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Need help, 2007 E60 M47 N2 520D engine dies when loaded
#1
2007 520D common rail dies when loaded. Car starts easy and idles fine with 400 bar rail pressure. Engine revs fine if I floor the pedal. But engine dies when I drive the car and floor the accel pedal. Engine can restart after 5 seconds cranking. Scan tool shows that actual fuel pressure is about half of nominal pressure when engine is loaded and DTCs 4560, 4570, and 4610 goes active.

Fuel supply pressure is good at 4.5 bar; high pressure pump was checked at Bosch center and is good, rail pressure sensor and regulator have been replaced.

Please help me........need some good advise....... Thank you....
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#2
I would start with the injector return flow test as the rest seems ok.
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#3
(07-13-2018, 02:33 AM)oceandiver86 Wrote: I would start with the injector return flow test as the rest seems ok.

I forgot to say. Injectors have been tested by Bosch center. Back leakage was very good........low leakage.

thanks for reply...
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#4
Few hints:
Did you use "Rail pressure control valve adaptation" ?
Are you sure Ecu is stock? maybe a bad remap?
Under hard load observe fuel rail pressure, real/nominal, if pressure is not reached it will cut out
Hot/cold? Had few bad bmw injectors, when hot, return leakage was much more
By the fault codes you don't have not enough pressure : pump,injectors,valve
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#5
(07-13-2018, 12:53 PM)dunkler Wrote: Few hints:
Did you use "Rail pressure control valve adaptation" ?
Are you sure Ecu is stock? maybe a bad remap?
Under hard load observe fuel rail pressure, real/nominal, if pressure is not reached it will cut out
Hot/cold? Had few bad bmw injectors, when hot, return leakage was much more
By the fault codes you don't have not enough pressure : pump,injectors,valve

I have not done rail pressure control valve adaptation. It does not show on Bosch ESI/KTS. Thanks for this tip.
ECU is stock.
Rail pressure is half of nominal and engine dies. This is the problem I have to solve.
Injectors, CR pump, already tested good by Bosch. Low pressure system all good. After everything rail pressure drops when loaded.

Thank you dunkler. I hope you have more tips.
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#6
Check voltage when it does. I had one where idle was fine but as soon as you put any kind of electrical load on it, it died. Turned out to be an alternator.
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#7
(07-14-2018, 04:41 AM)ateyourv8 Wrote: Check voltage when it does. I had one where idle was fine but as soon as you put any kind of electrical load on it, it died. Turned out to be an alternator.

Would be possible if there were not enough voltage for injectors to open like in main injection but instead opening as little to allow fuel and pressure to go along return system? dde uses capacitors to create enough energy to open injectors if im correct. How often theese fail?
maybe injector current with inductive current clamp and a scope would answer this, I think in cp1 systen voltage for open injector is about 70V dunno for cp3.
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#8
(07-14-2018, 11:01 PM)kirukisu Wrote:
(07-14-2018, 04:41 AM)ateyourv8 Wrote: Check voltage when it does. I had one where idle was fine but as soon as you put any kind of electrical load on it, it died. Turned out to be an alternator.

Would be possible if there were not enough voltage for injectors to open like in main injection but instead opening as little to allow fuel and pressure to go along return system? dde uses capacitors to create enough energy to open injectors if im correct. How often theese fail?
maybe injector current with inductive current clamp and a scope would answer this, I think in cp1 systen voltage for open injector is about 70V dunno for cp3.

Engine starts and idles fine at 800 rpm. Rail pressure is about 400 bar. Bosch ESI says that pressure should be 280 - 340 bar, so this is a bit high.

When i drive it on the road and floor the pedal, power is good. But when nominal pressure gets to 1400 bar, actual pressure reaches only 700 bar and car engine dies. I am able to restart after two attempts but car is on limp home mode because DTC 4560, 4570, AND 4610 is active.

These injector have about 80 volts. They are good because Bosch has tested them.

By the way, i replaced rail pressure sensor........problem is still the same.

I am seeing some irregular patterns on 12 volt rail pressure regulator. See attached.

I am also seeing similar irregular pattern on 5 volt waveform of rail pressure sensor.

I don't know what is causing this. It may be affecting rail pressure values.
RPCV Low Idle 3.pdf
File Type: .pdf
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Size: 56.54 KB

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#9
There's your problem ladie Big Grin Did you measure same way dde power? I think with ground problem we would see more high spikes but not sure. Once i had bmw e90 with loose negative battery clamp which created overvoltage and couple modules weren't working ok. And since on different circuits you see similar disturbance I 'd rather say it's power problem, but we can't exclude ground or intermittent shortage in other componment. Very interesting case, would work on this one with pleasure. Please share how it goes.
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Thanks given by: Poptest , diagnostix


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