2017 BMW 330E

Component: Engine Cooling System: Turbocharger Coolant Return Line/Fitting (Part # 11538854735). Defect Summary: The factory turbocharger coolant return line on the B48 engine uses a plastic quick-disconnect fitting and O-ring mechanism positioned directly under the turbo. Extreme thermal cycling causes this plastic to degrade, become brittle, and fail or separate without warning, resulting in immediate, catastrophic drainage of pressurized engine coolant. Failure of Manufacturer Requirements: This component fails basic durability, material safety, and engineering standards for pressurized cooling systems. The design is so fundamentally flawed that authorized factory-trained technicians cannot permanently remedy it using OEM parts; the connection mechanism fails to maintain a pressurized seal under standard operational heat. Freeway Safety Incident: While traveling at high speeds in high-velocity freeway traffic, the fitting failed catastrophically without warning. The sudden coolant loss forced an immediate engine stall/power failure in active lanes. Navigating the powerless vehicle out of the middle of the freeway while surrounding traffic swerved nearly caused a severe, high-speed multi-vehicle collision. Inadequate Remedy & Recurrence: The vehicle was taken to an authorized dealership (BMW of the Woodlands, TX) for repair. However, within one week of dealership service, the new OEM line/O-ring completely disconnected again. This recurring separation completely drains the coolant within days, causing subsequent engine stalls, rendering the car undrivable, and repeatedly placing occupants in extreme danger. Thermal & Fire Hazard: Each failure sprays pressurized coolant onto a hot turbocharger and exhaust manifold, creating immediate risks of blinding smoke, vision obscuration, and engine bay ignition, compounded by thermal risks to the 330e hybrid powertrain battery electronics.

Hybrid battery has a failed cell. It was confirmed by BMW diagnostics but BMW refused to repair/replace failed cell even though it was under full 8yr/80k mile warranty. BMW claimed it as wear and tear, even though 1 out of 5 cells completely failed. The failure caused the car to run at reduced speeds causing others cars around me on the freeway to be in danger as all of sudden I am unable to reach freeway speeds due to part failure. There was an error stored in the car per BMW diagnostics that called for failed Cell to be replaced per notes of the technician who ran the diagnostics. The vehicle was inspected and confirmed by BMW. Yes, there was an error on the infotainment of the car. I advised of the error to BMW.

Unsure of the exact cause, appears to be the high voltage battery/electric drive function that is faulty. It is creating a hazardous condition causing the vehicle to propel itself forward while driving in traffic and almost hitting other vehicles on the roadway when the electric drive fails or it switches between battery and the engine. If it’s not propelling itself forward, it’s unexpectedly decreasing power and preventing the vehicle from driving after stopping for traffic, traffic signals and traffic signs. Increasing the risk for a rear-end collision. The electric drive is failing & rapidly switching between battery & engine multiple times in a short period. Likely increasing risk for a fire hazard. This is putting the driver & others on the roadway at risk due to increased collision and fire risks. Ferman BMW has recreated the issue. They advised it needed 2 new batteries, standard and the auxiliary battery. Those were replaced and the vehicle still is having issues. Six replaced 3 times. They now blame it on the high voltage batteries & their age. HV batteries are covered under warranty, yet Ferman BMW states they are not because there’s no fault code. Their position is the electric drive malfunction message is a notification & not a fault code. Despite duplicating the issues, having notice of the hazard they refuse to fix it. The message states “ Electric drive is temporarily restricted. You can continue driving. After cooling/heating of high-voltage battery full electric drive power will immediately be available.” A brief search will reveal many others with the same issue and some were successful in getting it handled under warranty. The car has been inspected by Ferman BMW 6 times. This is an ongoing issue with this model and a hazard to the driver, passengers and others on the roadways. Similar issues: [XXX] [XXX] Issue started 2022 car was only 5 yrs INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

What component or system failed or malfunctioned, and is it available for inspection upon request? Coolant lines How was your safety or the safety of others put at risk? The car would state that it is overheating a month after oil change and fluids replaced Has the problem been reproduced or confirmed by a dealer or independent service center? Dealer confirmed that there is a coolant issue Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? It has been inspected by the dealership. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Engine light, coolant low warning, overheat warning, I am also having issues with car start/stop controls. With my car at 58k miles on it I don’t think the auxiliary battery should be having issues like it does. I read that some starters could be the issue but there is no recall on my vehicle which is in the USA. I have only had the car for 5 months and have significant auxiliary battery issues which ping off a lot of different sensors. They are listed in the photo.

The contact owns a 2017 BMW 330E. The contact stated that the driver's and passenger’s side door handles were sticky, soft, and melting. There was also an unknown residue on the door handles. The contact attempted to clean the door handles but they continued to leave black residue on the occupant's hands. The local dealer was contacted but the vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA for assistance. The failure mileage was approximately 45,000.

