2001 BMW 540I
4 recalls, 18 complaints - 19 TSBs
19V015000 Jan 14, 2019
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
Defect Description
BMW of North America, LLC (BMW) is recalling certain model year 2000-2003 525i Sedan, 530i Sedan, 540i Sedan, 2001-2003 525i Sports Wagon and 540i Sports Wagon vehicles, and 2000-2004 X5 SAV 3.0i, X5 SAV 4.4i, and X5 SAV 4.6is vehicles. This recall affects certain vehicles where the original steeri... Read more
Consequence
An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy
Owners are advised not to drive their vehicles until the vehicle has been remedied. BMW will notify owners, and dealers will inspect the vehicle for an optional sports steering wheel with an affected inflator. Dealers will replace the air bag module as necessary, free of charge. The recall began ... Read more
03V421000 Oct 24, 2003
AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE
Defect Description
ON CERTAIN PASSENGER VEHICLES, A MICROPROCESSOR IN THE AIR BAG CONTROL MODULE, WHICH ACTIVATES THE FRONT AIR BAGS, THE SIDE AIR BAGS, THE FRONT SEAT SAFETY BELT PRETENSIONERS, AND THE BATTERY SAFETY TERMINAL, MAY HAVE A MALFUNCTION THAT COULD LEAD TO AN UNINTENDED ACTIVATION OF ONE OR MORE OF THESE ... Read more
Consequence
UNEXPECTED DEPLOYMENT OF THE AIR BAG(S) COULD CAUSE SERIOUS INJURY IF AN OCCUPANT IS TOO CLOSE TO THE DEPLOYING AIR BAG(S). IN ADDITION, THE BATTERY SAFETY TERMINAL MAY ALSO BE ACTIVATED. IF THAT HAPPENS, THE STARTER CABLE WOULD BECOME DISCONNECTED FROM THE BATTERY, AND THE ENGINE COULD NOT BE RES... Read more
Remedy
DEALERS WILL REPLACE THE AIR BAG CONTROL MODULE. OWNER NOTIFICATION BEGAN NOVEMBER10, 2003. OWNERS SHOULD CONTACT BMW AT 1-800-831-1117.
02V138000 May 16, 2002
ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN
Defect Description
ON CERTAIN PASSENGER VEHICLES, THE ENGINE AUXILIARY/COOLING FAN OPERATION, INCLUDING VARIABLE SPEED, IS ELECTRONICALLY CONTROLLED. FAILURE OF THE FAN MOTOR CAN CAUSE THE ELECTRICAL CIRCUITRY OF THE FAN CONTROL UNIT TO OVERLOAD AND FAIL, CAUSING THE FAN TO STOP OPERATING.
Consequence
IF THIS WERE TO OCCUR, ENGINE OVERHEATING AND SUBSEQUENT ENGINE DAMAGE COULD RESULT. IN ADDITION, IT IS POSSIBLE FOR THE FAILURE OF THE ELECTRICAL CIRCUITRY TO CAUSE A FIRE IN THE FAN CONTROL UNIT LOCATED IN THE FRONT OF THE ENGINE COMPARTMENT.
Remedy
DEALERS WILL REPLACE THE FAN. OWNER NOTIFICATION BEGAN SEPTEMBER 28, 2001. THIS IS A SUPPLEMENT TO A RECALL THAT BEGAN DURING SEPTEMBER 2001 (SEE RECALL CAMPAIGN 01V206). OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHI... Read more
01V206000 Jun 21, 2001
ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN
Defect Description
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE ENGINE AUXILIARY/COOLING FAN OPERATION, INCLUDING VARIABLE SPEED, IS ELECTRONICALLY CONTROLLED. FAILURE OF THE FAN MOTOR CAN CAUSE THE ELECTRICAL CIRCUITRY OF THE FAN CONTROL UNIT TO OVERLOAD AND FAIL, CAUSING THE FAN TO STOP OPERATING.
Consequence
IF THIS WERE TO OCCUR, ENGINE OVERHEATING AND SUBSEQUENT ENGINE DAMAGE COULD RESULT. IN ADDITION, IT IS POSSIBLE FOR THE FAILURE OF THE ELECTRICAL CIRCUITRY TO CAUSE A FIRE IN THE FAN CONTROL UNIT LOCATED IN THE FRONT OF THE ENGINE COMPARTMENT.
Remedy
DEALERS WILL REPLACE THE FAN. OWNER NOTIFICATION BEGAN SEPTEMBER 28, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-800-831-1117.
