I gave some more thoughts about the new bracket being the reason for the rapture and I'm not entirely convinced.

There are 2 bolts that secure the cooler to the head/engine block which make it for a very rigid and solid mounting point. I can't see how the bracket mounted all the way over to the opposite side of the accordion that cracks would affect the rigidity of the accordion itself.

I do, however, have a theory on how it cracks which is improper alignment during assembly of the EGR cooler. Perhaps the cases reported (and others for that matter) had the EGR cooler cracked so as described in the bulletin, it was going to be replaced as part of the bracket installation.

The technician, for example, could have first bolted the cooler to the engine block that secured the two bolts on the flange that connect the cooler to the exhaust manifold. As a result he flange may have not been properly aligned resulting in stressed on the accordion that through the because of the heat cycles ultimately cracked.

I can't recall off the top of my head if INPA/DIS have a specific tightening sequence required, but when I reassembled my cooler after replacing the thermostat I:
1) loosely place the two bolts that attach the cooler to the engine block
2) position the flange and tight the two bolts
3) positioned the clamp over the EGR valve and secured it
4) went back and torqued the two bolts on the flange
5) torqued the two bolts that secure the cooler to the head
That came just as common sense to me since I've been wrenching for some time, but who knows if the ASE and BMW certified monkey at the dealership takes the same care...

Nonetheless, I could be entirely wrong... I'd just be very curious to understand how the bracket on the outlet side of the EGR cooler in question affects the accordion on the inlet...

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