E61 525d 2006 -- Sudden loss of power and harsh en (5er BMW - E60 / E61 Forum)

Good day all, 

Apologies for creating my first post on a fault and apologies for using English, but I am not yet good enough with German.

I live in Frankfurt, Germany, I got a second hand BMW 525d 11/2006, automatic gearbox, like two months ago, mainly to accommodate me with the holidays trips and my monthly business trips, I also own an Opel Astra 1,6 petrol. I was quite happy with the car, mainly my first with a car in the upper class and have already traveled about 5.000km. Mileage was 309.000km when I bought it. Had all services done not in BMW but a good indy and when I got it there was the service overdue warning and the infamous restrainer issue. Oil had a good 13.000km still, so after checking on the oils I postponed the service until I find another good indy in my area. Not yet done though.

Yesterday I was driving in the rain at 80km/h and raised Cruise Control to 100km/h. While it was revving up, in the left side there was some water gathering, was dry on the right. Since that time, the lady started loosing power, couldn't go from 80 to 100, not even keep 80. 
I pulled to the right, lowering speed. Eventually engine went off but could be started with no problems. Could rev up in idle ( gear in P or N ) but had a rough idle and eventually turning off when I selected D. Eventually I managed to drive the car for another 10 or so km to the Super Market, using Manual.
I had to kick down many times to even keep 40 and was trying to keep revs a bit high, in the area of 2-2,5 thousand. Was a problem going uphill and was a problem for the car to pull its weight in the two traffic lights. 
There I let the engine cool down for about 30 minutes and tried to set off for home again, a 10km distance. Car again couldn't pull its weight and the increased emissions warning came up. 
I called for ADAC but they took over an hour to appear so I cancelled them and drove the car back. Again having troubles to climb the easiest uphill but as soon as there was a downhill car was driving up to 60 or 80. Trip back was on automatic and speed changes only happened now and then with the revs being at the area of 2 to 2,5k, not likely for the car. Consumption was of course quite high as well.
Finally I reach home and while parking it, either with R or D engine went off like 5 or 6 times until I properly park. 

Had this symptoms, not as severe in my Astra, two months ago and it was the EGR and its manifold.But Astra has a petrol engine and BMW has a diesel. 

Heard a similar story with an Avensis diesel and it was the EGR and its manifold as well. Not sure if this applies in my case. 

What would be your advice ? Please, when referring to parts needing cleanup or anything I could do, take some more time to point these as I am totally inexperienced to the BMWs. 

So that was my first post and also the first fault from my BMW.

PS1: Forgot to mention that there was a smell like smoke or not well burnt fuel when I opened the bonnet and also that I don't have any kind of diagnostic tool as I didn't think I'd need it (Astra has a way to let you know of the fault codes and thought the same would apply to the BMW).

PS2: Went outside to check how things are. 
So idle is quite stable and is revving up quite good. I can also hear the turbo whistling. 
Issues come up when R or D is engaged. Idle then is unstable, engine feels like cannot rev up, didn't push it too hard though and eventually turns off.

Best way is to see your next BMW service point. Just let them check the fault log. ADAC can do a basic check and  - in case you're a member - it's for free.

Hi Allgäuer, thanks for your reply.

Didn't know that ADAC could do it, would have waited for them if I knew it, I'll probably call them again tomorrow. I am thinking of cleaning the EGR ( AGR in Deutsch ) and the manifolds around it. 

Do you know any good indy for BMW, apart from BMW themselves, in Frankfurt or around maybe? 

No sorry...I'm too far away from Frankfurt

Regarding your description it's hard to say what the reason for your problems really is. So I'd recommend a BMW dealer/service to check the fault log.  For community members in your area check this link.

Thanks again, looking for a diagnostics cable as well now...

OK back with the analysis by Carly...

Any deciphering would be more than welcome... 

