The BMW 740d F01 is the performance diesel in the fifth-generation 7 Series lineup, using a twin-turbocharged version of the N57 3.0-litre inline-six producing 306 hp (pre-LCI, 2009-2012) or 313 hp (LCI, 2012-2015). Paired with the ZF 8HP automatic and standard air suspension, it delivers genuine executive-class pace with diesel economy. Heavy depreciation makes these accessible on the used market, but the combination of twin-turbo diesel complexity, air suspension, and over 60 electronic modules means ownership costs stay firmly at flagship level.· more· less
Twin-turbo adds repair complexityAir suspension repairs are costly
Buy if: You want flagship diesel performance with motorway economy and can find one with complete BMW dealer history, confirmed EGR cooler recall, and no cold-start rattle.
Avoid if: You mostly drive short urban trips (DPF, EGR, and turbo actuator issues worsen) or cannot budget for air suspension and twin-turbo repairs in the four-figure range.
Air spring bladders degrade from temperature cycling, overworking and eventually killing the compressor · more· less
The F01 uses adaptive air suspension on all four corners as standard. The rubber air spring bladders degrade over time, typically beginning to fail between 100,000 and 160,000 km. Symptoms include one corner sagging overnight, the compressor running constantly at startup, or a suspension warning on the dashboard. Aftermarket struts from Arnott cost approximately €250-400 per corner, while OEM units run €600-900 each. Specialists recommend replacing struts in pairs. If the compressor fails from overwork, replacement adds €300-600 for aftermarket (Arnott WABCO OES) or €600-900 for OEM. A full suspension refresh (four struts plus compressor) can reach €2,500-4,000 at a specialist. The F01 system is more reliable than the E65's, but remains the single most common expensive repair on this generation.
EGR cooler leak (fire risk recall)
up to €1,5002 of 9
EGR cooler leaks coolant into the intake, creating a fire risk from smoldering soot and glycol mixture · more· less
BMW issued a recall affecting approximately 800,000 N47, N57, and B47 diesel vehicles worldwide. The EGR cooler can develop internal leaks, allowing coolant to mix with diesel soot at high temperatures. This can cause smoldering particles, a melting intake manifold, and in extreme cases fire. BMW acknowledged in 2022 that prior corrective actions were inadequate, issuing updated parts from a different supplier. Symptoms include coolant loss, reduced engine power, exhaust odor, or smoke from the engine compartment. BMW replaces the EGR cooler and inspects the intake manifold free of charge under the recall. If the recall has not been completed and the cooler has already damaged the intake manifold on a car outside warranty, repair costs can reach €1,000-1,500. This is the single most important safety item to verify before buying any F01 diesel.
Twin-turbo failure or actuator malfunction
up to €3,5003 of 9
Sequential turbo system is more complex than the 730d's single turbo, with actuator sticking and small turbo shaft wear as primary failure modes · more· less
The 740d uses a twin-turbo (sequential) setup with a small high-pressure turbo and a larger low-pressure turbo, controlled by electronically actuated wastegates and bypass valves. The variable geometry actuator on the small turbo tends to stick from carbon buildup, particularly on vehicles driven gently or on short trips. Symptoms include sudden loss of power, limp mode, and a drivetrain malfunction warning. BMW sells the turbo assembly only as a complete unit, making dealer replacement expensive at €2,500-3,500. Specialist turbo reconditioning shops offer actuator-only repair for €500-900, or a remanufactured turbo for €1,200-2,000 including labor. The small turbo's shaft bearings can also wear from oil starvation if maintenance is neglected. Regular spirited motorway driving and strict adherence to 15,000 km oil change intervals help prevent both failure modes.
