CEL on Just When Emissions Testing is Due

[Outrider]

'00 Z3C stock M52, 2.8L, 5 MT

As noted, I have a Check Engine Light. I have to clear the light so I can pass emissions.

I've read a lot of posts and a common answer to this is the O2 sensors in the exhaust manifolds. I looked mine over an they appeared to be original to the car. I ordered up a set of OE Bosch sensors in preparation for dealing with this problem.

I also saw a post from someone in the Great Dismal Swamp that said words to the effect of "you can't sort much out without codes."

I do need some help, and want to make it easy for our Z3 brain trust, so here's what INPA has to say:

E R R O R M E M O R Y R E P O R T -------------------------------------
Date: 07/08/17 09:55:21 ECU: MS420DS0 JobStatus: OKAY Variant: MS420DS0-------------------------------------------------------------
RESULT: 3 errors in error memory !-------------------------------------------------------------

228 lambda contol tolerance Bank 2 to big
Error frequency : 5
Logistic counter: 40
Engine speed 2176.00 1/min
load 130.73 mg/
Hub temperature cooling water 96.00 Grad C
lambda contol tolerance Bank 2 6.64 %
appear before (rel.) 2.00 h

Abweichung fett
CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan nicht vorhanden
sporadischer Fehler

Errorcode: E4 B1 05 28 44 18 C0 91 43 20-------------------------------------------------------------



227 lambda contol tolerance Bank 1 to big
Error frequency : 5
Logistic counter: 40
Engine speed 1856.00 1/min
load 125.28 mg/Hub
temperature cooling water 95.25 Grad C
lambda contol tolerance Bank 1 9.37 %
appear before (rel.) 1.90 h


Abweichung fett
CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan nicht vorhanden
sporadischer Fehler
Errorcode: E3 B1 05 28 3A 17 BF 98 43 21-------------------------------------------------------------

145 fuel system small leak recognition
Error frequency : 1 Logistic counter: 40
temperature cooling water at the start 29.25 Grad C
temperature intake air 30.75 Grad C
pulse duty factor LDP 1.30 ms
Engine speed 2496.00 1/min
appear before (rel.) 0.70 h

Kleines Leck TE-System


Fehler nach Entprellung gespeichert
Fehler momentan vorhanden
statischer Fehler

Errorcode: 91 71 01 28 67 69 0D 4E 43 2D =========================================

[bluptgm3]

Clearing the codes is good, but typically the ready codes need to be present in the ECU if your inspection interrogates the ECU. Takes a couple of drive cycles without a fault to set the ready codes, hopefully someone can chime in with more specifics.


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[jclausen]

Read the faults with an auto logic or ista your data has to much unnecessary information

[328 Power 04]

Seriously? The codes up there are perfectly fine.
In fact, they are the same exact codes ISTA would give you, with the same exact data.


You likely have a vacuum leak and your oxygen sensors adapted past the max agreed tolerable value to try to bring afr into check.

[bluptgm3]

You likely have a vacuum leak and your oxygen sensors adapted past the max agreed tolerable value to try to bring afr into check.

Look for cracks and/or splits in the intake boot/elbow.
How many miles on car? O2 sensors are typically 100k replacement items.



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[Mr Bingley]

Reset the codes and re-test after three drive cycles if the light stays off. Do you guys have self test kiosks there? Here we can self-test by plugging a remote reader at the kiosk into our OBDII port--this is very convenient for determining when I have completed three drive cycles, as the kiosk states that it can't connect until I have. I had to get 5 cars emissions passed this year and all 5 passed without issue.

[Outrider]

Update. My son and I replaced the two O2 sensors on the respective exhaust manifolds. The one closest to the firewall may have been loose. Both appeared to be original parts.

Cleared codes, drove it around for about 20 miles and the CEL popped back on. Didn't have time to run INPA on it, but will do so later and post.

Car only has 67K on it.

Here's what Carly had to say:

<===========================>
0. Motor Control:
<--------------------------->
Engine / Motor:
- Fault: Lambda contol tolerance Bank 2 too large
- Code: 0000E4
- Fault: Lambda contol tolerance too large bank
- Code: 0000E3

[328 Power 04]

The oxygen sensors were responding fine to get the mixture to enrich.
Your problem is a vacuum leak, and a separate problem with a fuel tank pressurization. Tank pressurization happens every few drive cycles. That one can be a leak at the tubing going to the purge valve, or maybe the gas cap.

[rf900rkw]

So factory code data from a factory scanner is too wordy? Wow.


It's rarely the O2 sensors. The problem is rather than the code saying you "you are too lean", the code says "the O2 sensor reports the mixture is too lean". So the messenger (O2 sensor)
is replaced. We have nearly twenty years of posts now... saying this is the way to fix it.