Complaint Statistics
18 total complaints
1 crashes
Top Reported Components
| Component | Complaints |
|---|---|
| ELECTRICAL SYSTEM | 4 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 2 |
| POWER TRAIN | 2 |
| STEERING | 2 |
| AIR BAGS | 2 |
| ENGINE | 2 |
| AIR BAGS:SIDE/WINDOW | 1 |
| ELECTRICAL SYSTEM:IGNITION | 1 |
| ELECTRICAL SYSTEM:WIRING | 1 |
| EXTERIOR LIGHTING | 1 |
ENGINE
Mar 3, 2026
Incident date: Mar 3, 2026
The contact owns a 2022 Ram 3500. The contact stated that while driving approximately 10-15 MPH, there was an abnormal rattling sound coming from the vehicle. The engine warning light was illuminated. The local dealer was contacted, and it was determined that the grid heater bolt had melted and fall... Read more
ELECTRICAL SYSTEM
Mar 21, 2023
Incident date: Nov 1, 2022
The contact owns a 2019 Land Rover Discovery. The contact stated after reversing and then shifting the vehicle into park, the warning light illuminated stating that the vehicle was in drive. The contact attempted to turn off the vehicle, but the vehicle failed to turn off. The contact disconnected t... Read more
POWER TRAIN
Mar 21, 2023
Incident date: Nov 1, 2022
The contact owns a 2013 Cadillac Escalade. The contact stated while driving 60 MPH and depressing the accelerator pedal, the vehicle downshifted unintendedly, and the vehicle shut off. The contact was able to veer to the side of the road. The check engine warning light and an unknown warning light w... Read more
ENGINE
Jan 14, 2020
Incident date: Apr 12, 2014
M62 V-8 ENGINES USED IN THE E-39 540 AND E-38 740 ARE NOTORIOUS FOR FAULTY TIMING CHAIN GUIDES. AT AROUND 125,000 THE PLASTIC CAN DISINTEGRATE CAUSING THE CHAIN TO SKIP A TOOTH. ONCE A TOOTH IS SKIPPED THE VALVES ARE CRUSHED AND THE ENGINE IS DESTROYED. THE COST TO REPLACE THE GUIDES IS EXTREMELY E... Read more
Crash
AIR BAGS
May 21, 2017
Incident date: Mar 10, 2017
TAKATA RECALL: BOTH THE MANUFACTURER (BMW NORTH AMERICA) AND THE LOCAL DEALER (UNITED BMW OF ROSWELL, GA) ARE REFUSING TO PERFORM THE INSPECTION OF THE AIR BAG INFLATOR ON THE REFERENCED VEHICLE, PER NHTSA RECALL CAMPAIGN NO. 17V-047. DEALER CLAIMS THAT NO INSPECTION IS REQUIRED SINCE MANUFACTURE'S ... Read more
AIR BAGS
Jul 1, 2016
Incident date: May 1, 2016
POSSIBLE TAKATA INFLATOR: AT FIRST THE PASSENGER AIRBAG LIGHT CAME ON OCCASIONALLY AND NOW THE PASSENGER AIRBAG LIGHT IS ON ALL AT THE TIME.
STEERING
May 5, 2015
Incident date: Mar 31, 2015
THE BRACKET THAT HOLDS THE POWER STEERING PUMP ON MY 2001 BMW 540I SNAPPED ON THE TOP AND BOTTOM PIECES OF THE BRACKET RESULTING IN MY BELTS AND PULLEYS TO BE THROWN AND DESTROYED. THE REPAIR IS VERY EXPENSIVE AND TIME CONSUMING. THIS IS BECOMING A MORE AND MORE COMMON PROBLEM ON THE E39 STYLE 1997-... Read more
STEERING
Feb 14, 2014
Incident date: Jan 15, 2014
POWER STEERING BRACKETS ON THESE CARS BREAK. HAPPENED TO ME AND THREW A BELT DURING A TURN. THIS IS AN EXTREME SAFETY HAZARD AS YOU HAVE NO POWER STEERING WHEN THE BRACKET BREAKS AND THE BELT IS THROWN. THIS IS A KNOWN ISSUE IF YOU SEARCH ON BMW FORUMS AND SHOULD BE ADDRESSED BY BMW! THIS IS HAPPENI... Read more
POWER TRAIN
Feb 10, 2011
Incident date: Feb 6, 2011
2001 BMW 540I REVERSE GEAR FAILURE ON ZF 5HP24 (A5S 440Z) TRANSMISSION. MY BMW WILL NO LONGER ENGAGE REVERSE, CAR FEELS LIKE IT IS STILL IN NEUTRAL.
