Recalls: BMW E91 3-Series Touring
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: BMW E91 3-Series Touring
2007-11 BMW E91 3-Series Touring: doors may not open and engine may stall
In February 2013, a recall was issued for BMW E91 3-Series Touring wagons that were available for sale from 1 March 2007 to 28 February 2011. In these vehicles, the plug-in contact of the battery-positive cable on the front power distributor (fitted behind the glove compartment) could be damaged by vehicle vibrations, impairing power supply to the vehicle. As a result, the door locks may not open and it may not be possible to start the vehicle. Furthermore, if the engine were to stall, power steering assistance may be lost and the electrical system may fail – such a situation would be apparent from the flickering of the instrument panel and power loss from the engine (PRA 2013/13476).
2009-12 BMW E91 3-Series with I6 engine: VANOS oil leak and ‘limp home’ mode
In June 2014, a recall was issued for BMW E91 3-Series Touring vehicles that had N51, N52 or N55 six-cylinder petrol engines and were available for sale from 1 October 2009 to 30 April 2012. In these vehicles, the bolted connection on the housing of the variable valve timing unit (VANOS) adjustment units could become loose. If this occurred, the units may develop an internal oil leak and then no longer adjust quickly enough due to the reduced oil pressure. The vehicle’s emergency engine mode would then be activated and the engine warning light would illuminate to warn the driver. If the vehicle was being driven and slowed down or stopped unexpectedly, it would pose an accident hazard to the driver and other road users (PRA 2014/14160).
2007-11 BMW E91 3-Series Touring: won’t unlock/start, may shut down due to electrical failure
In June 2018, a recall (campaign number 00 61 7704 00) was issued for BMW E91 3-Series Touring vehicles that were available for sale from 1 March 2007 to 31 October 2011. Due to a possible electrical connection failure to the car’s main battery power cable (where it connected to the fuse box), the car may lose power to several electrical systems within the vehicle. If this electrical fault occurred, it may not be possible to unlock or start the vehicle; in some cases, there may be a total electrical failure that causes the vehicle to shut down while it is being driven – this would pose a collision hazard. Prior to the electrical failure occurring, the driver may notice the dashboard icons flickering. For the VINs of the recalled vehicles, please see PRA 2018/16803.
2006-11 BMW E91 3-Series Touring: wiring and fan resistor could short circuit
In June 2018, a recall (campaign number 00 61 6604 00) was issued for BMW E91 3-Series Touring vehicles that were available for sale prior to 1 July 2011. In these vehicles, the electrical wiring and fan resistor for the interior fan blower motor could deteriorate over time – this could cause a short circuit, overheating or melting at the plug-in contact at the fan resistor and, ultimately, a fire. For the VINs of the recalled vehicles, please see PRA 2018/16813.
Problems and faults: BMW E91 3-Series Touring
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
BMW E91 320d: N47 timing chains
For 2.0-litre N47 four-cylinder turbo-diesel engines manufactured between March 2007 and March 2011, excessively sharp teeth on the crankshaft sprocket could damage, or break, the timing chain. Please note that in the event of breakage, catastrophic engine damage could result and the primary symptom of timing chain damage was a loud ticking noise from the rear end of the engine. For these engines, two situations applied:
- For models manufactured before May 2009, the timing chains, camshaft sprocket and crankshaft required replacement. Of these, the crankshaft had to be replaced because the sprocket was welded to it and the engine also had to be removed because the timing chains were positioned at the rear of the engine, Due to the cost of repair, some owners opted to replace the engine instead.
- For models manufactured from May 2009 to March 2011, the crankshaft did not require replacement since the design of the crankshaft sprockets had been changed. The timing chains and timing guides, however, still required replacement.
