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BMW 3-Series and 4-Series Forum (F30 / F32) | F30POST > Technical Forums > N47 and N57 Turbodiesel Engine / Drivetrain / Exhaust Modifications > 328d EGR failure along with Melted Intake Manifold
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      11-24-2018, 09:00 PM   #23
Alcuin49
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Info on EGR / Cooler failures

My 2014 has 106K miles and I started smelling diesel exhaust in the passenger compartment. Tear-down revealed that the exhaust flex pipe that connects the two ends of the EGR cooler had burned through - not replaceable separately. Coolers are back-ordered two months from European suppliers, none available in the US.
I talked to BMW North America - they are unwilling to give any info except to say that previous (including third party) repairs may be reimbursed upon dealer inspection. The official EGR cooler recall starts 17 Dec 2018.
The local BMW dealer was unhelpful and unfriendly, routing me to their Subaru service department presumably to get rid of me.
The US recall is for 40,000 cars, but globally the recall has expanded to 1.6 million vehicles.
Based on parts supply, I'm betting my F30 could be undriveable for many months. I bought a diesel Passat yesterday to fill those months.
https://static.nhtsa.gov/odi/rcl/201...8V755-4565.pdf
https://www.bmwblog.com/2018/10/23/b...lion-vehicles/

Last edited by Alcuin49; 12-03-2018 at 11:26 AM..
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      11-26-2018, 12:15 AM   #24
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I just purchased a 2015 328d wagon, The car was removed off CPO and sold to me without a warranty, none of the people at the dealership could tell me why, this recall explains that reason, they cannot sell a CPO vehicle with a recall..

I feel like I was taken advantage of now.
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      11-26-2018, 08:07 AM   #25
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Quote:
Originally Posted by Alcuin49 View Post
My 2014 has 106K miles and I started smelling diesel exhaust in the passenger compartment. Tear-down revealed that the cooling flex pipe that connects the two ends of the EGR cooler had burned through - not replaceable separately.
Hmm... I have been getting the occasional exhaust smell in the cabin as well, did you have any other issues? If it was actually a failure of the flex pipe and not the EGR valve itself, it sounds like the intake melt down might still be a possibility even for people with the EGR removed via tune or unplugged.
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      11-28-2018, 11:51 PM   #26
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Seems we bought ours as CPO in August before the merde hit the air stirrer. The dealership is probably having an "Oh crap" moment as we speak.
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      11-29-2018, 10:13 PM   #27
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Quote:
Originally Posted by Alcuin49 View Post
My 2014 has 106K miles and I started smelling diesel exhaust in the passenger compartment. Tear-down revealed that the cooling flex pipe that connects the two ends of the EGR cooler had burned through - not replaceable separately. Coolers are back-ordered two months from European suppliers, none available in the US.
I talked to BMW North America - they are unwilling to give any info except to say that previous (including third party) repairs may be reimbursed upon dealer inspection. The official EGR cooler recall starts 17 Dec 2018.
The local BMW dealer was unhelpful and unfriendly, routing me to their Subaru service department presumably to get rid of me.
The US recall is for 40,000 cars, but globally the recall has expanded to 1.6 million vehicles.
Based on parts supply, I'm betting my F30 could be undriveable for many months. I bought a diesel Passat yesterday to fill those months.
https://static.nhtsa.gov/odi/rcl/201...8V755-4565.pdf
https://www.bmwblog.com/2018/10/23/b...lion-vehicles/
I would tow it into the dealer. See what they advise. If they car is under safety recall and it is INOP because of it you should get a loaner for it. We had a saturn that had an ignition recall. Car had like 130k on it so no warranty what so ever, and they couldnt get the part for it. It sat dead on their lot for 4 months while we drove a brand new malibu rental the whole time on GM's dime
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      11-30-2018, 08:19 PM   #28
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I just had the EGR replaced under warranty last summer. Wonder if I get another? 2014 328d xi F31.
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      12-03-2018, 11:08 AM   #29
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My nearest BMW dealership (BMW Southpoint) wouldn't make an appointment for the EGR cooler repair over the phone "because the recall won't be officially announced until December 17." So, I rolled down two windows so I could breathe and drove there. In person they made an appointment for the recall work for Dec. 17. No offer of a loaner, no advice on not driving to avoid intake fire, no indication that they will actually have parts on the 17th.

I had thought when I bought this car that it could last a long time - I work 60 miles from home, so I run up the miles quickly. I have been meticulous about maintenance including things "not required", such as trans fluid change. I will sell the car as soon as it is repaired because of the ridiculously bad handling of this by both BMW USA and the local dealership.

Last edited by Alcuin49; 12-03-2018 at 11:15 AM..
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      12-03-2018, 11:46 AM   #30
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Quote:
Originally Posted by kdog_x View Post
Hmm... I have been getting the occasional exhaust smell in the cabin as well, did you have any other issues? If it was actually a failure of the flex pipe and not the EGR valve itself, it sounds like the intake melt down might still be a possibility even for people with the EGR removed via tune or unplugged.
I had no other issues - just the exhaust smell, but it progressed in 3 weeks from a little smell at stop signs to driving under 30 mph only possible with two windows open. Exhaust "putting" sound is audible from outside with the hood closed.

