E60 530d Electronic Actuator moving the wrong way!! Odd one...

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  1. E60 530d Electronic Actuator moving the wrong way!! Odd one... 
    #1
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    Cue_ball's Car Details
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    So my 530d is at a BMW specialists having is boost issues and fault codes sorted.

    Have so far done:

    NEW MAF
    NEW MAP
    NEW Stats (both)
    NEW Air Filter
    NEW Fuel Filter
    Swirl Flap Removal
    DPF remove and delete

    However, whilst the car now no longer has any fault codes popping up (bar glow plug controller which I can sort out another day) the garage says that the car is overboosting (3.4 bar would you believe). It wasn't previously due to faulty sensors above etc...

    They have looked into this without driving it (as 3.4 bar is very dangerous for the engine and it cant give enough fuel for that level anyway) and they seem to have noticed that the electronic turbo actuator is moving the wrong way.

    They have used DIS and performed the electronic actuator test and compared the movements of mine to an identical 2004 530d that also has an electronic actuator.
    Mine has good and full range of movement, no sticking and no other problems, it just moves the wrong way to the identical 530d they tested (which drives faultlessly, its just in for a service).

    So in theory what they think is happening is that the turbo is starting at its maximum possible power position (as opposed to the usual starting position) and then moving to the lower power position as you accelerate (as opposed to increasing power as you accelerate).

    Has anyone ever heard of this happening before? If so what the hell is potentially causing this?

    Car is running a standard and fully updated ECU map with no modifications (bar the above).

    Anyone got any ideas?

    Strange one this...
     
     

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    #2
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    Was it always like that?
    Maybe the wrong actuator was fitted, I believe there are some similar but different types.
     
     

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    #3
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    I dont really know as I had never had a great deal of boost until all the faults were cleared by fitting replacement sensors. Now I have too much boost and it has just been confirmed that the actuator is moving the wrong way to all other 530d's which I find really really strange...

    Unless as you say there has been an incorrectly fitted part at some point.

    Surely it wouldn't fit or plug in if it were the wrong part though?
     
     

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    I can't see how that can happen unless you have the wrong turbo and or actuator fitted.

    They make enough of an issue to ensure you have the EXACT model turbo to fit so I think there are loads which will fit a standard fitting but not be correct for the car.
    Did you check the model number of the one coming out against the new one?

    The garage who changed mine wouldn't even entertain ordering one in until they had physically seen mine.
    I did send them this picture but they still wanted to be certain


    This video shows the actuator, jump to 7.20 in this video

    At 7.36 you will see exactly how the elctronic one works, at least exactly the same as my 2004 E60 530D

    There is a test in DIS which switches the actuator exactly as you see it move in the video.

     
     

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    #5
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    Update...

    My indy has taken the actuator off the car for inspection having testing all the voltage values being sent from the ECU and finding them to be exactly the same as those on an identical car...

    He has looked over the turbo and found the vanes have a full and non sticky range of movement, there is the smallest amount of play in the shaft, if any at all (could be measured in microns as opposed to mm) and the turbo spins freely and bearings/seals look good.

    The actuator on the other hand is a different story - Its black plastic cover has a moulded date stamp from 2007 (the car is late 2004), the cast alloy rear of the actuator has a date stamp from 2004 but the stamped part number (after some googling) relates to a Ford Mondeo and the metal clips that hold the two together have scratches as if previously taken apart (which of course is fairly obvious given the above anyway).

    So at some point in the past, someone has done a lovely job of trying to fit a part designed & coded for a different car in a complete mish mash of rubbish...

    My question therefore is - as my turbo itself is in good condition with good vane movement, good seals and so forth, can I replace just the actuator (with the right part for my car/turbo) or do I need to buy a whole new set?

    Seems odd to waste a perfectly good turbo when its only the electronic actuator that controls the position of the vanes on said good turbo...

    Any help would be appreciated (mechanic is presently ringing around various turbo rebuilders & manufacturers to get their advice but would be good to hear from you guys too)...
     
     

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    #6
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    The turbo manufacturers say you need the complete lot, but there's loads of people (like Chris above) that have changed just the actuator without any issues.
     
     

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    That's certainly ringing true from the couple of phone calls I have made so far...

    So I could easily grab an actuator from Ebay or breakers and fit to my existing turbo and after my mech has checked the boost levels its running at, this can be fiddled with slightly to ensure its within parameters close enough not to cause any problems - I may face a small loss of power due to it not be coded exactly to my turbo but its a far better solution to having to pay out for a turbo and actuator at this point.

    My question now is what part numbers should I be looking for on the actuator? I note that the Garret turbo on my car is used in a few models but as they aren't sold separately I cant seem to find any reference to the part number (or numbers stamped into the actuator) that I should be looking for (dont want to end up with an actuator for a later Ford Mondeo again).

    Any help would be appreciated...
     
     

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    You're correct, they aren't sold separately, so it might be a little awkward.
    I would probably try and grab the part number for another similar 530d, if the garage still has access to the 2004 similar model they were comparing it with.
     
     

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    Wow - what a mission...

    So whilst most Hella Actuators look the same and have the same plugs there are many different variations that are only identifiable by their outer markings...

    The 530d from 2004 has a GT2260v Garret turbo which is matched to an actuator that will have G125 stamped into the alloy on the outer casing. G125 relates to the gearing and therefore movement of the arm.

    Thanks to Turbo Developments - Turbo Remanufacture - Reconditioned Turbochargers - Turbo Repairs for helping me out with that one, am going to see them tomorrow to grab the correct actuator for my car whilst giving them the one I have.
     
     

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    #10
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    Update - car is now possibly the best running, fastest 530d on the road - I have no smoke at all (despite not having a DPF).

    The car has had its ECU updated, the new actuator coded to the turbo, the EGR deleted and loads more.

    All thanks to Vehicle Diagnostics, DPF Removal, Engine Remap | Southampton Duda-Garage, Mario is a fantastic mech, and won't let your car leave his garage until it's running perfectly (even if it's missing a screw or he finds a bolt that is longer than spec it will be sorted!

    Really impressed and really happy - how many other 270bhp Diesel engines accelerate flat out with boots from 800revs and don't puff the slightest breeze of smoke from the exhaust!

    Thanks guys! Anyone in Hampshire should try his service!
     
     

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