[stefertje]

Hi from Amsterdam all!

Just have a question: at nov 2020 i got a message from my BMW dealer that a recall was in place for my car regarding EGR cooler. Went there, diagnosed: needs replacement 5 days later.
Now the last weeks i'm having coolant loss, somewhere about 1liter over 1000 km. I did search for leaks but nothing to be found.

My questions is: Did somebody had an leaking cooler after this was replaced by BMW?
Second question: On the "new" Korens Korea EGR cooler is a date on the sticker from 2017. I think that is odd since the cooler is replaced in 2020. Any suggestions?

Many thanks.

Br, Stef

[kevink1]

Here in the states I received a notice from BMW that the original fix for the EGR Cooler has been superseded. Apparently the fix wasn't a complete fix. So I find it plausible that your fix has failed.

The parts aren't available yet for me to have mine done yet. I'll check with the dealer later this month. Luckily, in my case there hasn't been a leak yet. I had a leak before the last fix 2 years ago (when I had asked about it, I was told it was normal. Obviously it wasn't). But my leak at the time was smaller than yours.

Have it checked. There are other possibilities, like cracked plastic, etc.

[stefertje]

I have checked the cooler with removing the mixing tube mounted on the intake manifold.
Everything looks good, no leakage on the EGR cooler.
Next question is, where is the coolant going?

Regarding the recall: i will call the BMW in the Netherlands to see if there is a new recall coming out or not.

[Nad]

Originally Posted by stefertje

I have checked the cooler with removing the mixing tube mounted on the intake manifold.
Everything looks good, no leakage on the EGR cooler.
Next question is, where is the coolant going?

Regarding the recall: i will call the BMW in the Netherlands to see if there is a new recall coming out or not.

Hi, I've been told that there's going to another EGR replacement program this year as all the cars that had their EGR replaced a couple of years ago are starting to fail again. Apparently, they used old stock/design which was faulty.

[stefertje]

Hi,

Checked with the dealer: the right one is installed in my car, no replacement needed since it was allready replaced earlier.
Checked the cooler internals: definitely no leakages through the EGR.

Problem is: I’m still using coolant but it’s not visible anywhere.
Any known issues with the N57 engines?

[agent_orange]

I had the EGR cooler replaced on my 2014 30d by the dealer 'technical campaign' in early 2021 and got a 2020-dated one.
Only currently using about 50mL of coolant per 5,000km, which is OK, but not as good as a 30 year old Honda that uses none.

Besides the EGR cooler, there aren't too many other common known internal coolant leak mechanisms on the N57, but several external ones including the expansion tank (all engines, not just N57), sometimes the water pump, and the plastic coolant outlet fitting on the intake side of the cylinder head cracking is common on N47 and N57 too.

[stefertje]

Thank for your reply.
Check the coolant pipe that’s known for cracks on these engines, is ok.
Checked the reservoir, no problem.
Don’t see any other signs of leakage, did not 100% focus on water pump but I think you should see leakage there right? I allready filled 2 liters.
In 2 weeks I will drive to France with my caravan, 1400 km of hard driving and I’m a bit afraid it wil use quite some coolant and was hoping to fix it before this.

Does anybody know or know stories about crack cilinder heads / head gasket etc on N57 Diesel engines?

[stefertje]

Well... it's been a while... today i needed to fill the coolant level up with 1 liter... found out that i have a leakage on the back of the EGR. There is a plastic pipe not mounted correctly (not straight in) so i have a leakage there... funny thing is that the leakage started after replacement of the EGR. Even funnier is that these rubbish technicians from BMW are ruining youre car by not working correctly...
I'm a back fan of BMW, always was but the service department lacks on service... it's just not how it was before.
I will not return for guarantee for this issue but just fix it myself instead...

[kevink1]

I have my second recall scheduled for next month. Hope I don't have this problem.

The time since my first recall fix a few years ago has been nice since I haven't had the slowly leaking coolant like I apparently was until the fix a few years ago. I probably had the condition that could cause the engine fire.

[kevink1]

Well, my car is in the shop today for the EGR cooler work and oil change.

