2023-2024 BMW Active Air Flap Faults SIB 51 12 19

BMW has issued Service Information Bulletin SIB 51 12 19 (Revision 6), superseding the September 2020 version, to address issues with the active air flaps, also known as kidney grill active air flaps. This bulletin provides diagnostic and repair procedures for a "BMW active air flap fault" that can cause a "Check Control Message" or the Malfunction Indicator Lamp (MIL) to illuminate in various 2023-2024 BMW models.

This bulletin applies to the 2023-2024 BMW X5, X6, X7, 8 Series (Convertible/Coupe), 3 Series Sedan, and Z4 Roadster. Owners of these vehicles may experience dashboard warnings related to the active cooling damper control system.

Symptoms

Owners may notice a "Check Control Message" or the Malfunction Indicator Lamp (MIL) illuminated on the instrument cluster. These warnings indicate a potential issue with the active cooling damper control system, which manages the kidney grill air flaps.

Fault Codes / DTCs

When a "BMW active air flap fault" occurs, one or more of the following diagnostic trouble codes (DTCs) may be stored in the vehicle's system:

Code	Description
138207	Active cooling damper control (AKKS), top: blockage at warm ambient temperature
21B043	Active cooling damper control (AKKS), top: blockage at all ambient temperatures
138222	Active cooling damper control (AKKS), above: positional deviation error detected at warm ambient temperature
138209	Active cooling damper control (AKKS), top: Control deviation at all ambient temperatures
13822B	Active cooling damper control (AKKS), top: Control deviation at all ambient temperatures
21B042	Active cooling damper control (AKKS), below: blockage at all ambient temperatures
138206	Active cooling damper control (AKKS), bottom, blockage at warm ambient temperature
138225	Active air-flap control, bottom: top limit position not detected
138224	Active air-flap control, bottom: bottom limit position not detected

Causes

Multiple factors can lead to a "BMW active air flap fault" and the associated warning messages. These include:

• Faulty upper and/or lower active air flaps.
• A software error within the Digital Motor Electronics (DME).
• Debris or blockages from external sources.
• An information error memory that does not necessitate a repair.
• For G20 models (3 Series Sedan) specifically, detached lower active air flaps.

Diagnosis and Repair Procedure Summary

The repair process for a BMW active air flap fault begins with a thorough inspection and diagnostic steps. For each stored fault code, the corresponding active air flap must be inspected for debris or mechanical blockages. If no external blockage is found, further diagnostic steps are required.

1. System Test Plan: Technicians will perform the system test plan ABL-DIT-AT1214_BX8_KJ for the active air flaps. If the flap fails this functional test, replacement is recommended.
2. Software Update: Vehicles require programming using ISTA 4.16.2x (I-Level S18A-19-03-530) or higher. This step is crucial for resolving software-related issues and ensuring proper flap operation.
3. Specific Fault Code Conditions:
   • For DTCs 0x138209, 0x13822B, 0x138222, 0x138207, and 0x21B043 (upper air flap faults): If the fault frequency is above 1, the system test plan is performed. If the flap fails, it's replaced, and the vehicle is programmed. If the fault frequency is 1 or less, the fault can be deleted without further action.
   • For G05 (X5) and G07 (X7) models: The serial number of the upper flap may need to be checked against an attached list. If it's on the list, the upper active air flap is replaced, and the vehicle is programmed.
   • For DTC 0x21B042 (lower air flap blockage): Environmental details are checked. If the fault occurred below 45°F, it's likely due to temporary icing, and the fault can be deleted. Otherwise, programming is required.
   • For DTC 0x138206 (lower air flap blockage): Fault code dates are checked. If the fault occurred multiple times on the same day, programming is performed. If it occurred on different days, the lower active air flap is replaced, and the vehicle is programmed.
   • For G20 (3 Series Sedan) models with additional faults, the underbody shield may need to be removed (following repair instructions 51 47 490) to inspect and re-clip disconnected lower active air flaps.

Required Tools or Parts

Specific parts required will depend on the diagnostic results. Technicians will obtain part numbers by entering the vehicle's chassis number into ETK/AIR. This ensures the correct upper or lower air flaps, or the air duct with flap control assembly for G29 models, are ordered. Additionally, small parts like screws, nuts, and seals must be replaced according to ISTA repair instructions.

Important Warnings

• Battery Charger: When programming the vehicle, it is mandatory to Always connect a BMW-approved battery charger/power supply (SI B04 23 10). This prevents voltage drops that could damage control units during the update process.
• Non-Warranty Repairs: Active cooling damper control-related fault codes or repairs caused by debris or blockages from outside influences are not considered defects in materials or workmanship and are not claimable under warranty.

Warranty Information

Repairs covered under warranty for a BMW active air flap fault will utilize specific defect codes and labor operations. These include:

• Defect Code 5174031200: For air flap control active above (actuator) permanently failed (including combined top and bottom active air flap repairs). Labor operation 51 64 700 (Replacing top flap control).
• Defect Code 5171431200: For bottom active air flap control (actuator) permanent failure. Labor operation 51 64 705 (Replacing bottom flap control).
• Defect Code 5171341300: For G20 models, bottom air flap/cooling flap (mechanics) broken/detached. This may involve labor operations 51 47 500 (Removing and installing/replacing underbody protection) and 51 99 000 (Work time to reinstall flaps, if disconnected).

Programming and encoding of control units (labor operation 61 00 730) may also be required and is claimable under specific conditions, often in conjunction with other open Technical Campaigns.

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Source: NHTSA ID: 11005449