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SI B11 03 14
Engine

November 2014
Technical Service

This Service Information bulletin supersedes SI B11 03 14 dated April 2014.
designates changes to this revision
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:
z

3FF1 air mass sensor

z

4595 rough controller Cylinder 6

z

459B rough controller Cylinder 5

z

4592 rough controller Cylinder 4

z

4596 rough controller Cylinder 3

z

4593 rough controller Cylinder 2

z

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.
The fuel injector zero-mass adaptation values in the DDE must be cleared after the carbon-cleaning procedure
is completed, and prior to test driving the vehicle.
Refer to the “Clearing the Zero-mass Adaptations” at the end of the carbon-cleaning procedure.
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.
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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.
z

Do not allow any dirt particles or foreign bodies to get into the system.

z

Use only fluff-free cloths.

z

Remove all traces of dirt contamination before dismantling lines or separate components.

z

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).

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Carbon blaster 81 29 2 208 034
For set-up and maintenance of the
carbon blaster, see attachment BMW
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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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
Professional Hook Set shown as an
example

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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).

Remove the swirl flap actuator (1).

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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.

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
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(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.

Installation
note:
Clean the sealing
surfaces.
Replace the
gasket (1).

Use an
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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).
Do not put the
valve cover into
a pressurized
parts washer.
Damage could
result to the
crankcase
breather/oil
separator.

CARBON BLASTING CYLINDER HEAD

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
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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

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
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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)
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