IllustrationI HAVE A DIESEL THAT THE SCR TANK THAT HOLDS THE DIESEL EMISSION FLUID HAS A FAULTY LEVEL SENSOR P203E ERROR CODE. A. CHECK ENGINE IIGHT IS ALWAYS ON. BMW HAS EXTENDED WARRANTY OF 10 YR/120,000 MILES. SEVERAL OF THE DIESEL BMW HAVE THIS TANK ASPART OF THE EXTENDED WARRANTY BUT NOT MINE. LIGHT HAS BEEN ON FOR A YEAR.
2015 BMW X3
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2015 BMW X3 do not stand out strongly from the model-year median of 86.
About this comparison →How this year compares
Owner complaints by model year
Compare all X3 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
150–25K
925–50K
1250–75K
775–100K
8100–150K
2150K+
53 reports with mileage · 52 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine. Review the 29 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 22 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. Review the 15 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
8 crash reports7 fire reports2 injury reports
Engine complaints
29 reportsI WAS DRIVING MY 2015 BMW X3 DIESEL ON ROUTE 2 WEST NEAR ROUTE 128 NORTH ENTRANCE, I LOST POWER AND "POWERTRAIN MALFUNCTION" WARNING ALERT CAME ON DISPLAY DASHBOARD, I WAS ABLE TO BARELY COAST THE VEHICLE OVER TO THE BREAKDOWN LANE OF ROUTE 2 WEST. AFTER PULLING OVER TO BREAKDOWN LANE IT STARTED TO SMOKE UNDER THE HOOD OF THE V…
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I WAS DRIVING MY 2015 BMW X3 DIESEL ON ROUTE 2 WEST NEAR ROUTE 128 NORTH ENTRANCE, I LOST POWER AND "POWERTRAIN MALFUNCTION" WARNING ALERT CAME ON DISPLAY DASHBOARD, I WAS ABLE TO BARELY COAST THE VEHICLE OVER TO THE BREAKDOWN LANE OF ROUTE 2 WEST. AFTER PULLING OVER TO BREAKDOWN LANE IT STARTED TO SMOKE UNDER THE HOOD OF THE VEHICLE AND WITH FEW MINUTES FIRE STARTED IN THE ENGINE COMPARTMENT AND LESS THAN 10 MINUTES VEHICLE ENGINE COMPARTMENT WAS FULLY ENGULFED IN THE FIRE. ON OCTOBER 11TH OF 2019, I HAVE MY 2015 BMW X3 BROUGHT TO WAGNER BWM OF SHREWSBURY MA TO PERFORM THE OPEN RECALL FOR EGR COOLER WHICH WAS NOTIFIED BY BMW MANUFACTURER. DEALER PERFORM THE INSPECTION FOR SIGNS OF CONTAMINATION OR CORROSION AND PERFORM COUPLE OF OTHER TEST, BUT DID NOT FOUND THE ISSUE AT THAT TIME, HENCE THERE WERE NO REPAIR WAS DONE TO CORRECT THE OPEN RECALL. BWM MANUFACTURES SHOULD HAVE REQUIRED ALL EFFECTED VEHICLE TO BE REPAIRED INSTEAD OF JUST LETTING DEALER INSPECTION THE VEHICLE, ESPECIALLY, BWM MANUFACTURE STATES THAT EGR MODULE COULD DEVELOP A COOLING-FLUID LEAK. HEATED COOLANT COULD MIX WITH DIESEL ENGINE SOOT AND MELT THE INTAKE MANIFOLD. THAT COULD LEAD TO FIRE.
