2003 540i6 M-Sport running rough under 3000rpms

[Alcyone]

So my car has 150k on it and started having a rough patch around the 1500rpm range and it sounds like it's hesitating/misfiring but it's more of a vibration than anything. Then at 2000rpms it's better, then It does it bad again around 2500rpms. Wtf?And now the idle is a little rough.
Then I had a #4 misfire. That was totally different, the car barely ran. So I determined it was the coil pack and rather just replace 1 I replaced them all with the cheapos from ECS and got new NGK spark plugs too. Cleaned the MAF and pulled and cleaned the throttle body and noticed a lake of oil in the intake manifold. So I cleaned all that out and replaced the CCV. Put it all back together and no more #4 misfire but the car still runs rough, maybe worse. Temperature doesn't really have any effect on it.
It seems like it's steadily getting rougher. And ever since i replaced the coils and plugs it now bucks at 1500rpms when your barely breathing on the throttle and coasting in traffic. But the car runs fine above 3k. Even kept up with a e93 m3 the other day. Lol.
I'm lost.
I figured if it was a fuel pump or filter it would starve fuel at higher rpms not lower. I plan on replacing them next just bc it has 150k.
Any suggestions?


So i hooked up my Peak Tool and got the following codes:

Current/Constant Codes:
7A - ambient temp sensor
8C - map controlled thermostat circuit/control
8D - engine cooling fan control
50 - secondary air system cyl 1-4
51 - secondary air system cyl 5-8

New codes since I unplugged the MAF and drove the car:
73 - air mass sensor
7c - intake air temp sensor
20 - idle speed control
3E - misfires/random cyl
32, 33, 34, 35, 36, 38, 39 ( NOT 37 ) - cyl misfires all but #3


Cold start video: https://docs.google.com/file/d/0Bzq_...lkS3ZQeVU/edit
Warm start video: https://docs.google.com/file/d/0Bzq_...N1WnFjaHM/edit
Vibration test video: https://docs.google.com/file/d/0Bzq_...ExLS0wV2M/edit

[mxchris727]

I'm thinking the intake manifold gaskets. Does the front of the engine sound like a vacuum? If so, then your OCV (oil separator valve) located behind the timing chain is damaged.

EDIT: I don't have the problem, my reply is now the first post for some reason...

[Alcyone]

I haven't noticed it. However I will check again.

I'm going to try to post a video if it will let me.

[tmvE39E53Z32TT]

Worth a shot.
http://forums.bimmerforums.com/forum...rough+idle+M62

[Alcyone]

I sprayed the entire intake area with carb cleaner and did not notice an idle change at all.
i drove the car with the MAF unplugged and it drove exactly the same as plugged in. But if i unplug it while running there is a definite change is rpm, so i think its working???

- - - Updated - - -

i posted up some videos but they really don't do it justice. the thing shakes like a cam'd up muscle car.
Also, i just replace the engine and trans mounts, so they are new.

[countryroad]

I am chasing something similar.

Sounds like you have taken care of spark, and air.

Fuel pump? Fuel pressure?

[edjack]

Not a good idea to unplug the MAF with the engine running.

You don't mention any stored codes. Even though the CEL is not on does not mean that there are no codes stored. Be sure to read the pending codes, too.

Report back.

[ViolinARC]

Not a good idea to unplug the MAF with the engine running.

You don't mention any stored codes. Even though the CEL is not on does not mean that there are no codes stored. Be sure to read the pending codes, too.

Report back.

+1...should be "de-energized" before connecting or disconnecting.

Quite possible the OSV or related tubing has failed. When replacing CCV, were you careful with the tube running to the front of the engine? That's the one going to the OSV. Do you still have oil in the throttle body?

Highly recommend replacing the fuel filter first. No reason to throw money at a new fuel pump imo. At least not at this stage of t-shooting...

[Alcyone]

Quite possible the OSV or related tubing has failed. When replacing CCV, were you careful with the tube running to the front of the engine? That's the one going to the OSV. Do you still have oil in the throttle body?

I didn't pull the throttle body yet to see if theres any more oil in it. it was smoking pretty bad at startup before, now its not. the CCV was definitely bad, i pulled it apart. The OSV tube is inside or outside the intake manifold? either way I was really careful with both tubes. and the running issue was long before i pulled any of that apart.

[ViolinARC]

You have a bunch of codes that need to be addressed. I recommend you clear everything, run a drive "cycle", pull the codes again and repost what pops back up. Def maf code was set by disconnecting. Hopefully no actual damage occurred due to the "energized" disconnect.

From the original codes, it looks like a failed SAP plus a couple other issues, which could be related to your main post.

Keep sending more info and hopefully someone here can actually provide a solid solution.

BTW, I just took my ride up to Tahoe and she didn't like either the altitude or "cold" weather because after cold start, she'd run a bit rough until fully warmed up. No codes tho...

[Alcyone]

I appreciate the help. I'm a pretty good diagnostic tech, but still learning about all the workings of BMWs.
dumb thought, I did a resonator and muffler delete last summer, lack of back pressure wouldn't have anything to do with it over time?
Also, it just seems like a misfire, but i've never had a slight misfire shake the whole car before. It almost feels like the harmonic balancer is out. It literally vibrates the entire car. And my friends 540i doesn't do that, but it smokes like a fiend on startup.

[ViolinARC]

Lol...your buddy most likely needs to replace his CCV before he fries the cats (if they exist). When mine did that, I originally thought the engine was toast. DIY replaced CCV and the smoke as well as the rough idle is gone.

I wish it was as simple for you man...

Edit: The muffler shouldn't be an issue but can't say that definitively. Anyone else?