The BMW 3 Series E91 335d is a remarkable blend of performance, luxury, and efficiency, making it one of the most desirable diesel-powered estate cars in its class. As part of the E90/E91 generation, the 335d offers impressive torque, excellent fuel efficiency, and the practicality of a wagon, making it an ideal choice for those who want both power and utility. Equipped with the powerful M57 3.0-liter twin-turbocharged inline-six diesel engine, the E91 335d delivers strong performance while maintaining good fuel economy, making it suitable for both long-distance cruising and everyday driving. However, like any vehicle, the BMW E91 335d is not without its issues. Over time, owners have reported various common problems that can affect the car’s performance, reliability, and overall ownership experience. Understanding these issues is crucial for current and prospective owners to make informed decisions about maintenance and care. This article explores the most common problems associated with the BMW 3 Series E91 335d and offers insights into potential solutions.
BMW 3 Series E91 335d Engine Problems
The engine is the heart of the BMW 3 Series E91 335d, delivering the performance and efficiency that drivers expect from a BMW diesel. The M57 engine is known for its robust power and durability, but it is also prone to several common issues that can impact the vehicle’s performance and driving experience. Addressing these problems proactively can help maintain the engine’s performance and longevity.
Diesel Particulate Filter (DPF) Clogging
One of the most common issues with the M57 engine in the 335d is diesel particulate filter (DPF) clogging. The DPF is designed to capture and store exhaust soot in order to reduce emissions. However, over time, the filter can become clogged, especially if the vehicle is frequently driven on short trips where the engine does not reach the necessary temperature to initiate a regeneration cycle. Symptoms of a clogged DPF include reduced engine power, increased fuel consumption, and warning lights on the dashboard. In some cases, the vehicle may go into "limp mode" to prevent damage. Regular highway driving at higher RPMs can help keep the DPF clear, but if clogging becomes severe, a professional DPF cleaning or replacement may be necessary. Ensuring the vehicle is driven under conditions that allow for regular DPF regeneration is crucial for maintaining optimal performance.
Turbocharger Failures
Turbocharger failures are another concern for BMW 335d owners. The M57 engine features a twin-turbo setup that provides impressive power and torque. However, the turbos are known to be prone to issues such as oil leaks, wastegate failures, and turbocharger bearing wear. Symptoms of turbocharger problems include loss of power, excessive exhaust smoke, and a whining noise from the engine bay. Regular maintenance, including using high-quality oil and allowing the engine to cool down after hard driving, can help prolong the life of the turbos. If a turbocharger fails, it may need to be rebuilt or replaced to restore engine performance. Monitoring turbocharger performance and addressing any issues early can help prevent more severe engine problems and ensure reliable operation.
EGR Valve and Cooler Issues
The exhaust gas recirculation (EGR) valve and cooler are components that can also present problems in the BMW 335d. The EGR system helps reduce nitrogen oxide (NOx) emissions by recirculating a portion of the exhaust gases back into the engine. However, the EGR valve and cooler can become clogged with carbon deposits, leading to reduced engine performance, increased emissions, and potential engine damage. Symptoms of EGR issues include rough idling, loss of power, and increased exhaust smoke. Regular cleaning or replacement of the EGR valve and cooler can resolve these issues and restore proper engine function. In some cases, owners may choose to have the EGR system deleted or bypassed, though this is not legal in all regions and may impact emissions compliance. Ensuring the EGR system is functioning correctly is important for maintaining engine efficiency and meeting emissions standards.
Intake Manifold Swirl Flap Failures
Intake manifold swirl flap failures are another common problem with the M57 engine. Swirl flaps are small butterfly valves located in the intake manifold that help improve fuel-air mixing at low RPMs. Over time, these flaps can become worn or damaged, potentially breaking off and being ingested into the engine, causing severe damage. Symptoms of swirl flap issues include rough idling, reduced power, and unusual engine noises. To prevent this, many owners choose to remove the swirl flaps and install blanking plates, which eliminates the risk of failure. Removing the swirl flaps can slightly reduce low-end torque, but it is generally considered a worthwhile trade-off for the improved reliability. Regular inspection of the intake manifold and swirl flaps can help identify issues before they lead to engine damage.
