4 recalls and 3 owner complaints on file with NHTSA for the 2018 BMW 540D.
4
recalls
3
owner complaints
0
complaints mentioning a crash
0
mentioning a fire
Recalls apply to specific production ranges. To see whether a particular car still has an open recall, enter its VIN at nhtsa.gov/recalls. Repairs for safety recalls are free at authorised dealers.
2018 BMW 540D recalls
Engine and engine cooling: exhaust system, emission control, gas recirculation valve (egr valve)
NHTSA campaign 24V588000 · reported August 8, 2024 · BMW of North America, LLC · 15 vehicles potentially affected
The problem
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 fix
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: exhaust system, emission control, gas recirculation valve (egr valve)
NHTSA campaign 22V614000 · reported August 10, 2022 · BMW of North America, LLC · 298 vehicles potentially affected
The problem
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.
The risk
A melting intake manifold increases the risk of fire.
The fix
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: sensing system, camera
NHTSA campaign 19V684000 · reported September 27, 2019 · BMW of North America, LLC · 257,473 vehicles potentially affected
The problem
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."
The risk
The lack of an image in the back-up camera display increases the risk of a crash.
The fix
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: engine
NHTSA campaign 18V465000 · reported July 11, 2018 · BMW of North America, LLC · 5,309 vehicles potentially affected
The problem
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.
The risk
A vehicle stall can increase the risk of a crash.
The fix
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.
Most reported problems
Areas named in owner complaints to NHTSA. One complaint can name several areas.
Engine2
Air bags1
Fuel/propulsion system1
What owners report
Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.
Jul 15, 2024 · Fuel/propulsion system
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 the actuator and…
Mar 5, 2024 · Air bags
My passenger restraint system randomly faults. Problem with passenger seat mat. Many BMW owners have reported the issue. Should be recalled by BMW.
Jul 20, 2022 · Engine
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 has acknowledged…
Yes. NHTSA lists 4 recalls for the 2018 BMW 540D, the most recent reported on August 8, 2024 (Engine and engine cooling: exhaust system, emission control, gas recirculation valve (egr valve)). Check a specific car by its VIN at nhtsa.gov/recalls.
What are the most common problems with the 2018 BMW 540D?
Owners have filed 3 complaints with NHTSA. The most frequently reported area is engine (2 complaints), followed by air bags (1).
How many 2018 BMW 540D complaints mention a crash or fire?
0 of 3 complaints report a crash and 0 a fire; 0 injuries were reported in total. Complaints are unverified reports from owners.
Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received July 15, 2024.