X4

Defect

The Safety Recall relates to the engine starter motor. The fault relates to the RSW22 starter RWT (reinforced water tightness). It was found that with RWT starters an increased abrasion of the magnetic contact can cause the growth of deposits at the lowest point of the relay interior. This in turn may increase the relay contact resistance resulting in false starts or even causing short circuits and possibly a thermal reaction. In case of a short circuit the possibility of a thermal event cannot be excluded. This may happen while attempting to start the vehicle or while driving due to vibrations causing a short circuit due to moving deposits.

Remedy

On the affected vehicles the starter motor will be replaced with a variant by another supplier with a different design. Until the repair has been completed it is recommended to not leave the vehicle running unattended after starting the engine.

Defect

Affected vehicles are already included in Safety Recalls within the markets they have previously resided in. The vehicles may be fitted with a driver and/or passenger airbag/s which if deployed may do so with excessive force causing sharp metal fragments to be released this may cause serious injury which could prove fatal to people in the vicinity.

Remedy

Vehicles will have the affected airbags checked and if necessary replaced.

Defect

For affected vehicles there is a concern involving water ingress and corrosion to the starter motor for where a short circuit cannot be ruled out. It is strongly recommended to park the vehicle outdoors and not in the immediate vicinity of buildings until the repair has been carried out.

Remedy

Replacement of the starter motor.

Defect

Affected vehicles may have had a retrofit or conversion of the airbag using a previously recalled airbag variant which if deployed may do so with excessive force causing sharp metal fragments to be released this may cause serious injury possibly fatal to people in the vicinity. The original factory fitment airbag for the vehicle is not affected.

Remedy

Vehicles will have the airbag checked and if necessary replaced.

Defect

On affected vehicles the three screws connecting the electric motor to the steering gear are potentially not fastened correctly.

Remedy

On affected vehicles the steering gear will be replaced

Defect

On affected vehicles ingress of transmission fluid may occur to the integrated transmission control unit within the mechatronic module

Remedy

On affected vehicles the transmission mechatronic module will be replaced

Defect

On affected vehicles risk of potential flooding could have occurred leading to salt water ingress whilst parked in port awaiting shipping

Remedy

The affected vehicles will be thoroughly checked cleaned and reworked as required

Defect

A possible degradation of airbag propellant tablets could lead to an over-aggressive combustion in the event the airbag is activated which may cause the inflator body to rupture.

Remedy

On affected vehicles the drivers airbag module will be replaced.

Defect

Undetected EGR System leaks may cause thermal activity in the intake manifold.

Remedy

The engine management control unit (DDE) will be programmed with improved software incorporating the latest OBD functionality.

Defect

Undetected EGR System leaks may cause thermal activity in the intake manifold.

Remedy

The engine management control unit (DDE) will be programmed with improved software incorporating the latest OBD functionality.

Defect

The Exhaust Gas Recirculation cooler may leak over time and cause thermal incident.

Remedy

On the affected vehicles the EGR cooler module will be replaced.

Defect

The Exhaust Gas Recirculation cooler may leak over time and cause thermal incident.

Remedy

On the affected vehicles the EGR cooler module will be replaced.

Defect

During a service visit the affected vehicles have been updated with software that could misinterpret certain input parameters for the engine management system.

Remedy

The control units will be reprogrammed with an improved version of software.

Defect

The Exhaust Gas Recirculation (EGR) Module could leak over time�and cause thermal incident.

Remedy

The EGR cooler will be internally inspected with an endoscope and replaced if evidence of leaking is found.

Defect

Leaking glycol coolant could create in combination with soot and oil sediments in the EGR module ignitable deposits.

Remedy

The EGR cooler will be internally inspected with an endoscope and replaced if evidence of leaking is found.

Defect

Leaking glycol coolant could create in combination with soot and oil sediments in the EGR module ignitable deposits.

Remedy

The EGR cooler will be internally inspected with an endoscope and replaced if evidence of leaking is found.

Defect

The battery cables on the 48V starter generator may not have been sufficiently secured during the production process.

Remedy

Check the screw connection of the 48V positive / negative battery cables on the starter generator and rework if necessary.

Defect

The cable lengths for the electric connection of the hall sensor integrated inside the seatbelt buckle could be too short.

Remedy

R; The front seat belt buckles will be checked and replaced if they are found to be faulty.

Defect

The swivel bearing/s on the front axle of the affected vehicles may not have been produced to specification.

Remedy

The swivel bearing/s on the affected vehicles will be replaced.

Defect

The EGR cooler may leakpresenting a fire risk

Remedy

A visual inspection of the EGR cooler to check for leaks and excessive build-up of deposits. The EGR cooler will be replaced on all affected vehicles

Defect

The EGR cooler may leakpresenting a fire risk.

Remedy

The EGR cooler will be replaced with an improved version.

Defect

The fault affects the brake system in particular the brake calipers on the rear axle. Because of a faulty coating hydrogen gas (approximately 10 ml) could be created in the coating of the piston of the brake caliper. This will be completely outgassed during the first 2 months after the production process causing longer brake pedal travel. Under certain circumstances the relevant brake pressure cannot be build up in the rear brake circuit. As a result the brake force of the system may be reduced by up to 30%. The driver may feel a soft brake pedal and a reduction of the brake performance. In certain cases the rear brake circuit could fail leading to increased risk of an accident.

Remedy

On the affected vehicles the brake system will be bled.

Defect

The sealing cap of the pressure-limiting valve in the fuel tank delivery module may be damaged. This concern could lead to a reduction in fuel transfer from the left side to the right side of the fuel tank. Therefore it is possible for the engine to stall even though the fuel gauge would show fuel present.

Remedy

Recall the vehicles that are likely to be affected and check the fuel pressure of the delivery module and the distance of the cap on the pressure-limiting valve. Where necessary the delivery module will be replaced.

Defect

ISOFIX mountings are fixed to a cross member. As a result of vibrations and type of seat used it is possible for the ISOFIX mountings to become insecure and in rare cases break off.

Remedy

Recall the vehicles that are likely to be affected and a metal angle bracket will be welded to each of the four ISOFIX brackets in the back seats to reinforce the mounting.