BMW is recalling more than 136,000 vehicles with fuel pumps that may fail and cause the engines to stall. BMW also says the in-tank fuel pumps can cause fuel leaks, possibly causing fires.
The long list of vehicles include the following:
- 2007-2011 BMW X5 3.0si
- 2007-2011 BMW X5 4.8i
- 2007-2011 BMW X5 M
- 2007-2011 BMW X5 xDrive30i
- 2007-2011 BMW X5 xDrive35i
- 2007-2011 BMW X5 xDrive48i
- 2007-2011 BMW X5 xDrive50i
- 2008-2011 BMW X6 xDrive35i
- 2008-2011 BMW X6 xDrive50i
- 2008-2011 BMW X6 M
- 2010-2011 BMW X6 ActiveHybrid
- 2010-2011 BMW 535i xDrive Gran Turismo
- 2010-2011 BMW 535i Gran Turismo
- 2010-2011 BMW 550i xDrive Gran Turismo
- 2010-2011 BMW 550i Gran Turismo
- 2011-2012 BMW 528i
- 2011-2012 BMW 535i
- 2011-2012 BMW 535i xDrive
- 2011-2012 BMW 550i
- 2011-2012 BMW 550i xDrive
- 2012 BMW 535i ActiveHybrid
- 2012 BMW 640i Convertible
- 2012 BMW 650i Convertible
- 2012 BMW 650i xDrive Convertible
- 2012 BMW 650i Coupe
- 2012 BMW 650i Coupe xDrive
The automaker says the fuel delivery module contains an in-tank fuel pump with wiring that may not have been crimped enough. Engineers determined the insufficient crimps can cause an increase in contact resistance which can lead to heating of the contact pins.
The plastic around the contact pins can melt and cause fuel to leak after refueling or when the vehicle travels around a corner. In addition to the possibility of fuel pump failure, leaking gas near an ignition source isn't good for anyone.
In June 2011, BMW started hearing customer complaints involving gas odors from the cars but believed a warning light would be good enough to tell consumers to have their cars serviced. But by September 2014, more warranty claims and customer complaints were coming in, so BMW issued a worldwide extended warranty program involving the fuel delivery module of affected vehicles which provided coverage for 10 years/unlimited mileage.
However, the automaker did decide to recall vehicles for the problem in China, then that recall was extended to Japan. By June 2016, BMW initiated a "service action" in Korea after Korean authorities asked BMW to do something about the gas odor complaints.
In the U.S., the automaker determined having a vehicle fixed under the extended warranty seemed to take care of the problem, but customers who didn't have their cars serviced were still having problems.
BMW says if a vehicle doesn't have the fuel delivery module replaced as part of the extended warranty, the smell of gasoline is only one possible problem. Owners have also complained about their cars failing to start, or cars that stall while driving.
BMW doesn't know of any accidents or injuries caused by the defect, but the automaker went ahead with a recall so owners will be pushed to have their cars repaired.
The BMW recall should begin December 5, 2016, when dealers will start replacing the fuel pump modules.
If you own one of the affected vehicles and it wasn't repaired under the extended warranty, feel free to call BMW at 800-525-7417.