August 10, 2022 NHTSA CAMPAIGN NUMBER: 22V614000
Coolant Leak Inside EGR Module May Cause Fire
A melting intake manifold increases the risk of fire.
NHTSA Campaign Number: 22V614
Manufacturer BMW of North America, LLC
Components ENGINE AND ENGINE COOLING
Potential Number of Units Affected 298
Summary
BMW of North America, LLC. (BMW) is recalling certain 2018 540d xDrive vehicles equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. The EGR cooler may leak internally, causing coolant to mix with diesel engine soot, which could result in smoldering particles and a melting intake manifold.
Remedy
Dealers will replace the EGR module, and the intake manifold will be inspected and replaced, if necessary, free of charge. Interim owner notification letters were mailed on October 7, 2022. Owner notification letters were mailed December 30, 2022. Owners may contact BMW customer service at 1-800-525-7417.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check if your BMW has a Recall
SIB 11 02 22
2022-10-17
RECALL 22V-614: EXHAUST GAS RECIRCULATION (EGR) COOLER
This Service Information Bulletin (Revision 1) replaces SI B11 11 21 dated August 2022.
What’s New:
- All necessary information to perform repairs for this recall (Correction, Procedure, Parts, Claim) is now available
Please perform the procedure outlined in this Service Information on all affected vehicles before customer delivery. In the event the customer has already taken delivery of the vehicle, please perform the procedure the next time the vehicle is in the shop.
MODEL
E-Series | Model Description | Production Date | Engine |
G30 | 5 Series Sedan | October 9, 2017 – June 25, 2018 | B57O |
AFFECTED VEHICLES
Affected vehicles which require this Recall to be completed will show it as “Open” when checked either in AIR, the “Service Menu” of DCSnet (Dealer Communication System), ISPA NEXT or Warranty Vehicle Inquiry.
SITUATION
BMW AG is conducting a Voluntary Safety Recall (effective August 11, 2022) on certain Model Year 2018 BMW 540d xDrive vehicles with a 6-cylinder (“B57O”) diesel engine that were produced between October 9, 2017 and June 25, 2018.
Please note that similar recalls were conducted in 2021 and 2018. This new recall affects the remaining diesel engine model subject to the EGR Cooler recall.
Over time, the Exhaust Gas Recirculation (EGR) system’s cooler could internally leak cooling fluid. If the fluid combines with diesel engine soot particles, this could damage the engine intake manifold, and increase the risk of a fire.
CORRECTION
Replace the EGR cooler and clean the EGR intake pipe
Perform an air intake system integrity test through ISTA and based off the results of the test plan, replace the intake manifold (if test failed)
Register the new EGR cooler through ISTA
PROCEDURE
See attachment B11 02 22 Replace EGR Cooler.
PARTS INFORMATION
Only use and invoice the part numbers below that apply.
Part Number | Description | Quantity |
11 71 8 570 655 | Exhaust gas cooler high temperature | 1 |
11 62 8 576 287 | Metal seal for exhaust-gas recirculation cooler | 1 |
11 71 2 249 909 | Torx screw for exhaust-gas recirculation cooler | 2 |
11 61 8 579 881 | Metal gasket | 1 |
07 14 9 390 155 | Hex bolt with washer (M8x28-10.9-ZNS3) | 2 |
51 71 6 966 566 | Hexagon screw with flange (M10x45) | 2 |
07 12 9 905 423 | Torx screw with bush for exhaust-gas recirculation cooler | 3 |
13 71 8 473 144 | O-ring (on clean air pipe) | 1 |
11 12 8 598 599 | O-ring (on the cylinder head cover) | 1 |
13 71 8 652 852 | O-ring (on clean air pipe) | 1 |
Sublet – Bulk Part Numbers
Part Number | Description | Quantity |
82 14 1467704 | BMW Antifreeze/Coolant (G30 – 1.5 gallon, concentrate) | Supported Sublet up to $60 as needed |
Intake manifold (if required)
Part Number | Description | Quantity |
11 61 8 477 030 | Intake pipe with air flap control | 1 |
13 62 8 637 896 | Boost pressure sensor | 1 |
Additionally, other materials and small parts that are not specified above, such as fluids, lubricants, one-time use screws, nuts, and seals, which must be replaced or installed according to the ISTA repair instructions/ETK, must be selected from the Electronic Parts Catalog, or other approved BMW resources, according to the respective vehicle type. Invoiced these items separately under the Recall repair Defect Code listed in this bulletin.