BASE: E60 E61
BUILD-YEAR: 2006
MODEL: 525 d alle/all (34)
FAULTS: 25
ECUs: 26
BATTERY: 13.3V
DEPTH: Normal communication
SPEED: normal
CONNECT: Fast Connection
VERSION: 9.3.2
DEVICE: >George iPhone< >iPhone OS<
WIFI: >Carly Adapter v00<
ELM: >ELM327 v1.4 v18<
COM+: >UNKNOWN<
<===========================>
0. Motor Control:
<--------------------------->
Engine / Motor:
- Fault: Charge pressure control error
- Code: 004530
- Fault: exhaust redirection control
- Code: 004501
- Fault: Particle filter system
- Code: 00480A
- Fault: Air mass meter
- Code: 003FF0
- Fault: Smooth control
- Code: 004B10
- Fault: Smooth control
- Code: 004B11
- Fault: exhaust redirection control
- Code: 004507
- Fault: Throttle actuator
- Code: 00483D
- Fault: Throttle actuator
- Code: 0043E2
<===========================>
1. ABS / DSC / Brake:
<--------------------------->
Active Roll Stabilization / Rollstabilisierung:
- ECU not present/no answer
<--------------------------->
Dynamische Stabilitaets Kontrolle / DSC:
- ECU OK, no fault code
<===========================>
2. Airbag:
<--------------------------->
Advanced Crash and Safety Management (ACSM):
- Fault: Passenger airbag head
- Code: 0093B1
- Fault: Safety battery terminal
- Code: 0093B2
<--------------------------->
Satellite front left door / Tuer vorne links:
- ECU not present/no answer
<--------------------------->
Satellite front right door / Tuer vorne rechts:
- ECU not present/no answer
<--------------------------->
Satellite B-pillar left / B-Saeule links:
- ECU not present/no answer
<--------------------------->
Satellite B-pillar right / B-Saeule rechts:
- ECU not present/no answer
<--------------------------->
Satellite center / Mitte:
- ECU not present/no answer
<--------------------------->
Airbag B-pillar left/ B-Saeule links:
- ECU not present/no answer
<--------------------------->
Airbag B-pillar right/ B-Saeule rechts:
- ECU not present/no answer
<===========================>
3. Transmission Control:
<--------------------------->
Transmission / Getriebe GS 19:
- Fault: :motor data
- Code: 00CF2A
<--------------------------->
Transmission / Getriebesteuerung:
- ECU not present/no answer
<--------------------------->
Gear switch / Gangschalter:
- ECU not present/no answer
<===========================>
4. Instrumentation:
<--------------------------->
Instrument cluster / Kombiinstrument:
- Fault: Debug Info Combi
- Code: 00A557
- Fault: Air suspension failure
- Code: 00A3C7
- Fault: Terminal shutdown
- Code: 00A559
<--------------------------->
Central info display / Zentrales Display:
- ECU OK, no fault code
<--------------------------->
Head-Up Display:
- ECU not present/no answer
<===========================>
5. Light/Rain Control:
<--------------------------->
Light / Licht:
- ECU not present/no answer
<--------------------------->
Rain/light sensor / Regen-Lichtsensor RLS:
- ECU OK, no fault code
<--------------------------->
Light / Licht:
- Fault: Dimmer potentiometer defective
- Code: 009CB1
- Fault: sorry, unknown DTC fault
- Code: 00A8C5
- Fault: sorry, unknown DTC fault
- Code: 00A8C4
- Fault: sorry, unknown DTC fault
- Code: 00A8C2
- Fault: Short circuit fault 1
- Code: 009CB9
- Fault: 30A terminal connection faulty
- Code: 009CA9
<--------------------------->
High-beam / Fernlichtassistent:
- ECU not present/no answer
<===========================>
6. Heating / AC:
<--------------------------->
Air conditioning / Klimaanlage:
- Fault: Short circuit to positive or open circuit (AUC)
- Code: 009C54
<--------------------------->
Additional heater / Zusatzheizung:
- ECU not present/no answer
<===========================>
7. Immobilizer System:
<--------------------------->
CAS:
- Fault: brake light
- Code: 00A0B0
<===========================>
8. Park distance control / PDC:
<--------------------------->
Park Distance Control / PDC:
- ECU OK, no fault code
<===========================>
9. Cruise Control:
<--------------------------->
Active cruise control / Aktive Geschwindigkeitsregelung:
- ECU not present/no answer
<===========================>
10. Sunroof / Roof:
<--------------------------->
Sunroof / Schiebedach:
- ECU not present/no answer
<===========================>
11. Audio / Navigation / Communication:
<--------------------------->
Multimedia-Changer / Wechsler:
- ECU not present/no answer
<--------------------------->
Speech recognition / Spracherkennungs-system:
