Overheating 2018 35d

[stocktree]

That sucks. Was this caused by an error from the mechanic who had worked on it?

[bmwPower99]

Originally Posted by Harv

Intake manifold failed and caught fire.
Ever since I got it back it smelled more dieselie than it used to. I chalked it up to the ECU’s and other modules being reset and it was learning.

It coughed, sputtered and felt like it ran backwards for a second in rush hour traffic while my family and I all loaded up with suitcases on our way to the airport for vacation in Maine.
Flights missed, trip canceled.

My enthusiasm has left the building.

BMW customer care (good will) offered me a 1000 off a new BMW till December 31’st for the last issue. What a joke.

John

In the UK Intake melting and setting the car on fire is why we have the egr cooler safety recall.

[Harv]

We also had (and mine was complied with) the EGR recall. I’ll have to look in my records but I think it’s under warranty until 100k miles.

John

[Clifton]

Originally Posted by Harv

We also had (and mine was complied with) the EGR recall. I’ll have to look in my records but I think it’s under warranty until 100k miles.

John

DOH!!! Sorry to hear about all of this, John. I was going to suggest EGR Recall, but looks like you are on it.

I've been a little suspicious of the EGR Recall overall. The recall is a targeted repair, but it does not take into account other issues that it might have caused, i.e., Clogged DPF, Engine wear from consuming coolant via intake, down stream pressure sensors, sticking EGR valve.

Add your case of overheating to that list. Makes me wonder if smoldering plastic from the intake/EGR/coolant issue could cause increased temps in the head leading to gasket failure. Hmmm....

Please keep us posted.

[Harv]

Yea, I’m of the opinion that this is what started the whole thing. The very first “issue” that it had was low coolant indication. This was soon followed by high engine temp as I pulled off the highway to check. I had let it cool, topped off the coolant and had no issues the next 4+ hours to Asheville (from Cleveland). I had BMW of Asheville check it over and they found nothing. When it got hot again in TN on the way home is when I think the head gasket popped or maybe before? Who knows? After the HG repair the overheating was gone and the coolant level was consistent. I took it on two, 2+ hour trips last weekend and it performed perfectly. The only criticism was a slight diesel exhaust smell after I’d shut down and get out of it. At first I wasn’t sure about that as the under hood had that new gasket smell.

Drove a Ford Raptor today.
Didn’t hate it but I don’t know if I’m a truck guy.

[jbfrancis3]

Beyond frustrating. The intake manifold must've been chock full of carbon deposits. Did the service advisor or tech if you spoke to them mention this? Not that it would have been cheap to replace; probably nearly $2k

Recognizing that it hasn't been dug into yet - is there any downstream damage anticipated from a failed intake? Or just replace the intake manifold and all should be good?

If I were in your shoes - and I'm pretty close - I'd be wondering what other emissions bullcrap I'll continue to chase even if this does get fixed. Items in the exhaust stream, for example. Not envious of the predicament and sorry to hear about the vacation derailment.

[Harv]

Well, the kicker was this was all disassembled during the head gasket repair. I asked about walnut blasting but they didn’t have the adaptor for the intake ports of the N57. The intake manifold wasn’t too bad and the tec said he would clean it. I’m in favor of maintaining the emissions system until I can’t. I do like the way it is stock (I’m no stranger to highly modified cars). The issue I grapple with is the emissions system is there for less (cancer causing) soot. However without it the engine runs better, is cheaper to own, and dare I say a more responsible use of a fossil fuel.



Who knows?

John

[Clifton]

Harv - Check out the recent thread. The Intake ports were clogged with gunk and there is a coolant pipe to put on your list if you are repairing the intake.

[Harv]

Originally Posted by Clifton

Harv - Check out the recent thread. The Intake ports were clogged with gunk and there is a coolant pipe to put on your list if you are repairing the the intake.

Great advice.

John

[Harv]

Emixon

I couldn’t figure out how to send a pic of my hpfp recall within the messages🤷*♂️

Here they are.

