2016 BMW 5 Series Fuel System Problems

Vehicle: 2016 BMW 528i xDrive (VIN: [XXX]) Safety Issue / Defect Description: Strong, hazardous raw gasoline fumes began entering the passenger cabin and trunk area. On XXX, the vehicle was brought to an authorized dealership (BMW of Sterling) for diagnostic evaluation. The dealership's technician conducted a multi-point inspection and produced video evidence documenting fluid leaking from the top of the plastic fuel tank. The dealership issued Repair Order Quote #$4,824.92 to "REPLACE FUEL TANK DUE TO FUEL LEAK" and declared the vehicle unsafe. Despite diagnosing a structural fuel tank leak that allows raw gasoline and fumes to migrate into the cabin—presenting an immediate fire, explosion, and toxic vapor risk—BMW of North America and the dealership have refused warranty coverage or goodwill assistance, claiming the tank is "not leaking actively enough" under Service Bulletin SI B01 03 22 (NHTSA ID: MC-10212779-9999). An uncontained raw fuel leak on a plastic fuel tank is a critical safety defect that requires immediate investigation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The vehicle developed a strong, toxic odor of raw gasoline inside the passenger cabin and trunk area. The vehicle was brought to an authorized franchise, BMW of Sterling, where technicians performed a multi-point inspection. The technician confirmed that the factory plastic fuel tank assembly is structurally defective and leaking raw fuel from the top weld seams. The dealer provided an official invoice quoting $4,824.92 to replace the tank due to the fuel leak, noting it is an active hazard, but refused to cover the failure under BMW’s active 15-year/150,000-mile extended warranty for N20 plastic fuel tanks (SI B01 03 22). Driving a vehicle with raw fuel pooling on the exterior of the tank and migrating into the cabin creates an immediate fire hazard and health risk to occupants."

The contact owns a 2016 BMW 535D. The contact stated while driving approximately 25 MPH, the vehicle experienced a loss of motive power. No warning lights were illuminated. The vehicle was towed to a local dealer where it was diagnosed with high-pressure fuel pump failure. The vehicle was left at the local dealer, where it remained for further repairs. The vehicle was not repaired. Upon further investigation, the contact related the failure to NHTSA Campaign Number: 21V586000 (Fuel System, Diesel); however, the VIN was not included. The manufacturer was made aware of the failure. The failure mileage was approximately 116,000.

HIGH PRESSURE FUEL PUMP HAS SUDDENLY FAILED CAUSING A IMMEDIATE ENGINE STALL WITHOUT WARNING. WILL NOT RESTART EVEN THOUGH IT DOES TURN OVER. CODE READS LOW FUEL PRESSURE AT FUEL RAIL. FUEL TANK LIFT PUMP IS WORKING CORRECTLY. THERE IS A RECALL FOR SOME 2014 TO 2016 535D FOR THIS FAILURE. WHY IS MINE NOT COVERED? 122,400 MILES.

The contact owns a 2016 BMW 535D. The contact received a recall notification for NHTSA Campaign Number: 21V907000 (Fuel System, Diesel) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

BMW 528I 2016 CAR THAT IS LITTLE OVER 4 YEARS LESS JUST HIT 35K MILEAGE LOST ALL ITS FUEL INJECTORS, COILS AND PLUGS. BELOW IS THE SUMMARY OF DIAGNOSIS. 35146 FUEL INJECTORS FAULTY. CONFIRMED SES LIGHT IS ON. DME STORED SOURCED FROM THE VEHICLE MISFIRE FAULTS ON MULTIPLE CYLINDERS. DME ALSO STORED FAULT 118002 "MIXTURE TOO RICH," WORKED THROUGH TEST PLAN. PERFORMED ENGINE TEST AND MANUFACTURER AND BACKED BY DETERMINED CYLINDERS 1, 2, AND 4 INJECTORS FAULTY. DIAGCODE: ITS LIMITED WARRANTY. D1350 00000000 01 002. REMOVED ALL SPARK PLUGS AND FOUND SPARK PLUGS 2, 3, AND 4 FUEL SOAKED. RECOMMEND REPLACE ALL 4 FUEL INJECTORS AND SPARK PLUGS. ALSO RECOMMEND REPLACE ALL 4 IGNITION COILS AS A PREVENTATIVE TOTAL COST ESTIMATED IS AROUND $4500; BMW NORTH AMERICA IS NOT ACKNOWLEDGED THERE IS AN ISSUE WITH CAR OR MODEL

The contact owns a 2016 BMW 535D. The contact stated that the engine warning light was illuminated. 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 local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available. The approximate failure mileage was 65,000.