EGR Recall - Now Blocked DPF - BMW X5, X5M, X6 & X6M Forum (G05/G06)

09-18-2024

Hi all,

So last week I got my recall done for the EGR cooler.

They changed the EGR cooler, EGR & Intake manifold. All changed and all fine till Monday when the CEL came on. No messages on dash.

Took it in to the local BMW and was charged for a diagnostic for it.

They investigated and found that:

DPF efficiency low and requires forced regen. Advised turbo low boost could be a result of the DPF being blocked.

Car is just over 56k miles, purchased at around 20k. Do around 20/30 miles daily on dual carriage way and occasional motorway.

Obviously this is a bit tricky to place the issue on the EGR, but i have a gut feeling that the EGR would of caused the premature blockage to the DPF.

Anyone had any similar experiences? I am taking this up with BMW UK now so hopefully we can come to an agreement to a fix.

09-20-2024

Hi
I’m afraid it looks like your about to embark on a seriously stressful journey with BMW
I had exactly the same issue as yours in Aug 23 on my 2019 GO5 with 65k miles (roughly)
It went in initially for a EGR health check and EML light
My X5 has been in the garage ever since. It broke down 150 miles after this work
I have basically become an R&D vehicle provider to BMW and they are replacing parts on a trial and error basis and expecting the customer to pay. I’m now entering a legal battle with them so wish me luck

Parts replaced so far
EGR cooler
EGR valve
DPF x 4
NOx sensors before and after CAT
Other sensors I can’t remember
Inlet manifold
Injectors

I’m now locked in a battle legally and I have no idea if I will ever get my car back. It’s currently worthless
I’m pretty sure all BMW owners with the Bosch EGR system will experience this at some point

The legal bit is that they issued a global recall for the EGR cooler in 2018 yet continued to build cars (all models) with faulty parts from Bosch.
These faulty parts are linked and causing the failures of other parts in the system but BMW won’t acknowledge that they are linked

Please post here if you are having similar problems with your car following EGR intervention or recall work
It will help build a picture that BMW can’t deny and the lawyers can use to strengthen the case for help to resolve the issues.
Help me fight now so that future customers/owners get the help they will need

Thanks

09-22-2024

Hi Paul,

Sorry to hear! Are you in the UK?

I have written to BMW UK in regards of my situation so i'm still awaiting their reply.

I have since gone to a DPF specialist to have a look and he's said that the DPF isn't blocked - he did a 'hard reset' and since then the light has been off and i did a motorway drive for an hour or so.

The soot mass level was around 40g - after the drive it dropped to around 10g.

I am only wondering if it's not going to trigger the automatic regeneration - as for some reason i cannot trigger to regeneration on Bimmerlink manually. I think there's a time limit to do it - probably cannot do it one after another although all the criteria was checked.

Car does drive fine for now BUT it still doesn't warrant that BMW can say no to the DPF change as it's a direct counter to the issues with the EGR.

I hope we get somewhere with them!

09-30-2024

Hey just came across this I have an x5 2020 go5 funny warranty runs out bang egr recall. Everything was grand last march took it to bmw as they sent the 2/3 letter out about software update for the egr no joke a few weeks later boom engine management light . Car been running a dream I thought that’s strange so filled her up with prem diesel as always btw I don’t do big miles much maybe 2/3 weeks max… anyways got red ex Dpf cleaner put the amount in as recommended. Give her a good blast on motorway then grand light off couldn’t believe it . Same thing happened maybe month two months later so did the same thing again and guess worked. About 4 months or so after can I just say while the engine management light came on no update on app or car why tho window washer fluid level low needs my attention 🤔. Good 25/30 min motorway journey near home light on flashing I went here we go tried and tried again red ex dpf cleaner as had another letter saying waiting on parts but to be assured that blew new updated software was monitoring the car for our safety! The light has been on since may/June the car jerks idle she’s spluttering threw the gears now sooty iv talked to bmw online said take it to your dealer now my local one I would not go back to after the TCP unit disaster I had under warranty and treatment not very nice! I said mate iv had 3 letters now no parts surly yous be up lifting the car like considering how dangerous didn’t know what to say. Low and behold last Friday message on system wow 🤩 recall due to early coolant leak! Disgusted with bmw and they can pay for anything else it needs we are told to wait car has hardly been driving I’m terrified it go on fire no point leaving it in there car park for weeks and weeks to get damaged! Iv photos and they are dated from everytime the engine management light came on iv screenshots of the conversation too with them online . I will be contacting them tomorrow and I want full diagnosis done and paperwork as they shall be replacing anything that related to the erg car well looked after services regularly . It’s a disgrace. Contact me anytime and we can hopefully gather information

09-30-2024

Sorry just would like to add I had an x5 2015 diseal 30d traded it in 2021 for the 2020 model I have now . The 2015 model also got a recall for EGR problem I had to leave it in too for software update few months before I traded it in so definitely been going on much longer. I shall try find if I have paperwork if not I shall request it.

