2008 BMW 520D Manual - engine replaced cranks but wont fire

[Jedayegeordie]

Hi everyone,

I'll make the story as short as possible. I have a 2008 520D m sport manual transmission.

My car was juddering and vibrating and when it was looked at by a local garage they suspected the problem was the gearbox. This was replaced with a reconditioned one.

The problem still persisted and the gearbox was again replaced however whilst on a test drive - the engine cut out. No noise, no violent stopping.

Upon inspection the crank shaft had snapped.

I sourced a reconditioned engine which was known to be working and had videos supplied of the engine running.

This has been installed however the car will not start. The mechanic began swapping over parts which they believed to be coded to my cars ECU and even the wiring harness in case there was any breaks in the wiring from removal.Still no joy.

The OBD reader showed no faults however I've connected a laptop to it using INPA which shows a lot of fault codes. The list is below but my question is - what could be causing so many errors to present themselves? The parts that have been transferred over were from a known working engine (My original one) so I find it difficult to believe they are all faulty.

any help is greatly appreciated. I've been without my car since october last year. I'm getting desperate now.

What I know has been done so far :

Wiring loom swapped from my original engine to new engine.
EGR Valve swapped
Fuel rail/injectors/glow plugs swapped

Fault codes found with INPA:

ZGM
93BD - 21 : Crash safety module
SZL
951A - 22 : Dynamic stability control
DME/DDE
42E2 - 31 : Changeover Rail Pressure Control
482F - 21 : Message error (wheel torque request, 0xBF), DDE receiver, DSC transmitter
4E1E - 21 : Swirl-valve controller, position sensor, signal
4330 - 31 : Rail-pressure regulating valve
4711 - 31 : Control Unit Internal Error 8
4A6E - 31 : DDE: Glow plug, cylinder 1, activation
4A5E - 21 : DDE: Glow plug, cylinder 2, activation
4A4E - 31 : DDE: Glow plug, cylinder 3, activation
4A3E - 31 : DDE: Glow plug, cylinder 4, activation
3EC0 - 31 : Camshaft Sensor – No Signal
4C12 - 21 : Message : DSC Status
4458 - 31 : Message (steering wheel angle, 0xC4) faulty, receiver DDE, transmitter SZL
4992 - 31 : Message (KOMBI, 0x1B4) faulty, receiver DDE, transmitter KOMBI
4121 - 21 : DDE Main Relay is Switching too Late or too Early
494A - 21 : DDE: Glow system
3F01 - 21 : Boost Pressure Sensor -Short circuit to B- or Open
4300 - 21 : DDE: Delivery control valve, activation
4390 - 21 : Boost Air Temperature Sensor – Short Circuit to B+
3EE0 - 21 : Coolant Temperature Sensor -Short Circuit to B+ o
41E2 - 21 : Exhaust Gas Recirculation – Open Circuit
DSC
5DCF - A0 : DSC: Hydraulic unit: pressure sensor, plausibility / DSC: Control module, undervoltage
5F48 - A0 : DSC: Interface, instrument cluster
5EBA - A0 : DSC: Steering-angle sensor, plausibility
D35A - A4 : DSC: No message (instrument cluster 615) / Message (terminal status, 0x130) missing, receiver DSC, transmitter Car Access System
CAS
A10A -24 : EWS4 timing challenge/response error Error will not cause a warning light Error is not currently present Test conditions have been completed Signal or value below threshold
A0B4 - 20 : CAS: Engine start, starter operation
A0B3 - 28 : CAS: Starting motor, terminal 50
KOMBI
931B - 24 : KOMBI: Outside-temperature sensor
A559 - 20 : Dashboard: Voltage supply has been switched off (standby current cutoff relay) / Dashboard: Dashboard: voltage supply switched off
PDC
93E7 - B2 : ACSM: Airbag sensor, door, front right: sensor type incorrectSM: Airbag sensor, door, front right: sensor type incorrect / ACSM/MRS: Airbag sensor, door, passenger's side, front: sensor type incorrect
9E39 - B2 : PDC: Wire, ultrasonic sensor, front center left
9E3A - B2 : DC: Wire, ultrasonic sensor, front center right
9E38 - B2 : PDC: Wire, ultrasonic sensor, front right

[naturalaspiration]

Find a competent garage.

[RUSSELLM]

naturalaspiration said:

Find a competent garage.

I tend to agree.

Looks like the codes have been read with no battery on the car

[Jedayegeordie]

The car is going to another garage which is a local BMW specialist however - they can't take it in until march.

The battery was connected and ignition on when the codes were read. They were cleared with INPA and then engine turned over again. The same list re-appeared.

[TX1]

Are you in the North East ( your nickname) ?
Newcastle area ? If so might be worth giving these guys a ring SC Motorworks in Shiremoor.

Edited by TX1 on Thursday 27th January 21:22

[Jedayegeordie]

I've spoken to them however they were unable to take the vehicle in at the moment.

I've managed to locate another BMW specialist in Ponteland who said they would be able to take it in but unlikely to begin work on it until march due to on going work. That's still quicker than anyone else though.

I spoke to the garage briefly before they closed yesterday and they now mentioned the fuel pump wasn't making any noise on ignition. I feel like they're causing more issues than they're fixing so the car will be taken off them on monday when I'm free.

[RUSSELLM]

I’ve not worked on BMW’s, but with that list of open circuit sensors on the engine ECU, it would suggest it’s missing a power/ground.

Normally, I’d just pick a three wire sensor, and see what’s missing. But with that list, I’d be fairly confident the engine ecu is missing at least one feed.

The fuel pump will no doubt be getting it’s signal from the ECU. Or in your case, I suspect it won’t.

This might sound an obvious question… But they have reconnected the engine earth, I take it ?

Edited by RUSSELLM on Friday 28th January 14:10

[Jedayegeordie]

I haven't asked the simple questions - mainly because I had a level of confidence in that a trained mechanic would cover the basics but at this stage anything is possible.

I'll be calling them in a few hours to see if they've made any progress and then I'll be having the car delivered back to me next week. It's going to a local BMW specialist.

[Paul-s45no]

It will need running through an injector bleed process on diagnostics if it hasn't already. I pulled the engine out of my 08 520d over Christmas for chains etc and it would not start until I carried out an injector bleed using Delphi 150

Hope this helps