You have a vacuum leak. There are two common sources on that motor. One is the lower intake boot. It likes to split at the IAC take-off. The other is there are three vacuum caps on the back of the plenum. They are a bear to reach, and you will never see them while the manifold is installed. And you have the easy version, E46's are worse.

Other possibilities are a bad CCV system. It's often blamed, but in reality doesn't just fail that often Usually it's killed by someone breaking the plastic hoses. And the last one I fixed turned out to be a bad valve cover gasket. No external oil leaks, but it was sucking a ton of air in.

Or move down here to the swamp. We have no smog testing... yet.

[Dakar Ole]

Yuppers! Our valve covers do get brittle and crack without our knowing it.

[Outrider]

I'll start the vacuum leak detection tonight and post what I find.

Since the intake boot is a likely culprit, what's the best way to check, short of a smoke generator I don't have?

Thanks for the tips.

[Outrider]

For those assessing the problem to be an air leak, you seem to have picked the source of my problems.

When I started looking at the lower air boot, I could see cracks in the IAC take-off tube. After a quick trip to the dealer, I replaced both air boots. When I started it up the CEL was gone.

I cleared codes, which I'll post later, and started building up some miles so my OBD II will be ready for emissions. The last remaining readiness is the secondary air system, which I'm sure will indicate ready with a few more start cycles.

Thanks for all the advice.

[Outrider]

Codes as promised. These are from after the new (and apparently unnecessarily replaced) O2 sensors were installed. I pulled these codes after installing the new intake boots. One immediate change after installing the intake boots... the CEL went out.

E R R O R M E M O R Y R E P O R T -------------------------------------
Date: 07/21/17 21:06:58
ECU: MS420DS0
JobStatus: OKAY
Variant: MS420DS0-------------------------------------------------------------

RESULT: 4 errors in error memory !-------------------------------------------------------------

228 lambda contol tolerance Bank 2 to big
Error frequency : 2 Logistic counter: 40
Engine speed 2880.00 1/min
load 130.73 mg/Hub temperature
cooling water 94.50 Grad C
lambda contol tolerance Bank 2 8.20 %
appear before (rel.) 0.90 h
Abweichung fett CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan nicht vorhanden sporadischer Fehler
Errorcode: E4 B1 02 28 5A 18 BE 95 43 56-------------------------------------------------------------

227 lambda contol tolerance Bank 1 to big
Error frequency : 2 Logistic counter: 40
Engine speed 2560.00 1/min
load 98.05 mg/Hub
temperature cooling water 93.75 Grad C
lambda contol tolerance Bank 1 12.11 %
appear before (rel.) 0.90 h
Abweichung fett CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan nicht vorhanden sporadischer Fehler

Errorcode: E3 B1 02 28 50 12 BD 9F 43 56-------------------------------------------------------------

245 throughput rate secondary air system to low Bank 1

Error frequency : 1
Logistic counter: 40
temperature cooling water at the start 35.25 Grad C
temperature intake air when start 36.00 Grad C
Engine speed 928.00 1/min
Battery Voltage 13.46 V
appear before (rel.) 0.10 h

Sekundaerluftdurchsatz zu gering Bank 1

CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan vorhanden statischer Fehler

Errorcode: F5 78 01 28 6F 70 1D 84 43 5E-------------------------------------------------------------

246 throughput rate secondary air system to low Bank 2
Error frequency : 1
Logistic counter: 40
temperature cooling water at the start 35.25 Grad C
temperature intake air when start 36.00 Grad C
Engine speed 928.00 1/min
Battery Voltage 13.46 V
appear before (rel.) 0.10 h


Sekundaerluftdurchsatz zu gering Bank 2 CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan vorhanden statischer Fehler


Errorcode: F6 78 01 28 6F 70 1D 84 43 5E ==============================

[328 Power 04]

Are you certain of having solved all vacuum leaks?


The Load signal is a bit low in the freezeframe data, but that depends on a few things.
In INPA can you go to Status menu, and Analog; find the Load variable, and with engine running note the value:
-at idle (normal 75-120mg/stroke)
-raised rpm standing still, should be higher
-driving at around 2000-3000 rpm you should see 175-250+mg/str
-full throttle, up to 500mg/str+

I still think that you have a vacuum leak remaining, but if the load values above are way off, it could be the maf.
If that isn't a problem, you need a fuel pressure test. When was the last time fuel filter was changed?



On cold start, it seems your secondary air pump isn't coming on.



How rough is the engine running?

[rf900rkw]

I read it that those were old codes. They were set between the O2 change and the boot install, then read later.

[328 Power 04]

You're right!

