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Home/Cars/BMW/3 Series/E90/E91 (2005-2012)/why does my BMW 3 Series E90/E91 smell like burnt plastic?

why does my BMW 3 Series E90/E91 smell like burnt plastic?

BMW 3 Series E90/E91 (2005-2012)

Severity: mediumDifficulty: medium2-4 hours
3 min read
438 words

Problem Statement

## Problem Statement The BMW 3 Series E90/E91 is emitting a burnt plastic smell, which may indicate an electrical issue, overheating components, or a malfunctioning part within the engine bay or cabin

Repair Time
2-4 hours

Safety Warnings

  • ⚠Safety Warnings:**
  • ⚠Disconnect the battery before working on electrical systems.
  • ⚠Allow the engine to cool before inspecting components to avoid burns.

Symptoms

  • •Burning smell resembling burnt plastic
  • •Possible smoke or haze in the cabin or engine bay
  • •Electrical components may become non-functional (e.g., lights, windows)
  • •Increased engine temperature readings
  • •Unusual sounds from electrical systems (buzzing or clicking)

Diagnostic Steps

  1. 1Inspect the engine bay for any visible signs of melted plastic or damaged wiring.
  2. 2Use an OBD-II scanner to check for error codes related to electrical systems or overheating.
  3. 3Check the operation of all electrical components (lights, windows, etc.) for any malfunctions.
  4. 4Inspect fuses and relays for any signs of damage or burning.
  5. 5Examine the cabin for any foreign objects that could be causing the smell (e.g., debris near the heater core).

Solution

Solution

1. Preparation

  • Tools Required: Safety goggles, gloves, flashlight
  • Ensure the vehicle is parked on a level surface and the engine is cool.
  • Disconnect the battery to prevent any electrical shorts.

2. Inspect and Remove Damaged Components

  • Tools Required: Socket set, pliers
  • Identify and remove any damaged wiring or connectors in the engine bay.
  • If any electrical components show signs of melting or damage, remove them for replacement.

3. Replacing Damaged Wiring or Components

  • Tools Required: Wire strippers, electrical tape, heat shrink tubing
  • Cut out damaged sections of wiring and strip the ends.
  • Use appropriate gauge wire to splice in new sections, solder, and insulate with electrical tape or heat shrink tubing.

4. Reassemble and Test

  • Reattach all removed components and wiring securely.
  • Reconnect the battery and start the engine.
  • Check for any new smells or signs of overheating.

Verification

After completing the repair, verify that the issue has been resolved:

  • Test the affected component to ensure it functions correctly
  • Check for any error codes or warning lights
  • Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

  • •Follow the manufacturer's recommended maintenance schedule
  • •Address warning signs early before they develop into major issues
  • •Use quality parts and fluids recommended for your vehicle
  • •Keep detailed records of all repairs and maintenance

Tools & Equipment Required

  • Ensure the vehicle is parked on a level surface and the engine is cool.
  • Disconnect the battery to prevent any electrical shorts.

Parts Required

  • Replacement wiring
  • Any damaged electrical components (e.g., fuses, relays)

Additional Information

Repair Time

2-4 hours

Difficulty

medium

Severity

medium

Tools

2 items

Parts

2 items

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