Need Suggestions on dealing with Dealer/BMWNA Injector and EGR Recall/Warranty

[dhoover1027]

Just had my EGR recall performed yesterday.
The dealer said they are getting about 3 kits in per week.
My service paperwork looks exactly like that posted from jbfrancis3. Above.
Now I have a torn and leaking CV boot front right. Grrrrrr.

[Nolimite39]

Thank you for dropping in with the news. I am assuming since you're paperwork mimics what's posted that you had the "Low Temp" SIB, still good to hear that parts are at least trickling in.

[Nolimite39]

Just had the recall performed yesterday (FINAFREAKINGLY). Had to keep checking back because neither BMWNA nor my local dealer thought to inform me. The only reason I found out was checking the BMWNA Recall search site. I did previously swap the injector and all that fuss is behind us.

[crystalworks]

I was able to get our EGR recall performed about a month ago. When I saw you update in here I was hoping BMW was going to owe me the $900 for the injectors I had them put in. No such luck. Guess we'll continue waiting for them to add the fuel injectors on MY 2015 X5d to the list.

[Nolimite39]

No sadly no word from BMWNA or the local dealer on the injectors. I'm not holding my breath. I swapped #6 a few months ago and the other (#5 IIRC) random injector error went with it as I figured it would since #6 was so far put of tolerance. I have developed a couple other issues though.
1 P011a coolant temp sensor correlation. I swapped both sensors but the error is still there. I know ISTA says the sensors are a secondary fault with a P011a but they were easy and cheap enough so I swapped them in hopes of taking care of it. I have a thermostat and changeover valve on the way because all the wiring checks out. I guess I should confirm I have 5V to the sensors but I've not had time, this way when I go in I'll have the parts on hand plus at 130k it's time for at least the T-stat.
2. Massive drop in "city" mpg, highway is a few miles worse but city is horrendous. Absolute loss of on tap power. Used to be you stomp on the go pedal from a stop and it takes off like a raped ape. Now it acts like it thinks for a couple seconds then goes. RPM doesn't go up, just kind of barely crawls and then once it's gained a little momentum (like 2mph) it books it. Similar when rolling up a hill or applying mild throttle, it acts like there's no power at all, even decelerate some if the hill is steep enough. Have to force it to downshift either with the pedal or with the shifter before it will go. Used to be a little throttle modulation in gear would be enough to make it pull up a hill. I did all of the drivetrain fluids in December prior to our trip to Angelfire and the car has been driving perfectly until about the first week of March. It did sit for most of February since it's the CEO's DD and she just had knee surgery so while she was going through initial recovery her X didn't move.
I'm honestly at a loss, there are no errors in ISTA nor CELs or idrive warnings. I've had thoughts that maybe the turbo or the converter lockup solenoid might be responsible. It doesn't seem like the lockup is staying engaged I'm not too well versed in slush boxes but I'm learning a lot just doing research. Planning on pulling the inlet on the turbo to get a feel of the condition but not really sure what to look for with the auto. Any thoughts?

[Nolimite39]

The saga continues. The next day after the recall was performed on the low temp EGR cooler, the car started throwing cooling temp plausibility and EGR cooler efficiency codes. Also started to feel sluggish at low revs. I called the dealer about the codes multiple times asking to talk to the SA that wrote up the recall and never got a call back. It got progressively worse until a few days ago when it threw a drivetrain malfunction message and cut power. It felt like you're driving without a turbo. I took it to the dealer this morning and approved the diagnostic $270. I also made it very clear that I'd be expecting their help with getting the EGR problem covered since the car has 127k miles on it and all signs point to the issues being an aftereffect of the recall work which I waited damn near 3 years for. An issue that would have revealed itself while the emissions extended warranty was still in effect. So I get the results back via their digital notification service, Please approve the following repairs:
1. High Temp EGR Cooler Replacement - $2400
2. Air Filter Replacement - $200
3. Remove Valve Cover to further diagnose metallic noise - $1900
WHAT THE EVERLIVING F*** DID I JUST PAY YOU $270 FOR?!?!?!

I call the SA to discuss.
Me: An EGR Cooler assembly and the two gaskets are 750 from FCP so you're telling me it takes your techs 7.5 hours at $220/hr to remove the old egr cooler and install the new one? Mind you its the high temp unit on the side of the engine, directly above the manifold. 3 or 4 hours would be believable tho still pretty heavy.

SA: Well that's the time we have per the system so that's what we have to charge.

Me: I paid you for diagnosis and now you're telling me I have to pay you more because you cant diagnose it properly without removing the valve cover.

SA: Well we need to go further in the engine to diagnose it and that takes labor time.

ME: So what happens if you open it up and can't find the issue? At that point I've paid $1900 for what?

SA: Well we would attribute that to the repair.

Me: And to go further or continue diagnosing you would . . . ask for me to approve more money.

SA: Well yes.

Me: So before long I'm on the hook for $20k of you poking around and still no solution?

SA: Well you have to understand we can only do what the system tells us.

