What 81 owners told NHTSA about the 2016 BMW 5 Series Hybrid Sedan Phev

The contact owns a 2016 BMW 528i. The contact stated that the vehicle was repaired under an unknown recall, and after the recall repair, while driving at an undisclosed speed, there was an abnormal oil-burning odor entering the cabin of the vehicle. The vehicle was taken to a local Midas, where it was discovered that oil was leaking onto the engine. The vehicle was not repaired due to the cost. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 32,400.

NHTSA ODI 11719874

On January 29, 2020, while driving my 2016 BMW 5 Series under normal operating conditions, the engine compartment caught fire without warning. Smoke and flames originated from the engine bay while the vehicle was in motion. I was forced to pull over and exit the vehicle immediately. The fire spread rapidly, and the vehicle was declared a total loss. At the time, both my insurance carrier and BMW representatives inspected the vehicle, but no definitive cause was identified. In January 2026, I received notification that this same vehicle is subject to BMW Safety Recall Campaign No. 24V-608, which states that liquid from the positive crankcase ventilation system can drip onto the water pump electrical connector, potentially causing a short circuit and, in rare cases, an engine fire. This recall describes the same failure event that destroyed my vehicle, which occurred before any recall remedy was available.

NHTSA ODI 11713522

My coolant line overheated. From the leaking water pump and pcv that exploded all over my engine causing it to overheat and now how has not turned back on. Ive been without a car for months and when I seen the recall and reached out to the dealer expressing my situation they said they would get back to me and have not called or emailed or even responded in months.

NHTSA ODI 11697057

During initial cold starts there is blue smoke billowing from the exhaust for approx 20 seconds. The odor is horrible.

NHTSA ODI 11687010

Multiple critical BMW engine components are manufactured from plastic, including the oil pan, coolant expansion tank, valve cover, and turbo inlet pipe. These parts are prone to premature failure from normal heat & stress, as confirmed by independent mechanics. Failures can cause sudden loss of oil or coolant, persistent oil leaks, overheating, loss of power, and roadside breakdowns. The use of plastic for an oil pan is concerning. Plastic cannot withstand impacts with common road hazards such as tire fragments, etc. Striking a retread at highway speed could easily crack the pan, dump all engine oil, and lead to catastrophic engine seizure, endangering people. In my case (2016 BMW 528i), several plastic components have already failed, including the oil pan, turbo inlet pipe, coolant expansion tank, valve cover, and multiple coil packs. While BMW considers coil pack replacement a normal maintenance item, there are widespread complaints of premature failures. Most of the heat-related plastic failures occur above 70,000 miles. Despite several related breakdowns, the previous owner and I avoided dangerous situations. These failures are widely documented by other owners online and by independent mechanics, who often recommend aftermarket aluminum replacements for improved safety and reliability. BMW is aware of these issues but continues to use plastic for critical components--they recently lost a class-action lawsuit related to internal plastic engine parts that caused catastrophic engine damage, showing prior knowledge of the risks. These failures also create environmental hazards, as leaking plastic oil pans & valve covers contaminate roads and driveways. Because repairs are $$$, many consumers delay fixing the problems, increasing both safety and environmental risks. This design prioritizes cost savings over durability and safety. These parts should be made of metal to withstand normal use and protect drivers, passengers, and the public from unnecessary hazards.

NHTSA ODI 11682147

Coolant pump failure engine failure also caused fire in engine bay. Insurance inspector. Pre shop inspection. No light were on prior to explosion.

NHTSA ODI 11681035

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 ODI 11676996

Very often, when I change the gear to 'Drive' or 'Reverse' I get a message on the dashboard screen - "secure Vehicle against rolling" and the car DOES NOT move unless I shift the auto gear lever several times or sometimes shut off the engine to get back to normal driving. Once when I was in such a situation, no matter what I do, the error message would not go away and I had to call the tow truck to get home. And when tow truck person brought the car home, the problem fixed itself!! I only have 81000 miles on this car. It is a very serious safety issue as far as I am concerned. PLEASE HELP.

NHTSA ODI 11676315

My vehicle is a 2016 BMW 528i xDrive. There is an active safety recall listed under NHTSA Campaign Number 24V-608, issued in August 2024. The affected component is the engine coolant pump. As of June 2025, no remedy has been made available by BMW, and I have been told by both BMW corporate and my local dealer that they cannot provide a fix or a timeline. This component is essential to keeping the engine within safe temperature limits. Failure of the coolant pump could lead to overheating and potentially increase the risk of fire, as the recall suggests. This places my safety and that of others on the road at risk every time I drive the vehicle. I rely on this car for regular transportation and feel I have no choice but to drive a vehicle with an unresolved critical safety issue. The vehicle has not yet experienced a failure or warning light specific to the coolant system, and it has not been inspected or repaired due to the lack of remedy. However, I should not be forced to wait indefinitely or risk a dangerous situation developing before action is taken. BMW’s failure to provide a remedy or meaningful updates in nearly a year shows a lack of urgency and accountability. I am submitting this complaint to formally document the issue and ask that NHTSA take action to compel BMW to issue a fix or provide alternatives to affected owners.

