2004 BMW 6 Series

On certain vehicles, the insulated bulkhead connector (used to join the two halves of the positive battery cable) may have been incorrectly installed during vehicle assembly.  Over time, the bolt connection could loosen, which would increase electrical resistance.  In addition, an incorrectly insulated bulkhead connector could allow humidity to accumulate at this location, causing current leakage.  These issues could cause the cable connection to overheat, which could result in a vehicle fire causing property damage and/or personal injury.  Correction: Dealers will inspect and, as necessary, secure the insulated bulkhead connector.  In addition, protective grease will be added to the area and the plastic battery positive terminal cover will be replaced.

On certain vehicles, a check valve in the brake vacuum pump may leak a small amount of lubricating oil.  Over time, this could result in contamination of the brake booster.  Loss of brake power assist could occur which, in conjunction with traffic, road conditions, and driver's reactions, could increase the risk of a crash causing property damage and/or personal injury.  Correction: Dealers will inspect and, if necessary, replace the brake booster and master cylinder.  Additionally, the brake vacuum line (including the check valve) will be replaced to eliminate the possibility of oil reaching the brake booster.

On certain vehicles, the digital engine management control unit was not produced according to specifications.  As a result, engine stalling will occur after a short period of operation.  The vehicle may not be able to be restarted.  Also, a loss of power steering and, after repeated actuation of the brake pedal, a loss of brake power assistance will occur.  If stalling were to occur, the driver would be unable to maintain vehicle speed or accelerate.  Steering and braking, while possible, would be difficult.  Depending on traffic conditions and the driver's reactions, this could lead to a crash.  Correction:  Dealers will replace the digital engine management control unit.

On certain vehicles equipped with an 8-cylinder engine, the circular retention clip at the quick-release coupling along the fuel supply line was inadvertently omitted.  As a result, it is possible that in a severe frontal crash, the quick-release coupling could separate.  If this happens, a small amount of fuel could leak and potentially ignite.  Correction:  Dealers will install a circular retention clip.

On certain 645CI cabriolet and 645CI coupe, the sun visor airbag warning label does not comply with the requirements of CMVSS 208.  These cars do not have advanced airbags but have the advanced airbag warning label from the 5-series.  Consequently, they are missing the warning to "not to sit unnecessarily close to the airbag".  Correction:  Dealer will install new correct sun visor.