Last edited by Alcuin49; 12-03-2018 at 11:48 AM.. Reason: added additional observations
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      12-06-2018, 04:36 PM   #31
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Hi,

I bought my 420xd at only 22000km (14000miles). At 30000km got the first revision and the BMW boys checked all the parts of the car, no problems reported. At 33000km the car started to shake, the boys found out that the EGR valve is faulty and that there is a recall so I got a new EGR valve and the coolant changed. at 37000km the car smoked on the highway at around 70mph. Result, EGR radiator got faulty and the intake manifold melted. The car was 1 month out of the warranty but luckily BMW covered all the parts and labor.

Ever since i'm disappointed and I feel that the engine does not have the same shape anymore.

This is how the pain looks:
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      12-07-2018, 04:38 PM   #32
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This serves as a reminder:

Je parle un petit peu franšais.
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      12-07-2018, 05:23 PM   #33
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Hah, moi aussi.
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      12-13-2018, 09:06 AM   #34
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Turns out the occasional fumes I was smelling were coming from a failed EGR cooler. You can see the soot around the cracked part.



And here's the crack all cleaned up

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      12-13-2018, 09:58 AM   #35
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What's ironic is that South Korea had the biggest political issue with this egr cooler, and melted intake manifolds and all....
Want to know where the EGR cooler was made?
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      12-13-2018, 01:16 PM   #36
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BMW is promising to reimburse for recent EGR cooler-related failures. US dealers have no parts and a technical service bulletin on the recall says "no repair is possible at this time" due to parts availability. My local dealer (BMW Southpoint) cancelled my repair appointment without telling me, so the car is parked. I just bought a used cooler from the UK on ebay.

Last edited by Alcuin49; 12-13-2018 at 01:24 PM..
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      12-13-2018, 09:54 PM   #37
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Quote:
Originally Posted by Alcuin49 View Post
BMW is promising to reimburse for recent EGR cooler-related failures. US dealers have no parts and a technical service bulletin on the recall says "no repair is possible at this time" due to parts availability. My local dealer (BMW Southpoint) cancelled my repair appointment without telling me, so the car is parked. I just bought a used cooler from the UK on ebay.
BMW did the same for me. I created an appointment for Dec. 17th and they called to cancel it. Fortunately, I have no symptoms for EGR failure as of yet. Knock on wood!
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      12-13-2018, 09:55 PM   #38
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Quote:
Originally Posted by kdog_x View Post
Turns out the occasional fumes I was smelling were coming from a failed EGR cooler. You can see the soot around the cracked part.



And here's the crack all cleaned up

Very interesting. Thank you for posting. Any symptoms besides the smell inside the cabin?
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      12-13-2018, 10:08 PM   #39
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The coolant was slightly low, like a 3-5,000 mile top off needed. No other major warning signs, no fires or anything!
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      12-14-2018, 01:10 AM   #40
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Quote:
Originally Posted by kdog_x View Post
The coolant was slightly low, like a 3-5,000 mile top off needed. No other major warning signs, no fires or anything!
Hopefully that means you caught it before any serious damage!
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      12-14-2018, 07:20 AM   #41
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Yeah, I still dont quite understand how a crack in that location would lead to a fire. Perhaps they crack internally as well.
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      12-14-2018, 11:11 AM   #42
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This crack is not the dangerous one. Looking at it, it could have been prevented by anchoring the tube to the wall of the unit, so it doesn't vibrate. Hoping the fixed version has it anchored.


The dangerous failure happens internally, and leaks coolant inside.
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      12-14-2018, 02:56 PM   #43
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Quote:
Originally Posted by kdog_x View Post
The coolant was slightly low, like a 3-5,000 mile top off needed. No other major warning signs, no fires or anything!
I have to top off my coolant about every 2500 km/s so mine must be leaking. I received my pre recall notice earlier this week
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      06-11-2021, 09:33 AM   #44
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Hey Everyone. Reading through this thread, it would seem that the EGR valve, cooler, and related components tend to be failure prone. I am currently working on my cousins 2014 F31 328d xDrive, and it has been throwing the drivetrain malfunction warning on occasion.

He dropped his car off so I could do a full fluid flush on his car. Transmission, transfer case, and the front and rear diffs. So i figured I would also try to troubleshoot the engine codes that I found.

I used an advanced code scanner that identifies and shows advanced trouble codes, (not the P codes) but the BMW specific codes when certain values are out of their range/tolerances.

My assumption is that the EGR is allowing more exhaust gas to pass into the intake than normal. I am worried that this could lead to the symptoms everyone is mentioning above, which would equate to costly repairs.

My intent is to remove and inspect the EGR valve, then clean it, to ensure it is not getting stuck slightly open due to the carbon build on the solenoid/valve assembly.

Does anyone have any other recommendations and/or concerns if the EGR valve is found to be in good health following cleaning?

Thanks in advanced. Sorry to hear so many of you have experienced melted intake manifolds. In my opinion, this is really not a good look for BMW to manufacture cars that could fail in a way that could put peoples lives at risk. Not to mention getting exhaust gases in the cabin.
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