"Fehler momentan nicht vorhanden sporadischer Fehler" = Error not present, sporadic error.


It's your secondary air pump only, at the moment. Which will fail your readiness if not fixed.

[Outrider]

I read it that those were old codes. They were set between the O2 change and the boot install, then read later.

This is correct. Happy to take another reading if that will help. I put about 10 miles on it this morning before waiving off. (I decided to beat the heat and get the lawn mowed.).

The OBD monitor on my Carly diagnostic tool still reports secondary air as not ready.

Not sure if this makes a difference regarding the secondary air pump, but it's pretty hot out.

Regarding the secondary air pump, can INPA be used to cycle it on?

[rf900rkw]

I have used INPA to run the SAS test, but not on that particular engine that I can remember. As we constantly are reminded, each INPA module is unique in it's specific coverage and capabilities.

[Outrider]

Here are the post O2 sensor, post new intake boot codes. I did find the likely source of the capillary leak. The tube that plugs into the top of the upper boot was loose. I fully seated the connection and cleared the codes you'll read below.

INPA now has no errors after about 15 miles. The OBD-II still has a few parameters that aren't ready. I decided to abort testing due to the approach of thunderstorms. That probably kills my opportunity for an emissions check this weekend, but I still want to get the car ready for its inspection.

E R R O R M E M O R Y R E P O R T -------------------------------------
Date: 07/22/17 13:20:45
ECU: MS420DS0
JobStatus: OKAY
Variant: MS420DS0-------------------------------------------------------------

RESULT: 3 errors in error memory !-------------------------------------------------------------

146 Capilary leakage 0,5mm
Error frequency : 1
Logistic counter: 40
temperature cooling water at the start 35.25 Grad C
temperature intake air 36.75 Grad C
pulse duty factor LDP 2.60 ms
Engine speed 896.00 1/min
appear before (rel.) 1.00 h
CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan vorhanden statischer Fehler

Errorcode: 92 71 01 28 6F 71 1A 1C 43 62-------------------------------------------------------------

246 throughput rate secundary air system to low Bank 2

Error frequency : 1
Logistic counter: 40
temperature cooling water at the start 35.25 Grad C temperature
intake air when start 36.75 Grad C
Engine speed 1600.00 1/min
Battery Voltage 13.57 V appear before (rel.) 0.50 h
Sekundaerluftdurchsatz zu gering Bank 2 CARB-Fehler
Fehler nach Entprellung gespeichert
Fehler momentan vorhanden statischer Fehler
Errorcode: F6 78 01 28 6F 71 32 85 43 67-------------------------------------------------------------
245 throughput rate secundary air system to low Bank 1
Error frequency : 1
Logistic counter: 40
temperature cooling water at the start 35.25 Grad C
temperature intake air when start 36.75 Grad C
Engine speed 1600.00 1/min
Battery Voltage 13.57 V appear before (rel.) 0.50 h
Sekundaerluftdurchsatz zu gering Bank 1 CARB-Fehler

Fehler nach Entprellung gespeichert
Fehler momentan vorhanden statischer Fehler
Errorcode: F5 78 01 28 6F 71 32 85 43 67 ================================================== ==

[rf900rkw]

Odd that the SAS started coding now. Make sure you didn't disturb or break the vacuum line to the control valve when you were changing the O2 sensors. It's right there at the lower edge of the VC along with the O2 wiring.

[Vintage42]

... Here we can self-test by plugging a remote reader at the kiosk into our OBDII port...

What kiosk is this? Must be provided by the emissions testing contractor. That ended here about ten years ago.

[Mr Bingley]

What kiosk is this? Must be provided by the emissions testing contractor. That ended here about ten years ago.

You just pull up to it, scan your bar code, plug in (wirelessly), and test--it even prints out your report. A very convenient addition to the testing regimen.

[Outrider]

Latest update. No codes, OBD-II says ready. Will run it through emissions tomorrow.

[Outrider]

CEL is back. While there may be other issues, vacuum lines are definitely part of the problem. Photo below is a not-so-wonderful photo of a thin vacuum line that is cracked and in need of replacement. This line snakes around the back of the engine.

I’m looking for advice about what, specifically, to replace as well as whether to use stock parts or to look at aftermarket specialty lines that are more durable.

D60F44E4-CF26-4913-BBA5-29E02F418D9E.jpg

I haven't pulled codes yet, but my inclination is to replace each of the lines because they’re all old as far as I can see.

[2002Z3]

Outrider, that is would be a good idea. I've found that if one vacuum hose is bad, they usually are all bad, or close to it. That is unless the one bad hose is close to a high heat source and the others are not. Even so, hose is cheap. Buy in bulk and have some left over for other cars. Good luck with your chase down.