WHILE THE CAR WAS PLUGGED IN OVERNIGHT IN THE GARAGE, (IT IS A HYBRID), A TERRIBLE ODOR WAS RELEASED AND CARBON MONOXIDE WAS DETECTED. FIRE DEPARTMENT WAS CALLED TWICE (THIS OCCURRED TWO NIGHTS IN A ROW) AND DETECTED HIGH LEVELS OF CO FROM INSIDE THE CAR AND FROM THE HOOD. WE NEEDED TO EVACUATE THE HOUSE EACH TIME. GAS COMPANY AND PLUMBER CONFIRMED THERE WAS NO OTHER ISSUES IN GARAGE. UPON REMOVAL OF THE CAR, ISSUES NO LONGER PERSIST. BMW CANNOT FIND ANYTHING WRONG WITH THE CAR, BUT I REFUSE TO TAKE THE CAR BACK, GIVEN SAFETY FOR MY FAMILY. THE VEHICLE WAS PARKED, TURNED OFF, LOCKED, AND CHARGING OVERNIGHT.

I'M LEASING BMW 330E. IN NOVEMBER 2017 I BROUGHT IT WITH 5,800 MILES FOR MAINTENANCE TO THE WEATHERFORD BMW; WAS ADVISED TREAD OF REAR SET OF TIRES IS DANGEROUSLY SHALLOW, UNDER 5 MM. THEY ALSO TOLD ME THAT FRONT SET IS STILL OK WITH 6 MM, BUT SOON NEEND TO BE ALSO REPLACED. I CONTACTED THE BMW NA, OFFERED A 50% DISCOUNT ON A SET OF NEW TIRES. THIS OCTOBER 2018 AT 2ND SERVICE SERVICE I WAS ADVISED THAT THE THREAD NOW ON THE REAR SET IS UNDER 3 MM AND PRESENTS A SAFETY HAZARD TO CONTINUE TO OPERATE. THE FRONT SET OF TIRES HAS ONLY 4 MM REMAINING THREAD. THE VEHICLE HAS ONLY 11,250 MILES ON THE ODOMETER. WHEN I CALLED THE BMA NA ABOUT THEIR LAST YEAR OFFER, I WAS TOLD THAT THEY HAVE "TAKEN THE OFFER OFF THE TABLE". BMW BILL FOR THE NEW 2 TIRE SET WITH BALANCING AND ALLIGNMENT AT $1,006.60 IS ATTACHED TO THIS EMAIL. THESE ARE RUN-FLAT CONTINENTAL CONTIPROCONTACT TIRES. THE CONTINENTAL TIRES COMPANY HAS RESPONDED TO MY ONLINE INQUIRY WITH THE ANSWER THAT THE ORIGINAL TIRES ON THE NEW CARS HAVE NO TREADWEAR WARRANTY, BUT THE REPLACEMENT OF THE SAME NEW TIRES DOES COME WITH A 40,000 MILES TREADWEAR WARRANTY. BMW SERVICE CHARGES $500- PLUS PER TIRE FOR REPLACENT, INCLUDING THE BALANCING, ALLIGNMENT AND TAX. SINCE THE AVERAGE MILEAGE IN THE USA PER CAR DRIVEN IS ABOUNT 12,000 MILES ANNUALLY AND THE BMW VEHICLES OWNERS, OR A LESSEES ARE SUPPOSED TO CHANGE IT AFTER JUST 12,000 BECAUSE THE NEW TIRES ARE WORN AND HAVE NO FACTORY, OR TIRE MANUFACTURER'S WARRANTY, THAT MEANS THAT THE ANNUAL COST FOR TIRES OF ONE BMW VEHICLE IS $2,000-. THAT IS UNACCEPTIBLE AND IS A DECEIVING PRACTICE. I SUSPECT THAT BMW FACTORY IN GERMANY PURPOSELY EQUIPPING THEIR NEW VEHCILES WITH SUBSTANDARD QUALITY UNWARRANTED CONTINENTAL RUN-FLAT TIRES TO WRECK ON UNSUSPECTING USA CONSUMERS THE COST OF ANNUAL REPLACEMENT WORTH OF $2,0000- PLUS ANNUALLY, OR $500- PLUS PER TIRE. PLEASE INVESTIGATE.

