NHTSA vehicle safety data
2018 BMW 540D Recalls & Complaints
The 2018 BMW 540D has 4 NHTSA recall campaigns and 3 owner complaints on file as of October 21, 2026. Recall repairs are usually free at an authorized BMW dealer.
NHTSA recall and complaint data for the 2018 BMW 540D. Recall data is refreshed daily from NHTSA.
2018 BMW 540D owner complaints
Owners have filed 3 complaints with NHTSA about the 2018 BMW 540D, describing incidents dated May 2, 2022 to June 30, 2024.
Most-cited components
- Engine 2 complaints
- Air Bags 1 complaint
- Fuel/Propulsion System 1 complaint
Newest complaints
ODI #11602418 · Filed
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 by…
ODI #11575506 · Filed
My passenger restraint system randomly faults. Problem with passenger seat mat. Many BMW owners have reported the issue. Should be recalled by BMW.
ODI #11474850 · Filed
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 dealership…
Coolant Leak Inside EGR Module May Cause Fire
NHTSA #24V588000 · Engine and Engine Cooling — Exhaust System — Emission Control — Gas Recirculation Valve (EGR VALVE) · NHTSA notice
Reported August 8, 2024 · BMW of North America, LLC
Potentially affected: 15 vehicles
Repair completion: 86.67% (latest rate the manufacturer reported to NHTSA; dataset updated October 21, 2026)
Owners notified October 7, 2024
Defect description
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.
Safety consequence
An EGR valve with smoldering particles and a melting intake manifold increases the risk of an engine fire.
Manufacturer 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.
Notes
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.
Coolant Leak Inside EGR Module May Cause Fire
NHTSA #22V614000 · Engine and Engine Cooling — Exhaust System — Emission Control — Gas Recirculation Valve (EGR VALVE) · NHTSA notice
Reported August 10, 2022 · BMW of North America, LLC
Potentially affected: 298 vehicles
Repair completion: 95.97% (latest rate the manufacturer reported to NHTSA; dataset updated October 21, 2026)
Owners notified December 30, 2022
Defect description
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 manifold.
Safety consequence
A melting intake manifold increases the risk of fire.
Manufacturer 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.
Notes
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.
No Back-Up Camera Display Image/FMVSS 111
NHTSA #19V684000 · Back Over Prevention — Sensing System — Camera · NHTSA notice
Reported September 27, 2019 · BMW of North America, LLC
Potentially affected: 257,473 vehicles
Repair completion: 96.64% (latest rate the manufacturer reported to NHTSA; dataset updated October 21, 2026)
Owners notified November 8, 2019 · Vehicles built May 7, 2018 – June 25, 2019 (per NHTSA)
Defect description
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 840i, 840i xDrive, M850i xDrive, X5 sDrive, X5 xDrive, X5 M50i, X6 xDrive, X6 M50i, 330i, 330i xDrive, M340i, M340i xDrive, Z4 sDrive, Z4 M40i, 740Le xDrive and 745Le xDrive, 2018-2019 640i xDrive Gran Turismo and Rolls-Royce Phantom, 2019 M850i xDrive Gran Coupe and Rolls-Royce Cullinan and 2020 Toyota Supra vehicles. The back-up camera and display settings can be adjusted such that the rear view image is no longer visible and the system will retain that setting the next time the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rearview Mirrors."
Safety consequence
The lack of an image in the back-up camera display increases the risk of a crash.
Manufacturer 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.
Notes
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.safercar.gov.
Crankshaft Sensor Firmware may Cause Stall
NHTSA #18V465000 · Engine and Engine Cooling — Engine · NHTSA notice
Reported July 11, 2018 · BMW of North America, LLC
Potentially affected: 5,309 vehicles
Repair completion: 98.21% (latest rate the manufacturer reported to NHTSA; dataset updated October 21, 2026)
Owners notified September 6, 2018 · Vehicles built May 17, 2018 – June 6, 2018 (per NHTSA)
Defect description
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 recall to a total of 5,309 vehicles including certain 2018-2019 BMW 540d xDrive, 230i M240i, M240i xDrive, X2 sDrive28i, X2 xDrive28i, X1 sDrive28i, X1 xDrive28i, 330i, 330i xDrive, 340i, 340i xDrive, 330i xDrive Gran Turismo, 530i, 530i xDrive, 540i, 540i xDrive, 530e, 530e xDrive, 640i xDrive Gran Turismo, 330e, 2019 430i Gran Coupe, 430i xDrive Gran Coupe, 440i Gran Coupe, 440i xDrive Gran Coupe, 430i, 430i xDrive, 440i, 440i xDrive, 740i, 740i xDrive, MINI Cooper, Cooper S, JCW, MINI Countryman (Cooper, Cooper All4, Cooper S, Cooper S All4, JCW All4), and MINI Clubman (Cooper, Cooper S, Cooper All4, Cooper S All4, JCW All4) vehicles.
Safety consequence
A vehicle stall can increase the risk of a crash.
Manufacturer 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.
Notes
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.safercar.gov.
Check your 2018 BMW 540D VIN
Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your BMW 540D at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.
Check a BMW VIN