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51 21 19_ACTIVE AIR FLAP FAULT DIAGNOSIS AND REPAIR

SIB 51 21 19
ACTIVE AIR FLAP FAULT DIAGNOSIS AND REPAIR

2020-05-18

This Service Information Bulletin (Revision 4) replaces SI B51 21 19 dated September 2019.
What’s New (Specific text highlighted):
• Parts Information section updated
• Warranty Information section updated

MODEL
Engineering
Designation
G01
G02
G12
G30
G32

Model Description

Production Date

X3 Sports Activity Vehicle
X4 Sports Activity Coupe
7 Series Sedan (Pre-LCI) (Including
ALPINA)
5 Series Sedan
640i xDrive Gran Turismo

Up to August, 2019
Up to August, 2019
Up to March, 2019
Up to August, 2019
Through June, 2019

SITUATION
A check control message or MIL (Malfunction Indicator Lamp) may be illuminated, with faults stored related
to the upper and/or lower active air flap(s).

CAUSE
Potential causes include:
Faulty upper air flap actuator (G01, G02, G12, G30, G32)
Faulty lower air flap assembly (G01, G02, G12, G30, G32)
Software error in the DME affecting the upper flap (G01, G02 only)

CORRECTION
Depending on the root cause, vehicle model, and location of flap (upper or lower), the vehicle may require
any, or a combination repair of one or more corrections:
Updated air flap actuator
Updated air flap assembly
Software update

PROCEDURE
Follow the diagnostic suggestions below exactly as written, to accurately determine which repair is required
for each specific vehicle.
Note: Reference your vehicle faults to the corresponding box below on the left. Follow the corresponding
correction in the box to the right.
A. Electrical Active air flap fault code(s) (All
models listed in this SIB)
This correction is to be used for all
situations where the following fault codes
are stored:
138402
279B00
138220

Correction A:
1. Replace the upper air flap actuator only, using
the actuator suggested using ETK/AIR.
Refer to attachment 1 “Upper air flap actuator
replacement instructions”.

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51 21 19_ACTIVE AIR FLAP FAULT DIAGNOSIS AND REPAIR

13820D
13820E

Note: Do not replace the complete upper air flap
assembly. The actuator of the upper air flap should be
replaced without a complete upper flap assembly, and
retested.
2. Retest the active air flap system using test plan
“Radiator Blind (ABL-DIT-AT1214_BX8_KJ)”.
Does the functional test discover errors?
NO: No additional repair is necessary.
YES: Follow the test plan instructions. Replace the
complete upper flap assembly if the test plan
instructs to do so.

B. Vehicle has upper active air flap fault
code(s) stored
(All models listed in this SIB)
This correction is to be used for all upper
air flap fault codes not outlined in
correction A.

Correction B:
1. Replace the upper air flap actuator only, using
the actuator suggested using ETK/AIR.
2. Retest the active air flap system using test plan
“Radiator Blind (ABL-DIT-AT1214_BX8_KJ)”.
Does the functional test discover errors?
NO: No additional repair is necessary.
YES: Follow the test plan instructions. Replace the
complete upper flap assembly if the test plan
instructs to do so.
Refer to attachment 1 “Upper air flap actuator
replacement instructions”.
Note: Do not replace the complete upper air flap
assembly. The actuator of the upper air flap should be
replaced without a complete upper flap assembly, and
retested.

C. Upper Active air flap fault code(s)
(G01/G02 ONLY)
21B043
138207
Note: This column should only be used
for G01/G02 with FCs 21B043 AND 138207
stored.
No additional active air flap faults can be
stored

Correction C:
Note: This correction is only valid for G01/G02
with both faults shown to the left. See above column for
all other vehicle/fault combinations.
1. Is the vehicle I-Level below S15A-18-11-500?
YES: Program the vehicle using the latest version of
ISTA to reach at least 18-11-500.

