KNOWN FAULTS · BMW

BMW Serie 3 (E90/E91/E92/E93) 335d (M57, 3.0) common problems.

2005–2012 · Diesel

Sources are not verified in real time and no entry confirms that your car is affected.

3 known faults with sources

Corrupted FRM3 module (lights and windows)Electrical and electronic systems

Engine / equipment: FRM3 footwell module (lights, indicators and windows): 1 Series E81 to E88, 3 Series E90 to E93, X1 E84, Z4 E89, X5 E70, X6 E71 and E72 and MINI R55 to R61
Period mentioned: 2004–2015
Symptoms: After a flat battery, a battery change or disconnection, or a jump start: lights, indicators or windows stop working, side or dipped lights stay on and diagnostics cannot communicate with the module (for example code 00A3C1).
Possible cause described: The module's EEPROM gets corrupted by low or unstable voltage: a flat battery, jump starting, overcharging from a faulty alternator or loose terminals. It is a module software fault, not a wiring fault.
Check for the garage: Check the battery and charging and try communicating with ISTA. If the module does not respond, it can be repaired by rewriting its EEPROM (specialist services or programmers) instead of being replaced, then coded. Use a voltage maintainer when working on the car.
Cost cited in the source: Repair by a specialist service: from about €20–60 plus postage; new module with dealer coding: considerably moreA rough figure from the original database, not an up-to-date quote.

Applies if: Only if the intake manifold has swirl flaps; some versions do not. Confirm at a garage.

Intake swirl flaps (M57)Intake

Engine / equipment: M57 3.0 six-cylinder diesel with swirl flaps (330d E46/E90, 525d/530d/535d E39/E60, 635d, 730d E65, X3 3.0d, X5 3.0d E53/E70, X6 30d/35d)
Period mentioned: 1998–2010
Symptoms: Usually none until it fails. A common early warning: oil seeping around the flap spindles on top of the engine. If a flap or its screw comes loose and enters a cylinder: sudden heavy knocking, loss of power, smoke and possible turbo damage as well.
Possible cause described: The metal flaps in the intake manifold collect soot and oil and their spindles wear over the years. The flap, its screw or part of the spindle can come loose and drop into the cylinder, damaging valves, piston and head. An owners' forum quotes BMW as having strengthened the spindles on later manifolds (from 4 to 4.5 mm), but other owners doubt the change removes the risk.
Check for the garage: At a garage: confirm whether the manifold has swirl flaps (some versions do not), look for oil around the spindles and play in the flaps, and check the history for earlier replacement or removal. With any new metallic knocking, stop the engine and do not restart it.
Cost cited in the source: Preventive inspection: workshop labour. If a flap enters the engine, a buyer's report quotes repair costs above €4,000.A rough figure from the original database, not an up-to-date quote.

Applies if: Only if fitted with the automatic gearbox described in the record.

ZF 6HP mechatronic sleeve leak and harsh shiftsAutomatic gearbox

Engine / equipment: ZF 6-speed automatic 6HP19/21/26/28 (E53, E60/E61, E63/E64, E65/E66, E85, E90–E93)
Period mentioned: Approx. 2001–2013
Symptoms: Oil drips or dampness by the electrical connector on the side of the pan, a bump on the downshift just before stopping, harsh or flared shifts (especially 3rd-4th and 4th-5th under throttle) and a limp mode that clears after restarting.
Possible cause described: The sealing sleeve between the mechatronic unit and the wiring harness has O-rings that harden and let oil out. A BMW bulletin says to replace it only for a real leak, not mere dampness, and warns that fitting it wrongly damages the connector pins and forces a mechatronic replacement. With low fluid the gearbox loses pressure. Harsh shifts can also come from worn solenoids or valve body, not only the sleeve.
Check for the garage: At a garage: read the gearbox codes, check the fluid level with the official procedure (correct temperature and engine running) and look for a real leak at the sleeve and pan gasket. After a fluid or parts change, the garage should reset adaptations. If limp mode persists, check solenoids and valve body before replacing the gearbox.
Cost cited in the source: Sleeve and pan gasket: minor repair. If fluid is lost and the gearbox is damaged, in a US forum case BMW offered a remanufactured gearbox for about $2,800 without fitting.A rough figure from the original database, not an up-to-date quote.