Exhaust Gas Recirculation (EGR) Cooler
Safety Recall 22V-614
Model Year 2018
BMW 540d xDrive
Diesel Engines (6-cyl. – B57O)
Last updated: August 10, 2022
Q1. Which BMW Group models in the US are potentially affected by this Safety Recall?
Certain Model Year 2018 BMW 540d xDrive vehicles with a 6-cylinder (“B57O”) diesel engine in the US are potentially affected.
Q2. What is the specific issue?
The issue involves the Exhaust Gas Recirculation (EGR) system which contains an integrated cooling component (“Cooler”). Over time, a leak of cooling fluid (glycol), could develop in the EGR Cooler.
Q3. What can happen as a result of this issue?
If cooling fluid leaks in the EGR Cooler, and combines with typical diesel engine soot deposits while the temperature is high (which is normal), this could create smoldering particles. In very rare cases, these particles could contact the engine intake manifold and cause damage by creating small holes in the manifold due to melting. In extremely rare cases, due to the holes in the manifold, this could increase the risk of a fire. If you are not the only driver of this vehicle, please advise all other drivers of this important information.
Q4. Are BMW Group models, which are not Diesel, affected? Why not?
No. They are not affected because they have a different engine design.
Q5. How did BMW Group become aware of this issue?
BMW Group became aware of this issue through its quality control procedures.
Q6. Can I determine if this issue exists in my vehicle?
While it’s highly unlikely that this issue will occur, if your vehicle has an unpleasant odor, i.e., an odor of exhaust gas and you hear an unusual noise from the engine compartment, your vehicle may be experiencing this issue. In rare cases, you may see smoke from the engine.
Q7. What should I do if I notice this condition in my vehicle?
If this condition occurs, pull off the road to a safe location away from traffic, and switch off the engine. Do not open the hood. All occupants should carefully exit the vehicle and move to a safe location away from traffic. Do not continue to drive your vehicle.
Contact BMW Roadside Assistance at 1-800-332-4269 immediately to have your vehicle brought to the nearest authorized BMW center. You may be responsible to pay for the tow if you no longer have coverage and reimbursement will be considered should the issue be confirmed to be related to this recall.
Q8. Can I continue to drive my vehicle (before I get my vehicle repaired)?
Yes. The likelihood of this issue occurring to your vehicle is extremely low. However, when you receive a letter asking you to have this Safety Recall performed by an authorized BMW center, please do so as soon as possible.
Q9. How will I be informed of this Safety Recall?
Owners of potentially affected vehicles will receive a letter in October via First Class mail advising them of this Safety Recall. When parts become available, they will receive another letter, requesting they schedule an appointment with an authorized BMW center as soon as possible to have this Safety Recall performed. For the latest updates to this Safety Recall, please visit bmwusa.com/recall.
To ensure BMW has your recent contact and vehicle information, owners should visit bmwusa.com/recall and click on “Manage recall notices and contact information”.
Q10. How will my vehicle be repaired?
The EGR Cooler will be replaced with an improved version. If it is determined that the EGR Cooler has leaked, the engine intake manifold will also be replaced.
Q11. How long will the repair take?
The repair will be performed for free, and could take up to several hours to perform.
Q12. Do I have to wait for my letter to have my vehicle serviced?
Yes. We are in the process of implementing this Safety Recall campaign to ensure that the necessary parts are at the BMW centers. For the latest updates to this Safety Recall, please visit bmwusa.com/recall.
Q13. I see a reference to the “TREAD Act Customer Reimbursement Plan” in my customer letter. Can you explain what that is about? Am I eligible for reimbursement?
If you have already had this repair performed at your own expense, you may be eligible for reimbursement of certain expenses that you incurred. Please visit bmwusa.com/recall and click on “Reimbursement for Prior Customer Pay Repairs Related to a Safety Recall (TREAD Act)”.
Chronology :
Please refer to BMW’s November 19, 2021 Part 573 report (NHTSA Recall ID 21V-907), and October 25, 2018 Part 573 report (NHTSA Recall ID 18V-755). After implementation of these recalls, the field continued to be monitored for any further actions, if warranted.
The vehicles subject to this 2022 decision have a different design and manufacturer of the EGR cooler than the vehicles subject to 21V-907 and 18V-755. At the time, the field data for the vehicles subject to this 2022 decision indicated that an action was not necessary.
