2016 BMW X5 fuel system problems

FUEL/PROPULSION SYSTEM

I am reporting a suspected high-pressure fuel pump safety defect involving my 2016 BMW X5 xDrive35d, VIN [XXX], with approximately 103,186 miles. The check engine light illuminated and BMW Fort Walton diagnosed failed fuel injectors and recommended injector replacement. I subsequently had the vehicle inspected by Techmaster in Fort Walton, Florida, where metallic shavings and debris were discovered within the high-pressure fuel system. After notifying BMW Fort Walton of these findings, I was advised that my VIN is not included in NHTSA Recall 21V-586: High Pressure Fuel Pump. I am concerned because the metallic contamination found in my vehicle appears similar or identical to the high-pressure fuel pump failure conditions addressed by Recall 21V-586. The contamination may also have caused consequential damage to the fuel injectors and other associated fuel-system components. I respectfully request that NHTSA review whether my vehicle, and potentially other BMW X5 xDrive35d vehicles currently excluded from Recall 21V-586, may be experiencing the same or substantially similar high-pressure fuel pump defect. Replacing only the failed injectors without identifying and correcting the source of metallic contamination could leave debris in the fuel system and potentially result in additional fuel-system failure. BMW Fort Walton has advised me that my VIN is outside the current recall population. I am requesting that this case be reviewed as a potential safety defect and possible issue with the scope of the existing recall. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11763414 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The High-Pressure Fuel Pump (HPFP) on my vehicle has experienced a catastrophic premature failure for the second time, presenting a severe and immediate safety hazard. This vehicle was previously serviced under NHTSA Recall 21V-586 in 2022 at 66,165 miles, during which the original defective fuel pump was replaced by an authorized BMW dealership. At approximately 123,000 miles, the replacement pump failed while the vehicle was in operation. When these high-pressure fuel pumps fail, they cause sudden engine stalling, a complete loss of propulsion while driving, and a loss of power-assist for steering and braking. This creates an immediate risk of a high-speed collision on public roadways, especially during highway transit. Furthermore, failure of this component can lead to internal mechanical destruction, creating a potential fuel leak or fire hazard. Because a replacement part mandated by a federal safety recall has failed in the exact same manner after limited mileage, the remedy provided under Recall 21V-586 is demonstrably inadequate to permanently resolve this safety hazard. BMW is currently refusing to cover the repair because the vehicle is just past the 120,000-mile extended warranty limit, leaving a known, recurring safety defect unaddressed. I am filing this complaint to urge NHTSA to investigate the failure rates of BMW's replacement recall pumps, as the current remedy does not guarantee long-term vehicle safety.

NHTSA complaint #11761597 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The component that failed appears to be the hybrid propulsion and charging system, including the high-voltage battery management system and/or integrated charging electronics. The vehicle will not accept a charge from any home or public charging source. The high-voltage battery was replaced approximately one year ago; however, the charging failure persists. The vehicle is available for inspection upon request. In addition to the charging failure, the vehicle displayed drivetrain malfunction and start/stop malfunction warnings. While driving on the highway at normal speed, the vehicle lost power and stopped, creating a hazardous situation in active traffic. This sudden loss of propulsion placed my safety and the safety of other drivers at risk, as surrounding vehicles were traveling at highway speeds. Prior to the failure, warning messages appeared intermittently, including charging system faults and start/stop malfunction alerts. These warnings began approximately one year ago around the time the charging issue started. The vehicle was previously serviced and the high-voltage battery was replaced; however, the underlying issue was not corrected. The root cause is UNKNOWN, but the symptoms suggest a failure within the hybrid control system, charging module, DC-DC converter, or related electrical components. The failure has been persistent and unresolved. I am concerned that defects within the hybrid propulsion system may lead to additional sudden loss of power events.

