2016 BMW 535D

9 complaints on file, page 1 of 1.

1. Filed Jul 29, 2025Failure Jul 23, 2025Las Vegas, NVEngine

   On [XXX], the coolant connector flange on my 2016 BMW 535d (VIN: [XXX] ) catastrophically failed, causing complete coolant loss. I immediately contacted BMW of Las Vegas and was instructed to drive it in despite fluid visibly leaking through the undercarriage. The next day, [XXX], BMW performed Recall 21V-907 (EGR cooler replacement), which involved draining and reconnecting the coolant circuit—but they left the failed flange in place. The failed flange connects directly to the new EGR coolant return hose installed under the recall. BMW had full access to the part but chose not to inspect or replace it. The dealer submitted a consequential damage claim to BMW North America, which was denied. The vehicle remains at the dealership unrepaired. This failure poses serious safety risks. Driving with active coolant loss could cause overheating, engine failure, or fire. Had I not stopped, this could’ve led to mechanical catastrophe. BMW re-pressurized the cooling system into a visibly broken flange, creating an unsafe condition. The failure was confirmed by BMW technicians and documented in a repair order. No warning lamps were active at the time of failure. I currently have an open case with BMW North America, but no contact has been made. I am requesting NHTSA review this matter as BMW failed to fully remedy a safety defect and ignored collateral damage tied directly to the recalled system. The failed part is available for inspection. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

   NHTSA complaint 11676996
2. Filed Apr 14, 2025Failure Apr 10, 2025116,000 milesBirmingham, ALFuel system, Diesel

   The contact owns a 2016 BMW 535D. The contact stated while driving approximately 25 MPH, the vehicle experienced a loss of motive power. No warning lights were illuminated. The vehicle was towed to a local dealer where it was diagnosed with high-pressure fuel pump failure. The vehicle was left at the local dealer, where it remained for further repairs. The vehicle was not repaired. Upon further investigation, the contact related the failure to NHTSA Campaign Number: 21V586000 (Fuel System, Diesel); however, the VIN was not included. The manufacturer was made aware of the failure. The failure mileage was approximately 116,000.

   NHTSA complaint 11654425
3. Filed Apr 4, 2025Failure Apr 3, 2025San Gabriel, CAEngineFire

   Valve cover leak Oil filter housing leak Super common that these items leak in the bmw N57 diesel engines. Increased risk of fire. I am in the Facebook group with many other owners of the same engine, and almost everyone runs into the same problems by 100,000 miles.

   NHTSA complaint 11652697
4. Filed Jul 25, 2024Failure Jul 25, 2024Mission Viejo, CAFuel/propulsion system

   HIGH PRESSURE FUEL PUMP HAS SUDDENLY FAILED CAUSING A IMMEDIATE ENGINE STALL WITHOUT WARNING. WILL NOT RESTART EVEN THOUGH IT DOES TURN OVER. CODE READS LOW FUEL PRESSURE AT FUEL RAIL. FUEL TANK LIFT PUMP IS WORKING CORRECTLY. THERE IS A RECALL FOR SOME 2014 TO 2016 535D FOR THIS FAILURE. WHY IS MINE NOT COVERED? 122,400 MILES.

   NHTSA complaint 11604602
5. Filed Aug 12, 2022Failure Aug 6, 2022Hollister, CAEngine, Power train

   A recall campaign No. 21V-907 was issued for my car on November 19, 2021 for the EGR Cooler. In the past 6 months I've had to add engine coolant to the cooling system reservoir and I made sure it is not leaking on the ground. On 8-8-22 I had a check engine light(MIL) with a stored code of P2004 which indicated: Intake manifold runner control (IMRC) is stuck in the open position. According to your recall letter, an EGR Cooler leak could develop and the coolant could mix with the soot deposits in the intake manifold and under certain conditions it could result in a fire. I have experienced a reduction in engine power, a warning symbol of low engine coolant, and an unpleasant exhaust odor so I contacted Stevens Creek BMW in San Jose, CA and spoke to the Service Manager. He said they are not able to fix my car due to the BMW EGR Cooler not being available. Can you help?

   NHTSA complaint 11479056
6. Filed Aug 2, 2022Failure Jun 1, 202065,000 milesMoorpark, CAEngine, Fuel system, Diesel

   The contact owns a 2016 BMW 535D. The contact stated that the engine warning light was illuminated. The contact received notification of NHTSA Campaign Number: 21V907000 (Fuel System, Diesel) however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available. The approximate failure mileage was 65,000.

   NHTSA complaint 11477184
7. Filed Jan 21, 2022Failure Jan 21, 2022Ferndale, MIFuel system, Diesel

   The contact owns a 2016 BMW 535D. The contact received a recall notification for NHTSA Campaign Number: 21V907000 (Fuel System, Diesel) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

   NHTSA complaint 11448370
8. Filed Oct 3, 2018Failure Oct 3, 2018NEW Douglas, ILUnknown or other

   REDUCTANT TANK SENSOR FAILURE

   NHTSA complaint 11133207
9. Filed Mar 5, 2018Failure Feb 4, 201816,000 milesDowney, CATires

   1 ST TIRE BLOWN 13000 MILES AT 45 MPH ON LAKE HAVASU CITY,AZ 2ND TIRE BLOWN 16000 MILES AT 65 ON 5FWY LOS ANGELES,CA AT 14 000 MILES HAD TO REPLACE A TIRE FOR A PUNTURE SO NO BIG DEAL BUT 3 GOODYEAR EAGLE LS 245/45R18 RUN ON FLAT BEFORE 20 000 MILES THATS A CONCERN SAFE TO DRIVE THE CAR

   NHTSA complaint 11076396