EGR COOLER FAILED AT 70,000 +/- MILES. WASN'T LEAKING COOLANT INSIDE, BUT WAS LEAKING EXHAUST GASSES INTO CABIN AND WAS NOT COVERED UNDER RECALL CAMPAIGN. BMW COULD NOT PROVIDE NEW UPDATED PART, BUT CHARGED US FOR 'NEW / OLD STYLE UNIT' FOR ABOUT $2600. TRIED TO WORK ISSUE OUT WITH BMW CORP ON EMISSION WARRANTY, BUT WAS UNSUCCES…
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EGR COOLER FAILED AT 70,000 +/- MILES. WASN'T LEAKING COOLANT INSIDE, BUT WAS LEAKING EXHAUST GASSES INTO CABIN AND WAS NOT COVERED UNDER RECALL CAMPAIGN. BMW COULD NOT PROVIDE NEW UPDATED PART, BUT CHARGED US FOR 'NEW / OLD STYLE UNIT' FOR ABOUT $2600. TRIED TO WORK ISSUE OUT WITH BMW CORP ON EMISSION WARRANTY, BUT WAS UNSUCCESSFUL. VEHICLE STILL HAS UNSATISFIED RECALL ON IT FOR EGR COOLER. VEHICLE ALSO IS NOT ISSUING A 'DEF' NOTIFICATION. I HAVE BEEN IN THIS INDUSTRY FOR 44 YEARS AND KNOW THAT THIS VEHICLE SHOULD BE CALLING FOR DEF. I HAVE DEALT WITH THIS IN FORD, PETERBILT AND KENWORTH VEHICLES AND BMW'S SYSTEM IS NOT REPORTING.
BMW DIESEL RECALL - WHILE DRIVING ON HIGHWAY MY VEHICLE CAUGHT FIRE AND BURNED. THE CAR IS A TOTAL LOSS. THERE WAS NO WARNING LIGHTS WHEN THE CAR WAS STARTED TO INDICATE ANYTHING WAS WRONG. THE CAR LOST POWER AT 72 MPH AND MY HUSBAND WAS ABLE TO GET THE CAR TO THE SHOULDER OF THE HIGHWAY.
CHECK ENGINE LIGHT ON DIESEL ENGINE COME ON MULTIPLE TIMES SINCE CAR HIT 40K MILES. LUCKILY IT'S UNDER WARRENTY, OVER 10K IN REPAIRS IN 2 MONTHS. NEW FILE INJECTORS, OIL PUMP, DTF FILTER, ECT.
ON MARCH 4, 2018, WHILE AT A RED LIGHT AT AN INTERSECTION IN BOCA RATON, FL, ALL OF SUDDEN, NO WARNING, MY BMW X3 STARTED TO SMELL OF SMOKE, THEN SMOKE STARTED TO COME OUT OF THE HOOD. I HAD TO BARELY MAKE IT TO THE SIDE OF THE ROAD, LEAVE IT AT AN ENTRANCE OF A PLAZA, WHICH THEN BEGAN TO SMOKE OVERWHELMINGLY. ONCE I MADE IT OUT…
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ON MARCH 4, 2018, WHILE AT A RED LIGHT AT AN INTERSECTION IN BOCA RATON, FL, ALL OF SUDDEN, NO WARNING, MY BMW X3 STARTED TO SMELL OF SMOKE, THEN SMOKE STARTED TO COME OUT OF THE HOOD. I HAD TO BARELY MAKE IT TO THE SIDE OF THE ROAD, LEAVE IT AT AN ENTRANCE OF A PLAZA, WHICH THEN BEGAN TO SMOKE OVERWHELMINGLY. ONCE I MADE IT OUT OF THE CAR, THE FLAMES CAME OUT OF THE HOOD AND THE CAR BECAME FULLY ENGULFED WITHIN SECONDS.
