Coolant Loss, 640D - EGR Cooler, again? FFS.

[Ninja59]

My car went in September for slight coolant loss, which following testing was identified as a leaking egr valve (not cooler), coolant level was sitting just below max.

October - having covered about another 800 miles, i discover to my frustration that the coolant level has dropped, again. This time from just below max to half way. Pressure tested and the car passes no problem, coolant topped up.

November - yesterday, with an interim service (not following the silly CBS) I discover the coolant has made a slight deviation of around 5mm downwards from just below max (just over 1500 miles covered since).

I have spoken with the service manager, who has agreed that i top it up, take some photos and send over for reference for next Friday when it goes in (I took photos of all the coolant levels above which he has copies of already) and he has agreed to loan me a car and do some further pressure checks due to the coolant level going down albeit slightly, both hot and cold.

But, at the back of my mind (and have already pushed for it be checked, again) is my third (yes 3rd!) EGR cooler (apparently a modified one fitted in January!). So do I need a 4th EGR cooler?

Or is my issue elsewhere (hopefully simple)?

I have checked my N57 coolant pipe on the side of the block (another infamous leak point) and can see no white deposits, checked around the termostat, waterpump area and can see no white deposits and around the egr valve and cooler assembly externally with no apparent obvious coolant deposit.

MPG wise possibly slightly down but my mileage is tiny at the moment (and so is the distance), but when I have had a slightly longer journey I would say it is about 1 MPG maybe below where I would expect, but I have put this down to the cooler weather. Performance wise the car is on point, thermostat is reaching a nice 88 degrees, oil temp on point at 100.

Edited by Ninja59 on Tuesday 24th November 16:15

[S8QUATTRO]

I had a an issue with mine about 1000 miles after the egr recall job was done. The dealer said a plastic outlet on the side of the block was leaking and not part of the warranty. I had a feeling they didnt put everything back together properly but needed the car on the road asap.

I got annoyed with the dealer after they stripped it down and built it back up to tell me with part that was faulty...

Quoted me £400 ish for the job and then said they were too busy to do it, for 2 weeks!

I asked for the part number the same afternoon and the tw*ts had it in stock! £15 part and £200 labour at a specialist had the car back on the road in 3 days. Indy also said a few bits didnt seem to be put back together very well!

I ended up selling the car because i couldn't be bothered with the potential reliability problems

I would advise finding a decent local specialist

[Ninja59]

Yeah the coolant pipe has been an issue on some N57's already checked there and found no issues like leaks or white stains.

I have a horrible feeling the cooler is going albeit slowly, again, as the car seems to use a little now and again after a reasonable distance.

Interestingly though, since I posted this the car mysteriously seemed to give some coolant back so I don't know with the heaters on more whether it had a slightly bit of air maybe? (it is not all back, if nothing else it is being pressure tested and the cooler checked next week).