- ECU not present/no answer
<--------------------------->
Phone / Telefon:
- Fault: Error in the Bluetooth BT interface
- Code: 00A379
<--------------------------->
Hifi Amplifier / Verstaerker:
- ECU not present/no answer
<--------------------------->
Tuner Antenna / Antenne:
- ECU OK, no fault code
<--------------------------->
Hybrid Radio USA:
- ECU not present/no answer
<--------------------------->
Digital Satellite-Tuner USA:
- ECU not present/no answer
<--------------------------->
Headphones / Kopfhoerer Schnittstelle:
- ECU not present/no answer
<--------------------------->
Navigation:
- ECU not present/no answer
<--------------------------->
CD-Changer / Wechsler:
- Fault: Ring break diagnosis error
- Code: 00D810
<--------------------------->
Audio-System:
- ECU OK, no fault code
<--------------------------->
Video:
- ECU not present/no answer
<--------------------------->
DAB:
- ECU not present/no answer
<===========================>
12. Seats:
<--------------------------->
Backrest width / Lehnenbreiteverstellung:
- ECU not present/no answer
<--------------------------->
Backrest width / Lehnenbreiteverstellung:
- ECU not present/no answer
<--------------------------->
Seats / Sitze:
- ECU not present/no answer
<--------------------------->
Seats / Sitze:
- ECU not present/no answer
<===========================>
13. Systems:
<--------------------------->
Gateway:
- ECU OK, no fault code
<--------------------------->
Steering column switch / Lenkstockschalter:
- ECU OK, no fault code
<--------------------------->
Fuel pump / Kraftstoffpumpe:
- ECU OK, no fault code
<--------------------------->
Tire pressure control / Reifendruck Kontrolle:
- ECU not present/no answer
<--------------------------->
Passive Go System:
- ECU not present/no answer
<--------------------------->
Power Module:
- ECU not present/no answer
<--------------------------->
Night Vision:
- ECU not present/no answer
<--------------------------->
Flexible Bus-Interface / Schnittstelle:
- ECU not present/no answer
<--------------------------->
Car Communication Computer CCC:
- ECU OK, no fault code
<--------------------------->
MASK:
- ECU OK, no fault code
<--------------------------->
Center-Konsole:
- ECU OK, no fault code
<--------------------------->
Night Vision Camera:
- ECU not present/no answer
<--------------------------->
Car Communication:
- ECU OK, no fault code
<===========================>
14. Anti-theft alarm system:
<--------------------------->
Interior protection / Innenraumschutz:
- ECU not present/no answer
<--------------------------->
Theft alarm / Diebstahl Warnanlage:
- ECU not present/no answer
<===========================>
15. Chassis:
<--------------------------->
Air suspension / Luftfederung:
- ECU OK, no fault code
<--------------------------->
Electronic damper / Elektronische Daempfer:
- ECU not present/no answer
<--------------------------->
Central Control / Zentrale Bedieneinheit:
- ECU OK, no fault code
<===========================>
16. Body:
<--------------------------->
Automatisches Front Steering:
- ECU not present/no answer
<--------------------------->
Trailer / Anhaenger:
- ECU OK, no fault code
<--------------------------->
Car Body Module:
- ECU OK, no fault code
<--------------------------->
Tailgate / Hecktuer:
- ECU not present/no answer
<===========================>
17. Other:

Take note that this is the first one. I haven't cleared the codes at all.

Lady is now back in order and I post here the solution, maybe other members are assisted by it: 

I bought a band new Throttle Valve and fitted it in but problem wasn't solved so last Friday I called ADAC, they scanned and towed the car to an Indy (good one, highly recommended PM me for Frankfurt area).

Steuerklappe Drosselklappe Saugrohrklappe BMW 5er (E60, E61), 7er (E65,E66,E67) | eBay

Throttle valve helped the car in a way, was better but revving and idling issues were there. 
Indy replaced that part (hope it helps, found it in UK Ebay for your ease): Pierburg Exhaust Pressure 722796010 | eBay 

After that was changed engine is good as new. It seems that half cleaning of EGR was enough and the faulty part was that. 

Hope my experience in this case will help other members. 

Will come back with new posts as I'm planning some retrofitting projects on the lady. 

Thanks everyone for the replies, the assistance and for giving me directions.