4 recalls across 1 model year
The BMW 540D has 4 recalls, all affecting the 2018 model year, with the most serious being an exhaust gas recirculation cooler that can leak internally, mix coolant with diesel soot, produce smoldering particles, and melt the intake manifold, raising the risk of an engine fire.
The EGR cooler issue has been addressed more than once, as the initial repair did not fully resolve the problem for some vehicles, leading to a follow-up recall for 2018 models that had already been through the first repair. On the engine side, some 2018 models were built with crankshaft sensor firmware that misreads input from the crankshaft reluctor ring, which can cause the engine to stall unexpectedly while driving. There is also a backup camera recall on 2018 models where the camera image can fail to appear when reversing, removing rear visibility the driver would otherwise rely on.
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