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For additional/different faults, see the
above column for diagnosis

Afterwards, continue to step 2.
NO: Continue to step 2.
2. Perform a functional test of the active air flap
system using test plan “Radiator Blind (ABL-DIT-

AT1214_BX8_KJ)”.
Does the functional test discover errors?
NO: No additional repair is necessary.
YES: Replace the upper air flap actuator only,

using the actuator suggested using
ETK/AIR. Afterwards, continue to step 3.
Refer to attachment 1 “Upper air flap actuator
replacement instructions”.
Note: Do not replace the complete upper air flap
assembly. The actuator of the upper air flap should be
replaced without a complete upper flap assembly, and
retested.
3. Retest the active air flap system using test plan
“Radiator Blind (ABL-DIT-AT1214_BX8_KJ)”.
Does the functional test discover errors?
NO: No additional repair is necessary.
YES: Follow the test plan instructions. Replace the
complete upper flap assembly if the test plan
instructs to do so.
D. Vehicle has lower active air flap fault
Correction D:
code(s) stored
This correction is to be used for all lower air 1. Replace the complete lower active air flap assembly
flap fault codes.
following ISTA repair instructions.
Note: Failures of the lower active air flap will
require a complete air flap replacement.
General information for any repairs to G12
or G30 produced before July, 2016:
If one faulty flap is found to be defective, BOTH upper
and lower active air flap ASSEMBLIES must be
replaced together.
Vehicles produced before July, 2016 are not permitted
to have merely a flap actuator replaced. A complete

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assembly must be replaced.
Note: Due to complexity, actuator replacement is only permitted for upper air flap assemblies.
Failures of the lower active air flap will require a complete air flap replacement.
For any vehicle that returns for active air flap faults after following this bulletin, a TSARA assistance case
should be submitted.

PARTS INFORMATION
Part Number
Refer to ETK
Or:
Refer to ETK
And/or:
Refer to ETK

Description
Air flap control (drive), active, upper (see below)

Quantity
1

Air flaps, upper (assembly)

1

Air flaps, lower (assembly)

1

Important: If the Air flap control (drive), active, upper is the issue and it is available
separately (per ETK), then only replace the upper flap drive to correct this issue.
Only in conjunction with parts: When applicable, if ETK/EPC item identifies additional part(s)
that must also be replaced/installed in-conjunction with performing a covered repair, these
required additional items are also covered under the terms of this extended limited warranty.
Also refer to ETK/EPC and the repair instructions for onetime-use fasteners/screws and other
information regarding repair-related gaskets, seals, fluid and/or lubricants that also need to be
replaced/used and claimed.

WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty for Passenger Cars and Light Trucks.
Beyond the New Vehicle Limited Warranty, additional extended upper and lower active air flap coverage
may also apply, please refer either to SI B01 01 19 (10 years/120,000 miles) or B01 12 19 (15
years/150,000 miles) as applicable.
Defect Code:

5164041200

Air flap/cooling flap, top (radiator grille)
permanently failed

Or:
5171348300

Air flap/cooling flap, bottom switches
incorrectly/does not switch

.
Labor Operation

Description

Labor Allowance

00 00 006

Performing vehicle test (with vehicle diagnosis system –
checking faults) (Main work)

Refer to AIR

Performing vehicle test (with vehicle diagnosis system –
checking faults) (Plus work)

Refer to AIR

Connect an approved battery charger/power supply
(indicated in AIR as Charging battery)

Refer to AIR

Or:
00 00 556
And:
61 21 528

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If you are using a Main labor code for another repair, use the Plus code labor operation 00 00 556 instead
00 00 006
And, additionally for the:
e-VehiclesLabor Operation Description
61 25 910

Recharging high-voltage battery unit (to high voltage
charging socket)

Labor Allowance
Refer to AIR

And, as necessary:
Labor Operation Description

Labor Allowance

61 00 006

Work time (WT)

