Defect
On certain vehicles, a wrong part may have been installed by a BMW dealer during recall 11 81 22RC (Transport Canada recall no. 2022-452). As a result, a second repair is required. On certain 540d xDrive models, the exhaust gas recirculation (EGR) cooler could crack internally and leak. If this happens, you may notice the following symptoms: a warning symbol in the instrument cluster displaying a loss of coolant, reduced engine power, an unpleasant exhaust odour, an unusual noise from the engine and/or smoke from the engine compartment.
Safety Risk
A cracked EGR cooler could create the risk of an engine fire.
Remedy
BMW will notify owners by mail and advise you to take your vehicle to a dealership to inspect and, if necessary, replace the EGR module and the intake manifold with updated parts.