THE VEHICLE WAS IN MOTION ON THE HIGHWAY ON THE LEFT LANE OF TRAFFIC AT A SPEED OF 65MPH IN "EDRIVE" MODE. AS EXPECTED, IT SHIFTED FROM ELECTRIC TO COMBUSTION ENGINE AT 65MPH THOUGH THE AT THIS POINT THE CAR STARTED COASTING, AS IF IT WAS IN NEUTRAL, EVEN THOUGH THE INDICATOR ON THE GEAR SHIFT SHOWED "D". THE "CHECK ENGINE" LIGHT ALSO WENT ON. I FIRST ATTEMPTED TO SWITCH BACK TO ELECTRIC DRIVE ONLY ("MAX EDRIVE MODE") BUT TO NO AVAIL. I THEN DECIDED TO COAST TO THE EMERGENCY LANE TO THE RIGHT OF THE HIGHWAY BUT AFTER I MADE MY WAY TO THE MIDDLE LANE, THE TRAFFIC SLOWED DOWN AND I HAD TO USE THE BRAKE AND NO LONGER HAD ENOUGH MOMENTUM TO MAKE IT SAFELY TO THE EMERGENCY LANE. I FRANTICALLY TRIED SEVERAL TIME TO SHIFT THE "D" MODE SEVERAL TIME BUT ONLY MANAGED TO PUT THE GEAR SHIFT IN "N" (WITH NO WAY OF PUTTING IT BACK IN "D" MODE). AS OF LAST RESORT (I WAS NOW COASTING AT 10~5 MPH IN THE MIDDLE LANE OF THE HIGHWAY), I PRESSED THE START/STOP BUTTON AND THAT SOMEHOW RESET THE SYSTEM AND I WAS ABLE TO ACCELERATE ONCE AGAIN AND THE CHECK ENGINE LIGHT WENT OFF. I HAVE NOT HAD ANY ISSUE SINCE THIS INCIDENT (7/18 7PM PST) AND HAD IT CHECKED THE NEXT DAY BY THE DEALERSHIP WHO GAVE ME THE FOLLOWING EXPLANATION: CONNECTED CHARGER AND RAN SHORT TEST. FOUND FAULT FOR HIGH VOLTAGE BATTERY SHUT OFF DUE TO LOW CHARGE LEVEL. VEHICLE WAS NOT CHARGED CAUSING THE CUSTOMER COMPLAINT. CLEARED FAULTS CHARGED VEHICLE AND TEST DROVE. NO ISSUES AT THIS TIME I AM NOT SATISFIED BY THE EXPLANATION: MY BATTERY WAS NOT FULLY DEPLETED (THE CAR DROVE ON ELECTRIC SHORTLY AFTER THE INCIDENT WHEN I EXITED THE HIGHWAY).

I WAS DRIVING THE CAR WITH TWO PASSENGERS AND THE CAR SUDDENLY BECAME TOTALLY UNRESPONSIVE. I MANAGED TO COAST TO THE SHOULDER OF THE ROAD ON A VERY BUSY STREET. I CONTACTED BMW AND REPORTED THE PROBLEM. THE YELLOW ENGINE LIGHT WAS ON AND IT WAS STUCK IN PARK. I COULD NOT GET IT TO GO INTO REVERSE OR DRIVE. I TURNED THE CAR OFF AND ON TO NO AVAIL. THIS IS THE SECOND TIME THIS HAS HAPPENED. AFTER ABOUT 15 MIN THE CAR STARTED AND I MANAGED TO DRIVE TO MY HOUSE WHICH WAS CLOSE TO WHERE IT DIED ON THE ROAD. A TOW TRUCK IS ON ITS WAY TO BRING IT TO FLEMINGTON BMW. I REPORTED THE INCIDENT AT APPROXIMATELY 5:05 PM TO BMW CUSTOMER RELATIONS (TAWNY) WHO PROVIDED ME WITH YOUR WEBSITE. THE FIRST TIME THE CAR WAS BROUGHT INTO SERVICE THEY COULD NOT FIND ANY FAULT CODES WITH THE CAR AND THEY TOLD ME THAT IT WAS FUNCTIONALLY FINE. THEY ASKED IF I MIGHT HAVE ACCIDENTALLY TURNED THE CAR OFF WHILE DRIVING. BMW TOWED THE CAR TO THE DEALER AFTER THE FIRST INCIDENT. I DO NOT REMEMBER THE EXACT DATE BUT THIS COULD BE DETERMINED THROUGH ROAD SIDE ASSISTANCE. I TOLD BMW THAT THE CAR IS DANGEROUS AND I WOULD NOT DRIVE IT UNLESS THEY CAN DETERMINE WITH CERTAINTY WHAT IS WRONG. HAD I BEEN UNABLE TO COAST TO THE SIDE OF THE ROAD, THIS COULD HAVE RESULTED IN A LIFE THREATENING SITUATION. THE CAR WAS IN MOTION ON BOTH INSTANCES WHEN IT BECAME TOTALLY UNRESPONSIVE. ONCE AGAIN, THE CAR WAS IN PARK AND COULD NOT BE MOVED INTO REVERSE OR DRIVE FOR APPROXIMATELY 15 MIN BEFORE IT STARTED UP AGAIN.