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BMW 5 Series Forum - Technical Talk on the BMW E39, E60, E61, F10 and F07 GT.

2004 E60 530D Glowplug Controller Replaced

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Thread: 2004 E60 530D Glowplug Controller Replaced

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2004 E60 530D Glowplug Controller Replaced

#1

chr15gb
BMW Master Car Details

29-09-2012, 15:04 At last got around to changing my Glowplug controller. Had the car 10 Months and had Glowplug errors since I have had it.

When I got the Swirl Flaps removed I had all 6 glowplugs replaced but it only reduced the errors from 5 out of 6 to 3 out of 6. I measured the Glowplugs and got 0.7 Ohms between the centre core and the block (Range is 0.5 to 2.5 Ohm) so they are all good.
Join Date: Location: Posts: Images: Thanks: Aug 2011 Brizzle 396 2 104

Bought a replacement Glowplug Controller (Beru 79 delivered) and fitted today, all in done within 4 hours but several coffee breaks and it wasn't a race! TIS Guide sounds easy... HA HA!!!! one of the most fiddly jobs I have done. Read some online guides Manifold Off, standard guides as per Swirl Flap Removal 10mm Socket, an 11mm Deep socket and short extension bar for the manifold

Thanked 118 Times in 88 Posts

I have no idea how people do this without removing the coolant hose. Three bolts to take out.

I also removed the Starter Motor cable as it runs right across the only space you can get your hand at the plugs. There is another bolt behind the Oil Filter housing which I removed to give a little more flex in the pipes. Now you can see the damn thing

You can't get sockets on square but they do bite enough to remove and tighten afterwards

I managed to remove the large plug from the controller with the nuts loosened enough to move the controller about a bit (but still on the studs), squeeze the clips as hard as you can, they do make a click when the tabs are free, then withdraw. The round power one was a swine, I forced a flat bladed screwdriver under the tab (in yellow), turned the screwdriver to open one side and gently but firmly withdrew this plug (the opposite clip is still housed but came out okay).

Once the plugs are off it is a case of manipulating it through the myriad of pipes

My car is now completely error free .

Last edited by chr15gb; 20-08-2013 at 18:10.

The Following 5 Users Say Thank You to chr15gb For This Useful Post:
530ben (10-09-2013),ahjclassic (13-03-2013),lmsvvavr (29-09-2012),mjojom (29-09-2012),ssd (07-10-2012)

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#2

mjojom
BMW Maestro Car Details Join Date: Location: Posts: Thanks: Jul 2011 UK 684 234

29-09-2012, 17:39 nice mate, but 4 hrs even with the coffees is a bit too much well done

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The Following User Says Thank You to mjojom For This Useful Post:
chr15gb (29-09-2012)

#3

chr15gb
BMW Master Car Details

29-09-2012, 17:50 ha ha, I did give the EGR a quick clean too but yes, could have done it quicker but I set a whole day aside. If I rush it I normally lose a socket down that black hole my car has.

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Aug 2011 Brizzle 396 2 104

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#4

mjojom
BMW Maestro Car Details Join Date: Location: Posts: Jul 2011 UK 684

30-09-2012, 01:29 true, rushing this things is no good, very nice guide. thanks

Thanks:

234

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#5

veeshy
Bimmer Fan Car Details Join Date: Location: Posts: Thanks: Mar 2013 LONDON 6 1

12-03-2013, 10:57 Chris i thought you only need to replace the controller if you get errors for every glowplug cyclinder. This wasn't the case for you was it?

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#6

digby
BMW Maestro Car Details Join Date: Location: Posts: Thanks: Feb 2010 France 585 4

12-03-2013, 12:40 you need to replace the controller if you get errors reported for known good glow plugs As its very unlikely that 3 or more will fail at the same time then multiple failed glow plug errors are quite likely to come from a failed controller and yes - its a swine to change

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#7

veeshy
Bimmer Fan Car Details Join Date: Location: Posts: Thanks: Mar 2013 LONDON 6 1

12-03-2013, 16:57 Thanks Digby Just had all 6 changed over the weekend and had I know that i might of had the controller replaced too, thought it was a good idea to get the swirl flaps done at the same time too. Issit worth while getting the glowplug controller and both thermostats replaced together? need a new throttle valve also but not sure where or when to get that involved as they don't appear to come cheaply and cant seem to find many used ones.

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#8

digby
BMW Maestro Car Details Join Date: Location: Posts: Thanks: Feb 2010 France 585 4

12-03-2013, 17:35 the glow controller and thermostats are 2 different jobs the controller "needs" inlet manifold removal (it can be done without but i wouldn't) Thermostats change needs the radiator fan out plus a few other bits at the front of the engine If you do it yourself you can do it as 2 separate jobs If you are having it done then i guess there is not much money to be gained by doing both jobs together - unless you can get a discount from the garage Are your stats shot or is it preventative maintenance ?

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#9

veeshy
Bimmer Fan Car Details Join Date: Location: Posts: Thanks: Mar 2013 LONDON 6 1

12-03-2013, 18:28

Originally Posted by digby

the glow controller and thermostats are 2 different jobs the controller "needs" inlet manifold removal (it can be done without but i wouldn't) Thermostats change needs the radiator fan out plus a few other bits at the front of the engine If you do it yourself you can do it as 2 separate jobs

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If you are having it done then i guess there is not much money to be gained by doing both jobs together - unless you can get a discount from the garage Are your stats shot or is it preventative maintenance ?

Thanks for the advice. Just want to get all the bits done and dusted and not have to worry about the car till the service is due. As for the thermostats, they dont seem to reach the 90C anytime soon, im looking at around 45min-1hour. So based on that i was told defo need them replaced. May carry out another run after work whilst connected to INPA to see what i get.

#10

chr15gb
BMW Master Car Details

12-03-2013, 20:08 I woudn't do both stats and controller in one go. Less than an hour for the stat is very optimistic unless you are experienced with it, there are lots of subtle lessons to learn which only become apparent afterwards. I wasn't prepared to bend the EGR Cooler up out of the way, I removed the whole cooler complete with exhaust manifold pipe. I should have removed the MAF/Turbo pipe to get access easier but didn't think and struggled on with blu tack on

Join Date: Location: Posts: Images: Thanks:

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the end of a socket to avoid dropping it lol. Most just bend the cooler pipe but if that splits, it's another World of hurt to sort out. You can live with Glowplug errors for now, Stats should be the priority. I wouldn't bother faffing with INPA, if you don't get to 90 degrees within 10 minutes, they need changing. I can watch mine climb gradually up to 90, then it drops right back down to low 80's (because the stat has opened), then climbs back up again and sits stable at 93 when driving steadily on a motorway. Some people state any Glowplug errors will prevent a Regen... the jury is out on that one, I have my own experience to draw on but for absolutely sure, you will not be regenning with low temps. This means for sure your DPF is sprinting towards getting blocked every time you drive it. Having done the Controller - I would love to see how anyone can do that from the bottom or without removing the manifold. Everything is far too congested around it.

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