Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade:
A
B
C
D
F
ungraded
What breaks on a 2016 BMW 535D
Every complaint is filed against a part. Follow any row for the complaints about that part alone.
Fuel & Propulsion
436.4%
Median failure at 90,500 miles
Engine & Cooling
436.4%
0 crashes, 1 fires · median 65,000 mi
Other & Unspecified
19.1%
Tires
19.1%
Median failure at 16,000 miles
Transmission & Drivetrain
19.1%
When it fails
Odometer readings owners gave when they filed. About half of all
complaints include one.
10,000 – 24,999 miles
125.0%
50,000 – 74,999 miles
250.0%
100,000 – 149,999 miles
125.0%
When owners complained
A spike years after the car went on sale usually means a part wearing
out on schedule across the whole fleet — the kind of pattern no single
owner can see from inside their own car.
Mar 2018peak 4Jul 2025
NHTSA investigations into the 2016 BMW 535D
An investigation is the step before a recall: the agency has seen enough
complaints to look into a pattern itself. An open one means it thinks
something may be wrong and nothing has been fixed yet.
2
investigations are
still open.
EA23001Opened 17 Mar 2023Still openFUEL SYSTEM, DIESEL:DELIVERY:FUEL PUMP
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...
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...
Complaints that involved harm
Reports where the owner recorded a crash, a fire, an injury or a death.
San Gabriel, CAFire
ENGINE
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 — an unverified report by a vehicle owner.
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
Las Vegas, NV
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)
NHTSA complaint #11676996 — an unverified report by a vehicle owner.
at 116,000 milesBirmingham, AL
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.
NHTSA complaint #11654425 — an unverified report by a vehicle owner.
San Gabriel, CAFire
ENGINE
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 — an unverified report by a vehicle owner.
Mission Viejo, CA
FUEL/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 — an unverified report by a vehicle owner.
Hollister, CA
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 — an unverified report by a vehicle owner.
Hollister, CA
ENGINE
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 — an unverified report by a vehicle owner.
at 65,000 milesMoorpark, CA
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 — an unverified report by a vehicle owner.
at 65,000 milesMoorpark, CA
ENGINE
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 — an unverified report by a vehicle owner.
Ferndale, MI
FUEL 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 — an unverified report by a vehicle owner.
NEW Douglas, IL
UNKNOWN OR OTHER
REDUCTANT TANK SENSOR FAILURE
NHTSA complaint #11133207 — an unverified report by a vehicle owner.
at 16,000 milesDowney, CA
TIRES
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 — an unverified report by a vehicle owner.