2016 BMW 535D — Problems, Recalls & Safety Data

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)

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.

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.

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.

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?