NHTSA complaint #11719865 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Subject: Consequential Damage and Failure of Remedy regarding Recall 24V-608 Incident Description: "I am reporting a failure of the manufacturer to provide an effective remedy for Safety Recall 24V-608 (Electric Water Pump) and subsequent consequential damage to the High-Voltage battery system. In September 2023, at approximately 78,000 miles, this vehicle exhibited 'Drivetrain Malfunctions' including Fault Code 0x222626 (EME: internal fault - active short circuit requested) and 0x22271C (Overvoltage in intermediate circuit). The BMW dealer (Fields BMW) failed to diagnose the root cause and instructed me to 'keep driving'. Since the release of Recall 24V-608, it is clear these 2023 faults were early indicators of the coolant pump short-circuiting. This persistent electrical instability has now resulted in a permanent failure of Cell Supervision Circuit #3, causing the high-voltage contactors to open and leaving the vehicle disabled. The dealer is currently attempting to charge for diagnostics and battery removal. I am asserting that the lack of a timely remedy for the coolant pump (which was only recently shielded per the recall) caused a power surge that 'fried' the internal battery circuitry. This is a safety issue as the vehicle experienced a sudden loss of propulsion while in motion. I request that NHTSA investigate BMW’s refusal to cover battery failures caused by the electrical interference of the recalled coolant pump."

NHTSA complaint #11707138 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

High pressure fuel pump replaced after the original recall and fail again 45k miles later during driving.

NHTSA complaint #11665204 — an unverified report by a vehicle owner.

FUEL SYSTEM, DIESEL

The contact owns a 2016 BMW X5. The contact stated that the vehicle was repaired under NHTSA Campaign Number: 21V586000 (Fuel System, Diesel); however, the repair failed to prevent the failure from occurring. The contact stated that on three separate occasions, the same recall failure had occurred. The vehicle was towed to the same local dealer where it was diagnosed with a fuel pump failure due to debris inside the fuel pump. The vehicle was not repaired due to the cost. The manufacturer was made aware of the failure. The failure mileage was approximately 40,239.

NHTSA complaint #11657914 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Fuel injectors, transfer case prop shaft

NHTSA complaint #11621362 — an unverified report by a vehicle owner.

FUEL SYSTEM, DIESEL:DELIVERY:FUEL PUMP

The contact owns a 2016 BMW X5. The contact stated while driving at approximately 50 MPH, the vehicle stalled. The message "Drivetrain Failure" was displayed on the instrument panel. The vehicle failed to restart. The vehicle was not drivable and was towed to a dealer where it was diagnosed that the high-pressure fuel pump had failed. The contact stated that the fuel system needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 129,000.

NHTSA complaint #11617222 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The engine light came on while I was 250 miles from home and on a Saturday. Was able to contact my dealer's service department who said to drive home and just monitor for any issues and hopefully it will be ok. I brought the vehicle in for diagnostic check following week. Faults were for the diesel particulate filter sensor and recommended $1300. replacement. They couldn't tell me if this part would impair the driving ability of the vehicle, but the cost seemed excessive for a sensor so I haven't made the repair yet (nor driven far) pending checking more into this. They said the vehicle may go into limp mode at any time which would be a safety issue. This sensor has been on a limited warranty extension-10 years/120,000 miles for the same model/engine as mine for 2014-2015 models (mine is 2016). [XXX] with 2016 X3 added in 2019. I have to ask why the 2016 yr with a faulty sensor like mine is not part of this extended warranty?? My vehicle has 80K miles and 8 yrs old.and the dealer says the part is faulty. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11550584 — an unverified report by a vehicle owner.

FUEL SYSTEM, DIESEL

The contact owns a 2016 BMW X5. The contact received notification of NHTSA Campaign Number: 21V907000 (Fuel System, Diesel) however, the part to do the recall repair was not yet available. The dealer was made aware of the issue. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact had not experienced a failure. VIN tool confirms parts not available

NHTSA complaint #11476886 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

ACCORDING TO THE MANUFACTURER STICKER BMW X5 5.0 GETS 15/21MPG. I WISH I GET ANYWHERE NEAR THAT. I GET ABOUT 11 AVERAGE MPG. I TOOK THE CAR TO THE DEALER TWICE AND I CALLED BMW NORTH AMERICA AND THEY SAID THAT IS THE WAY IT IS. YOU WILL NEVER GET WHAT YOU SEE ON THE STICKER. SO WHEN YOU BUY A CAR NEVER TRUST WHAT THEY SAY ON THE STICKER PRICE.

NHTSA complaint #11043266 — an unverified report by a vehicle owner.