Glow Plug and Glow Plug Module Failures
Glow plug and glow plug module failures are common in diesel engines, including the M57. The glow plugs are responsible for heating the combustion chambers during cold starts to ensure efficient ignition. The glow plug module controls the operation of the glow plugs. If the glow plugs or the module fail, the engine may have difficulty starting in cold weather, and the check engine light may illuminate. Symptoms of glow plug issues include rough starting, white smoke during startup, and poor fuel economy. Replacing faulty glow plugs and the module can resolve these issues and restore proper cold-start performance. Regular testing and replacement of glow plugs as part of routine maintenance can help prevent starting issues, especially in colder climates.
Transmission and Drivetrain Issues
Transmission and drivetrain issues can affect the BMW 3 Series E91 335d, impacting both the automatic transmission and the drivetrain components. The transmission and drivetrain are essential for delivering the engine’s power to the wheels, and any issues can affect the vehicle’s performance and drivability.
Automatic Transmission Problems
For automatic transmission models, owners may experience issues such as harsh shifting, delayed engagement, or transmission fluid leaks. The ZF 6HP automatic transmission used in the 335d is generally reliable, but it can develop problems over time, especially if not properly maintained. Symptoms of transmission issues include rough or delayed gear changes, slipping gears, and transmission warning lights on the dashboard. Regular maintenance, including changing the transmission fluid and filter, can help prevent many of these issues. If problems persist, it may be necessary to have the transmission diagnosed and repaired by a professional. Addressing transmission issues early can prevent more significant damage and ensure smooth and reliable operation.
Differential Issues
Differential issues can also arise in the BMW 335d. The differential is responsible for distributing power to the wheels and allowing them to rotate at different speeds during cornering. Over time, the differential can develop issues such as noise, vibration, and leaks. Symptoms of differential problems include whining or clunking noises from the rear of the vehicle, especially when accelerating or turning. Regularly checking the differential fluid and replacing it as needed can help prevent wear and extend the life of the differential. If noise or vibration is detected, it may be necessary to have the differential inspected and repaired or replaced. Proper maintenance of the differential is crucial for maintaining the vehicle’s handling and performance.
Driveshaft and CV Joint Issues
The driveshaft and CV joints are components that transfer power from the transmission to the wheels. Over time, these components can wear out, leading to vibrations, noise, and reduced drivability. Symptoms of driveshaft or CV joint issues include clunking noises during acceleration or deceleration, vibrations felt throughout the vehicle, and difficulty in maintaining smooth power delivery. Regular inspection of the driveshaft and CV joints, along with timely replacement of worn components, can help prevent more severe drivetrain problems. If issues are detected, addressing them promptly can restore smooth operation and prevent further damage to the drivetrain.
Suspension and Steering Issues
Suspension and steering issues can significantly affect the BMW 3 Series E91 335d’s handling and ride quality. The suspension system is responsible for providing a smooth and comfortable ride while maintaining control and stability. However, several common suspension and steering problems can arise in the E91 335d, impacting the vehicle’s performance and safety.
Worn Suspension Bushings
Worn suspension bushings are a common problem that can affect the BMW 335d’s handling and ride comfort. Suspension bushings are rubber or polyurethane components that cushion the connection points between suspension parts, such as control arms and sway bars. Over time, these bushings can deteriorate due to exposure to road conditions and weather elements, leading to clunking or knocking noises when driving over bumps, along with uneven tire wear. Worn bushings can also affect the vehicle’s handling and stability, leading to a less controlled and comfortable driving experience. Replacing worn suspension bushings with high-quality replacements can improve handling and reduce noise. Regular inspections of the suspension system can help identify and address issues early, ensuring a smooth and comfortable ride.
