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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, 10:00 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 12:26 PM.
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      11-26-2018, 01:15 AM   #24
dieseldave
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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, 09:07 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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      11-29-2018, 12:51 AM   #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, 11:13 PM   #27
n00bkiller944
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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, 09:19 PM   #28
CO_Steve
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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, 12:08 PM   #29
Alcuin49
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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 12:15 PM.
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      12-03-2018, 12:46 PM   #30
Alcuin49
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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 12:48 PM. Reason: added additional observations
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      12-06-2018, 05:36 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, 05:38 PM   #32
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This serves as a reminder:

Je parle un petit peu franšais.
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      12-07-2018, 06:23 PM   #33
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Hah, moi aussi.
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-2014 328d Wagon, self-tuned, 245hp/400ft-lbs.
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      Today, 10:06 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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      Today, 10:58 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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