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So I've had two low coolant warnings in my 2018 540i, one at about 21,000 miles and another recently at 28,000. This car is driven mostly highway 80+ on long trips to Florida or South Carolina from Northeastern PA. BTW this 5 series has the best balance of driving and comfort of all the BMW's that I've owned.
The dealer topped off the coolant the first time then I did it myself at 28K but brought it in for a pressure test. Found nothing, no coolant on the garage floor, no high temp on gauge, but a little coolant residue found on the top of the tank after the cap was removed. Agree that the cap is extremely hard to unscrew; I had to use a vice-grip for leverage, and the cap was replaced during the dealer visit as a precaution.
Interesting theory about evaporation in the intercooler but aside from that no real failure analysis or solutions other than topping off the coolant level. /X3
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