[t-photo]

Hi, Im new to the forum, I drive a 02 320D 150bhp sedan

I am not very knowledgeable on the mechanics of the engine and its components. So I apologise for vague descriptions and any incorrect terminology.

I have not seen my car since it broke down but I will explain what happened and what the mechanic has told me on the phone.

Last week, when I started my car, it begin misfiring and cut out. It wouldn't start again so I took it to my mechanic. He told me an injector had shut down and replaced it for me.

I had the car back a few days and I thought it was very loud since I got it back. Yesterday I noticed it was dropping way down in power when I accelerated and then it started misfiring again.

I brought it back to my mechanic, who had a quick look at it today. He said there's no compression in cylinder 4 and that some "flap" (I'm guessing around the cylinder head) has broken up and been sucked into the engine, probably damaging the piston and a couple of valves.

He says that he does not know the extent of the damage yet but a repair job is looking to be well over the 1000 euro mark.

I have two questions:

1. Is it a coincidence that the injectors were been worked on last week and this problem has now arisen? Is it possible this "flap" got damaged while the mechanic was working on changing the injectors?
Would the change in engine volume have been related to this or been an indicator of the problem?

2. Has this happened to anyone else? Is this a huge repair job? The mechanic says that I will probably need to replace a piston and couple of valves.

Many thanks in advance to anyone who reads or replies to this thread!!!

Tom

[bastardE38]

Your engine has electronic unit injectors (EUI) being fed fuel from a high pressure common rail. In order for just one of your injectors to misfire, it has to be an electronic problem and not fuel, because of the common rail. Which is common among EUI diesel engines. So that was probably a legitimate repair.

A number of common failure points have been highlighted in the engines produced prior to the introduction of the M47TU2D20, chief among which is a 'swirl flap' mechanism employed within the inlet manifold to help with emissions. These consist of a number of butterfly valves within each individual inlet tract. These flaps are secured to an actuating rod via two small screws. It has become clear that over time these screws can come loose via vibration etc. When this happens they can end up being drawn into the respective cylinder, causing significant damage to piston, cylinder head and valves. If unlucky further damage can be caused to the turbo if the screw then makes its way through the exhaust valve into the manifold and subsequently into the turbo. Now, whether your mechanic "nudged" this problem to happen instead of letting it take its natural course, thats up to you. I hope this helped.

[t-photo]

Thanks for the reply bastardE38

Went to see the mechanic today and its definitely a swirl flap that broke off. It was injector 3 that shut down last week and the swirl flap broke on cylinder 4, so I don't think there's any connection between the two.
The mechanic says he cannot determine how much damage is done or weather or not its worth fixing, until he strips the head.

I recommended installing the PMW Blanks if he is repairing it. He says that this can effect the performance and the car will produce more fumes. Any thoughts or experience of this??

I bought the car in February and already have spent 2500 euro on unexpected repairs. This my second 320d and the last on was as bad, so I'm really losing faith in BMW. :-(

I will post an update when the mechanic gets back to me!

Thanks again

[bastardE38]

No problem.

Doing a swirl flap delete would be a good idea. Those blanks should fit right in the holes. I dont think it will effect the performance, at least not in a negative way. With the flaps installed you suffer from "dead spots" in the intake manifold runner. Removing them could only improve airflow.

Dont lose faith in BMW, just in that engine. Get a petrol engine. I understand that you are in Ireland and i know that diesel is cheaper in europe, but with the money you save on unexpected repairs, you can put into a nice BMW that works and puts a smile on your face.