2016 BMW 535D

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.

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.

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.

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.

ENGINE

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)

FUEL 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.