BMW E91 323i (N52): ticking noise from camshaft lifters
In September 2009, BMW issued technical service bulletin SI B11 09 07 for E91 323i Touring vehicles with N52 engines that were produced prior to 31 November 2008. In these vehicles, an occasional ticking or rattling noise from the camshaft hydraulic lifters (HVA) may occur during cold engine starts. It is understood that the ticking was caused by an insufficient quantity of air-free oil for the HVA elements. To fix, however, the twelve (12) exhaust camshaft hydraulic valve lifters needed to be replaced (part no. 11 33 7 605 330).
A revised cylinder head was phased into production from 1 October 2008 and fully implemented on 31 November 2008, as per the following casting numbers –
- N51 (B30): 7588277.01;
- N52 (B30): 7588273.01; and,
- N52K (B30): 7588271.01.
2009-12 BMW E91 325i, 330i and 335i: rattling noise, loss of power and ‘Service Engine Soon’
In October 2014, BMW issued Service Information Bulletin SI B12 14 10 for BMW E91 325i, 330i and 335i Touring models produced from September 2009 to April 2012 that had N52 and N55 engines. According to the bulletin, these vehicles may exhibit the following symptoms:
- A rattling noise from the engine compartment;
- A loss of engine power;
- Illumination of the ‘Service Engine Soon’ lamp; and,
- A range of faults stored in the DME related to VANOS and camshaft position.
The bulletin attributed these symptoms to one or both (intake and/or exhaust) of the VANOS gear assemblies having faulty assembly bolts. As a result, one or more of the four assembly bolts may have loosened or broken. If the VANOS gear assembly bolts were found loose or broken, the affected VANOS gear assembly was to be replaced.
BMW E91 3-Series: N51/N52/N54 VANOS faults
In October 2010, BMW issued technical service bulletin SI B11 02 08 for E91 3-Series Touring vehicles:
- With N52 engines produced from March 2005 to June 2006; and,
- With N51, N52K and N54 engines produced from July 2006
In these vehicles, the ‘Service Engine Soon’ (MIL) lamp may illuminate and be accompanied by a reduction in engine performance/performance; this may occur after driving with the engine at normal operating temperature. If the ignition is cycled, the engine then usually performs normally. Furthermore, the following fault codes are stored in the DME:
- 2A82 VANOS intake – stiff; jammed mechanically;
- 2A87 VANOS exhaust – stiff; jammed mechanically; or,
- 3100 Boost-pressure control, deactivation – boost pressure build up prohibited (N54 engine only).
These VANOS faults may be caused by insufficient oil pressure supply to the inlet VANOS adjustment unit. To effectively move the camshafts to the target positions in the specified time and under all engine conditions, sufficient oil pressure supply to the VANOS control pistons was required. When engine operation required that the VANOS quickly advance or retard the intake or exhaust camshaft, fault 2A82 or 2A87 may occur if the camshaft is ‘late’ or does not reach the target position. In this situation, engine power may be reduced and a check control message be displayed.
According to the service bulletin, a mechanical restriction or electrical failure of the VANOS solenoid and/or the electrical circuit could cause insufficient oil supply to the VANOS assemblies.
Depending on the diagnosis, both VANOS solenoids may need to be replaced (as well as the engine oil and filter). If there was excessive wear to the camshaft bearing ledge, the camshaft hook ring seals and the affected camshaft bearing ledge would require replacement.
