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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

2020-09-23

This Service Information Bulletin (Revision 8) replaces SI B51 21 19 dated September 2020.
What’s New (Specific text highlighted):
• Warranty

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
13820D

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

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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51 21 19_ACTIVE AIR FLAP FAULT DIAGNOSIS AND REPAIR

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 4. Perform a functional test of the active air flap
system using test plan “Radiator Blind (ABL-DITflap fault codes.
AT1214_BX8_KJ)”.
Note: With the introduction of ISTA 4.23.x, the active air
flap functional test plan diagnostics have been
improved.
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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51 21 19_ACTIVE AIR FLAP FAULT DIAGNOSIS AND REPAIR

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:

5174031200

:

Or:
5171431200

Air flap control active above (actuator) permanently
failed (Including combined top and bottom active air
flap repairs)
Bottom active air flap control (actuator) permanent
failure

:
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-Vehicles
Labor 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

And, as required for the:
G01, G02 and G12 (excluding 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)

Refer to AIR

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)

Or, as required for the:
G30 and G32 (excluding the ALPINA B7)
Labor Operation Description
Replace upper air flap control active (after vehicle
51 74 610
diagnosis)
Or:

Labor Allowance

51 74 600

Replace the upper air flap (after vehicle diagnosis)

Refer to AIR

Replace upper air flap and air duct (after vehicle
diagnosis)

Refer to AIR

Replacing bottom air duct (lower) (after vehicle
diagnosis)

Refer to AIR

Refer to AIR

Or:
51 74 602
Or:
51 74 601
Or:

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51 21 19_ACTIVE AIR FLAP FAULT DIAGNOSIS AND REPAIR

Replace upper air flap control active and air duct
lower (after vehicle diagnosis)

Refer to AIR

Or, for the:
G12 (ALPINA B7 Model only)
Labor Operation Description
51 99 000

Labor Allowance

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

16 FRU

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

12 FRU

Or:
51 99 000
Or:
51 99 000

C. Work time for replacing top (including the drive only,
if available and applicable) and bottom air flap control 16 FRU
(after vehicle diagnosis)

And, additionally for
Vehicle’s equipped with an ACC Sensor that require a Bottom Air Flap replacement:
Labor Operation Description
66 99 000

Labor Allowance

Work time to prepare the lower active flap for the reinstall of the ACC sensor (with 51 64 705, 51 64 715,
ALPINA repair B or ALPINA repair C)

3 FRU

Adjusting ACC sensor

Refer to AIR

And:
66 31 502

Work time labor operation codes 61 00 006, 51 99 000 and 66 99 000 are not considered a Main labor
operation.
As applicable to your center, please refer to SI B01 01 20 or B01 07 20 for claiming your diagnosis work
time, job/repair work time (WT), WT and repair-related explanation procedures.
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.

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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).

QUESTIONS REGARDING THIS BULLETIN
Technical inquiries
Warranty inquiries
Parts inquiries

Submit feedback at the top of this bulletin
Submit an IDS ticket to the Warranty Department
Submit an IDS ticket to the Parts Department

Supporting Materials
picture_as_pdf B512119 Attachment 1.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.