After further worldwide field monitoring, and a comprehensive review of field data, including statistical forecasting, it was indicated that the specific EGR cooler for the vehicles subject to this 2022 decision may not be sufficiently robust over a vehicle’s lifetime. Therefore, BMW has decided to perform a worldwide field action for these specific vehicles, and to also include the US market. As of the 2022 decision, there are still no known incidents in the US.
On August 3, 2022, in an abundance of caution, BMW decided to conduct a voluntary safety recall.
BMW has not received any reports, nor is BMW otherwise aware, of any accidents or injuries related to this issue.
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
BMW | 540D | 2018 |
8 Associated Documents
Defect Notice 573 Report
RCLRPT-22V614-6498.PDF 214.555KB
RCLRPT-22V614-6498
Manufacturer Notices(to Dealers,etc) – SIB re BMW Recall 22V-614: Exhaust Gas Recirculation (EGR) Cooler
RCMN-22V614-7591.pdf 279.766KB
RCMN-22V614-7591
Recall Acknowledgement
RCAK-22V614-7331.pdf 645.016KB
RCAK-22V614-7331
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-22V614-3428.pdf 812.06KB
RIONL-22V614-3428
Remedy Instructions and TSB
RCRIT-22V614-6977.pdf 248.87KB
RCRIT-22V614-6977
ISSUED Owner Notification Letter(Part 577)
RCONL-22V614-9591.pdf 609.157KB
RCONL-22V614-9591
Recall Quarterly Report #1, 2022-4
RCLQRT-22V614-4268.PDF 211.134KB
Recall Quarterly Report #2, 2023-1
RCLQRT-22V614-3765.PDF 211.239KB
RCLQRT-22V614-3765
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For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V614&docType=RCL
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SAMPLE Company BMW of North America, LLC BMW Group Company Mailing Address PO Box 1227 Westwood NJ 07675- 1227 Telephone (800) 525-7417 Fax (201) 930-8362 E-mail CustomerRelations@ bmwusa.com Internet bmwusa.com October 2022 Dear BMW Owner / Lessee: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. BMW AG has decided that a defect, which relates to motor vehicle safety, exists in certain Model Year 2018 BMW 5 Series diesel engine models. Our records indicate that you are the owner of a potentially affected vehicle. Why are we contacting you? We are informing you of a safety recall on your vehicle although we are not able to perform the remedy at this time. We will notify you with a follow-up letter as soon as we are able to perform this safety recall. What could happen? The engine’s Exhaust Gas Recirculation (EGR) Cooler could develop an internal leak. Cooling fluid could mix with typical diesel engine soot deposits. With high temperatures normally present in the EGR module, this might result in smoldering particles. If these particles contact the engine intake manifold, they could create small holes due to melting, increasing the risk of a fire. If you notice an unpleasant odor, i.e., an odor of exhaust gas and you hear an unusual noise from the engine compartment, your vehicle may be experiencing this issue. You may see smoke from the engine. If this occurs, carefully move away from traffic as soon as possible, pull over to a safe location, and shut off the power. Do not continue to drive the vehicle. All occupants should exit the vehicle and move to a safe location away from traffic. Dial 911 in the event of an emergency. If it is not an emergency, contact BMW Roadside Assistance at 1-800-332-4269 If you are not the only driver of this vehicle, please advise all other drivers and passengers of this important information. If you are a vehicle lessor, Federal Regulations require you to forward this notice to your lessee within ten days What will BMW do? When the remedy is available, the EGR Cooler will be replaced, and the intake manifold will be checked and, if necessary replaced, for free which could take several hours. There may be some options to help overcome the inconvenience of bringing your vehicle in for service, if needed. Contact your local BMW center to check what may be available. What if I have additional questions? For the latest updates, to read the FAQs, and the topics below, please visit bmwusa.com/recall. Address change or sold the vehicle? Click “Manage recall notices and contact information” to let us know. Looking for information about possible reimbursement if you already had this repair performed at your own expense? Click “Reimbursement for Prior Customer Pay Repairs Related to a Safety Recall (TREAD Act)” Should you have any questions about this recall, please contact your authorized BMW center. If you need additional assistance, please contact BMW Customer Relations. If your BMW center is unable to remedy the defect without charge or within a reasonable period of time, you