2016 BMW 535D problems, complaints & recalls

2016 BMW 535D recalls (5)

• Recall 21V907000Nov 19, 202150,404 vehicles
  FUEL SYSTEM, DIESEL

  BMW of North America, LLC (BMW) is recalling certain 2013-2018 328d, 328d xDrive, 2014-2018 328d Sports Wagon, 328d xDrive Sports Wagon, 2014-2016 535d, 535d xDrive, 2015 740Ld xDrive, 2015-2017 X3 xDrive28d SAV, and 2014-2017 X5 xDrive35d SAV diesel 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.

  Risk: A melting intake manifold increases the risk of a fire.

  Remedy: Dealers will replace the EGR cooler and inspect the intake manifold, replacing it as necessary, free of charge. This recall includes all vehicles previously recalled under 18V-755. Vehicles previously recalled under 18V-755 will need to have the new remedy performed for this recall. An interim owner notification letter was mailed on January 18, 2022. The remedy is expected to be available in June 2022. Owner notification letters were mailed on July 6, 2022. Owners may contact BMW customer service at 1-800-525-7417.

• Recall 21V586000Jul 29, 202111,216 vehicles
  FUEL SYSTEM, DIESEL:DELIVERY:FUEL PUMP

  BMW of North America, LLC (BMW) is recalling certain 2014-2018 328d, 328d xDrive, X5 xDrive35d, 2014-2016 535d, 535d xDrive, 2015 740Ld xDrive, and 2015-2017 X3 xDrive28d vehicles. The high-pressure fuel pump may fail.

  Risk: Fuel pump failure can cause an engine stall while driving, increasing the risk of a crash.

  Remedy: Dealers will replace the high-pressure fuel pump, free of charge. Owner notification letters were mailed on January 14, 2022. Owners may contact BMW customer service at 1-800-525-7417.

• Recall 18V755000Oct 25, 201844,368 vehicles
  ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)

  BMW of North America, LLC (BMW) is recalling certain 2013-2018 BMW 328d and 328d xDrive, 2014-2018 328d Sports Wagon and 328d xDrive Sports Wagon, 2014-2016 535d and 535d xDrive, 2015 740Ld xDrive, 2015-2017 X3 xDrive28d SAV and 2014-2017 X5 xDrive35d SAV vehicles equipped with an Exhaust Gas Recirculation (EGR) module with an integrated cooler. If the EGR cooler leaks internally, the coolant can mix with diesel engine soot. The high EGR temperatures may result in these particles possibly smoldering and melting the intake manifold.

  Risk: The melting intake manifold can increase the risk of a fire.

  Remedy: BMW will notify owners, and dealers will inspect and replace the EGR cooler as necessary. If a leak has already occurred, the engine intake manifold will also be replaced. These repairs will be made free of charge. The recall began May 13, 2019. Owners may contact BMW customer service at 1-800-525-7417.

• Recall 16V914000Dec 20, 20163,506 vehicles
  AIR BAGS

  BMW of North America, LLC (BMW) is recalling certain model year 2017 BMW 640i, 640i xDrive, 650i, 650i xDrive, M6, 535i, 535i xDrive, 430i, 430i xDrive, 440i, 440i xDrive, M4, X1 sDrive28i, X1 xDrive28i, i3, i8, Rolls-Royce Dawn, Mini Clubman Cooper, Clubman Cooper S, Cooper All4, Cooper S All4, Mini 4-Door Cooper, Cooper S, Mini 2-Door Cooper, Cooper S, John Cooper Works and 2016 BMW 528i, 528i xDrive, 535i, 535i xDrive, 550i, 550i xDrive, M5 and 535d vehicles. The affected vehicles have seat- mounted side air bag inflator initiators that may fail to ignite during a crash.

  Risk: If the air bag inflator initiator fails to ignite, the seat-mounted air bag will not deploy, increasing the risk of injury.

  Remedy: BMW will notify owners, and dealers will replace the air bag modules, free of charge. The recall began February 6, 2017. Owners may contact BMW customer service at 1-800-525-7417.

• Recall 15V718000Oct 30, 20157,162 vehicles
  CHILD SEAT · SEATS:MID/REAR ASSEMBLY

  BMW of North America, LLC (BMW) is recalling certain model year 2016 528i, 528i xDrive, 535i, 535i xDrive, 535d xDrive, M5, 550i, 550i xDrive, and 535d sedans. The affected vehicles have an inboard lower anchor for child restraints on the left rear seat that may have been bent downwards, preventing the child seat from fully engaging both lower anchors. As such, these vehicles may fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 225, "Child Restraint Anchorage Systems."

  Risk: If the child seat is not properly attached to the lower anchors, it can increase the child's risk of injury in the event of a crash.

  Remedy: BMW will notify owners, and dealers will inspect and, if necessary, repair the inboard lower anchor on the left rear seat, free of charge. The recall began on December 28, 2015. Owners may contact BMW customer service at 1-800-525-7417.

NHTSA defect investigations

• EA23001Opened Mar 17, 2023Openled to recall 24V957

  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 engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a compreh…

• EA21002Opened Sep 17, 2021Open

  Desiccated Air Bag Inflator Rupture

  From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.C…

Recent 2016 BMW 535D complaints

Excerpts of the newest owner complaints, lightly cleaned of personal details. Complaints are unverified owner reports.

1. Filed Jul 29, 2025NVEngine

   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…

   NHTSA complaint #11676996 · source
2. Filed Apr 14, 2025116,000 miALTowedFuel, Hybrid & EV Propulsion

   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:…

   NHTSA complaint #11654425 · source
3. Filed Apr 4, 2025CAFireEngine

   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 · source
4. Filed Jul 25, 2024CAFuel, Hybrid & EV Propulsion

   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 · source
5. Filed Aug 12, 2022CAEngineTransmission & Drivetrain

   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…

   NHTSA complaint #11479056 · source
6. Filed Aug 2, 202265,000 miCAEngineFuel, Hybrid & EV Propulsion

   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…

   NHTSA complaint #11477184 · source
7. Filed Jan 21, 2022MIFuel, Hybrid & EV Propulsion

   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 · source

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Source: U.S. National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation public data, as of Oct 10, 2026. Complaints are submitted by owners and are not verified by NHTSA or by us; a complaint does not prove a defect exists. View this vehicle on NHTSA.gov Methodology