2).
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Remove the swirl flap actuator (1).
Carefully pry out the swirl flap
linkage, starting at the actuator end (1)
and then prying at the opposite end (2).
Remove the screws for the swirl flap
(1). Repeat for the remaining five swirl
flaps.
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Page 7 of 16
Slide out the swirl flap (1). Repeat for
the remaining five swirl flaps.
Note:
Remove all intake seals (1). Replace
these with new gaskets when
reinstalling.
Remove all bolts, seals and fasteners
(2) from the intake manifold before
cleaning. These parts will be
reinstalled.
Recommended procedure for Manifold Cleaning
Send the intake manifold and swirl flaps to an engine machine shop or equivalent automotive parts
repair/reconditioning (i.e., radiator repair shop) facility for ultrasonic cleaning or a suitable, mild solvent parts
cleaning “hot tank” process. Ensure that all ports, swirl and tangential flaps are toughly cleaned.
Use an appropriate parts cleaner (1)
and spray clean the throttle plate and
throttle bore (2).
Note:
Do not spray any cleaner onto the
electrical components of the valve.
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Installation note:
Clean the sealing surfaces.
Replace the gasket (1).
Use an appropriate parts cleaner (1)
and spray clean the inner bore of the
EGR valve (2).
Note:
Scrape away any excessive buildup
before spraying with parts cleaner. Do
not spray any cleaner onto the
electrical components of the valve.
Valve Cover Cleaning
Wipe out excessive carbon buildup in
the swirl ports of the valve cover (1).
CARBON BLASTING CYLINDER HEAD
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Page 9 of 16
3412072
Remove the protective cap in the
direction of the arrow.
Installation note:
Reinstall the protective cap with some
grease.
Crank the engine at the central bolt
using 01 6 480 in the direction of
rotation until the piston of the 1st
cylinder is in the TDC setting. Secure
the crankshaft in the TDC setting with
special tool 11 6 080.
Important!
Do not turn the engine back.
Special tool 11 6 080 must be removed
before starting the engine.
Make note of the rotation of the
camshafts (2) and the position of the
camshaft lobes (1) when cylinder 1 is
at TDC.
The position of the camshaft lobes for
the next cylinder to be cleaned must be
in the TDC position for that next
cylinder.
After each cleaning, the engine must
be cranked over to the TDC of the next
cylinder to be cleaned (firing order 1 5
3 6 2 4).
Note:
Do not crank the engine backward!
(A) Exhaust cam
(E) Intake cam
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Remove the top from the carbon
blaster (1) and fill with walnuts (2).
Do not overfill the cylinder!
Fill the cylinder until the material is
approximately 30mm (1) below the air
inlet port on the side of the cylinder.
Reinstall the top.
Close the main valve (1) on the
blasting tool (2).
Connect the compressed air (3).
Note:
Operating pressure 6 - 8 bar
Screw together the necessary blasting
wand 2 356 969 (968, 969 or 970) (1)
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Page 11 of 16
and actuator (2).
There are slotted markings on the front
section of the wands (969 and 970).
During the blasting process, only pull
the wands out of the vacuum adapter
until the mark becomes visible. Wand
968 will have a painted mark (after the
wand has been modified by the center).
Tangential ports:
Connect the vacuum cleaner (1) to
vacuum adapter 2 356 967 (2) and
direct towards the tangential swirl port
of the 1st cylinder.
Open the main valve on the blasting
tool and switch the vacuum cleaner on.
Insert the blasting wand (3) into the
adapter (2).
Open the actuator valve (4).
After the wand is inserted into the
adapter:
Unlock trigger (1). When the trigger is
moved to stage one (2), only
compressed air flows through the
blasting wand.
In stage two (3) (trigger is fully
pressed), granulate is added (blasting
process).
Alternate between stage one and two
when blasting. This will ensure the
ports are not overfilled with blasting
media.
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Page 12 of 16
Swirl Ports:
Insert adapter 2 356 966 (1) into the
swirl port as shown. Attach a shop
vacuum to the large port on the adapter
(2).
Use adapter 2 356 970 (straight outlet)
first and apply walnuts for about 5-10
seconds. Switch to the 2 356 968
(lateral outlet) adapter and apply
another cleaning for about 10-15
seconds. Remove the 966 adapter.
Move both wands up and down and
rotate during cleaning to expose the
entire swirl port to the walnuts.
The cut-away photo shows carbon
buildup in the swirl port. After this
initial cleaning, there will still be
carbon deposits in the tight channel
that bends into the bottom of the swirl
port (1).