I WOULD LIKE TO FILE A COMPLAINT ABOUT BMW OF NORTH AMERICA MISSING RECALLS ON MY VEHICLE IN 2015. I WAS NOT AWARE THE RECALL AND INFORMED ABOUT THE CAMSHAFT TIMING ADJUSTMENT VANOS ENGINE STALL ISSUE. THE ISSUE IS ABOUT THE BOLTS THAT SECURE THE HOUSING FOR THE VARIABLE CAMSHAFT TIMING ADJUSTMENT (VANOS) UNIT LOOSEN OVER TIME …
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I WOULD LIKE TO FILE A COMPLAINT ABOUT BMW OF NORTH AMERICA MISSING RECALLS ON MY VEHICLE IN 2015. I WAS NOT AWARE THE RECALL AND INFORMED ABOUT THE CAMSHAFT TIMING ADJUSTMENT VANOS ENGINE STALL ISSUE. THE ISSUE IS ABOUT THE BOLTS THAT SECURE THE HOUSING FOR THE VARIABLE CAMSHAFT TIMING ADJUSTMENT (VANOS) UNIT LOOSEN OVER TIME AND MAY POSSIBLY BREAK WHICH REDUCES THE POWER OF ENGINE OR STALL. I OWN A 2012 BMX X3 2.8I (VIN: 5UXWX5C58CLXXXXXX), STARTING LAST YEAR, MY CHECK ENGINE LIGHT HAS BEEN ON AND OFF FROM TIME TO TIME. I DID NOT UNDERSTAND THIS DEFECTIVE VANOS DESIGN WAS THE REASON UNTIL LAST MONTH I CHECKED MY VEHICLE IN FOR ENGINE PROBLEMS WITH RPM AUTOMOTIVE, THEY RAN A FULL DIAGNOSTICS AND CONFIRMED WITH ERROR CODES 130C01,130108 AND 131508 WHICH INDICATES VANO AND CAMSHAFT POSITION SENSORS FOR MY N52T 6-CYLINDER ENGINE. I CONTACTED BMW DEALER AT ORANGE PARK, FL, THEY IGNORED MY REQUEST AND TOLD ME MY VEHICLE IS NOT ON THE RECALL LIST. I HAVE DONE THE RESEARCH AND CONFIRMED MY VEHICLE X3 XDRIVE 28I IS ON THE RECALL LIST. PLEASE SEE THE RECALL AT HTTPS://WWW.EDMUNDS.COM/CAR-NEWS/BMW-RECALLS-156137-VEHICLES-FOR-LOOSE-BOLTS-THAT-COULD-LEAD-TO-ENGINE-STALL.HTML . I AM CONTACTING YOU TO REPORT THEIR RECALL MALPRACTICES, ENGINE SAFETY ISSUES AND FRAUD WARRANTY PROMISES. *JS PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
WHEN RAINY DAY , MY CAR SOMETIMES CAME OUT SMOKE ON A CITY STREET. I TOOK INTO DIFFERENT BMW DEARLER, BUT THEY CLAIM THAT IS THE DESIGN OF THE CAR, BECAUSE THE AVIATOR TOO CLOSE WHEN RAINING IT WILL CAME OUT SMOKE. I RECORDED AND SHOW TO THE SERVICE ADVISOR AND HE SHOW IT TO THE MECHANIC AND HE TOLD ME THAT IS WHAT THE MECHA…
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WHEN RAINY DAY , MY CAR SOMETIMES CAME OUT SMOKE ON A CITY STREET. I TOOK INTO DIFFERENT BMW DEARLER, BUT THEY CLAIM THAT IS THE DESIGN OF THE CAR, BECAUSE THE AVIATOR TOO CLOSE WHEN RAINING IT WILL CAME OUT SMOKE. I RECORDED AND SHOW TO THE SERVICE ADVISOR AND HE SHOW IT TO THE MECHANIC AND HE TOLD ME THAT IS WHAT THE MECHANIC TOLD HIM.
THERE WERE A TOTAL OF 4 INCIDENCES. 2/21/15 TOOK BMW X3 XDRIVE28I TO DEALER WITH 112 MILES ON CAR, AFTER CAR ENGINE REVVED HIGHER AS I WAS COMING DOWN A HILL TO A COMPLETE STOP. I HAD TO PRACTICALLY STAND ON THE BRAKE FOR CAR TO STOP. ACCELERATION LASTED ABOUT 4 SECONDS AFTER STOPPING. HAD TO KEEP MY FOOT ON BRAKE DURING THAT TI…