may notify the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424- 9153), or go to http://www.safercar.gov. Please be assured that your safety is important to us, and we sincerely apologize if this recall causes any inconvenience. We recommend that you and your passengers wear your safety belt at all times. Sincerely, BMW of North America, LLC Spanish translation on back side Traducción en español en el lado inverso 000001 BMW IMPORTANT SAFETY RECALL This notice applies to your vehicle, Recall Campaign No. 22V-614: EGR Cooler Remedy is Unavailable SAMPLE Empresa BMW of North America, LLC BMW Group Company Dirección de correo postal PO Box 1227 Westwood NJ 07675- 1227 Teléfono (800) 525-7417 Fax (201) 930-8362 Correo electrónico CustomerRelations@ bmwusa.com Sitio web bmwusa.com Octubre de 2022 Estimado propietario o arrendatario de un vehículo BMW: Le enviamos este aviso de conformidad con la Ley Nacional de Tránsito y Seguridad de los Vehículos Motorizados (National Traffic and Motor Vehicle Safety Act). BMW AG ha determinado que algunos vehículos de los modelos de motor diésel de la Serie 5 de BMW, del año 2018, tienen un defecto relacionado con la seguridad de los vehículos motorizados. Nuestros registros indican que usted es el propietario de un vehículo posiblemente afectado. ¿Por qué nos comunicamos con usted? Le informamos sobre una retirada de su vehículo por motivos de seguridad, aunque no podemos brindarle una solución al problema en este momento. Le enviaremos otra carta de notificación en cuanto podamos realizar esta retirada por motivos de seguridad. ¿Qué podría suceder? Podría producirse una fuga interna en el enfriador de la recirculación de gases de escape (EGR) del motor. El líquido refrigerante podría mezclarse con los depósitos de hollín típicos de los motores diésel. Con las altas temperaturas que se presentan normalmente en elmódulo EGR, esto podría derivar en partículas incandescentes. Si estas partículas entran en contacto con el colector de admisión del motor, podrían crear pequeños agujeros al derretirse, lo que aumentaría el riesgo de incendio. Si siente un olor desagradable, como a gases de escape, y escucha un ruido raro en el compartimento del motor, es posible que su vehículo esté teniendo este problema. Puede que vea humo saliendo del motor. Si esto sucede, aléjese con cuidado del tráfico lo antes posible, deténgase en un lugar seguro y corte el suministro. No siga conduciendo el vehículo. Todos los ocupantes deben salir del vehículo y dirigirse a un lugar seguro lejos del tráfico. En caso de emergencia, llame al 911. Si no es una emergencia, llame a Asistencia en la carretera de BMW(BMWRoadside Assistance) al 1-800-332-4269. Si usted no es la única persona que conduce este vehículo, comparta esta información importante con todos los demás conductores y pasajeros. Si es arrendador del vehículo, las reglamentaciones federales exigen que reenvíe este aviso a su arrendatario en un plazo de diez días. ¿Qué hará BMW? Cuando el repuesto esté disponible, se reemplazará el enfriador de la EGR y se revisará el colector de admisión y, de ser necesario, se reemplazará de forma gratuita, lo que podría demorar varias horas. Podría haber algunas opciones para ayudar a subsanar el inconveniente de traer su vehículo para que se realice el servicio, de ser necesario. Comuníquese con su centro de BMW local para consultar qué opciones hay. ¿Qué debo hacer si tengo más preguntas? Para obtener las últimas actualizaciones, leer las preguntas frecuentes y sobre los temas a continuación, visite bmwusa.com/recall. ¿Cambió de dirección o vendió el vehículo? Haga clic en “Manage recall notices and contact information ” (Gestionar avisos de retirada e información de contacto) para informarnos. ¿Busca información sobre un posible reembolso si ya le hicieron esta reparación y la pagó usted mismo? Haga clic en“Reimbursement for Prior Customer Pay Repairs Related to a Safety Recall (TREAD Act)” (Reembolso por reparaciones previas pagadas por el cliente y relacionadas con una retirada de seguridad [Ley TREAD]) Si tiene alguna pregunta sobre esta retirada, comuníquese con el centro autorizado de BMW. Si necesita más ayuda, comuníquese con el Servicio de Atención al Cliente de BMW. Si el centro de BMW no puede resolver el defecto sin cargo o en un plazo razonable, usted puede notificar al administrador de la Administración Nacional de Seguridad de Tránsito en Carreteras (National Highway Traffic Safety Administration), en 1200 New Jersey Ave., S.E., Washington, DC 20590, llamar a la Línea gratuita directa de seguridad vehicular (Vehicle Safety Hotline) al 1-888-327-4236 (TTY: 1-800-424-9153) o visitar el sitio web http://www.safercar.gov. Le aseguramos que nos importa su seguridad y le pedimos sinceras disculpas si esta retirada le causa algún inconveniente. Recomendamos que usted y sus pasajeros usen el cinturón de seguridad en todo momento. Atentamente. BMW of North America, LLC La solución al problema no está disponible English translation on front side Traducción en inglés en el frentec 000001 BMW IMPORTANTE RETIRADA POR MOTIVOS DE SEGURIDAD Este aviso se aplica a su vehículo, Campaña de retirada n.º 22V-614: Enfriador de la EGR