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Use the pick set to loosen up the
remaining carbon buildup. The carbon
is soft, and the “feel” of the pick will
be different once the carbon is scraped
off the swirl port.
After scraping with picks, apply
another blast of walnuts to the swirl
port, first with adapter 2 356 970 for
10-15 seconds and then switch to
adapter 2 356 968 and blast for another
10-15 seconds.
Repeat the blasting/pick scraping
again, if needed, until the swirl port
and intake valve is clean.
Before cleaning, the swirl port and
valve (1) will look similar to the photo
(borescope used).
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There will still be some carbon buildup
(1) in the tighter areas of the swirl port
after the initial cleaning. This is when
the pick set is used to scrape/loosen
this carbon.
Use the walnut blaster/scraping/walnut
blaster combination until the swirl port
and valve are clean (1). It may take
more than one application to complete.
Note:
Do not leave any used walnut shells in
the swirl port (1). The excess shells
can be cleared out with compressed air
sprayed from the walnut blaster wand
(stage one).
Remove locking pin 11 6 080 from the flywheel and continue to the next cylinder for cleaning.
Reassemble the cleaned intake manifold and manifold components, and install the EGR valve and throttle valve
onto the intake.
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Page 15 of 16
Install the valve cover and intake manifold and check the vehicle after repairs for leaks (air or fuel). Connect to
ISTA/D and clear faults. Test drive vehicle and recheck for fault codes and repair/correct as necessary.
PARTS INFORMATION
Note:
Unless it is necessary for another reason, replacing the intake manifold is not required when performing this
procedure.
Part Number
Description
Quantity
13 62 7 796 699
O-ring, camshaft position sensor
1
11 12 7 796 378
Valve cover gasket
1
11 61 7 790 198
Gasket, intake
6
11 61 2 246 945
Gasket, intake
6
11 61 2 245 439
Gasket, EGR valve to intake
1
13 62 7 792 261
Grommet, pressure sensor
1
13 54 7 792 098
1
13 53 7 794 553
O-ring, leakage lines
6
13 53 7 787 236
O-ring, injector
6
13 53 2 247 156
Washer, injector
6
13 51 2 248 189
Washer, fuel return line
2
07 14 6 963 730
2
07 14 6 954 965
ASA Bolt with circlip M12 x 1.5 x 39
1
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle/SAV Limited Warranty or the BMW Certified Pre-Owned
Program.
Defect Code:
11 12 03 76 00
Labor Operation:
Labor Allowance:
Description:
00 00 006
Refer to KSD2
Performing “vehicle test” (with vehicle
diagnosis system – checking faults)
Refer to KSD2
Connect an approved battery
charger/power supply(indicated in KSD2
as “Charging battery”)
Refer to KSD
Removing and installing/sealing the
cylinder head cover (includes removing
and installing the intake manifold)
and
61 21 528
and
11 12 601
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Page 16 of 16
and
11 99 000
32 FRU
Work time for disassembling,
assembling the intake manifold and
cleaning the applicable removed parts.
Also included is carbon-cleaning the
valves of the 6 cylinders.
Labor operation code 00 00 006 is a Main labor operation. If you are using a Main labor code for another repair,
use the Plus code labor operation 00 00 556 instead.
If the microfilter casing is already removed to perform another repair, use the associated labor operation 11 12 614
instead.
Refer to KSD2 for the corresponding flat rate unit (FRU) allowance. Enter the Chassis Number, which consists of
the last 7 digits of the Vehicle Identification Number (VIN). Click on the “Search” button, and then enter the
applicable flat rate labor operation in the FR code field.
Even though work time labor operation code 11 99 000 ends in “000,” it is not considered a Main labor operation.
Also, since the “work time” FRU allowance to be claimed is specified, a separate punch time is not required.
Sublet – Cleaning the Intake Manifold
Sublet Code 3
Sublet amount; see below
Reimbursement for third-party
repair
Invoice this eligible sublet work on the repair order at the actual cost charged with no handling or markup. The
sublet amount must also include any discounts or allowances. Itemize the sublet amount in the claim comment
section.
ATTACHMENTS
View PDF attachment B110314_1174_Vacuum_System_Arrangement_(M57T2TOP_SCR).
View PDF attachment B110314_Preliminary_Work.
View PDF attachment B110314_BMW_Group_Carbon_Blaster.
[ Copyright ©2014 BMW of North America, Inc. ]
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