2016 BMW 528I Owner Complaints

Vehicle: 2016 BMW 528i xDrive (VIN: [XXX]) Safety Issue / Defect Description: Strong, hazardous raw gasoline fumes began entering the passenger cabin and trunk area. On XXX, the vehicle was brought to an authorized dealership (BMW of Sterling) for diagnostic evaluation. The dealership's technician conducted a multi-point inspection and produced video evidence documenting fluid leaking from the top of the plastic fuel tank. The dealership issued Repair Order Quote #$4,824.92 to "REPLACE FUEL TANK DUE TO FUEL LEAK" and declared the vehicle unsafe. Despite diagnosing a structural fuel tank leak that allows raw gasoline and fumes to migrate into the cabin—presenting an immediate fire, explosion, and toxic vapor risk—BMW of North America and the dealership have refused warranty coverage or goodwill assistance, claiming the tank is "not leaking actively enough" under Service Bulletin SI B01 03 22 (NHTSA ID: MC-10212779-9999). An uncontained raw fuel leak on a plastic fuel tank is a critical safety defect that requires immediate investigation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11753570

Incident

Jul 14, 2026

The vehicle developed a strong, toxic odor of raw gasoline inside the passenger cabin and trunk area. The vehicle was brought to an authorized franchise, BMW of Sterling, where technicians performed a multi-point inspection. The technician confirmed that the factory plastic fuel tank assembly is structurally defective and leaking raw fuel from the top weld seams. The dealer provided an official invoice quoting $4,824.92 to replace the tank due to the fuel leak, noting it is an active hazard, but refused to cover the failure under BMW’s active 15-year/150,000-mile extended warranty for N20 plastic fuel tanks (SI B01 03 22). Driving a vehicle with raw fuel pooling on the exterior of the tank and migrating into the cabin creates an immediate fire hazard and health risk to occupants."

NHTSA ID

11751663

Incident

Jul 13, 2026

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 ID

11719874

Incident

Dec 15, 2025

Mileage

32,400 mi

I have 2016 BMW 5 series car, for past two to three years headlights are getting condensation inside on colder months. Dealer is not able to fix the condensation, they are advising to replace the headlights. Some of my friends replaced OEM headlights, but after few years they are started condensation, it’s looked like defect from manufacturer, I had few Honda vehicles older than my BMW car, they never had any condensation complaints. It’s look like manufacturer used cheap materials causing condensation, it is causing low light at night times may lead to accidents. Please look at this issue and consider it as a safety issue and please recall these headlights. Dealer is asking $2500 + $500 labor to fix each headlight. All of my friends are having same problem, I bet other BMW car owners too. Please issue a recall on this safety issue.

NHTSA ID

11716890

Incident

Dec 1, 2024

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 ID

11713522

Incident

Jan 29, 2020

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 ID

11697057

Incident

Jun 5, 2025

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

NHTSA ID

11687010

Incident

Aug 1, 2025

A critical component failure has rendered my 2016 BMW 528xi inoperable and unsafe. The water pump failed, forcing the car into a safety "limp mode," limiting its speed to approximately 40 miles per hour. This issue mirrors NHTSA Recall 24V-608 regarding an electrical connector on the water pump that can short circuit, potentially causing a "thermal event or fire." The problem began with dashboard warnings about overheating, despite the coolant reservoir being full. Following these warnings, the vehicle entered "limp mode," posing a significant safety risk in normal traffic. The potential for fire is also a major concern. An independent service center has confirmed the water pump and its electrical connector as the point of failure. The failed component is available for inspection by a NHTSA investigator. I contacted BMW's customer relations line and was informed that no remedy is currently available. I must wait for an official letter before any action can be taken, including reimbursement. The representative did not provide a case number, making it impossible to track my complaint. The vehicle has not been inspected by the manufacturer, law enforcement, or an insurance representative. I am unable to transfer the title because the car cannot pass a safety inspection in its current state. I am in a severe catch-22: I must receive a recall letter for a vehicle that I am unable to finalize ownership of. This failure to assist an owner with a known safety recall has left me stranded with a dangerous, undrivable vehicle.

