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BMW 3-Series and 4-Series Forum (F30 / F32) | F30POST > Technical Forums > N47 and N57 Turbodiesel Engine / Drivetrain / Exhaust Modifications > After EGR cooler recall, check the work: a small rant and information
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      08-20-2021, 12:59 PM   #1
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After EGR cooler recall, check the work: a small rant and information

I figured I should mention this here.


After getting the EGR cooler recall done at my dealership in the summer of 2020 (at least the 2020 X3 M40i loaner was nice!), I noticed that I would get raw diesel exhaust smells in the cabin through the vents on cold starts.



I first thought it was the seal for the turbo VNT actuator, but after putting my hands around there, I found the problem:




After valve cover gasket and Simple Green:




The gasket between the EGR cooler and the exhaust manifold is completely missing.

Here is what it looks like normally:






That area lets out plenty of exhaust gas, and you can see evidence of it from the soot marks on the head and turbo actuator housing.
My problems were that I'd get a lot of exhaust fumes in the cabin, especially on startups.


I fixed it myself; I won't let my dealer touch the car anymore.
BMW Part number 11628576287 (~$8)






Bonus Round!


1. My dad's X3 28d came from the dealer 2 weeks ago, EGR cooler recall completed by the same dealer:





2. My local friend's 328d sedan had the EGR cooler recall done at the same dealer:





3. A friend in Europe showed me a picture of his X3 18d sDrive (with the N47), and it too was the same:






It looks like there are "forgetful" techs everywhere. Check your car. I'm curious how many other missing gaskets there are around. Make your dealer fix it.
My dealer's service manager tried to convince me that the gasket is not visible when it's installed.
I'd be willing to claim that it's invisible when it's not installed!


What's funny is that it comes in the BMW EGR cooler recall parts kit from BMW:



(at my BMW dealership, I went into the shop to see my car while it was in progress).






tl;dr check your EGR cooler to exhaust manifold gasket. Dealer techs don't always install them. This is 4 examples I know of.
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Last edited by Enabled; 08-20-2021 at 02:09 PM..
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      08-20-2021, 01:46 PM   #2
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Appreciate the heads-up.
Good job OCBMW in NY, though I may torque it a bit to see if I can get rid of that minimal leakage.
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      08-20-2021, 02:48 PM   #3
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Guess I drew the short straw at OCBMW. The cooler was replaced under the recall.
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Last edited by catskillclimber; 08-24-2021 at 07:49 AM..
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      08-20-2021, 02:51 PM   #4
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At least yours didn't spray exhaust out onto the head/actuator housing. New turbo? (why?)

We're up to 5!
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      08-20-2021, 03:29 PM   #5
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Quote:
Originally Posted by Enabled View Post
At least yours didn't spray exhaust out onto the head/actuator housing. New turbo? (why?)
I can smell exhaust from the flange but I am surprised I don't see any evidence of a leak.

I think the new turbo may be related to the cooler recall. The recall was done at 92k. At 122k I noticed a whine when on the throttle. Wife's car so I don't know how long it was audible. Found foreign object damage on the compressor side. There were some hard rubber bits in the intercooler. They are black and one had yellow paint on it. I didn't find any breaches in the piping so I suspect something fell in when the airbox was out for the cooler replace.
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      08-20-2021, 03:34 PM   #6
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Yikes, how many others are running around with the same issues?

Sorry to hear of your troubles Enabled, I can definitely relate in not letting the stealership ever touch my cars again.

You want a job done right? Do it yourself or pay a good Indy to do it. You would think with this being a recall which BMW pays the dealer for, they'd do a good job.

Pride in workmanship is highly lacking these days.
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      08-22-2021, 12:02 AM   #7
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Back when Enabled first had this happen to him he kindly warned me and I checked mine. BMW East Bay did the job properly and the gasket was there.
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      08-22-2021, 12:48 AM   #8
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Quote:
Originally Posted by FaRKle! View Post
Back when Enabled first had this happen to him he kindly warned me and I checked mine. BMW East Bay did the job properly and the gasket was there.
You drew the short straw and had your EGR cooler replaced?

Looking at where it's installed, that gasket wouldn't be touched if the EGR cooler passed the inspection.
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      08-23-2021, 12:14 PM   #9
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Quote:
Originally Posted by capt_slow View Post
You drew the short straw and had your EGR cooler replaced?

Looking at where it's installed, that gasket wouldn't be touched if the EGR cooler passed the inspection.
Oh whoops, no I didn't need EGR replacement. When I typed that reply I was thinking they had to undo that to check.
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      08-24-2021, 12:14 AM   #10
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Quote:
Originally Posted by andreigbs View Post
Pride in workmanship is highly lacking these days.
I'm not giving excuses and I may be way off base but when the dealership is taking $180-200 for labor rates then paying an average salary of $50k to your mechanics it tends to bread resentment for the work.
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      09-15-2021, 04:20 AM   #11
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I have f31 2017,I had problems the car shook a lot, jerked, automatic.. After new egr car is like new
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      12-03-2021, 08:50 PM   #12
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Quote:
Originally Posted by andreigbs View Post
Yikes, how many others are running around with the same issues?

Sorry to hear of your troubles Enabled, I can definitely relate in not letting the stealership ever touch my cars again.

You want a job done right? Do it yourself or pay a good Indy to do it. You would think with this being a recall which BMW pays the dealer for, they'd do a good job.

Pride in workmanship is highly lacking these days.
I started getting burning oil smell in cabin right after EGR recall. Is it the black cover near engine oil inlet? I see oil dripping on exhause pipe (CAT?) in engine bay near passenger side?
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      12-04-2021, 12:49 PM   #13
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They did the EXACT same thing when they did mine! Gasket was missing and it sounded off AND there was black soot all around the area.
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      12-12-2021, 07:21 PM   #14
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thanks for the tip! I'm waiting on parts to get this recall work done
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      01-25-2023, 01:33 PM   #15
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This all looks and sounds familiar.





eta: you can see some soot accumulation, though not as much as I'd expect:



And I used a tissue rather than my finger because the engine is still hot:


Last edited by BimmerVest; 01-25-2023 at 02:07 PM..
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      01-26-2023, 12:03 PM   #16
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Ugh - now I need to go check. Great thread
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