The 2018 BMW 540D has 4 recalls, the most serious being an EGR cooler that can leak internally, allowing coolant to mix with diesel soot and produce smoldering particles that melt the intake manifold and risk an engine fire. Recalls 1 and 2 describe the same underlying defect, with one specifically covering vehicles where a prior repair attempt did not fully resolve the issue. On the engine side, the crankshaft sensor may carry incorrect firmware that prevents it from properly reading crankshaft rotation, which can cause the engine to stall unexpectedly while driving. There is also a camera concern: the backup camera can fail to display an image when reversing, reducing visibility of obstacles or pedestrians behind the vehicle.
At a glance
What can fail
The exhaust gas recirculation cooler may leak internally, allowing coolant to mix with diesel soot and create smoldering particles that can melt the intake manifold.
What the fix does
Dealers will inspect and replace the EGR module and intake manifold as 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 exhaust gas recirculation cooler may leak internally, allowing coolant to mix with diesel soot and create smoldering particles that can melt the intake manifold.
What the fix does
Dealers will replace the EGR module and inspect the intake manifold, replacing it if needed, at no cost.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The backup camera display can be adjusted to hide the rear view image, and the vehicle remembers this setting when put in reverse, leaving the screen blank.
What the fix does
Dealers will update the backup camera software at no cost to restore the display functionality.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The crankshaft sensor has incorrect firmware that prevents it from reading the crankshaft reluctor ring properly, which can cause the engine to stall.
What the fix does
Dealers will replace the crankshaft sensor at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