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Company BMW <J; North America, LLC BMW Group Company Mailing Adm-ess PO Box 1227 WestWOOd NJ07675- 1227 Telephone (800)525 7417 Fax (201) 930 8362 E-mail CustomerRelations@ bmwusacom 000001 Internet tmwusa.oom BMW IMPORTANT SAFETY RECALL This notice applies to your vehicle, Recall Campaign No. 22V-614: EGR Cooler December 2022 Dear BMW Owner/ Lessee: Remedy is Available This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. BMW AG has decided that a defect, which relates to motor vehicle safety, exists in certain Model Year 2018 BMW 5 Series diesel engine models. Our records indicate that you are the owner of a potentially affected vehicle. Why are we contacting you? We are pleased to inform you that we are ready to perform t performed, please contact your authorized BMW center · Please visit bmwusa.com/dealer to locate your nearest BM t ecall. If you have not had this recall ed’ ly to schedule an appointment. What could happen? The engine’s Exhaust Gas Recircu lation (EGR) Coole mix with typical diesel engine soot deposits. w· n internal leak. Cooling fluid could normally present in the EGR module, this might result in smoldering particles. If t e pa t the engine intake manifold, they could create small holes due to melt ing, increasin If you notice an unpleasant odor, i.e., engine compartment, your vehicle ma nd you hear an unusual noise from the issue. You may see smoke from the engine. If this occurs, caref location, and shut off the powe . vehicle and move to a sa locatio possible, pull over to a safe w.i.1.1,11;;u.u:.i.u.LJU.u.u.i…11.s..uu..u … All occupants should exit the . vent of an emergency. If it is not an emergency, cont Ro sistance at 1-800-332-4269 If you are not the important infor notice to your ehicle, please advise all other drivers and passengers of this are a vehicle lessor, Federal Regulations require you to forward this days aced, and the intake manifold will be checked and, if necessary replaced, for free which could take several hours. There may be some options to help overcome the inconvenience of bringing your vehicle in for service, if needed. Contact your local BMW center to check what may be available. What it I have additional questions? For the latest updates, to read the FAQs, and the topics below, please visit bmwusa.com/recall. Address change or sold the vehicle? Looking for information about …._ possible reimbursement if you already .,.. had this repair performed at your own expense? Click “Manage recall notices and contact information” to let us know. Click “Reimbursement for Prior Customer Pay Repairs Related to a Safety Recall (TREAD Act)” Should you have any questions about th is recall, please contact your authorized BMW center. If you need addit ional assistance, please contact BMW Customer Relations. If your BMW center is unable to remedy the defect without charge or within a reasonable period of t ime, you may notify the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, call the toll-free Vehicle Safety Hotline at 1-888-327 -4236 (TTY: 1-800-424- 9153), or go to http://www.safercar.gov. Please be assured that your safety is important to us, and we sincerely apologize if this recall causes any inconvenience. Sincerely, BMW of North America, LLC Spanish translation on back side Traducci6n en espafiol en el lado inverso Ernpresa BMW of North America, LLC BMW Group Company Direcci6n de correo postal PO Box 1227 Westwood NJ 07675- 1227 Telefono (800) 525-7 4 17 Fax (201) 930-8362 Correo electronico CustomerRelations@ bmwusacom 000001 Sit ioweb bmwusa.com BMW IMPORTANTE RETIRADA POR MOTIVOS DE SEGURIDAD Este aviso se aplica a su vehfculo, Campana de retirada n.0 22V-614: Enfriador de la EGR Diciembre de 2022 Hay una reparacion disponible Estimado propietario o arrendatario de un vehfculo BMW: Le enviamos este aviso de conformidad con la Ley Nacional de Transito y Seguridad de los Vehfculos Motorizados (National Traffic and Motor Vehicle Safety Act). BMW AG ha determinado que algunos vehfculos de los modelos de motor diesel de la Serie 5 de BMW, del afio 2018, tienen un defecto relacionado con la seguridad de los vehfculos motorizados. Nuestros registros indican que usted es el propietario de un vehfculo posiblemente afectado. «
