Vehicle: 2016 BMW 528i xDrive (VIN: [XXX]) Safety Issue / Defect Description: Strong, hazardous raw gasoline fumes began entering the passenger cabin and trunk area. On XXX, the vehicle was brought to an authorized dealership (BMW of Sterling) for diagnostic evaluation. The dealership's technician conducted a multi-point inspection and produced video evidence documenting fluid leaking from the top of the plastic fuel tank. The dealership issued Repair Order Quote #$4,824.92 to "REPLACE FUEL TANK DUE TO FUEL LEAK" and declared the vehicle unsafe. Despite diagnosing a structural fuel tank leak that allows raw gasoline and fumes to migrate into the cabin—presenting an immediate fire, explosion, and toxic vapor risk—BMW of North America and the dealership have refused warranty coverage or goodwill assistance, claiming the tank is "not leaking actively enough" under Service Bulletin SI B01 03 22 (the federal safety agency ID: MC-10212779-9999). An uncontained raw fuel leak on a plastic fuel tank is a critical safety defect that requires immediate investigation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
BMW 528I fuel leak problems
15 of the 833 owner complaints about the BMW 528I describe fuel leak, most of them for the 2008 model year.
- owner complaints
- 15
- worst model year
- 2008
- typical mileage
- 95,000
By model year
- 20162
- 20104
- 20092
- 20086
- 20011
Often reported together
Fuel smell 4Fuel pump 2Headlights 1Fire or smoke 1Check engine light 1
What owners say
The vehicle developed a strong, toxic odor of raw gasoline inside the passenger cabin and trunk area. The vehicle was brought to an authorized franchise, BMW of Sterling, where technicians performed a multi-point inspection. The technician confirmed that the factory plastic fuel tank assembly is structurally defective and leaking raw fuel from the top weld seams. The dealer provided an official invoice quoting $4,824.92 to replace the tank due to the fuel leak, noting it is an active hazard, but refused to cover the failure under BMW’s active 15-year/150,000-mile extended warranty for N20 plastic fuel tanks (SI B01 03 22). Driving a vehicle with raw fuel pooling on the exterior of the tank and migrating into the cabin creates an immediate fire hazard and health risk to occupants."
The contact owns a 2010 BMW 528I. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated and flashed. The vehicle was towed to the dealer where it was diagnosed that fuel was leaking form the engine. The contact was unaware of what part needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was unknown.
For a while now, I had been smelling gas around the car. I had it smogged and it passed but the technician told me that it smelled as if it were running rich because he smelled gas. It did not make sense to me that it could be running rich because it would not have passed smog then. I went to the supermarket recently and as I came out, I saw a small puddle of liquid under the left rear seating area. I touched it and smelled it and it was gas. My car leaves a little puddle of gas wherever I park now. I just saw a video on YouTube called "My BMW 535i has a fuel leak." That has been the problem a lot of people are having with their biodegradable BMW plastics. In the video, the young man describes that the fuel filter starts leaking and he has to spend $190.00 in parts. I don't have that money to be throwing away right now. Please look into and help us out.
The contact owns a 2010 BMW 528I. The contact stated that the vehicle was experiencing rough starts and the failure persisted while driving. The vehicle was taken to the dealer where it was diagnosed that the motor mounts had collapsed and needed to be replaced. Additionally, the oil pan gasket was leaking and needed to be replaced. The contact was also informed that the fuel sending unit needed to be replaced due to a fuel leak. The parts were replaced; however, upon replacing the oil pan gasket, the dealer noticed fragments of vanos adjuster units bolts used to fasten the intake and exhaust camshaft inside the oil pan. The dealer informed the contact that the cylinder head cover needed to be taken apart to verify whether the motor mounts were fractured. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 132,000. Manufacturer Safety recall issued the federal safety agency #22V‑119 Recall #22V‑119:407 POSITIVE CRANKCASE VENTILATION (PCV) VALVE HEATER Status: Remedy Available
The car started to leak gas from the tank.
Fuel smell in the driver side rear. The fuel pump leaks fuel.
The car smells as fuel is leaking and the headlights blink in and out... My trunk stop opening with key fob
My car had an fuel leak which had to be repaired asap
Fuel sending unit cracked leaking fuel and smell. Replaced at bmw dealership.
Related recalls
Fuel system, gasoline: delivery: fuel pump
- What is wrong
- BMW of North America, LLC (BMW) is recalling certain model year 2007-2011 BMW X5 3.0si, X5 4.8i, X5 M, X5 xDrive30i, X5 xDrive35i, X5 xDrive48i and X5 xDrive50i, 2008-2011 X6 x Drive35i, X6 xDrive50i and X6 M, 2010-2011 X6 ActiveHybrid, 535i xDrive Gran Turismo, 535i Gran Turismo, 550i xDrive Gran Turismo and 550i Gran Turismo, 2011-2012 528i, 535i, 535i xDrive, 550i and 550i xDrive and 2012 535i ActiveHybrid, 640i Convertible, 650i Convertible, 650i xDrive Convertible, 650i Coupe and 650i Coupe xDrive vehicles. The affected vehicles have in-tank fuel pumps that may have insufficiently crimped wire contacts.
- Risk
- The loose wires may cause the connector to melt, resulting in a fuel leak. Additionally, the fuel pump may stop working, possibly causing an engine stall and increase the risk of a crash.
- Remedy
- BMW will notify owners, and dealers will replace the fuel pump module, free of charge. The recall began February 2017. Owners may contact BMW customer service at 1‑800‑525‑7417.
Recall number 16V746000 · Recall details
Questions about the BMW 528I fuel leak
Which BMW 528I years have fuel leak problems?
The model years with the most reports are 2008 (6 complaints), 2010 (4 complaints) and 2009 (2 complaints).
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