The defect
BMW of North America, LLC. (BMW) is recalling certain 540d xDrive vehicles that were previously repaired under recall number 22V-614. The exhaust gas recirculation (EGR) cooler may leak internally, causing coolant to mix with diesel engine soot, which could result in smoldering particles and a melting intake manifold.
The risk
An EGR valve with smoldering particles and a melting intake manifold increases the risk of an engine fire.
The remedy
Dealers will inspect and replace the EGR module and the intake manifold as necessary, free of charge. Owner notification letters were mailed October 7, 2024. Owners may contact BMW customer service at 1-800-525-7417.
NHTSA's own wording · initiated by MFR
Vehicles covered
| Model | Model years |
|---|---|
| BMW 540d | 2018 |
Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| BMW 540d | 2018 | 3 | 4 |
Other engine and engine cooling recalls in 2024
27 of the 950 recall campaigns reported to NHTSA in 2024 concerned the engine and engine cooling; BMW of North America, LLC filed 347 campaigns in all.
| 24V970000 23 Dec 2024 | Indian Motorcycle Company |
| 24V851000 20 Dec 2024 | Ford Motor Company |
| 24V945000 19 Dec 2024 | Lamborghini (Automobili Lamborghini) |
| 24V926000 12 Dec 2024 | Chrysler (FCA US, LLC) |
| 24V924000 11 Dec 2024 | Daimler Trucks North America, LLC |
| 24V873000 19 Nov 2024 | Nova Bus (US) Inc. |
| 24V820000 31 Oct 2024 | Honda (American Honda Motor Co.) |
| 24V645000 29 Oct 2024 | Autocar, LLC |
NHTSA recalls (public domain) · all recalls of 2024