BMW 540D (BMW) - Exhaust Gas Recirculation Issue (2024)
Check Your Product
According to the National Highway Traffic Safety Administration (NHTSA)
Product
2018 BMW 540D
Brand
BMW
Lot Codes / Batch Numbers
Not specified in NHTSA notice. Check official source for details.
Products Sold
Model Year 2018
BMW of North America, LLC is recalling certain 2018 BMW 540D vehicles due to engine and engine cooling:exhaust system:emission control:gas recirculation valve (egr valve) issues. An EGR valve with smoldering particles and a melting intake manifold increases the risk of an engine fire..
Summary derived from NHTSA notice
Reason for Recall
As stated by NHTSA
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.
Reported concern (NHTSA)
An EGR valve with smoldering particles and a melting intake manifold increases the risk of an engine fire.
Recommended Action
Per NHTSA guidance
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.
Verify this information on the official source
For complete details and official instructions, check the National Highway Traffic Safety Administration (NHTSA) directly.
View official NHTSA recall noticePage updated: Jan 10, 2026