2018 BMW 540D Recall: Exhaust gas recirculation (EGR) cooler may leak internally, causing…
NHTSA campaign 24V588000 · Engine and Engine Cooling · filed Aug 8, 2024 · verified Jul 30, 2026
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.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →The fix — what to do
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.
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Affected vehicles
Related recalls
More BMW 540D recalls
Other campaigns involving BMW vehicles
Source: NHTSA recall database, campaign 24V588000. Data last verified Jul 30, 2026.