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THERE WERE A TOTAL OF 4 INCIDENCES. 2/21/15 TOOK BMW X3 XDRIVE28I TO DEALER WITH 112 MILES ON CAR, AFTER CAR ENGINE REVVED HIGHER AS I WAS COMING DOWN A HILL TO A COMPLETE STOP. I HAD TO PRACTICALLY STAND ON THE BRAKE FOR CAR TO STOP. ACCELERATION LASTED ABOUT 4 SECONDS AFTER STOPPING. HAD TO KEEP MY FOOT ON BRAKE DURING THAT TIME. IT HAPPENED A SECOND TIME ON THE WAY TO DEALER; GOING UP A SLIGHT HILL, WHILE COMING TO A COMPLETE STOP. PRIOR TO THE ABOVE DATE, ON 2/16/15, CAR ALSO ACCELERATED BY ITSELF WHILE DRIVING ABOUT 55 MPH ON THE HIGHWAY. I HAD TO STEP ON BREAK TO SLOW DOWN. LATER THAT DAY THE CAR ACCELERATED BY ITSELF WHILE ROLLING IN A PARKING LOT. I HAD TO BREAK HARD TO STOP IT. ON 2/21/15 THE DEALER REQUESTED BMW NA TO SEND THEIR ENGINEERS TO CHECK OUT THE CAR. 2/24/15 BMW NA ADVISED ME THAT "THE CAR ONLY DOES WHAT YOU TELL IT TO DO WITH ONE OF THE CONTROLS.THE ENGINEERS WILL BE GOING TO THE DEALERSHIP TO CHECK IF ANYTHING IS WRONG WITH" MY 2015 X3 XDRIVE. I ADVISED THEM "THEY WERE LOOKING FOR THE WRONG THING SINCE THERE IS SOMETHING WRONG WITH A CAR THAT ACCELERATES WHEN YOU ARE STEPPING ON THE BREAK." THEY "SHOULD BE LOOKING FOR WHAT IS WRONG WITH MY X3." 3/4/15 BMW NA ADVISED THAT ENGINEERS HAD LOOKED AT THE CAR AT THE DEALERSHIP AND IT WILL TAKE 7 TO 10 BUSINESS DAYS FOR THEIR DECISION. 3/10/15 BMW NA ADVISE ME THAT THE ENGINEERS CHECKED OUT MY X3 AND THE CAR IS "PERFORMING AS DESIGNED". I ASKED "IS THE X3 DESIGNED TO ACCELERATE WHEN YOU ARE TRYING TO STOP THE CAR?" THE DEALER ALSO SAYS THERE IS NOTHING WRONG WITH THE CAR. WHEN I TOLD DEALER "IF IT STARTS ACTING UP AGAIN I WILL BRING IT RIGHT BACK" DEALER SAID "THAT'S UP TO BMW". SINCE MY BMW X3 SOMETIMES ACCELERATES WHEN YOU ARE TRYING TO STOP AND WHILE AT ROAD SPEED, SOMETHING IS WRONG WITH THE CAR. EVERYTHING HAS TO GO THROUGH THE COMPUTER. MIGHT IT BE THE COMPUTER PROGRAM DESIGN? *TR
Official recalls
724V608000 · Electrical System:wiring:connectors/plugs/receptacles; Engine And Engine Cooling:cooling System:pump
Aug 13, 2024
BMW of North America, LLC. (BMW) is recalling certain 2012-2015 X1 sDrive28i, X1 xDrive28i, 2012-2016 Z4 sDrive28i, 528i, 528i xDrive, 328i, 328xi, 2016-2018 X5 xdrive 40e, 2014-2016 228i, 228xi, 428i, 428i xDrive, 328xi Gran Turismo, 2013-2017 X3 sDrive28i, X3 xDrive28i, 2015-2018 X4 xDrive28i, 2015-2016 428xi vehicles. An improperly sealed electrical connector on the water pump may be exposed to water and short circuit.
Consequence & remedy
Consequence: An electrical short increases the risk of a fire.
Remedy: Dealers will inspect and replace the water pump and plug connector as necessary, and install a protective shield, free of charge. Owner notification letters were mailed on March 28, 2025. Owners may contact BMW customer service at 1-800-525-7417.
Additional source detail variants (2)
Electrical System:wiring:connectors/plugs/receptacles
BMW of North America, LLC. (BMW) is recalling certain 2012-2015 X1 sDrive28i, X1 xDrive28i, 2012-2016 Z4 sDrive28i, 528i, 528i xDrive, 328i, 328xi, 2016-2018 X5 xdrive 40e, 2014-2016 228i, 228xi, 428i, 428i xDrive, 328xi Gran Turismo, 2013-2017 X3 sDrive28i, X3 xDrive28i, 2015-2018 X4 xDrive28i, 2015-2016 428xi vehicles. An improperly sealed electrical connector on the water pump may be exposed to water and short circuit.
Consequence: An electrical short increases the risk of a fire.
Remedy: Dealers will inspect and replace the water pump and plug connector as necessary, and install a protective shield, free of charge. Owner notification letters were mailed on March 28, 2025. Owners may contact BMW customer service at 1-800-525-7417.
