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My 35D has just been quarantined by BMW. I now have a loaner from Enterprise until the new EGR arrives from Germany. The dealership told me they use a camera inserted into EGR to determine one of three classifications - 1) no evidence of leaking coolant - no action required. 2) evidence of leakage but minimal soot contamination - a non urgent replacement of the valve as soon as possible. 3) heavy soot deposits - vehicle impounded immediately pending replacement of the EGR assembly and a loan car made available at no cost.
As well as the potential fire risk due to a EGR valve leaking coolant, they advised that continued use could also damage the DPF. They also said that the EGR valve used the same coolant circuit as the rest of the engine so if you have to keep topping up the engine coolant, it could be an indication of the EGR fault.
I now have the use of my first ever hybrid - if only it was an i8!!
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