BMW 535d xDrive diesel fumes in cabin on startup with check engine light due to secondary EGR valve issue on BMW 535d xDrive

Some BMW 535d xDrive owners report experiencing diesel fumes in the cabin during startup, which may be linked to a faulty EGR valve or EGR cooler. This issue can be exacerbated by a crack in the EGR corrugated pipe, a common fault that allows exhaust fumes to enter the cabin. Additionally, some owners note that BMW has initiated voluntary technical campaigns to address problems with faulty EGR valves and modules in diesel engines, which could be relevant to their situation. In some cases, resolving the issue may involve fixing high-pressure EGR cooler problems, replacing microfilters, cleaning the blower motor and air ducts, and addressing coolant system issues. Furthermore, loose exhaust clamps have also been identified as a potential source of diesel smells. It is recommended that owners experiencing these symptoms have their vehicle inspected by a qualified mechanic or BMW service center to diagnose and resolve the problem promptly, ensuring optimal performance and safety.