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From: Broadcast Messaging System To: DL-BMS_Message_Monitors Subject: BMW Recall 22V-614: Exhaust Gas Recirculation (EGR) Cooler Date: Thursday, August 11, 2022 8:20:48 AM Publish Date: From: Expiration Date: August 11, 2022 Technical Service August 25, 2022 DCSnet Message Urgent Subject: BMW Recall 22V-614: Exhaust Gas Recirculation (EGR) Cooler BMW AG is conducting a Voluntary Safety Recall (effective August 11, 2022) on certain Model Year 2018 BMW 540d xDrive vehicles with a 6-cylinder (“B57O”) diesel engine that were produced between October 9, 2017 and June 25, 2018. Please note that similar recalls were conducted in 2021 and 2018. This new recall affects the remaining diesel engine model subject to the EGR Cooler recall. Over time, the Exhaust Gas Recirculation (EGR) system’s cooler could internally leak cooling fluid. If the fluid combines with diesel engine soot particles, this could damage the engine intake manifold, and increase the risk of a fire. The EGR cooler will need to be replaced. If a leak is detected in the intake manifold, it will also be replaced. The Recall Notice and Q&A have been attached for further information. The bulletin will be updated when additional information becomes available. Sincerely, Technical Service Attachments: B110222 Recall Notice[1660219252649].pdf B110222[1660219252649].pdf B110222_22V-614-G30d-EGR-Cooler-(FAQ)-(10Aug2022) [1660219252649].pdf B110222 Recall Notice[1660219252649].pdf B110222[1660219252649].pdf B110222_22V-614-G30d-EGR-Cooler-(FAQ)-(10Aug2022)[1660219252649].pdf Recipients: BMW Passenger Cars, All Offering, All Region, All Areas, All Departments, All Personnel BMW Passenger Cars, CC-All 8/11/22, 8:42 AM 11 02 22_RECALL 22V-614: EXHAUST GAS RECIRCULATION (EGR) COOLER 1/1 SIB 11 02 22 RECALL 22V-614: EXHAUST GAS RECIRCULATION (EGR) COOLER 2022-08-11 MODEL E-Series Model Description Production Date Affected Engine Type G30 5 Series Sedan October 9, 2017 – June 25, 2018 B57O AFFECTED VEHICLES Vehicles which require this Recall Campaign to be completed will show it as “Open” when checked either in AIR, the “Service Menu” of DCSnet (Dealer Communication System), ISPA Next or Warranty Vehicle Inquiry. SITUATION BMW AG is conducting a Voluntary Safety Recall (effective August 11, 2022) on certain Model Year 2018 BMW 540d xDrive vehicles with a 6-cylinder (“B57O”) diesel engine that were produced between October 9, 2017 and June 25, 2018. Please note that similar recalls were conducted in 2021 and 2018. This new recall affects the remaining diesel engine model subject to the EGR Cooler recall. Over time, the Exhaust Gas Recirculation (EGR) system’s cooler could internally leak cooling fluid. If the fluid combines with diesel engine soot particles, this could damage the engine intake manifold, and increase the risk of a fire. The EGR cooler will need to be replaced. If a leak is detected in the intake manifold, it will also be replaced. The Recall Notice and Q&A have been attached for further information. The bulletin will be updated when additional information becomes available. Supporting Materials picture_as_pdf B110222_22V-614-G30d-EGR-Cooler-(FAQ)-(10Aug2022).pdf picture_as_pdf B110222 Recall Notice.pdf Copyright ©2022 BMW of North America, Inc. Attachment to B11 02 22 August 2022 SAFETY RECALL NOTICE To: All Center Operators, Sales Managers, Service Manager, Parts Manager and Warranty Processor RE: Recall 22V-614: Exhaust Gas Recirculation (EGR) Cooler – B11 02 22 BMW AG is conducting a Voluntary Safety Recall (effective August 11, 2022) on certain Model Year 2018 BMW 540d xDrive vehicles with a 6-cylinder (“B57O”) diesel engine that were produced between October 9, 2017 and June 25, 2018. Please be reminded that it is a violation of federal law (The Safety Act) for you to sell, lease or deliver any new motor vehicle covered by this notification until the recall repair has been performed. This means that centers may not legally deliver new motor vehicles to consumers until they are fixed or use/sell replacement equipment/parts subject to this recall. Note also that substantial civil penalties apply to violations of the Safety Act. Also, you should not sell, lease or deliver any Certified Pre-Owned or used vehicles subject to a safety recall until the repair is completed. Please follow any special instructions that we provide to you for the return or disposition of recall parts. We appreciate all your assistance with this Recall. Attachment to B11 02 22 August 2022 Exhaust Gas Recirculation (EGR) Cooler Safety Recall 22V-614 Model Year 2018 BMW 540d xDrive Diesel