[PETERNETTE]

Hi,

I have a 2017 530D MSport Touring G31 B57 and have an ECU warning light. Running OBD diagnostics I see it is an 2F8500 error – Swirl-Flap Controller, Position Sensor, Signal Too Low. The issue is intermittent, but now more often than not after engine start.

I have some questions if anyone is able to advise please:

1) Might this relate to the EGR recall issue? My vehicle has been checked and had the software update but no hardware changed or evidence of leaks,. I clearly don’t want to touch it if it is recall related as the dealership should own the issue if it is.

2) Assuming it’s not recall related, is there an easy way to resolve.....dare I suggest a bit of WD40 around the back of the actuator motor (I can see the coupling between the flap rod and the motor so it’s quite accessible. Worth a try??

3) If I decide to take a closer look, then is there a YouTube (I haven’t found one) showing removal of the plastic inlet manifold assembly so I can inspect the flaps and see if they are caked with deposits? (I have owned the car from new and it’s done 70,000 with full BMW service history........so never touched it myself).

Any other advice welcomed! (I don't fancy the "mod" that involves removing the flaps as I would rather keep the factory spec).

Thanks in anticipation,

Peter

[pault1980]

Not sure if you got this sorted but yes it could be related. I recently had my EGR cooler replaced on my 530D under recall down here in Australia and was told that the recall could include replacement of the intake manifold IF there was signs of EGR cooler leakage which apparently sludges up the intake and swirl flaps. Turned out my cooler wasnt leaking and my intake was fine so I only got the replacement EGR cooler.
BMW initially ran a recall for a software update that would somehow supposedly provide an early warning if there was problems with the EGR cooler but as far as I'm aware, have now stepped it to replacing the EGR cooler on all cars.

[PETERNETTE]

Hi Paul, Many thanks for the reply. No....not sorted this yet. To be honest I reckon it's a job I could do myself , (cleaning inlet manifold and swirl flaps), BUT clearly don't want to go there if it is EGR recall related as then I would clearly expect BMW to cover it. (What I want to avoid is the dealer saying, it's not related and hitting me with a big bill)!
Cheers,
Peter

[pault1980]

I'm surprised you havent been called in for an EGR cooler replacement yet as the software update was just a stopgap while they got their EGR cooler supplies up to speed.
BMW should have a website there where you can enter your vin and check if there is an outstanding recall on it? That's how I discovered mine had been listed for the cooler to be replaced. It may be listed as a "technical update" or along those lines- BMW here in Australia at least try to avoid using the word "recall".
If its up for recall, I'd book it in and add in a comment that your concerned about whether the intake manifold may have been affected by the EGR cooler if it has leaked and ask if this would be covered. It'll at least give them a heads up that you are aware of the potential and avoid them trying to cash in on it.
Lastly, has your coolant level ever needed any top up with no obvious sign of leakage? Thats usually a sure sign of EGR cooler leaking internally.

[PETERNETTE]

Thanks so much Paul. So the dealer had it in for the s/w recall associated with EGR monitoring, and in June they had it in again, BUT they didn't have the parts so actually my EGR cooler itself is still awaiting replacement. Called dealer today and booked in for the EGR cooler replacement at end of September. TBH I am doubting my EGR has leaked, so suspect that I won't get anywhere with the inlet manifold....last thing I want is them replacing the manifold at £1000 plus (cashing in as you say), when I reckon it just needs a good clean, (and I am minded to do that myself). I believe that the EGR cooler is replaced without removing the inlet manifold, so suspect they have no cause to go near it (unless there's evidence the EGR cooler has leaked).
I have had no issues with coolant loss, which again suggests the EGR cooler is still intact.
Thanks again Paul....I'll post an update here as things progress.

[Luke G31]

I had exactly the same error message and I suspected worn out swirl flaps. I disassembled them and yes, they were very worn. So I replaced them for new, but the error kept coming back, even after flaps reinitialization.
So I went to replace the actuator, but still, error kept coming back.

I took the car to BMW specialist and he discovered a defective ECU. After changing defective memory in the ECU for a new one, everything started to work as expected.

I was told the memory chips in the ECU are very low quality - Chinese - so I got it replaced for German made memory, which should be much better

EDIT: as he was doing the reinitialization, he could clearly see the actuator going from 0% - 100% without any issues, so the issue wasn't mechanical. He discovered the ECU defect when he was trying to re-flash the ECU and it always got stuck at certain percentage and never finished.

[PETERNETTE]

Thanks Luke - blimey - that sounds like a nightmare! Having looked at the actuator, I think it is "sticking" as the calibration at startup seems less than smooth so I am hoping that a good clean up will resolve for me. Any tips to remove the inlet manifold would be appreciated! :-)

[PETERNETTE]

So today I removed the inlet manifold - was really caked up so gave it a good clean and refitted. Problem is I still have the same error - frustrating as I can see the actuator is working so not sure if it is a sensor issue, a tolerance issue, or whether it's an ECU issue. (It's a pain in the ass)!

UPDATE 8th November 2024
They say patience is a virtue! So I drove a round trip of about 150 miles and then reconnected my Launch OBDII analyser and reset the fault codes again. This time it seemed to successfully reset and for the past few days I have had no errors! :-) So it seems my cleaning of the inlet manifold did the job! It was actually not that difficult to do (if messy)! I cleaned with degreaser and carb cleaner initially then I used a jet washer and dried it out before applying a little lubricant on the swirl flap shaft.
This is what it looked like when I removed it: https://ibb.co/KGNQJFj
And after cleaning: https://ibb.co/x7tDpGK

I did balls up when I disconnected the ECU plugs as one of them was not fully seated when I reconnected.....gave me a shock as when I reconnected the battery and tried to start the car it retuned a Drivetrain error and wouldn't start. Retracing my steps I noticed one of the plugs was a few mm higher than the others and this was indeed the culprit.

Anyway, assume I am all fixed unless I return with another update! Hope this helps others.

UPDATE 29th November
So, once again, I spoke too soon. The same error returned. The car has been good to me......75K miles and cost me nothing for any repairs so I have treated her to a new (OEM) inlet manifold. Not cheap, but now no error lights and peace of mind. A big price to pay considering the car was running fine and I suspect the error was a frankly overzealous self check indicating a bit of play in the swirl flap shaft, but I am so delighted with the car (performance, fuel economy, comfort etc).

[BMSMB]

Just got a similar error and check engine light related to the 'swirl flap actuator position sensor, range: below lower physical limit.' When the engine is off, the 'actual' flap position is below the 'target,' but while driving, both values move in sync. I haven’t seen any recall notices for this issue in Canada, so it seems like I’ll be paying out of pocket. Does anyone know what the repair typically costs and what parts need replacing?

[PETERNETTE]

New inlet manifold (OEM) with swirl flaps and actuator motor circa £1,450 fitted (That's GBP). Manifold itself circa £1,050, remainder fitting.

[titofla]

I have the same issue in a X1 (F48).

I already changed the air intake manifold (NTY Brand) and the servo-motor. (BOSCH brand)

MIL error code it´s still on, I tried to delete it with a LAUNCH diagnosis machine, but the error comes back.

Exactly As BMSMB said, When the engine is off, the 'actual' flap position is below the 'target,' but while driving, both values move in sync.

-How to solve this situation?
-Maybe ISTA is needed to coding/adapt values in the new servo?