NHTSA upgrades 2014–2022 BMW, Bosch and 2 other makes’ vehicles probe to engineering analysis: High pressure fuel pump failure

Vehicles under investigation

As listed in NHTSA’s investigation file. Not every vehicle of a listed model is necessarily affected.

What ODI says

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

Official summary by NHTSA’s Office of Defects Investigation for EA23001, quoted in full (U.S. government work, public domain).

What owners have reported

Owners filed 19,733 complaints with NHTSA about the model years in this investigation, reporting 1,081 crashes, 404 fires, 851 injuries, 16 deaths. These are all complaints on file for those vehicles, about any problem, not only this one; complaints are unverified owner reports.

Recalls and problems for these vehicles

• BMW X5 recalls by model year
  BMW X5 complaints, TSBs and investigations
• BMW X3 recalls by model year
  BMW X3 complaints, TSBs and investigations
• BMW 328D recalls by model year
  BMW 328D complaints, TSBs and investigations
• BMW 535D recalls by model year
  BMW 535D complaints, TSBs and investigations
• Jeep Grand Cherokee recalls by model year
  Jeep Grand Cherokee complaints, TSBs and investigations
• Jeep Wrangler recalls by model year
  Jeep Wrangler complaints, TSBs and investigations

Related recalls

NHTSA links these recall campaigns to EA23001.

• Ford F-550 SD (2020) Recall: Fuel Pump Failure Risk
  NHTSA campaign 24V957000December 20, 2024

Timeline

1. March 17, 2023ODI opens engineering analysis EA23001
2. December 20, 2024NHTSA recall 24V957000 (recall date)
3. OpenNo closing date yet