4 recalls across 1 model year
The BMW 540D has 4 recalls, all covering the 2018 model year, with the most serious being an exhaust gas recirculation (EGR) cooler that can leak internally, allowing coolant to mix with diesel soot, producing smoldering particles and melting the intake manifold, which raises the risk of an engine fire.
A prior repair attempt for the EGR cooler issue did not fully resolve the problem, and a follow-up recall was issued for vehicles that had already been serviced. On the mechanical side, the crankshaft sensor on 2018 models can carry incorrect firmware that prevents it from properly reading crankshaft rotation, which can cause the engine to stall unexpectedly while driving. The 2018 model year is also included in a broader recall covering the backup camera, which can fail to display an image when reversing, reducing visibility behind the vehicle.
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