Engines (6-cyl. – B57O) Last updated: August 10, 2022 Q1. Which BMW Group models in the US are potentially affected by this Safety Recall? Certain Model Year 2018 BMW 540d xDrive vehicles with a 6-cylinder (“B57O”) diesel engine in the US are potentially affected. Q2. What is the specific issue? The issue involves the Exhaust Gas Recirculation (EGR) system which contains an integrated cooling component (“Cooler”). Over time, a leak of cooling fluid (glycol), could develop in the EGR Cooler. Q3. What can happen as a result of this issue? If cooling fluid leaks in the EGR Cooler, and combines with typical diesel engine soot deposits while the temperature is high (which is normal), this could create smoldering particles. In very rare cases, these particles could contact the engine intake manifold and cause damage by creating small holes in the manifold due to melting. In extremely rare cases, due to the holes in the manifold, this could increase the risk of a fire. If you are not the only driver of this vehicle, please advise all other drivers of this important information. Q4. Are BMW Group models, which are not Diesel, affected? Why not? No. They are not affected because they have a different engine design. Q5. How did BMW Group become aware of this issue? BMW Group became aware of this issue through its quality control procedures. Q6. Can I determine if this issue exists in my vehicle? While it’s highly unlikely that this issue will occur, if your vehicle has an unpleasant odor, i.e., an odor of exhaust gas and you hear an unusual noise from the engine compartment, your vehicle may be experiencing this issue. In rare cases, you may see smoke from the engine. Q7. What should I do if I notice this condition in my vehicle? If this condition occurs, pull off the road to a safe location away from traffic, and switch off the engine. Do not open the hood. All occupants should carefully exit the vehicle and move to a safe location away from traffic. Do not continue to drive your vehicle. Contact BMW Roadside Assistance at 1-800-332-4269 immediately to have your vehicle brought to the nearest authorized BMW center. You may be responsible to pay for the tow if you no longer have coverage and reimbursement will be considered should the issue be confirmed to be related to this recall. Q8. Can I continue to drive my vehicle (before I get my vehicle repaired)? Yes. The likelihood of this issue occurring to your vehicle is extremely low. However, when you receive a letter asking you to have this Safety Recall performed by an authorized BMW center, please do so as soon as possible. Q9. How will I be informed of this Safety Recall? Owners of potentially affected vehicles will receive a letter in October via First Class mail advising them of this Safety Recall. When parts become available, they will receive another letter, requesting they schedule an appointment with an authorized BMW center as soon as possible to have this Safety Recall performed. For the latest updates to this Safety Recall, please visit bmwusa.com/recall. To ensure BMW has your recent contact and vehicle information, owners should visit bmwusa.com/recall and click on “Manage recall notices and contact information”. Q10. How will my vehicle be repaired? Attachment to B11 02 22 August 2022 Exhaust Gas Recirculation (EGR) Cooler Safety Recall 22V-614 Model Year 2018 BMW 540d xDrive Diesel Engines (6-cyl. – B57O) Last updated: August 10, 2022 The EGR Cooler will be replaced with an improved version. If it is determined that the EGR Cooler has leaked, the engine intake manifold will also be replaced. Q11. How long will the repair take? The repair will be performed for free, and could take up to several hours to perform. Q12. Do I have to wait for my letter to have my vehicle serviced? Yes. We are in the process of implementing this Safety Recall campaign to ensure that the necessary parts are at the BMW centers. For the latest updates to this Safety Recall, please visit bmwusa.com/recall. Q13. I see a reference to the “TREAD Act Customer Reimbursement Plan” in my customer letter. Can you explain what that is about? Am I eligible for reimbursement? If you have already had this repair performed at your own expense, you may be eligible for reimbursement of certain expenses that you incurred. Please visit bmwusa.com/recall and click on “Reimbursement for Prior Customer Pay Repairs Related to a Safety Recall (TREAD Act)”.