Me: F*** it, I'll come pick up the car. (after hanging up the phone-I hope you choke on the $270, pricks).

I'm mostly blowing off steam at this point because I somewhat expected this but I also expected that they would at least try to help with the EGR issue given I was checking with them every few months on the recall and in fact it was on one of my monthly checks I found out the parts were available, never received a notice or a call.
So is this the standard approach that everyone's Dealers and SAs take? Or am I just so loveable that they decide to try to slide it in me without even buying me dinner?

[crystalworks]

Originally Posted by Nolimite39

The saga continues. The next day after the recall was performed on the low temp EGR cooler, the car started throwing cooling temp plausibility and EGR cooler efficiency codes. Also started to feel sluggish at low revs. I called the dealer about the codes multiple times asking to talk to the SA that wrote up the recall and never got a call back. It got progressively worse until a few days ago when it threw a drivetrain malfunction message and cut power. It felt like you're driving without a turbo. I took it to the dealer this morning and approved the diagnostic $270. I also made it very clear that I'd be expecting their help with getting the EGR problem covered since the car has 127k miles on it and all signs point to the issues being an aftereffect of the recall work which I waited damn near 3 years for. An issue that would have revealed itself while the emissions extended warranty was still in effect. So I get the results back via their digital notification service, Please approve the following repairs:...

I'll let you know, going to have to pay the diag as well soon... but yes that sounds very standard. The wife's car developed a CEL shortly after the recall (a week). I have not looked at it because it drives okay and I am remodeling the garage. At 106k now so going to take it after I replace the DEF transfer pump that they wanted $2800 for (450 from FCP + 2 hours of my time) so they can't blame the failed pump.

Dealing with the dealer sucks.

[Nolimite39]

A couple updates.
1. The drivetrain malfunction ended up being a ruined turbo, I pulled the turbo and found a bunch of small rectangular metal chunks falling out of the turbine housing, possibly pieces of the vnt vanes, I'm yet to pull the old turbo apart to see. I replaced the turbo with a food used one and the car was a s good as new. It still had a bit of an odd metallic grinding noise which may or may not be the upper timing chain. But I wasn't willing to go that deep into it especially since #2.
2. My wife, decided she had enough of the issues with a car we were expecting 250k miles without major failure. We sold the car to autonation yesterday. I'm still kind of sick to my stomach because I loved that car but alas, it was either that or my SCd 4.6. So if anyone is interested in a 35d with 127k miles there should be one popping up shortly from autonation.

[crystalworks]

Originally Posted by Nolimite39

A couple updates.
1. The drivetrain malfunction ended up being a ruined turbo, I pulled the turbo and found a bunch of small rectangular metal chunks falling out of the turbine housing, possibly pieces of the vnt vanes, I'm yet to pull the old turbo apart to see. I replaced the turbo with a food used one and the car was a s good as new. It still had a bit of an odd metallic grinding noise which may or may not be the upper timing chain. But I wasn't willing to go that deep into it especially since #2.
2. My wife, decided she had enough of the issues with a car we were expecting 250k miles without major failure. We sold the car to autonation yesterday. I'm still kind of sick to my stomach because I loved that car but alas, it was either that or my SCd 4.6. So if anyone is interested in a 35d with 127k miles there should be one popping up shortly from autonation.

Sorry to hear that. Alas, we just got back from a road trip to west Texas and the wife has come to the same conclusion yours did. We are getting an intermittent 2C2200 CEL for "Coolant temp sensor upstream of low temp EGR coole. Coolant temp signals: implausible with each other." Never had EGR codes before getting the latest EGR recall performed and now we do.

So I have to take it back into them for the same $270 diag you paid. But even if it's something like a vacuum line, sensor, or other affordable repair... @ 108k miles a full front end rebuild is nearing as well as a litany of other things. Before the trip I replaced the front driveshaft (because U-joint explosions suck) and the DEF transfer pump that BMW wanted $2800 for.

So yes, my wife has reached the same decision yours has even though she loves this thing. Sucks that BMW just can not build a decent diesel.

[Nolimite39]

That's the same code I had. Move the secondary EGR cooler vacuum actuator arm by hand. If it's not completely smooth and feels like it gets stuck then it's the cooler flap. Thats exactly what happened to ours, the flap fell off the rod and just bounced around in the housing. Luckily it was too big to fit through the inlet and outlet so it just lived in the cooler housing. The secondary cooler new is around $500 and takes about 4 hours to replace. Much cheaper than the $2400 the dealer will want to charge. If you're going to get rid of the csr I'd suggest getting a good used on on ebay. That's what I wish I would have done.

BTW We ended up replacing the 35d with a CX90. And let me tell you. Granted it doesn't feel entirely as special as the 35d did it's a hell of a vehicle. Kudos to Mazda for building a contender. The 3.3 turbo is a wonderful engine and their.version of the 8 speed is something to really keep an eye on. They stick that engine into a midsized RWD sedan and the Germans might have to check themselves.