I was either mis-informed or mis-understood when I scheduled it back around Christmas. I was thinking it was a several hour repair, but not one that they could do on a weekend so I took a long weekend to go to the dealership. Also I arranged loaner since the last time I had this repair they were missing a part and it took a couple weeks to ship from Germany.

Got the loaner, and learned that it is a several day repair. So I may need to return to work and then come back in a week to get the car.

The electronics sure look different in a 2023 330i than in my 2015 X3.

[Browns0803]

Gidday from Canada,

In October 2020 I had my EGR and intake manifold replaced under Canadian BMW recall 2018-587. In June 2022 I had my EGR replaced again under recall 2021-711. I experienced consistent coolant loss after the 2nd repair, topping up with 250ml of coolant a couple of times and travelling 2200km before I got the limp engine code, loss of power, loud air rush sound. Back to the dealer.

In August 2022 I got another EGR and intake manifold replaced under warranty again. Special submission made to BMW Canada required for approval. Since that repair I have travelled about 7000km and have "lost" about 4.2l of coolant. No visible leaks. I think the exhaust smells funny, but maybe it's all in my head.

Today had the car into the dealership to investigate coolant loss. No visible leaks. Coolant pressure test okay. I think they are discounting the fact it could possibly be the EGR for the 4th time. Thoughts on what else it could be? Head gasket possibly? I was told it can just evaporate....and to stop in the next time it is low for a free top up. WTF?

I am going to ask them to borescope the EGR and make sure it is black and sooty and not a gummy mess. Any other suggestions appreciated!

Will update with more news as soon as I have some.

[stefertje]

Regarding the last post: This is way to much coolant to simply loose.
I was thinking about a head gasket but the N57 (3.0D 6 cilinder) never has an leaking head gasket. Even, i think that head gaskets are not regularly changed on BMW engines.

What engine do you run?

[Browns0803]

Hello Stef!

I am running the N57 (2014 535d). According to my Googling around, if not EGR or head gasket, the next potential culprit is a cracked cylinder. Still waiting for the borescope results at this point. With the amount of coolant that has "disappeared", I can't help but think I may be on the verge of a major problem.

The dealer recommended a rad flush and fill, in case there was some old coolant in there that was "not circulating". I am not making this up...

[535d2014]

Originally Posted by Browns0803

Hello Stef!

I am running the N57 (2014 535d). According to my Googling around, if not EGR or head gasket, the next potential culprit is a cracked cylinder. Still waiting for the borescope results at this point. With the amount of coolant that has "disappeared", I can't help but think I may be on the verge of a major problem.

The dealer recommended a rad flush and fill, in case there was some old coolant in there that was "not circulating". I am not making this up...

Any update on this? I am running into the same issue and the dealer is giving me the run around?

[nvgoldendog]

Hi everyone. I came across this posting and thought I should chime in here. On my 2017 N57 F15 X5 Diesel vehicle, in November 2021 it starting consuming coolant on a weekly basis. As it was still in warranty I took it to BMW dealer. They determined it was the EGR cooler leaking and a new campaign came out to replace it however the parts were not available. My shop foreman opened a TSARA case with BMW and got approval to install the existing inventory/old EGR Cooler for now until the new recalled version came out. Additionally he worked on the vehicle for almost 3 months. He is a very smart guy, I know him personally. He discovered in additon to the EGR situation, more damage from this. This is what is on my paperwork

50450 EGR COOLER LEAKING CAUSING DAMAGE TO INTAKE MANIFOLD CHARGED BATTERY, INTERROGATED FAULT MEMORY, FOUND FAULT CODES 255B00 240500 272E00 290900 IN FAULT MEMORY, FOLLOWED DIAGNOSTIC CHART OF SIB 010520, PERFORMED TEST PLAN AS PER SIB, R AND I EGR VALVE TO INSPECT FOUND EGR COOLER LEAKING COOLANT INTERNALLY, INSPECTED INTAKE MANIFOLD AND FOUND DAMAGE, REPLACED EGR COOLER WITH INTAKE MANIFOLD AS PER SIB, CLEARED FAULT MEMORY, DEFECT CODE 1171900400.