Shock Absorber Wear
Shock absorber wear is another concern for BMW 335d owners. Shock absorbers are critical components that control the movement of the vehicle’s suspension, reducing bounce and maintaining tire contact with the road. Worn shock absorbers can result in a rough ride and reduced handling performance. Drivers may notice bouncing or swaying when driving over uneven surfaces, as well as excessive body roll during cornering. Leaking fluid from the shock absorbers is a clear indication of wear. Replacing worn shock absorbers with new ones can restore ride comfort and handling. Choosing high-quality components is essential to ensure long-lasting performance and maintain the vehicle’s driving dynamics. Regular maintenance and inspection of shock absorbers can help detect wear early and prevent further suspension problems.
Steering Rack Issues
Steering rack issues can also affect the BMW 335d, leading to poor steering response and increased effort required to turn the wheel. The steering rack is a component of the steering system that converts the rotational motion of the steering wheel into linear motion, allowing the wheels to turn. Owners may experience loose or imprecise steering, fluid leaks from the steering rack, and noise when turning the wheel. These issues can compromise the vehicle’s handling and safety, making it difficult to maintain control, especially during high-speed driving or emergency maneuvers. Inspecting and repairing or replacing the steering rack and associated components can resolve these issues. Regular maintenance, such as checking the power steering fluid level, can help prevent problems and ensure precise steering control. Addressing steering issues promptly can enhance the vehicle’s safety and driving experience.
Alignment Problems
Alignment problems are another common issue that can affect the BMW 335d’s handling and tire wear. Wheel alignment refers to the angle and direction at which the wheels are set, and proper alignment is crucial for optimal handling and tire longevity. Misalignment can be caused by worn suspension components, hitting potholes, or improper installation of new parts. Misaligned wheels can result in uneven tire wear, reduced fuel efficiency, and poor handling characteristics. Drivers may notice the vehicle pulling to one side when driving, along with uneven tire wear and an off-center steering wheel when driving straight. Performing a wheel alignment can correct misalignment issues and improve handling. Regular inspections of the suspension system can help identify and address alignment problems early, ensuring a safe and enjoyable driving experience. Proper alignment not only enhances handling but also extends tire life and improves overall vehicle efficiency.
Interior and Comfort Issues
Interior and comfort issues can detract from the overall driving experience in the BMW 3 Series E91 335d. While the vehicle is known for its elegant design and premium materials, certain problems can affect the comfort and enjoyment of both drivers and passengers. Maintaining a comfortable and functional interior is essential for a pleasant driving experience, and addressing common issues can help preserve the vehicle’s value and appeal.
Air Conditioning System Malfunctions
One common problem is air conditioning system malfunctions. The air conditioning system is responsible for maintaining a comfortable cabin temperature and providing fresh airflow to the vehicle’s interior. However, the AC system in the BMW 335d can experience issues such as insufficient cooling, strange noises, or unpleasant odors. These issues can be caused by a variety of factors, including refrigerant leaks, faulty compressors, or clogged filters. Drivers may experience weak or warm airflow from the vents, along with unusual noises when the AC is running. Regular maintenance, such as recharging the refrigerant and replacing the cabin air filter, can help maintain the AC system’s performance. If issues persist, a professional diagnosis and repair may be necessary to restore the air conditioning system to optimal functionality. Maintaining a properly functioning air conditioning system ensures a comfortable cabin environment, especially during hot weather conditions.
Interior Trim Wear
Interior trim wear is another concern for BMW 335d owners. The interior trim components, such as the dashboard, door panels, and seat upholstery, can experience wear and tear over time. Factors such as exposure to sunlight, regular use, and spills can contribute to fading, cracking, and deterioration of interior materials. Faded or cracked dashboard and trim pieces, along with worn or torn seat upholstery, can diminish the interior’s appearance and comfort. Regular cleaning and conditioning of interior materials can help prevent wear and maintain the vehicle’s aesthetic appeal. Replacing worn or damaged components can restore the interior’s appearance and comfort, enhancing the overall driving experience. Using high-quality cleaning products and protective treatments can extend the life of interior components and keep the cabin looking fresh and inviting.