Engine And Engine Cooling:cooling System:pump
BMW of North America, LLC. (BMW) is recalling certain 2012-2015 X1 sDrive28i, X1 xDrive28i, 2012-2016 Z4 sDrive28i, 528i, 528i xDrive, 328i, 328xi, 2016-2018 X5 xdrive 40e, 2014-2016 228i, 228xi, 428i, 428i xDrive, 328xi Gran Turismo, 2013-2017 X3 sDrive28i, X3 xDrive28i, 2015-2018 X4 xDrive28i, 2015-2016 428xi vehicles. An improperly sealed electrical connector on the water pump may be exposed to water and short circuit.
Consequence: An electrical short increases the risk of a fire.
Remedy: Dealers will inspect and replace the water pump and plug connector as necessary, and install a protective shield, free of charge. Owner notification letters were mailed on March 28, 2025. Owners may contact BMW customer service at 1-800-525-7417.
21V907000 · Fuel System, Diesel
Nov 19, 2021
BMW of North America, LLC (BMW) is recalling certain 2013-2018 328d, 328d xDrive, 2014-2018 328d Sports Wagon, 328d xDrive Sports Wagon, 2014-2016 535d, 535d xDrive, 2015 740Ld xDrive, 2015-2017 X3 xDrive28d SAV, and 2014-2017 X5 xDrive35d SAV diesel vehicles equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. The EGR cooler may leak internally, causing coolant to mix with diesel engine soot, which could result in smoldering particles and a melting intake manifold.
Consequence & remedy
Consequence: A melting intake manifold increases the risk of a fire.
Remedy: Dealers will replace the EGR cooler and inspect the intake manifold, replacing it as necessary, free of charge. This recall includes all vehicles previously recalled under 18V-755. Vehicles previously recalled under 18V-755 will need to have the new remedy performed for this recall. An interim owner notification letter was mailed on January 18, 2022. The remedy is expected to be available in June 2022. Owner notification letters were mailed on July 6, 2022. Owners may contact BMW customer service at 1-800-525-7417.
21V586000 · Fuel System, Diesel:delivery:fuel Pump
Jul 29, 2021
BMW of North America, LLC (BMW) is recalling certain 2014-2018 328d, 328d xDrive, X5 xDrive35d, 2014-2016 535d, 535d xDrive, 2015 740Ld xDrive, and 2015-2017 X3 xDrive28d vehicles. The high-pressure fuel pump may fail.
Consequence & remedy
Consequence: Fuel pump failure can cause an engine stall while driving, increasing the risk of a crash.
Remedy: Dealers will replace the high-pressure fuel pump, free of charge. Owner notification letters were mailed on January 14, 2022. Owners may contact BMW customer service at 1-800-525-7417.
18V755000 · Engine And Engine Cooling:exhaust System:emission Control:gas Recirculation Valve (egr Valve)
Oct 25, 2018
BMW of North America, LLC (BMW) is recalling certain 2013-2018 BMW 328d and 328d xDrive, 2014-2018 328d Sports Wagon and 328d xDrive Sports Wagon, 2014-2016 535d and 535d xDrive, 2015 740Ld xDrive, 2015-2017 X3 xDrive28d SAV and 2014-2017 X5 xDrive35d SAV vehicles equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. If the EGR cooler leaks internally, the coolant can mix with diesel engine soot. The high EGR temperatures may result in these particles possibly smoldering and melting the intake manifold.
Consequence & remedy
Consequence: The melting intake manifold can increase the risk of a fire.
Remedy: BMW will notify owners, and dealers will inspect and replace the EGR cooler as necessary. If a leak has already occurred, the engine intake manifold will also be replaced. These repairs will be made free of charge. The recall began May 13, 2019. Owners may contact BMW customer service at 1-800-525-7417.
16V683000 · Air Bags:frontal:driver Side:inflator Module
Sep 21, 2016
BMW of North America, LLC. (BMW) is recalling certain model year 2015 BMW X3 sDrive28i, X3 xDrive28i, X3 xDrive35i, X3 xDrive28d, X4 xDrive28i and X4 xDrive35i vehicles, and model year 2014-2015 X5 xDrive35i, X5 sDrive35i, X5 xDrive50i, and 2014 X5 xDrive35d vehicles. The affected vehicles have a driver's frontal air bag inflator that may have been improperly welded.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator housing could separate from the base plate and result in metal striking the vehicle occupants, potentially resulting in serious injury or death.