PARTS REPLACED
11-71-7-810-871 EGR-VALVE:117051
1171600 REMOVE AND INSTALL/REPLACE THE
1171600 REMOVE AND INSTALL/REPLACE THE
EXHAUST-GAS RECIRCULATION COOLER
EXHAUST-GAS RECIRCULATION COOLER
1002 WB
1002 WB
1199000 WORK TIME WITHOUT SPECIFICATION/ENGINE
1002 WB
1199000 WORK TIME WITHOUT SPECIFICATION/ENGINE
1002 WB
1161551 REPLACE INTAKE PLENUM
1002 WB
1 11-71-7-794-785 O-RING:889520
1161551 REPLACE INTAKE PLENUM
1002 WB
1 11-71-7-794-785 O-RING:889520
1 11-71-7-799-853 PIPE UNION:116064
1 11-71-7-799-853 PIPE UNION:116064
1 13-62-8-637-896 SENSOR, CHARGE-AIR
PRESSURE:136040
1 13-62-8-637-896 SENSOR, CHARGE-AIR
PRESSURE:136040
1 11-71-8-476-993 EXHAUST COOLER: 889700
1 11-71-8-490-221 AGR SMALL PARTS SET:889700
1 11-71-8-476-993 EXHAUST COOLER: 889700
- - - e aa
.
--
1 11-71-8-490-221 AGR SMALL PARTS SET:889700
- - -
ea


In August of 2023 the recalled new version came out and it was replaced. Here is the info from that work order:

LINE OPCODE TECH TYPE HOURS
NET
TOTAL
A 0011270600B110821 Recall: Exhaust Gas Recirculation
I
-
N57T High TemperatureBll 08 2121-907
CAUSE: PER FISB
0071290 REPLACE EXHAUST-GAS RECIRCULATION COOLER,
INCLUDING EXHAUST-GAS RECIRCULATION VALVE
1655WBCRC
(
I
0071820 PERFORMING ADDITIONAL WORK FOR PRESSURE
SENSOR FUNCTIONAL CHECK
1655WBCRC
(
I
0071821 ADDITIONAL WORK: ENTER COMPONENT
IDENTIFICATION OF NEW EXHAUST-GAS
RECIRCULATION COOLER IN DIAGNOSTIC SYSTEM
1655WBCRC
t
I
0071824 ADDITIONAL WORK: REPLACE EXHAUST-GAS
RECIRCULATION COOLER LINE TO COOLANT PUMP
(
1655WBCRC
'
0071822 ADDITIONAL WORK: CLEAN EXHAUST-GAS
RECIRCULATION PIPE
(DO NOT USE WHEN
REPLACING INTAKE SYSTEM)
1655WBCRC
t
1 11-71-7-822-350 EXHAUST GAS COOLER HIGH
TEMP:117010
)
1 11-71-8-490-640 AGR SMALL PARTS SET:889700
2 11-71-7-799-853 PIPE UNION:116064
l
1 61-13-1-369-832 HOLDER: 613040
)
l
1 11-61-8-512-504 O-RING:119990
)
1
1 11-14-8-490-569 ACOUSTIC COVER FRONT:111040
l
)
1 11-53-7-827-410 LINE EGR RADIATOR -COOLANT
PU:111060
!
I
1 11-65-8-595-650A WTY VACUUM HOSE
I
1 82-14-1-467-704 BM ANTIFREEZE:832540
(N
I
FC: 0011270600
PART#: 11-71-7-822-350


In December 2023 I noticed the vehicle needed coolant a couple of times, and I just figured since it was cold out that was the reason. February 2024 now, In the last three weeks I have filled it up with almost 3 gallons of coolant, which for sure is NOT normal. As this vehicle is now at 79,900 miles I took it to my independent shop to see what was going on. EGR Cooler is leaking. I contacted the dealer and dropped it off today. This will now be the 3rd EGR Cooler that is leaking, and the current version is the newly designed replacement model. It looks like others on here are also having the same issue with the new part.

[bmwPower99]

2nd recall completed Jan 2023. Last 4 months I 've had to top up twice. Bought a delete kit. I do need to make sure it's not the plastic pipe housing cracking though.