Gas Recirculation Valve (egr Valve) problems of the 2003 BMW X5

The temperature was about 5 degrees f. After driving a short distance, there was a large amount of smoke from tailpipes and smoke from engine compartment. Engine oil warning message and ses light illuminated. The engine hesitated and misfired. After stopping, the back of the X5 was covered in oil. The engine compartment was covered in oil and oil coated the exhaust manifold. The X5 had to be towed to the dealer. The dealer indicated the ccv was frozen and it was common in these cars. When the ccv freezes, it can suck the oil from the oil sump through the ccv into the intake manifold. The valve cover gasket usually blows from the increased pressure. If enough oil is sucked in through the intake manifold, it can hydrolock the engine, breaking piston rods, etc or the engine can seize from lack of oil. BMW is aware of this design flaw in these cars when operated in cold climates and is providing some relief for some of the cars that experience this issue. The valve cover gasket was replaced. Oil had to be vacuumed from the spark plug wells. The ccv and associated hoses were replaced with a newer insulated design. The dipstick tube was replaced. The oil filter was replaced. Any oil that may remain is drained and new oil was added. The engine compartment was degreased.

1. The weather outside was -10 degrees celcius. 2. I own a 2003 BMW X5, 4. 4 litre engine, v8. The crank case valve froze shut, causing oil to spill into the engine. This problem has occurred twice - once last winter (2010) and this winter (2011). It has cost me a total of $1,600 this year and $3,000 last year to repair. 3. Spark plugs needed to be replaced, engined needs to be cleaned, and a new heater blanket was installed last year, but failed to keep the valve from freezing shut again this year!.

Oil separator froze causing high pressure and blown seals. Initial cost about $1100 to repair. Dealer states this "happens all the time" to X5's in cold weather. Temp was in the single digits. In January 2013 oil separator froze two more times;however, this time damaging the engine - cost over $5000 to repair - basically totaling the car. With about 15 minutes of research, this appears to be a common and known issue on BMW X5 3. 0, 4. 4 and 4. 8 engines from 2001 to 2008. . . Looks like the parts were redesigned in 2009. Looks like a simple preventive maintenance routine and insulated oil lines would have prevented the "catastrophic engine failure" and dangerous condition of tailpipe fire, or being stranded in zero degree weather (which seems to be a condition required for the failure). Owner of car is the original owner, with all maintenance being done at local BMW dealerships including major services at 60k and 90k so there appears there is no "preventive maintenance" included in either of these major service milestones for the known oil separator defect. A recall on this defect to install the small amount of parts to prevent "catastrophic engines failure" and dangerous conditions "being stranded in single digit weather" seems like a logical choice. . . Or at least changing major service milestones to add preventive maintenance so the probability of the failure can be reduced.

I have a new BMW 3. 0 X5 with 3,500 miles and had my vehicle die and requiring towing to the dealer with a crank case valve freeze up draining oil all thru the engine and requiring a non original designed replacement valve that no serice tech feels with be reliable below 10 degrees above zero. I live in minnesota and this is not acceptable for a new vehicle in this weather. Now my vehicle is no longer reliable and it presents a safety issue because this could happen on the highway or any where. No guarantees of it not happening again. I purchased the vehicle from the dealer new only five months ago.