2018 BMW 540D Engine Problems

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 stays in its semi closed state. The result is when you give it full throttle, it spews out plumes of black smoke that is thick and the equivalent to rolling coal on a deleted diesel truck. The car still runs, but this poses a danger to those behind you and not very environmentally friendly to spew out soot. BMW's solution is a $6,000 repair bill, because the entire intake manifold has to be replaced for that linkage. This will be a guaranteed fail again - considering I had a check engine light for swirl...

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 the issue and describes it as follows: "The soot that you have seen and the smell is coming out of the wastegate shaft which by design there is a tolerance for it to move, but due to back pressure from the soot build up before the regen has occurred there is some soot that comes out." This problem happens every time I start and drive the car. The dealership is stating that this is not covered by the factory warranty. An exhaust leak like this is a serious passenger safety issue.