2016 BMW X5

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

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.

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

The contact owns a 2016 BMW X5 PHEV. The vehicle was serviced under NHTSA Campaign Number: 24V608000 (ENGINE AND ENGINE COOLING, ELECTRICAL SYSTEM), but the failure persisted. The contact stated that a month after the repairs were completed, the coolant connector would stay on and drain the battery. The contact stated that after the vehicle was turned off at night, the coolant connector overheated and the battery drained. The contact needs to jump-start the battery every day. The vehicle was taken to the dealer, and the dealer refused to repair the vehicle, stating that it was already repaired. The contact stated that the coolant connector damaged the EME (Electrical Machine Electronics). The dealer confirmed that the problem may be EME. The vehicle remained at the dealer unrepaired. The contact stated that the failure is worsening. The manufacturer was not made aware of the failure. The failure mileage was 114,865.

NHTSA ID

11735914

Incident

Mar 27, 2026

Mileage

114,865 mi

Spontaneous sunroof shatter.

NHTSA ID

11731996

Incident

Apr 17, 2026

I am having a high voltage system box fault. I am within warranty but the dealership is denying me. My in service date is 6-2016.

NHTSA ID

11728895

Incident

Dec 10, 2025

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 ID

11719865

Incident

Dec 16, 2025

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 ID

11707138

Incident

Sep 23, 2023

During a recent auto collision my airbags did not deploy. I swerved to avoid another vehicle entering the intersection from my left, he hit my rear left driver's side quarter panel and I subsequently hit a tree. This was noted by the paramedics first on scene as well as by the firemen and police when they arrived. I have notified BMW of North America, USAA insurance (my insurance company), and now you. The vehicle is a total loss and was towed to Leesburg Virginia by roadrunner wrecker service.com

NHTSA ID

11707095

Incident

Dec 24, 2025

Because of this water intrusion, the following safety systems have malfunctioned or failed: • ABS and DSC (stability control) warnings • Chassis stabilization warning • Frontal collision and pedestrian warning malfunction • Airbag system warning • Loss of audible warning tones • MOST bus communication failure • Electrical modules intermittently shutting down or throwing codes These failures affect braking, stability control, crash avoidance, and driver alerts, creating a significant safety risk while driving. This is not normal wear or maintenance. Many BMW owners have reported the same issue: clogged or poorly designed sunroof drains that route water directly into areas containing critical electronics. Once water reaches these modules, it causes electrical shorts and safety system failures that require expensive repairs. BMW dealerships typically diagnose this as “water damage,” but the location of the drains and the placement of the electronics indicate a design flaw that allows a simple drain issue to disable major safety systems. I am filing this complaint because the water intrusion should not be able to cause total failure of ABS, DSC, collision warning, and airbag-related systems. This is a safety-related design defect, not wear and tear. I request NHTSA review and investigate BMW sunroof drain failures and their impact on essential vehicle safety functions.

NHTSA ID

11700942

Incident

Sep 19, 2025

I am reporting a safety issue related to the BMW recall 18V-755 affecting the EGR cooler on my 2016 BMW X5 diesel. My vehicle experienced symptoms consistent with a failing EGR cooler, including coolant loss and engine warning lights. Despite this recall being active for my model and VIN, BMW has denied coverage, stating either that the cooler was already replaced twice or that my vehicle is not eligible—without providing sufficient documentation or explanation. I am concerned that the recall remedy was not properly applied or that faulty replacement parts were used. I am requesting that NHTSA investigate whether BMW is properly honoring recall 18V-755 and ensuring safe, effective remedies are provided to affected customers like myself. I also request investigation into the lack of transparency and failure to document completed recall work. My VIN is [XXX] , and I can provide dealer records, service history, and diagnostic reports upon request. * What component or system failed or malfunctioned, and is it available for inspection upon request? EGR Cooler, it is available for inspection. * How was your safety or the safety of others put at risk? The vehicle is now showing dangerous symptoms consistent with a thermal event risk, which this recall specifically warned about. The EGR cooler is leaking coolant into the intake system, which can mix with soot and lead to engine fires, according to BMW’s own technical documentation. * Has the problem been reproduced or confirmed by a dealer or independent service center? Yes and the cooler has been replaced twice. * Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? It has been inspected at Fremont BMW once, Valley BMW twice. * Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Yes, low coolant warning, loss of coolant with no leaks. Problem first occurred April 2024 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION AC

NHTSA ID

11677407

Incident

May 29, 2025

N63TU1 CLASS ACTION SETTLEMENT SVC CAMPAIGN: OIL CONSUMPTION DIAGNOSIS/REPAIR

The Exhaust Gas Recirculation (EGR) Cooler (with EGR Valve) and the Auxiliary Exhaust Gas Recirculation (EGR) Cooler limited warranty for defects in materials and / or workmanship has been extended to 25 years without mileage limit as determined from the original first in-service / delivery date.

The electric auxiliary heater assembly limited warranty for defects in materials and / or workmanship has been extended to 10 years / 120,000 miles as determined from the original first in-service / delivery date

The High-Voltage (HV) Battery Assemblys Cell Modules Temperature Sensors (Internal NTC repair kit-specific) limited warranty for defects in materials or workmanship has been extended to 10 years / 120,000 miles as determined from the original in-service/first delivery date

The High-Voltage (HV) Battery AssemblysCell Modules Temperature Sensors (Internal NTC repair kit-specific) limited warranty fordefects in materials or workmanship has been extended to 10 years / 120,000 miles asdetermined from the original in-service/first delivery date.

The vehicle demonstrates a power loss and the malfunction indicator lamp (MIL) on. The following fault codes may be stored in the DDE: 24CE00 Hot film air mass meter: Ratio of measured to calculated air mass too high 27F000 Charge air hose monitoring in idle: Charge air hose fallen down 290900 Air system, air to EGR air mass flow plausibility: Measured air mass compared to calculated air mass too high 290A00 Air system, air to EGR air mass flow plausibility: measured air mass compared to calculated air mass too high and high charging pressure control deviation