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-614 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : BMW of North America, LLC Submission Date : AUG 10, 2022 NHTSA Recall No. : 22V-614 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : BMW of North America, LLC Address : P.O. Box 1227 Westwood NJ 07675-1227 Company phone : 18005257417 Population : Number of potentially involved : 298 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2018-2018 BMW 540d xDrive Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : DIESEL Descriptive Information : Approximately 298 Model Year 2018 BMW 540d xDrive Diesel engine vehicles were equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooling component (“cooler”) that, over time, could start to internally leak glycol coolant. Basis for recall population determination: Supplier production information was used to identify the start date and end date of potentially affected EGR modules, of a specific design configuration. Recall component difference to non-recall component: Recall component was not produced with sufficient long-term durability characteristics. Production Dates : OCT 09, 2017 – JUN 25, 2018 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : This safety recall involves the Exhaust Gas Recirculation (EGR) module with an integrated cooling component (“cooler”). Over time, it is possible for an internal leak to start within the EGR cooler. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : During vehicle operation, if an internal coolant leak were to start within the EGR cooler, the fluid could mix with normal diesel engine soot/sediment. In combination with high temperatures normally present in the EGR module, Part 573 Safety Recall Report 22V-614 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 this might result in smoldering particles. In very rare cases, this could lead to the melting of the intake manifold, and in extremely rare cases result in a possible fire. Description of the Cause : NR Identification of Any Warning that can Occur : During vehicle operation, the driver may be alerted to this condition by one or more of the following: A warning symbol in the instrument cluster displaying a loss of engine coolant, a reduction in engine power, an unpleasant odor (exhaust gas), an unusual noise from the engine compartment, and/or smoke from the engine compartment. Involved Components : Component Name 1 : EGR module Component Description : EGR module Component Part Number : 8570655 Supplier Identification : Component Manufacturer Name : Benteler Automobiltechnik GmbH Address : Ziegeleistrasse 7 Lichtenau-Kleinenberg Foreign States Country : Germany Chronology : Please refer to BMW’s November 19, 2021 Part 573 report (NHTSA Recall ID 21V-907), and October 25, 2018 Part 573 report (NHTSA Recall ID 18V-755). After implementation of these recalls, the field continued to be monitored for any further actions, if warranted. The vehicles subject to this 2022 decision have a different design and manufacturer of the EGR cooler than the vehicles subject to 21V-907 and 18V-755. At the time, the field data for the vehicles subject to this 2022 decision indicated that an action was not necessary. After further worldwide field monitoring, and a comprehensive review of field data, including statistical forecasting, it was indicated that the specific EGR cooler for the vehicles subject to this 2022 decision may not be sufficiently robust over a vehicle’s lifetime. Therefore, BMW has decided to perform a worldwide field action for these specific vehicles, and to also include the US market. As of the 2022 decision, there are still no Part 573 Safety Recall Report 22V-614 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 known incidents in the US. On August 3, 2022, in an abundance of caution, BMW decided to conduct a voluntary safety recall. BMW has not received any reports, nor is BMW otherwise aware, of any accidents or injuries related to this issue. Description of Remedy : Description of Remedy Program : The EGR module will be replaced, and the intake manifold will be checked and replaced if necessary. Owners will be notified by First Class mail and instructed to take their vehicle to an authorized BMW center to have the remedy performed for free. Owners who have replaced the EGR cooler at their own expense prior to the recall notification may be eligible for reimbursement according to BMW Group’s reimbursement plan in accordance with 49 CFR 573.13 and 49 CFR 577.11. How Remedy Component Differs from Recalled Component : Recalled Component: EGR module p/n – 8 570 655 Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Notification to dealers is planned to begin and end on August 10, 2022. Notification to owners is planned to begin and end on October 3, 2022. Planned Dealer Notification Date : AUG 10, 2022 – AUG 10, 2022 Planned Owner Notification Date : OCT 03, 2022 – OCT 03, 2022 * NR – Not Reported
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