Seat Belt Issues
Seat belt issues are also reported by some BMW 335d owners. Seat belts are essential safety components designed to protect occupants in the event of a collision. However, seat belts may fail to retract properly or become difficult to latch, compromising safety and convenience. Warning lights for seat belt issues may appear on the dashboard, indicating a problem that requires attention. Inspecting and repairing or replacing faulty seat belt components can resolve these issues. Ensuring that seat belts are kept clean and free of obstructions can help maintain their functionality and ensure passenger safety. Regular checks of seat belt operation and condition can help identify potential issues early and prevent failures during critical moments.
Audio System Malfunctions
Audio system malfunctions can also occur in the BMW 335d, affecting sound quality and functionality. The audio system is an integral part of the driving experience, providing entertainment and information for drivers and passengers. However, drivers may experience distorted or no sound from the speakers, along with malfunctioning radio or CD player controls. Diagnosing and repairing or replacing faulty audio system components can restore functionality and enhance the in-car entertainment experience. For complex issues, consulting a professional with experience in BMW audio systems is advisable to ensure proper repairs and maintain the vehicle’s audio quality. Regular maintenance of the audio system, including checking connections and cleaning components, can help prevent issues and ensure a reliable and enjoyable listening experience.
Sunroof Problems
The BMW 335d often comes equipped with a sunroof, which can also present issues. Owners may experience problems such as water leaks, malfunctioning mechanisms, or noisy operation. Water leaks can occur due to clogged drainage channels or deteriorated seals, leading to water ingress into the cabin. This can cause damage to interior components and create an unpleasant driving environment. The sunroof mechanism can also fail, resulting in difficulty opening or closing the sunroof smoothly. Regular maintenance, including cleaning the sunroof channels and inspecting seals for wear, can help prevent leaks and ensure proper functionality. If mechanical issues arise, professional repairs may be necessary to address sunroof problems effectively. Maintaining the sunroof system can enhance the vehicle’s comfort and enjoyment, providing a pleasant driving experience.
Door Lock Actuator Failure
The door lock actuator is a component that can also present problems in the BMW 335d. This component controls the locking and unlocking of the vehicle’s doors. Failure of the door lock actuator can result in doors that do not lock or unlock as expected, affecting the vehicle’s security and convenience. Drivers may experience issues with the central locking system, where one or more doors fail to respond to the remote key or central locking button. Replacing the faulty door lock actuator can resolve these issues and restore proper function. Regular inspection and maintenance of the locking system can help identify potential problems early and prevent failures. Ensuring the door lock system is in good condition can enhance the vehicle’s security and ease of use.
Conclusion
The BMW 3 Series E91 335d is a well-designed and popular vehicle, but it is not without its common problems. Owners and prospective buyers should be aware of the potential issues with the engine, electrical systems, transmission, suspension, and interior components. Regular maintenance and prompt attention to problems can help mitigate these issues and ensure the vehicle’s longevity and performance. Addressing these challenges proactively can lead to a more reliable and enjoyable ownership experience.
For those experiencing these common problems or seeking preventative maintenance, European Auto Pro offers expert services and solutions. Our experienced technicians are well-versed in BMW repairs and maintenance, ensuring your vehicle receives the care it deserves. We provide comprehensive diagnostic and repair services tailored to the specific needs of BMW 335d owners. Whether you’re facing engine issues, electrical problems, or suspension concerns, our team is equipped to handle all aspects of your vehicle’s maintenance and repair needs. Visit us at 253 Goodwood Road, Kings Park, 5034 South Australia for professional assistance with your BMW 335d. Our commitment to quality service and customer satisfaction ensures that your vehicle remains in top condition, providing you with peace of mind and confidence on the road.
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