BMW E91 3-Series: N51, N52 and N52K engine deposits
In February 2008, BMW issued technical service bulletin SI B 13 01 07 for E91 3-Series Touring models with N51, N52 or N52K engines. In these vehicles, deposits in the injection and induction system may cause driveability complaints and the ‘Service Engine Soon’ light to be illuminated. This condition could be caused by:
- Deposits at the fuel injector’s tip which affected fuel flow and the air/fuel mixture ratio. Symptoms included hesitation or stumble during acceleration or loss of power; poor fuel efficiency; increased HC and CO emissions; and, the ‘Service Engine Soon’ lamp to illuminate due to misfire faults;
- Carbon deposits at the valves and on the intake manifold ports absorbing fuel during the warm-up phase, causing a leaner air/fuel mixture. Carbon deposits (or build-up) could also disturb the mixture flow at low throttle conditions and/or idle speeds. Symptoms of carbon deposits included a loss of power; unstable and/or rough idle; increased HC, CO and NOx emissions; and, the ‘Service Engine Soon’ lamp to illuminate due to intermittent misfire faults; and,
- Combustion Chamber Deposit Interference (CCDI) when there was contact between carbon deposits on the piston crown and the cylinder head. The noise created by this contact may be misdiagnosed as a ping, knock or other mechanical failure. CCDI occurs first as a cold start noise that can fade as the engine reaches operating temperature. As deposits build, there is an increase in compression temperature that may cause pre-ignition detonations. Symptoms include knocking, pining, poor acceleration, increased NOx emissions and engine idle speed surges.
BMW E91 335i: N54 high-pressure fuel pump failure
In December 2010, BMW issued technical service bulletin SI B13 09 10 for BMW E91 335i Touring vehicles that were powered by the N54 engine and manufactured from 28 March 2006 to 26 February 2010. In these vehicles, the driver may experience:
- Extended engine cranking time before start;
- The ‘Service Engine Soon’ indicator lamp may illuminate; and,
- Reduced engine performance due to activation of a ‘Safe Mode’, accompanied by an audible signal and illumination of the ‘Engine Malfunction’ warning light.
Furthermore, the fault code 2FBF (‘fuel pressure on – release injection, pressure too low’) may be stored in the DME.
This condition was attributable to a malfunction of internal components in the high-pressure fuel pump. To fix, an updated DME calibration improved the engine starting strategy and robustness of the HDP high-pressure fuel pump. If required, the high-pressure fuel pump (including the low-pressure fuel sensor) would also be replaced.
For Australia, BMW initiated a ‘technical campaign’ to replace the fuel pumps of vehicles within the affected VIN range. In the USA, however, this service bulletin was issued as part of a recall campaign (Campaign No. 10E-AO2). It is understood that the fuel pump warranty was also extended to 10 years or 120,000 miles (193,000 kilometres).
BMW E91 335i (N54): clanking noise
In February 2009, BMW issued technical service bulletin SI B11 13 07 for BMW E91 335i vehicles with N54 engines that were manufactured prior to 1 January 2009. In these vehicles, there may be a metallic, clanking noise that occurs up to six or seven times that is heard from the exhaust system (near the engine or turbocharger area) that is heard:
- During a deceleration from approximately 3500 rpm; or,
- During a heavy application of the accelerator without a drive gear engaged.
According to the service bulletin, the cause of this noise was a failure of the wastegate valve to completely close due to the mechanical tolerances of the wastegate actuator. As a result, the wastegate valve repeatedly clanked against its seating surface.
If the clanking noise was still present after reprogramming the DME, both the turbocharger wastegate actuators were to be replaced.
BMW E91 335i (N54): rattling wastegte
The wastegate rod has some slack at the joint/bearing where it comes off the actuator and meets the wastegate arm. As a result, rattling noises may come from the wastegate actuator arms and the wastegate itself. If the wastegate was rattling, the valve seats may wear and prevent the wastegate from fully closing – this could cause low boost pressure, the on-board diagnostics to issue a 30FF fault code (for low boost pressure) and the vehicle to enter ‘limp home’ mode. For vehicles under warranty with damaged turbochargers, BMW would replace the turbochargers and either added a part to the joint or replaced the joint to remove the slack/play. As a result of a class action in the USA, BMW North America extended its warranty of the turbocharger to eight years or 82,000 miles (132,000 kms) for any failure caused by a defect in the turbocharger’s wastegate. For vehicles that are not under warranty, an aftermarket solution involves:
- fitting a titanium bush through the turbo body for the wastegate arm;
- remanufacturing the actuator rod to the wastegate arm bush; and,
- remanufacturing the wastegate valve.