NHTSA ID

11683511

Incident

Aug 19, 2025

My driver headlight is constantly getting moisture trapped in it. It’s been replaced twice and the seals were checked, but it keeps happening and shorting out my headlight. It’s $4000 to fix. Just had it replaced 1.5 weeks ago and it’s broken already. I took it to bmw the moment I noticed the moisture was back and they told me it was fine. This is a widespread problem and they are not fixing their product

NHTSA ID

11682405

Incident

Aug 14, 2025

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 ID

11682147

Incident

Aug 4, 2025

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

NHTSA ID

11681035

Incident

Aug 12, 2025

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 ID

11676315

Incident

Jul 24, 2025

The contact owns a 2016 BMW 528I. The contact stated that while the vehicle was parked and running, the contact became aware of an abnormal burning odor. There was no warning light illuminated. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); however, the part to do the recall repair was not yet available. The dealer was contacted and confirmed that parts were not yet available. The manufacturer was not made aware of the failure. The approximate failure mileage was 45,000. VIN tool confirms parts not available.

NHTSA ID

11675593

Incident

Jul 23, 2025

The contact owns a 2016 BMW 528I. The contact stated that while her son was driving at undisclosed speeds, there was an abnormally loud knocking sound coming from the vehicle. The contact stated that there was coolant leaking from the vehicle. The contact was adding coolant to the coolant reservoir every other day. The contact stated that the vehicle was smoking and there was an abnormal rattling sound coming from the vehicle and the engine was overheating. The vehicle was inoperable. The coolant message was displayed. There were no warning lights illuminated. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); 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 failure mileage was unknown. VIN tool confirms parts not available.

NHTSA ID

11675103

Incident

May 1, 2024

The contact owns a 2016 BMW 528I. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); 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 not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

NHTSA ID

11671590

Incident

Jul 7, 2025

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 ID

11669076

Incident

Aug 13, 2024

The contact owns a 2016 BMW 528I. The contact received notification of NHTSA Campaign Number: 24V608000 (ENGINE AND ENGINE COOLING, ELECTRICAL SYSTEM); however, the part to do the recall repair was unavailable. 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.

NHTSA ID

11667146

Incident

Sep 15, 2024

The contact owns a 2016 BMW 528I. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); 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 dealer was made aware of the issue and confirmed that parts were not yet available. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. VIN tool confirms parts not available.

NHTSA ID

11666277

Incident

Jun 11, 2025

The contact owns a 2016 BMW 528I. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); 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 dealer was made aware of the issue and confirmed that parts were not yet available. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

NHTSA ID

11663133

Incident

Aug 24, 2024

The contact owns a 2016 BMW 528I. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power. There was no warning light illuminated. The vehicle was towed to an independent mechanic, where it was diagnosed that the electrical connector on the water pump had failed and needed to be replaced. The vehicle was not repaired. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); however, the part to do the recall repair was unavailable. The dealer was contacted and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure. The failure mileage was approximately 68,000. VIN tool confirms parts not available.

NHTSA ID

11662659

Incident

May 22, 2025

Mileage

68,000 mi

The contact owns a 2016 BMW 528i. The contact stated that while his partner was driving at undisclosed speeds, there was smoke coming from the engine and entering the cabin through the vents while the heater was activated. There was an abnormal burning odor entering the cabin. The contact also observed the burning odor while driving the vehicle. There were no warning lights illuminated. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); however, the part to do the recall repair was not yet available. The local dealer was not 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 failure mileage was approximately 80,000. VIN tool confirms parts not available.

NHTSA ID

11661790

Incident

Dec 1, 2024

Mileage

80,000 mi

The contact owns a 2016 BMW 528i. The contact received notification of NHTSA Campaign Number:24V608000(ENGINE AND ENGINE COOLING) however, the part to do the recall repair was unavailable. 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 .

NHTSA ID

11658922

Incident

Aug 15, 2024

Due to the nature of the car potentially catching on fire and a remedy still not being available I am concerned about my safety and of those around me since the car is used to be operated daily for commuting to work.

NHTSA ID

11657941

Incident

Apr 30, 2025

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 ID

11655918

Incident

Apr 10, 2025

The contact owns a 2016 BMW 528I. The contact received notification of NHTSA Campaign Number: 24V608000 (Engine and Engine Cooling, Electrical System); 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.

NHTSA ID

11654845

Incident

Apr 15, 2025