This page covers 5 recalls and EPA fuel economy for the 2016 BMW 535d.
30 mpg combined
7.8 L/100km
Midsize Cars
Fuel economy data from fueleconomy.gov (EPA / U.S. Dept. of Energy). Annual cost based on 15,000 mi/yr at 55% city driving and current fuel prices. MPG is U.S. gallons; L/100km converted.
The 2016 BMW 535D has 5 recalls, the most serious being an exhaust gas recirculation module that can cause the intake manifold to melt and catch fire.
The EGR fire risk has been the subject of multiple recall filings covering the same defect, and prior repair attempts did not fully resolve the issue. Alongside that, the high-pressure fuel pump can fail without warning, stalling the engine while the vehicle is in motion and raising the risk of a crash. Together, these two issues represent the most significant safety concerns on this vehicle.
On the occupant safety side, the inboard lower anchor for child restraints on the left rear seat may have been bent downward during assembly, preventing a child seat from locking properly onto both lower anchors and reducing its ability to restrain a child in a crash. There is also an airbag concern: the initiator inside the seat-mounted side airbag may fail to ignite, leaving the bag completely undeployed in a collision and removing a layer of protection from the occupant sitting next to it.
At a glance
What can fail
The exhaust gas recirculation cooler can leak internally, allowing coolant to mix with engine soot and create smoldering particles that may melt the intake manifold.
What the fix does
Dealers will replace the EGR cooler and inspect the intake manifold, replacing it if needed, at no cost.
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Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The high-pressure fuel pump may fail, potentially causing the engine to lose fuel pressure and stop running.
What the fix does
Dealers will replace the high-pressure fuel pump at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The EGR cooler can leak internally, allowing coolant to mix with diesel soot. High temperatures may cause these particles to smolder and damage the intake manifold.
What the fix does
Dealers will inspect and replace the EGR cooler. If leakage already occurred, the intake manifold will also be replaced at no cost.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The seat-mounted side airbag inflator initiators may fail to ignite in a crash, preventing the airbag from deploying.
What the fix does
Dealers will replace the affected airbag modules at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The inboard lower anchor for child seats on the left rear seat may be bent downward, preventing a child seat from connecting to both anchors properly.
What the fix does
Dealers will inspect the inboard lower anchor on the left rear seat and repair it if needed, at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