Performing vehicle diagnosis – test module

Work time labor operation code 61 00 006 is not considered a Main labor operation; however, it does require
an individual punch time and an explanation on the repair order and in the claim comments section.
And, as required:
All models except the ALPINA B7
Labor Operation Description
51 64 700

Labor Allowance

Replacing top flap control (including the drive only, if
available and applicable) (after vehicle
diagnosis)Replacing top flap control (after vehicle
diagnosis)

Refer to AIR

Replacing bottom flap control (after vehicle
diagnosis)Replacing bottom flap control (after vehicle
diagnosis)

Refer to AIR

Or:
51 64 705
Or:
51 64 715

Replacing top (including the drive only, if available and
applicable) and bottom air flap control (after vehicle
Refer to AIR
diagnosis)Replacing top and bottom air flap control
(after vehicle diagnosis)

Or, for the:
G12 (ALPINA B7 Model only)
Labor Operation Description
51 00 001

Labor Allowance

Work time for replacing top flap control (including the
drive only, if available and applicable) (after vehicle
diagnosis)

15 FRU

Work time for replacing bottom flap control (after
vehicle diagnosis)

11 FRU

Or:
51 00 001

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Or:
51 00 001

Work time for replacing top (including the drive only, if
available and applicable) and bottom air flap control
15 FRU
(after vehicle diagnosis)

Work time labor operation code 51 00 001 is not considered a Main labor operation. Also, since the work
time FRU allowance to be claimed is specified, a separate punch time is not required. However, it still
requires an explanation on the repair order and in the claim comments section.
And, as applicable, for the:
G01/G02 only, when the Vehicle i-Level is below S15A-18-11-500Labor Operation Description
61 00 730

Programming/encoding control unit(s)

Labor Allowance
Refer to AIR

Refer to AIR for the corresponding flat rate unit (FRU) allowances.
During this workshop visit, the affected vehicle may also show one or more programming and encoding
Technical Campaign repairs open, the programming and encoding procedure may only be invoiced one
time.
Update the vehicle to the required I-level or higher by performing and submitting for one of the open
Technical Campaigns instead. Please be sure to also perform any additional work (before and/or
after) the campaign repairs require and/or close the remaining open programming and encoding
Technical Campaign repairs as outlined in the corresponding Service Information Bulletin.
Only if the above situation does not apply, when applicable, the programming and encoding procedure is
then covered under the terms of the BMW New Vehicle Limited Warranty for Passenger Cars and Light
Trucks or the corresponding additional extended coverage that is also noted in this bulletin.
Programming and Encoding - Vehicle Control Units (RO and Claim Comments Required)
The programming procedure automatically reprograms and encodes all vehicle control modules which do
not have the latest software I-level. If one or more control module failures occur during this programming
procedure:
Please claim this consequential control module-related repair work (including performing the IRAP Control
Unit Recovery procedure first as required, refer to the SIB in AIR) under the defect code listed in this bulletin
with the applicable AIR labor operations.
Please explain this additional work (The why and what) on the repair order and in the claim comments
section
For control module failures that occurred prior to performing this programming procedure:
When covered under an applicable limited warranty, claim the applicable test plan and the corresponding
control module-related repair work using the applicable defect code and labor operations in AIR (including
diagnosis with separate punch times).

Supporting Materials
picture_as_pdf B512119 Attachment 1 Upper air flap actuator replacement instructions.pdf

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B51 21 19 attachment 1 Upper air flap actuator replacement instructions

August 2019

1. Remove the upper active air flap, following the repair instructions within ISTA for the specific
vehicle by VIN.
2. Remove screws (see arrows) from upper active air flap actuator (1) as shown below:

3. With the active air flap actuator removed, manually open the flaps.
4. Install the replacement active air flap actuator.
5. Install screws, tightening to the following specifications:
G01/G02-3nm
G12, G30, G32- 2nm
6. Reinstall the upper air flap following ISTA repair instructions.