BMW xDrive40d
Successor to the M57 with aluminium crankcase and piezo injectors. Extremely smooth and torquey. EGR cooler, DPF and turbocharger are the main wear points.
Diesel Muscle
R6 diesel in the coupe-SUV — better than it sounds.
Engine Weaknesses 6
The N57D30 timing chain can break; plastic guide rails break and block the oil pump. Damaged valves and bearing shells follow. No reliable audible advance warning.
Symptoms: Rattling or clattering on cold start (warning sign!). Often no advance warning — engine dies suddenly.
Main bearings and connecting rod bearings wear from around 150,000–200,000 km. The aluminium crankcase with steel bearing housings has differing thermal expansion coefficients. Bearing shells can spin — catastrophic engine damage.
Symptoms: Dull knocking or hammering from the engine block under load; oil pressure warning; metallic tapping; engine oil with metallic particles
Leaking EGR coolers cause gradual coolant loss. BMW carried out a voluntary service campaign. Overheating from coolant shortage risks a cracked cylinder head. Repair costs without goodwill are very high.
Symptoms: Gradual coolant drop with no visible external leak; white-blue exhaust smoke; sweet smell inside the cabin; engine warning light; overheating warning
The N57 bi-turbo system shows bearing wear at high mileage. Broken turbine blades can destroy the cylinder bores and cause total engine failure. Repair costs often exceed €8,000.
Symptoms: Whistling or rattling from the turbo area; sharply reduced power delivery; blue or white exhaust smoke; engine warning light; limp mode
Diesel injectors wear at high mileage. Diagnosis via cylinder balance test and return flow measurement. Individual injector replacement possible at around €450 including installation.
Symptoms: Rough running especially at idle (engine "runs like a tractor"), hesitation, increased fuel consumption, smoke clouds.
Glow plugs and the glow plug control unit fail regularly at higher mileages. The fault memory often shows all plugs as defective even though only the control unit is faulty. Cold-start problems and DPF overload possible in frost.
Symptoms: Glow plug warning light stays on; difficult starting below 5°C; slight judder in the first minute after cold start
Vehicle Weaknesses 8
Like the predecessor E71, the rear air suspension on the F16 frequently develops leaks. BMW revised the design but production faults in the air springs continued to be reported, requiring both springs to be replaced.
The electric parking brake actuators on the F16 fail from around 70,000–90,000 km. The brake can neither be engaged nor released — a known issue on BMW vehicles with electric parking brakes.
Identical juddering to the E71: transfer case multi-plate clutch slips when the VTG oil is not changed every 90,000 km. Often completely fixable with an early oil change; repair costs up to €6,000 for actual failure.
Despite revisions, the N63TU V8 continues to suffer from carbon deposits in the intake tract and seized injectors. Coolant losses, spark plug well damage and turbo hose abrasion were reported up to 50,000 km.
The electric parking brake actuator fails after 70,000–90,000 km. Parking brake won't engage automatically or won't release. The control unit can be repaired or replaced.
The AdBlue dosing system on F16 diesel engines is prone to failures of the pump, injector and heating element. AdBlue freezes particularly in cold conditions and with ageing batteries.
The xDrive transfer case on the F16 is sensitive to mismatched tyre rolling circumferences and multi-plate clutch wear. Juddering under hard acceleration, metallic clonking from the centre.
The electric tailgate on the F16 shows hydraulic strut or control unit failures from around 40,000–60,000 km. The tailgate no longer opens or closes automatically, which is very inconvenient in everyday use.