10-08-2024

Hi All
I have to give praise where it’s due, after I was able to prove that when I first registered the EML with them in 2023 I was still in warranty, the approach from BMW UK changed overnight
Car is still in the garage with no end date in sight. However they have committed to resolving the issue whatever the cost.
Not sure what the next steps are but will keep you informed
I personally think it’s a software issue that isn’t allowing an auto regen under a certain set of circumstances. They won’t create a recall on this unless it becomes a widespread issue and while they can lay off the cost to the customers, why would they admit to anything

10-09-2024

I have ordered a PM sensor for my G05 - just awaiting for it to be delivered - hopefully this will resolve my issue and i won't need to change DPF as i can regen normally, but when soot level goes up it basically throws up the EML, then of course it doesn't regen.

m4forum has been amazing in helping with the diagnosing. Will keep you updated.

04-06-2025

R34L15T wrote
Hi all,

So last week I got my recall done for the EGR cooler.

They changed the EGR cooler, EGR & Intake manifold. All changed and all fine till Monday when the CEL came on. No messages on dash.

Took it in to the local BMW and was charged for a diagnostic for it.

They investigated and found that:

Car is just over 56k miles, purchased at around 20k. Do around 20/30 miles daily on dual carriage way and occasional motorway.

Obviously this is a bit tricky to place the issue on the EGR, but i have a gut feeling that the EGR would of caused the premature blockage to the DPF.

Anyone had any similar experiences? I am taking this up with BMW UK now so hopefully we can come to an agreement to a fix.

Hi I have a X3 2016 2.0D had the egr recall in July 2024 and recently developed a drivetrain error followed by several fault codes to do with exhaust back pressure and sensors. It turns out there is a major blockage between the dpf and EGR. My car has 65000miles and regularly serviced and do a mixture of local journeys and motorway runs. I think it's too much of a coincidence that everyone is experiencing these issues since the recall

An image attached to this post, provided by the poster

04-23-2025

X3 2016 wrote
Hi I have a X3 2016 2.0D had the egr recall in July 2024 and recently developed a drivetrain error followed by several fault codes to do with exhaust back pressure and sensors. It turns out there is a major blockage between the dpf and EGR. My car has 65000miles and regularly serviced and do a mixture of local journeys and motorway runs. I think it's too much of a coincidence that everyone is experiencing these issues since the recall

Did you manage to get it all cleared and been running fine since?

09-25-2025

I’ve the same problem 2 series gran tourer 2021 42000 miles , got a egr valve put didn’t help then new dpf pipes the a regen and now back to where I started keeps going into limp mode

10-19-2025

Hi All
Sorry it’s been so long since I replied. It’s been a long journey

After my car being away for 12 months and BMW spending £22k to get the problem resolved, I got the car back and it ran ok for 4 months
Then it was back to the same problem.
DPF efficiency too low

I had already had my fill of Sytner UK and would never use them again due to the disrespectful attitude towards me. I’m close to saying I will never by a BMB again after 25 years of ownership

The only solution I have been able to find that works 100% was to remove the DPF and EGR as well as do the Add Blue at the same time

I have now ran the car for 4 months and it hasn’t missed a beat.
Better fuel economy (plus 8mpg) Better performance and total peace of mind.
Yes, I know that it’s against MOT rules but I have been looking around and there is an increasing amount of MOT inspectors that understand the predicament and are willing to overlook this issue, that’s if they find it.
The visual aspect of the delete is not very visable and the emissions are not that bad

BMW have a lot to answer for and I’m sure will be held to account in the future. I would certainly be prepared to take part in any legal action case

10-28-2025

It really is a massive coincidence that the DPF blocks up prematurely since this whole EGR problem! As I wrote above before bmw expected me to pay for more diagnostics due to the r hinge management might not coming off after the EGR replacement! She said we can’t get the light off it seems something with the DPF!!!! Dirty dirty tricks I said well from what I have been reading up about it’s that the dpf has blocked up prematurely them due to the egr problem! Her attitude was shocking and I’m a woman by the way! So car came back no paperwork lol had to ring about it ask for it also how rude and argumentative the woman was! I got a guy out that does dpf cleaning etc for a look . He knew straight away dpf the amount of black soot around the exhausts terrible I can smell
Itt too. He had a look about and plugged it in to diagnostic anddddd!!! Says the DPF is cracked! Shambles I love the car big family but bmw gangsters

03-13-2026

Hi,

Same issues as explained above. I own a X1 2015 25d since more than two years now. It was bought from a private seller. Car was maintained well and in very good condition with the facts lesser known. The car got called in for an EGR cooler recall and have been facing issues since then. Sytner tried to blame it on the blocked DPF first and then our short distance city driving. Gave them a record of long distance travel and argued the fact it is impossible that the DPF would not regenerate after doing a 360 mile return journey. They replaced the DPF for free after all the hassle. Car was driving okay for a few months and then back to square one. Limp mode, drivetrain fault etc. etc.
Took it to the local garage and they cleaned the dpf pipe which was blocked. Returned the car after a day and within a week drivetrain fault back on. This fault came up after a 200 mile return journey. Something doesnt seem to be right.
All the explanation above makes so much sense. I may have to now enter a legal battle too.
Any recommendation will be much helpful and appreciated. Tired of this!!

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EGR Recall - Now Blocked DPF

EGR Recall - Now Blocked DPF