BMW E91 335i (N54): delay and jolt when accelerating from rest
In January 2009, BMW issued technical service bulletin SI B24 03 08 for BMW E91 335i vehicles with N54 engines and 6HP19TU transmissions that were produced from March 2007. In these vehicles, the driver may experience delayed engagement of the forward gears and a harsh jolt when accelerating from rest – this only occurred during the engine’s warm-up phase and did not occur in ‘Sport Mode’. According to the service bulletin, this condition was attributed to an ‘unfavourable’ Neutral Idle Control (NIC) calibration for the EGS software.
BMW E91 3-Series: ZF transmission faults
In December 2008, BMW issued technical service bulletin SI B24 01 08 for E91 3-Series Touring vehicles with N52K or N54 engines and ZF automatic transmissions that were manufactured prior to February 2008. In these vehicles, the ‘Transmission’ warning light may illuminate and the transmission enter its fail safe mode. Furthermore, fault code 4F81 (‘ratio monitoring, clutch A’) may be logged in the EGS control module, as well as 507B/507C (‘parking gear sensor implausible’) or 507D (‘parking gear incorrectly disengaged’). The service bulletin attributed these faults to:
- A low transmission fluid level; or
- An internal transmission pressure leak caused by a defective adapter seal between the transmission housing and the Mechatronic unit.
If the Mechatronic adapter seal was found to be defective (i.e. cracks or seal damage), it was to be replaced.
BMW E91 3-Series: ZF transmission sealing sleeve seepage
In March 2010, BMW issued technical service bulletin SI B 24 08 06 for BMW E91 3-Series Touring vehicles with ZF six-speed 6HP19/21 or 6HP26/28 transmissions that were manufactured up to April 2008. In these vehicles, transmission fluid seepage may be visible in the area of the transmission oil pan; the service bulletin attributed this condition to the tightness of the Mechatronic sealing sleeve’s O-ring. Only if a visible leakage trace indicated a substantial loss of transmission fluid was the Mechatronic sealing sleeve (part no. 24 34 7 588 725) to be replaced.
BMW E91 3-Series: white flakes/powder from air conditioning vents
In November 2007, BMW issued technical service bulletin SI B 64 12 07 for BMW E91 3-Series Touring vehicles that were produced from 31 May 2006 to 9 September 2007. In these vehicles, white flakes or powder may appear to be emitted from the air conditioning vents. The service bulletin attributed this condition to the surface oxidation of the evaporator and stated that it only occurred with evaporators manufactured by Denso (identified by the label on the front of the air conditioning housing behind the radio. To fix, the evaporator was to be replaced (part no. 64 11 9 179 802) and the air conditioning housing and ducts were to be cleaned of any residual flakes or powder with a damp cloth.
Problems and faults: BMW E91 3-Series Touring
- The engine may overheat due to either an electrical problem between the electric water pump and control module or the water pump itself.
- The ‘check engine’ light may illuminate and there may be an error code for excessive torque converter lockup slip – this may be due to the failure of a seal on the torque converter.
- If the air conditioning begins to blow warm after driving for about an hour, there may be an air leak near the evaporator sensor. If the air conditioner makes hissing noises, adding 90g more refrigerant to the system may fix the problem.
- For models fitted with rear seat air conditioning, the decorative trim on the centre console can become hot when rear heating is selected – this can cause discomfort if the driver’s knee contacts the console.
- If the headlights vibrate while driving, an additional headlight support is required to be installed.
- Remote central locking may stop working because one of the door latches, or the gas door latch, draws too much electrical power and blows the fuse.
- For vehicles fitted with xenon lights, the power mirrors and windows may stop working if a connector behind the headlight gets wet and corrodes.
- Power steering assistance may fade due to internal wear of the power steering pump.
- The universal garage door opener may not accept a code from a different source (new transmitter or new owner) if the batteries in the transmitter are low.
