BMW struggles to cope with scale of EGR valve recall

BMW owners left without cars for months while waiting for EGR repairs as BMW suppliers face unprecedented demand

BMW struggles to cope with scale of EGR valve recall

Owners of BMWs that were recalled for an exhaust gas recirculation (EGR) valve leak are reported to have been left without their cars for up to eight weeks as the German car-maker struggles to obtain replacement parts quickly enough.

The recall, issued last October, affects 268,000 cars in the UK including examples of the 3 Series, 4 Series, 5 Series, 6 Series, X3, X4, X5 and X6.

The recall specifies that the exhaust gas recirculation cooler can in some cases leak glycol liquid on four and six-cylinder diesel engines.

Notifying owners more than four months ago, BMW said that the leak – in ‘extreme’ scenarios’ – combine with soot at high temperatures and lead to the intake manifold melting, which could in turn cause a fire to break out.

Both four and six-cylinder diesel engines are affected depending on the model.

Four cylinder cars built between December 2014 and August 2016 are affected, while six-cylinder cars produced between July 2012 and June 2015 are also part of the recall.

Cars impounded at dealerships

It’s been reported that hundreds of thousands of EGR parts are needed worldwide to resolve the fault, placing unprecedented demand on BMW’s suppliers.

Due to the potential fire risk, a significant number of cars have been impounded at dealerships.

Owners have sent complaints to Auto Express, which range from long waits with poor communication and unsuitable hire cars that are not a like-for-like replacement for the BMW’s they paid for.

Others also claimed they had not been sent recall letters regarding the problem and were only notified of the issue when their cars went in for routine services at their local branches.

A BMW spokesman told Auto Express that the car maker was “working to complete this action as quickly as possible,” but the scale of the recall had caused “significant challenges in terms of parts supply and workshop capacity”.

“Where customers have experienced longer delays, we have sought to minimise any inconvenience as best we can, including providing several thousand courtesy cars to keep customers mobile,” he added.

GW reader, Paul Richards said: “I stopped to help someone with a 3 Series.

“The manifold wasn’t just melting it was ablaze. Luckily his fire extinguisher was enough to put out the fire and didn’t need mine.

“I used to work for BMW, but that was a long time ago, we didn’t have these sorts of problems.”

Have you come across this fault in your workshop? Share your comments and experiences below.

Home Page Forums BMW struggles to cope with scale of EGR valve recall

This topic contains 7 replies, has 2 voices, and was last updated by  Praba 3 months ago.

Viewing 7 posts - 1 through 7 (of 7 total)
  • Author
  • #171987 Reply

    Paul Hopwood

    Since when has “up to eight weeks” been months?

    #172313 Reply


    I am still waiting after 2.5 months (early january) for my 530D to be fitted with new egr cooler, no updates and I am losing out on my remaining BMW warranty time as I am not even driving the car.

    #173516 Reply

    Jonathan Beale

    My 5 series burst into flames last September. I was lucky to get out in time. No warning lights on dash. Informed BMW and they didn’t want to know.

    #174168 Reply

    Peter W Shulver

    My wife’s 3 series saloon is currently been impounded by BMW as it has the Egr problem and we had to fight to get a loan car and not like for like. My 325 Tourer is due to be sorted for the same problem but i won’t let them have it until my wife’s car is returned and so far no one appears to be able to tell us anything. I have tried to speak to BMW but the really don’t want to know. Both my wife and I drive automatics and I have ongoing medical treatment appointment and live well off the bus and train routes so we need transport, the only BMW dealer in Cornwall is an 80-mile round trip. A company like BMW should have done more planning before they started this, people buy a certain size and make of car because they need that car even if they can’t give you a loan BMW it should be a like for like car! We will never buy another BMW

    #176820 Reply


    Agree with the sentiment here. Whilst I have great sympathy for the dealers I have nothing but contempt for BMW corporate. They have no interest in customers , their only interest is minimising cost. My 70k BMW is off the read for who knows how long and I am apparently supposed to be grateful that they have arranged for Enterprise to sort a loaner. My last 4 cars have been BMWs my next will be a Mercedes.

    #177666 Reply

    John Wilson

    My 640d went in today for the EGR recall. The dealer and staff were excellent in BMW Irvine, Ayrshire. My car is a five years old and they have given me an Xdrive 3.0D X4 msport to use while they source the parts. The courtesy car had only 8 miles on the clock. Thank you BMW for your excellent service and support.

    #177911 Reply


    My 520d was dropped for Recall EGR cooler change in Thames ditton dealer, unfortunately still no update. they informed it may take 8 weeks plus Hire car given but You have to get £150 plus £50 deposit for Insurance for any future damage

Viewing 7 posts - 1 through 7 (of 7 total)


Reply To: BMW struggles to cope with scale of EGR valve recall

Your email address will not be published. Required fields are marked *

Have your say!

1 1

Lost Password

Please enter your username or email address. You will receive a link to create a new password via email.