Safety Recall 22V-614 – Exhaust Gas Recirculation (EGR) Cooler – 2018 BMW 5 Series

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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

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Manufacturer Notices(to Dealers,etc) – SIB re BMW Recall 22V-614: Exhaust Gas Recirculation (EGR) Cooler

RCMN-22V614-7591.pdf 279.766KB

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Recall Acknowledgement

RCAK-22V614-7331.pdf 645.016KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V614-3428.pdf 812.06KB

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Remedy Instructions and TSB

RCRIT-22V614-6977.pdf 248.87KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V614-9591.pdf 609.157KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V614-4268.PDF 211.134KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V614-3765.PDF 211.239KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V614&docType=RCL

 


 

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  • 【 Read & Clear/Reset Engine/ABS/SRS/Transmission Diagnostic Scan Tool 】LAUNCH CRP123 OBD2 Scanner can test Engine, Transmission, ABS and Airbag four systems, also reads and resets code, displays data stream graphic, stores and playbacks dynamic data stream,helps to quick analysis and diagnosis.
  • 【 Error Fault Code Reader】Except the full 10 modes OBD2 diagnostic functions like, retrieving I/M readiness, Freeze Frame Data, Read Dynamic Data stream and V-ehicle Information, O2 Sensor Test, EVAP Test of F-uel Tank System (Mode 8) and Advanced On-board Monitoring (Mode 6), launch crp123 obd2 scanner can not only reveal what error codes your car is producing, but also erase your v-ehicle’s check engine light after problem fixed, the DTC help and explanation also tell you the exact problem.
  • 【 Live Data Graphing + Read/Record/Playback Data stream + Print diagnostic data 】Live Data Graphing,more intuitive to know your vehicle’s problem.Large size Color Screen ;Print Function:Print the diagnose result easily; with user manual and register & update tutorial video uploaded in the link by us,you can Look up it anytime by ONE-CLICK.
  • 【 Find Your Vehicles Here】Launch CRP123 obd2 scanner Supports mainstream vehicles on the world,fit for ACURA VW AUDI AUST FORD BENZ BMW CHRYSLER FIAT GM HOLDEN HONDA HYUNDAI INFINITI JAGUAR ISUZU KIA LANDROVER LEXUS MAZDA MITSUBISHI NISSAN OPEL PORSCHE SAAB SEAT SKODA SMART MERCEDES SPRINTER SUBARU SUZUKI SCION TOYOTA USA FORD VOLVO PEUGEOT CITROEN RENAULT EUROFORD.Etc.
Bestseller No. 10
TOPDON Upgraded AD600 OBD2 Scanner, Diagnostic Tool, ABS SRS Transmission Engine Code Reader, 8 Reset Services Scan Tool, Oil/Brake/BMS/SAS/DPF/TPMS/ETS Reset, Injector Coding, Lifetime Free Update
  • 【Updated New Version AD600】Discover the improved version of TOPDON AD600 OBD2 scanner. Now immerse yourself in a seamlessly diagnostic experience with Android 11.0 OS. With an upgraded 32G ROM, this scan tool offers ample storage and faster performance. The 5-inch display with 1280x720 resolution offers high-definition clarity, ensuring easy readability for every diagnostic detail.
  • 【Professional 4 Systems Diagnostics】For car owners dealing with common issues such as engine, transmission, ABS, and SRS, the TOPDON AD600 code scanner delivers professional diagnostic services. It easily reads and clears fault codes, analyzes data streams and more, ensuring a quick identification of problems. Additionally, the DTC Lookup function provides corresponding fault code analysis.
  • 【8 Hot Reset Functions】Say goodbye to costly trips to the repair shop for resetting after routine maintenance such as changing oil, replacing tires, or installing new brake pads. The AD600 diagnostic tool effortlessly tackles common automotive challenges with just one click. Cut costs and cut the hassle with its 8 reset functions: Oil/BMS/ABS/SAS/EPB/DPF/TPMS/Throttle.
  • 【Support for 10,000+ Car Models】The upgraded AD600 car scanner now supports 67+ global brands and 10,000+ models, ensuring compatibility with a diverse range of vehicles. Whether American, German, French, or Japanese, the AD600 diagnostic scanner has you covered. (Note: Contact TOPDON customer service for vehicle compatibility inquiries before purchase).
  • 【Lifetime Free Updates】The AD600 diagnostic tool offers a lifetime of free upgrades with convenient one-click updates via Wi-Fi. Our dedicated TOPDON technical team continuously enhances our product's software, providing users with expanded vehicle support and an improved user experience through regular updates.

Last update on 2024-05-16 / Affiliate links / Images from Amazon Product Advertising API

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