Timing chain stretch (pre-October 2010 engines)
up to €3,0004 of 9
Rear-mounted chain stretches and tensioner weakens, causing cold-start rattle and risk of chain skip · more· less
The N57 timing chain is located at the rear of the engine, making replacement labor-intensive. Early production engines (before October 2010) are more susceptible to premature chain stretch due to a weaker tensioner design. The chain typically gives warning before catastrophic failure with a metallic rattle during the first 5-30 seconds of cold starts. Replacement at an independent specialist typically costs €1,500-2,500, while a BMW dealer may charge €2,500-3,000. Later engines (post-October 2010) and LCI models with the N57TU have improved tensioner components and are significantly less prone. Regular oil changes every 10,000-15,000 km (not BMW's extended 25,000 km interval) help extend chain life. The N57 is substantially more durable than the notorious N47 four-cylinder in this regard.
Oil filter housing gasket leak
up to €6005 of 9
Rubber O-ring hardens from heat cycling and seeps oil, typically after 100,000 km · more· less
The oil filter housing gasket is one of the most common oil leaks on the N57. The rubber O-ring hardens after prolonged heat exposure, typically after 100,000-150,000 km. The gasket itself costs approximately €10-20. Independent shops charge approximately €200-400 including labor, while BMW dealers may charge €400-600. This is a straightforward repair but should not be ignored, as oil can drip onto the exhaust manifold or serpentine belt. Often done together with the valve cover gasket as a preventive measure during the same service visit.
DPF clogging from short-trip driving
up to €2,5006 of 9
Diesel particulate filter fails to regenerate on short urban trips, eventually blocking completely · more· less
The DPF requires sustained high-temperature driving to regenerate. Cars used primarily for short urban trips accumulate soot faster than it can burn off. When the DPF warning light appears, a forced regeneration drive at motorway speeds (30+ minutes above 3,000 rpm) may clear it. Professional DPF cleaning costs €300-600, while full DPF replacement runs €1,500-2,500 including labor. Ash buildup from oil consumption cannot be regenerated and requires physical removal. Cars with regular motorway use rarely experience this problem. The DPF typically lasts 130,000-180,000 km before eventual replacement.
Electrical module and iDrive malfunctions
up to €2,0007 of 9
iDrive crashes, CAS module faults, and parasitic battery drain from modules failing to enter sleep mode · more· less
The F01 contains over 60 electronic control modules communicating via multiple bus systems. The CAS4 (Car Access System) module controls key authentication and start authorization; it is sensitive to voltage spikes and can fail, preventing the car from starting. Replacement runs €400-800 plus coding. The iDrive CIC head unit can freeze or reboot unexpectedly, with replacement costing €500-1,500 depending on specification. Parasitic battery drain is common when modules fail to enter sleep mode, draining the battery within 2-3 days. Diagnosis of drain issues alone can cost €200-400 at a specialist. A quality battery tender (CTEK MXS 5.0 or similar) is essential for any F01 that sits for more than a few days.
Piezo injector failure
up to €3,0008 of 9
Piezo injectors can develop internal leaks from moisture or ceramic stack degradation, causing misfires · more· less
The N57 uses Bosch piezo fuel injectors that can develop internal faults over time. Moisture in the fuel (attracted by ethanol content) can crack the ceramic piezo wafers under pressure, leading to injector leaks or misfires. A single replacement injector costs approximately €300-400, with labor adding €150-250 per injector. Most failures affect one or two injectors rather than all six simultaneously. Fuel quality matters significantly: using premium diesel from reputable stations and adding a diesel fuel treatment periodically helps prevent this issue. Failed ceramic fragments can also damage the high-pressure fuel pump if not addressed quickly.
Swirl flap and intake carbon buildup
up to €1,2009 of 9
Intake swirl flaps stick from carbon deposits, causing rough idle and reduced power · more· less
The N57 uses variable intake swirl flaps that become clogged with carbon deposits from the EGR system. Over time, the plastic linkages can become brittle and snap. Symptoms include rough idle, reduced power, and error codes. An intake manifold replacement at a BMW dealer costs approximately €700-1,200 including labor. Aftermarket aluminum swirl flap blanking kits offer a permanent solution for approximately €50-100 plus €200-300 labor. Many specialists recommend blanking the flaps during any EGR work to prevent recurring issues.