Remedy: BMW will notify owners, and dealers will replace the driver's front air bag, free of charge. The recall began on November 1, 2016. Owners may contact BMW customer service at 1-800-525-7417.
16V333000 · Child Seat:latch Strap
May 23, 2016
BMW of North America, LLC (BMW) is recalling certain model year 2011-2017, X3 sDrive28i, X3 xDrive28i and X3 xDrive35i, vehicles manufactured July 2, 2010 to April 14, 2016, 2015-2017 X3 xDrive28d vehicles manufactured March 10, 2014 to March 31, 2016, and 2015-2017 x4 xDrive28i, X4 xDrive35i and X4 xDriveM40i vehicles manufactured March3, 2014 to April 15, 2016. The affected vehicles have lower anchor bars for securing child restraint seats that may become damaged when using the European-ISOFIX-type, rigid-style connector, child restraint system.
Consequence & remedy
Consequence: Damaged lower anchor bars may increase the child's risk of injury in the event of a crash.
Remedy: BMW will notify owners, and dealers will weld a reinforcing bracket to the lower anchor bars and the vehicle body, free of charge. The recall began on July 13, 2016. Owners may contact BMW customer service at 1-800-525-7417.
14V648000 · Visibility:rearview Mirrors/devices:exterior
Oct 16, 2014
BMW of North America, LLC (BMW) is recalling certain model year 2015 X3 and X4 Sports Activity Vehicles manufactured July 28, 2014 to July 29, 2014. The affected vehicles may have been produced with a driver's side exterior rearview mirror that was designed to meet non-US market requirements. Thus, these vehicles fail to comply with the Federal Motor Vehicle Safety Standards No. 111, "Rearview Mirrors."
Consequence & remedy
Consequence: The driver may not notice that vehicles viewed in the mirror are closer than they appear, increasing the risk of a crash.
Remedy: BMW will notify owners, and dealers will replace the driver's side exterior rearview mirror, free of charge. The recall began on December 16, 2014. Owners may contact BMW customer service at 1-800-525-7417 or CustomerRelations@bmwusa.com.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
2EA23001 · High Pressure Fuel Pump Failure
Opened Mar 17, 2023 · No close date supplied
Status: open (inferred from source dates) · Fuel System, Diesel:delivery:fuel Pump
The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA and BMW.During the investigation FCA filed recalls 22V406, 22E048, 22V767, and 22E087 which include vehicles not identified in the initial subject population by ODI. ODI also received recall 21V586, involving loss of motive power due to failed CP4 fuel pumps on certain BMW manufactured vehicles. An information request letter response received from BMW indicated that failed pumps on their vehicles were caused by an interaction between pump internal components and US market diesel fuel, leading to increased slip and eventual particle-generating wear surface. Additional work will be done to identify whether a similar root cause is associated with the FCA recalled population and if similar wear dynamics occur on pumps supplied to vehicle manufacturers other than those included in the recalled population.ODI has upgraded this investigation to an EA in order to 1) determine engineering specifications of internal pump components that are correlated with pump failure leading to loss of motive power or other safety related hazards, 2) identify vehicle populations equipped with alleged defective pump variants, 3) assess if vehicles equipped with alleged defective pump variants result in an unreasonable risk to motor vehicle safety and 4) gather and review any other relevant information related to high pressure fuel pump failure associated with the subject populations of recalls 21V586, 21V880, 21E094, 22V406, 22E048, 22V767, and 22E087.Review of the above information will allow NHTSA to confirm root cause and recall remedy viability, and identify and evaluate vehicle populations equipped with pump components that may pose an unreasonable risk to motor vehicle safety.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11257550, 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11377871, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11446542, 11448163, 11453556, 11458918, 11460558, 11469337
EA21002 · Desiccated Air Bag Inflator Rupture
Opened Sep 17, 2021 · No close date supplied
Status: open (inferred from source dates) · Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Additional source detail variants (2)
Air Bags:frontal:driver Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.