[milkyway]

To OP/Harv/John, thank you for sharing this with us, please keep us updated. I have read/followed this thread. I believe you had not done the latest EGR recall with available remedy starting early this year. Please correct me if I'm wrong. If that's the case, your 18 35d loss of coolant, burned intake manifold are the exact syndrome and damage this EGR recall tries to address and avoid. I think you need get the dealer/BMW accountable for all this ordeal. I can't believe the dealer(s) didn't check/do this recall when you first brought it in with loss of coolant and overheat.

[Harv]

This latest fiasco is all covered under the extended warranty. My car had been complied with when the original recall came out. I’ll look in my records to see how it was complied with.

John

[milkyway]

Glad to know at least it's all covered by extended warranty. Please let's know if your EGR cooler and even the intake manifold (if pressure test fails) were changed per the latest recall starting early this year (your posted recall letter was the old one when remedy EGR cool was not available, did you get new one with remedy early this year?). If it was done, either the job wasn't done right or the recall replacement doesn't fix the issues. I'm afraid it was not done before you experienced this fiasco.

Originally Posted by Harv

This latest fiasco is all covered under the extended warranty. My car had been complied with when the original recall came out. I’ll look in my records to see how it was complied with.

John

[Harv]

The receipt above shows it was completed (date obscured) 10/27/22. New cooler and stuff but same intake. I was not having any problems when it was done.

John

[milkyway]

Originally Posted by Harv

The receipt above shows it was completed (date obscured) 10/27/22. New cooler and stuff but same intake. I was not having any problems when it was done.

John

Sorry not noticing the EGR replacement receipt earlier. Interesting. So, looks like your same/old intake manifold already had a lot carbon deposit/soot mixed with leaking coolant before new EGR cooler replacement or/and new EGR cooler didn't do job for some reasons. When the intake burned, did you happen to know any coolant loss, too?

[Harv]

Originally Posted by milkyway

did you happen to know any coolant loss, too?

Not this time around……..

John

[milkyway]

Originally Posted by Harv

Not this time around……..

John

I bet you have asked/going to ask the dealer/BMW why this(burned intake manifold) happened with all those prior fix and preventive work, to get the bottom of it. Hopefully they can give you an honest answer. My wild guess is the old intake manifold and cylinder head intake ports might have enough old carbon deposit mixed with old leaked coolant (wish this is part of EGR recall and they cleaned them thoroughly or/and installed a new intake manifold when they did the EGR recall and head gasket replacement) , and they couldn't handle the exhaust volume and temperature with the new EGR.

[Harv]

Just so the time line is sure

The egr cooler recall was completed in 2022. There were no problems at that time with the egr cooler but the recall was done.

Then this spring, May 18, 2023 is when the first symptom (low coolant level) came about (beginning of this thread).

Head gasket replacement.

Few days of trouble free driving with two 2.5hr trips each way with no problems.

Then the egr intake failure.

John

[jbfrancis3]

So you noted earlier the intake wasn't too bad and I saw the technician noted "Intake OK".

Dumb question: what's the difference between the large plastic primary intake and the EGR intake (which failed)?

[Harv]

Originally Posted by jbfrancis3

So you noted earlier the intake wasn't too bad and I saw the technician noted "Intake OK".

Dumb question: what's the difference between the large plastic primary intake and the EGR intake (which failed)?

No. “The intake wasn’t too bad” was during the head gasket replacement. The Tec note saying it was ok was during the warranty egr replacement in 2022.

I’m guessing that the egr intake is the forward bolted on piece of the intake manifold.

John

[milkyway]

Originally Posted by Harv

No. “The intake wasn’t too bad” was during the head gasket replacement. The Tec note saying it was ok was during the warranty egr replacement in 2022.

I’m guessing that the egr intake is the forward bolted on piece of the intake manifold.

John

What cautght fire, intake manifold or EGR? Although they are bolted together by some kind of mixing/combining pipe, they’re still different parts. It would be very surprising EGR caught fire because it’s almost new, and mostly metal (except the valve, which might be still the old/clogged one not replaced/cleaned during the recall service )rather than plastic intake manifold.

[Harv]

Originally Posted by milkyway

What cautght fire, intake manifold or EGR? Although they are bolted together by some kind of mixing/combining pipe, they’re still different parts.

The EGR failed causing normal carbon deposits in the intake to catch fire, thus melting the intake.

In the EGR recall you can see this under “what can happen”.

John