Reliable drivetrain, but twin-turbo and flagship complexity add to costs
The N57 twin-turbo inline-six is a fundamentally strong engine, with well-maintained examples regularly exceeding 300,000 km. The ZF 8-speed gearbox is equally robust with fluid changes every 60,000-80,000 km (ignore BMW's lifetime fill claim). The main cost drivers are the twin-turbo system (more complex than the 730d's single turbo), air suspension, diesel emissions equipment, and aging electronics. Pre-October 2010 engines carry a moderate timing chain risk. The EGR cooler recall must be verified as completed on any F01 diesel. Cars with consistent motorway use and complete service history are significantly more reliable than those used predominantly for short urban trips.
Service history
Complete BMW dealer or specialist records essential. Verify oil changes at 15,000 km intervals maximum, not BMW's extended 25,000 km interval.
Tires
Check tread depth, age (date codes), and uneven wear patterns. Rear tires wear faster on RWD models.
Cold start
Must start engine completely cold. Listen for unusual rattling in the first 30 seconds (timing chain indicator) and turbo whistle.
Test drive
Minimum 30 minutes including motorway speeds. Check for smooth gear changes, stable idle, and no warning lights.
Specific for this vehicle
Check air suspension ride height overnight
Ask the seller to leave the car parked overnight. If one corner sits lower in the morning, that air spring is leaking. Listen for the compressor running at startup.
Verify EGR cooler recall completion
Contact BMW with the VIN to confirm the EGR cooler recall has been performed with the updated 2022 parts from the new supplier. This is the most important safety check.
Cold start rattle and turbo spool-up
Start the engine completely cold. Listen for metallic rattling in the first 5-30 seconds (timing chain wear). Also listen for smooth sequential turbo engagement during acceleration, with no hesitation or surging.
+ 5 more checksShow less
Check for oil leaks underneath
Look under the engine for oil residue, particularly around the oil filter housing and valve cover area. Common leak points on the N57.
Test all electronics and iDrive thoroughly
Cycle through every iDrive menu, test all seat adjustments, check parking cameras for clarity, and verify Bluetooth connectivity. Module failures are common and expensive.
Verify gearbox fluid has been changed
BMW claims the ZF 8HP is filled for life, but specialists strongly recommend fluid changes every 60,000-80,000 km. Check service records for this.
DPF soot level diagnostic check
If possible, have a specialist read the DPF soot level with ISTA diagnostic software. A heavily loaded DPF on a car used for short trips is a warning sign.
Check production date for timing chain risk
Engines built before October 2010 have the weaker tensioner design. Verify production date from the VIN or door jamb sticker.
Recalls and Technical Service Bulletins
EGR cooler leak causing fire risk (N57 diesel, multiple production years, updated parts issued 2022)Critical - verify completed
Diesel fuel filter heater electrical short circuit (Aug 2008 - Nov 2009 production)Verify completed
VANOS adjustment unit bolt loosening (Oct 2009 - Apr 2012, N55 petrol only)Not applicable
Takata airbag inflator replacement (applicable to certain production dates)Verify with VIN
The EGR cooler recall is particularly critical due to the fire risk. BMW has updated this recall multiple times as prior fixes proved inadequate. Ensure the latest 2022 replacement parts have been fitted. Contact BMW with the VIN to verify all recalls have been completed.
Warranty Status
Factory warranty (2 years)Expired on all F01 models
Rust perforation warranty (12 years)Expired on pre-2014 models, expiring soon on later cars
Extended warrantyAvailable through BMW dealers and third-party providers
All F01 740d models are well outside their original 2-year factory warranty. Given the complexity of the twin-turbo system, electronics, and air suspension, an extended warranty from a reputable provider can be worthwhile if it covers these specific components. Read exclusions carefully, particularly regarding turbo and suspension coverage.
Sources: Research draws on model-specific owner forums and owner communities, recall information from official authorities, German automotive press, and multiple workshop cost references cross-checked against each other.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.
