RecallRepo

2018 BMW 540d Recalls

Recalls on record Updated July 2026

The 2018 BMW 540d has 4 NHTSA recall campaigns affecting an estimated 263,095 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 4 complaints with NHTSA, most often about the engine. Last updated July 5, 2026.

Recall campaigns

ENGINE AND ENGINE COOLING 24V588000 2024-08-08 15 affected
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.

Consequence

An EGR valve with smoldering particles and a melting intake manifold increases the risk of an engine fire.

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.

ENGINE AND ENGINE COOLING 22V614000 2022-08-10 298 affected
Defect

BMW of North America, LLC. (BMW) is recalling certain 2018 540d xDrive vehicles equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. The EGR cooler may leak internally, causing coolant to mix with diesel engine soot, which could result in smoldering particles and a melting intake…

Consequence

A melting intake manifold increases the risk of fire.

Remedy

Dealers will replace the EGR module, and the intake manifold will be inspected and replaced, if necessary, free of charge. Interim owner notification letters were mailed on October 7, 2022. Owner notification letters were mailed December 30, 2022. Owners may contact BMW customer service at 1-800-525-7417.

BACK OVER PREVENTION 19V684000 2019-09-27 257,473 affected
Defect

BMW of North America, LLC (BMW) is recalling certain 2018 540d, 2018-2020 530i, 530i xDrive, 540i, 540i xDrive, M550i xDrive, M5, 530e, 530e xDrive, X3 sDrive, X3 xDrive, X3 M40i, X3 M, and 2019-2020 X4 xDrive, X4 M40i, X4 M, X7 xDrive, X7 M50i, 740Li, 740Li xDrive, 750Li, 750Li xDrive, 8 Series Convertible and Coupe…

Consequence

The lack of an image in the back-up camera display increases the risk of a crash.

Remedy

BMW will notify owners, and dealers will update the back-up camera software, free of charge. The recall began November 8, 2019. Owners may contact BMW customer service at 1-800-525-7417 or Rolls-Royce at 1-877-877-3735. Toyota owners may contact Toyota customer service at 1-888-270-9371.

ENGINE AND ENGINE COOLING 18V465000 2018-07-11 5,309 affected
Defect

BMW of North America, LLC (BMW) is recalling certain 2018 BMW 540d xDrive vehicles. The crankshaft sensor may be equipped with incorrect firmware, preventing the sensor from properly processing input from the crankshaft reluctor ring, possibly resulting in a vehicle stall. On September 12, 2018, BMW expanded the…

Consequence

A vehicle stall can increase the risk of a crash.

Remedy

BMW will notify owners, and dealers will replace the crankshaft sensor, free of charge. The recall began September 6, 2018. Owners may contact BMW customer service at 1-800-525-7417.

Complaints by component

ENGINE
2
AIR BAGS
1
FUEL/PROPULSION SYSTEM
1
Total complaints4

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“The 540d has swirl flaps on the intake manifold to regulate air intake so it adjusts how much air the intake manifold feeds the engine. There's an actuator motor that connects to the swirl flap shaft that connects via a plastic linkage. When the linkage breaks, the flaps are no longer controlled…”

FUEL/PROPULSION SYSTEM · reported 2024-06-30

“The 540d has swirl flaps on the intake manifold to regulate air intake so it adjusts how much air the intake manifold feeds the engine. There's an actuator motor that connects to the swirl flap shaft that connects via a plastic linkage. When the linkage breaks, the flaps are no longer controlled…”

ENGINE · reported 2024-06-30

“My passenger restraint system randomly faults. Problem with passenger seat mat. Many bmw owners have reported the issue. Should be recalled by bmw.”

AIR BAGS · reported 2023-09-01

“There is an exhaust leak which has developed in the turbo. This causes untreated fumes and soot to be emitted in the engine compartment. This untreated exhaust makes its way into the passenger cabin, putting passengers at safety risk due to untreated exhaust fumes entering the cabin. The…”

ENGINE · reported 2022-05-02

Defect investigations

Investigation EA23001 Opened 2023-03-17 · open

High pressure fuel pump failure

The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2018 BMW 540d as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.