The Exhaust Gas Recirculation (EGR) cooler can fail, leading to coolant leaks into the intake manifold. This can cause significant engine damage, including potential intake manifold melting, a critical fire risk. Multiple recalls address this issue. Estimated repair cost: $1,500 - $3,000.

High-Pressure Fuel Pump Failure

The high-pressure fuel pump is a critical component that can fail, leading to engine stalling and potential fuel system contamination. A recall has been issued for this component. Estimated repair cost: $1,000 - $2,000.

Airbag Inflator Failure

Defective airbag inflators pose a significant safety risk. Recalls have been issued to address this potential failure, which could lead to improper airbag deployment. Estimated repair cost: $500 - $1,500.

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2016 BMW 535d Maintenance guide

Name: Maintenance dataset for 2016 BMW 535d
Creator: Carfocal

v1.0Updated Jul 4, 2026Daniel Wilson4 Sources Analyzed4 Critical Recalls

MAINTENANCE SUMMARY

The 2016 BMW 535d demands diligent maintenance, particularly concerning its diesel powertrain. Key concerns include the EGR cooler system, which has seen multiple recalls and can lead to intake manifold issues, and the high-pressure fuel pump.

View Critical Issue: EGR Cooler Failure

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Reliability Score

Est. Annual Maintenance Cost

$1,000 - $1,500

TSBs & Recalls

128 TSBs | 6 Recalls

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Key Takeaways

Prioritize inspection and repair of the EGR cooler system due to potential fire risk.
Address the high-pressure fuel pump recall and consider proactive replacement.

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Critical service intervals

Common failure analysis

Symptoms and prevention guidance