NHTSA ODI 11669076

Concern- smoke coming out of back exhaust at start up Cause - TAYLOR BMW (dealership) - possible needs updated oil line, turbo may be leaking internally Correction- dealership pulled faults to see if cat efficiency faults were present, saw none. Did verify smoke on startup. Doesn’t look like the turbo oil feed line has been changed (updated with check valve). There is some oil encrusted on the body of turbo. Would replace all lines since turbo removal is required for any of them; however once cat is off and if the chamber inside is wet with oil, at that point it would need a turbo as well as the lines. The above is the written diagnosis from dealership and I was quoted a price ranging from $2600- 4600- In 2016, NHTSA issued a notice for certain models/ years regarding the turbocharger feed lines (extending warranty for that part to 10 years / 120k miles). My 2016 was CPO and has only 84k (all maintenance performed by BMW) and I believe it should fall under eligible vehicles. I have reached out to BMW customer care, spoken with a case manager , all to no avail.

NHTSA ODI 11655918

I've gotten my car fixed multiple times and nothing has worked. My car is leaking coolant severely it overheats constantly I get the red and the yellow message. My heater is self stopped working and my car on the freeway has stopped from going 75 to 80 miles dropping all the way to 20 miles.

NHTSA ODI 11653684

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 ODI 11652697

Leak error messages that cannot be removed until recall issue with fluid leak is fixed. Leak is corroding engine fuel lines and can cause a fire Will driving. The remedy is taking to long to be deployed. Need assistance with this issue.

NHTSA ODI 11643709

I have an Issue with my car cause Engine Coolant smells like oil burning and smoke coming inside the car through AC and also having a recall issue but no remedy available with BMW so spend my money and get repaired from outside mechanic, BMW reported me that if there is no remedy available right now so we can't do anything so I get repaired outside and spend 1500$.

NHTSA ODI 11636766

Do to the water pump recall and the water pump electrical connector on my vehicle, it is no longer in driving condition and has caused engine overheating and damage. I am still paying for a car I cannot drive. I need help

NHTSA ODI 11631740

On our 2016 BMW 528i, the valve cover had to be replaced at 82,723 miles. We took the car in to Galleria BMW in D'Iberville, MS on [XXX] for an oil change and the mechanic reported there was oil on the engine and that he needed to replace the valve cover because this was a fire hazard. I was surprised the valve cover needed to be replaced and not just the gasket. Their service advisor said due to the high heat environment and age, the plastic valve cover would wear and deteriorate like a tire. I thought, what if this happened when I did not need an oil change and drove a few thousand miles with leaking oil on my engine. I think it is appalling plastic parts would be used in that environment. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11615371

2016 BMW 528i with 65,000 miles. Oil leaking from pan and told by mechanic that premature failed oil pan gasket and warping of oil pan well known by the manufacturer but they refuse to address the problem leaving the repair bill for customers. Poor design should not be the purchaser's responsibility.

NHTSA ODI 11561401

Bmw had recalled the n20 engine for timing chain guides replacement up to year 2015. The original timing chain guides were orange in color but also found to an inferior part from manufacturer. Bmw had replaced the original guides to a white color as supposed to a better product. Now then my 2016 model 528xi not only has the original orange color chain guides or let's say inferior part from manufacturer because my manufacturer date my car is 08/2015..

NHTSA ODI 11554223

The contact owns a 2016 BMW 528I. The contact stated that when he started the vehicle, he heard an unusual rattling sound. The vehicle was taken to the dealer to be diagnosed. The vehicle was diagnosed with a stretched timing chain guide. The contact was informed that the timing chain needed to be replaced. The vehicle remained at the dealer unrepaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 88,000.

NHTSA ODI 11544725

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 ODI 11479056

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 ODI 11477184

MY 2016 BMW 550I XDRIVE M SPORT IS USING/BURNING ONE QUART OF OIL EVERY 750-800 MILES, THE ODOMETER READS 36,343 MILES, VERY LOW MILES FOR THIS CAR TO BE USING THAT MUCH OIL, I BOUGHT IT IN AUGUST OF 2019 WITH 34,654 MILES ON IT. YOU CAN SEE THAT I DON'T DRIVE IT THAT MUCH, HAVE NEVER HAD THE CAR ON ANY KIND OF TRACK. THE BMW DEALERSHIP IN SCHERERVILLE INDIANA SAYS THIS KIND OF OIL CONSUMPTION IS NORMAL.!!! THERE IS NO WAY THIS EXPENSIVE LUXURY CAR SHOULD BURN ANY KIND OF OIL WITH THIS LOW OF MILES. I REALLY WANT THIS COMPLAINT TO BE HEARD!! THANK YOU.

NHTSA ODI 11308861