EXTERIOR LIGHTING
May 21, 2010
Incident date: May 16, 2010
3RD (HIGH) TAIL LIGHT BULB AND SOCKET OVERHEATS AND MELTS, RENDERING THE LIGHT INOPERABLE AND POSSIBLY CAUSING A FIRE HAZARD. *TR
ELECTRICAL SYSTEM
May 21, 2010
Incident date: May 16, 2010
3RD (HIGH) TAIL LIGHT BULB AND SOCKET OVERHEATS AND MELTS, RENDERING THE LIGHT INOPERABLE AND POSSIBLY CAUSING A FIRE HAZARD. *TR
ELECTRICAL SYSTEM
Mar 19, 2009
Incident date: Mar 10, 2009
ELECTRICAL SHORT IN FAULTY THERMOSTAT CAUSED ALL WIRING TO MELT AND LEAD TO A DAMAGE OF MAIN COMPUTER. *TR
POWER TRAIN:AUTOMATIC TRANSMISSION
Feb 5, 2009
Incident date: Feb 5, 2009
ON MY 2001 BMW 540I WITH 84000 MILES WHEN THE CAR IS PUT INTO REVERSE IT WILL NOT REVERSE JUST FILLS LIKE IT IS IN NEUTRAL. *TR
POWER TRAIN:AUTOMATIC TRANSMISSION
Dec 8, 2005
Incident date: Dec 3, 2005
I OWN A 2001 BMW 540I. I WILL PUT THE CAR IN DRIVE, THE CAR WILL MOVE REALLY SLOW, AS I GIVE IT A LITTLE GAS TO GO, THE CAR WILL ONLY REV UP THEN JUMP INTO GEAR. THIS WILL CAUSE A VERY STRONG JERK TO THE CAR. THE CAR ONLY HAS 70,000 MILES, I FEEL THAT IT IS MUCH TOO SOON FOR A $65,000 CAR TRANSMISSI... Read more
ELECTRICAL SYSTEM:WIRING
Jan 16, 2003
Incident date: Oct 24, 2002
BMW 540I ELECTRICAL PROBLEMS / DAMAGE TO INTERNAL HEATING AND ELECTRICAL EQUIPMENT. THEY POSE A HAZARD DUE TO EXTREME TEMPERATURE CHANGE IN THE CAR INTERIOR. THE HOT / AND COLD SENSATION LEAVES THE DRIVER FEELING SICK / NAUSEOUS.
ELECTRICAL SYSTEM
Jan 16, 2003
Incident date: Oct 24, 2002
BMW 540I ELECTRICAL PROBLEMS / DAMAGE TO INTERNAL HEATING AND ELECTRICAL EQUIPMENT. THEY POSE A HAZARD DUE TO EXTREME TEMPERATURE CHANGE IN THE CAR INTERIOR. THE HOT / AND COLD SENSATION LEAVES THE DRIVER FEELING SICK / NAUSEOUS.
ELECTRICAL SYSTEM:IGNITION
Jan 22, 2002
Incident date: Jan 15, 2002
VEHICLE FAILS TO START. TOWED TO DEALER. UNABLE TO LOCATE SOURCE OF PROBLEM. PLEASE PROVIDE FURTHER DETAILS.*AK
AIR BAGS:SIDE/WINDOW
Mar 28, 2001
Incident date: Mar 23, 2001
CONSUMER WAS TRAVELING 60MPH ON INTERSTATE AND SIDE/ TOP AIRBAGS EXPLODED. AFTER THEY EXPLODED, WARNING LIGHTS CAME ON AND VEHICLE LOST POWER. DEALER GAVE CONSUMER A LOANER CAR . CONSUMER'S VEHICLE WAS BEING INSPECTED.*AK
EPA Fuel Economy, 2001 BMW 540I
| Trim / Engine | City MPG | Highway MPG | Combined MPG | Fuel Type | Annual Fuel Cost |
|---|---|---|---|---|---|
| 4.4L 8-cyl, Automatic 5-spd (Rear-Wheel Drive) | 16.0 | 22.0 | 18.0 | Premium | $4,300 |
| 4.4L 8-cyl, Manual 6-spd (Rear-Wheel Drive) | 14.0 | 21.0 | 16.0 | Premium | $4,800 |
| 4.4L 8-cyl, Automatic (S5) (Rear-Wheel Drive) | 14.0 | 19.0 | 16.0 | Premium | $4,800 |
CO2 Emissions: -1.0 g/mile (Compact Cars)
Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.
Technical Service Bulletins, 2001 BMW 540I
19 manufacturer communications from 11 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.
Most Affected Components
| Component | Bulletins |
|---|---|
| 140000 AIR BAGS | 5 |
| 110000 ELECTRICAL SYSTEM | 3 |
| 350000 EQUIPMENT | 2 |
| 072100 FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP | 1 |
| 015000 STEERING:HYDRAULIC POWER ASSIST SYSTEM | 1 |
| 016000 STEERING:ELECTRIC POWER ASSIST SYSTEM | 1 |
| 120000 EXTERIOR LIGHTING | 1 |
| 355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL | 1 |
B510819
Jan 16, 2024
133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
The basic conditions for initializing the power windows are not met.
B510819
Jan 16, 2024
110000 ELECTRICAL SYSTEM
The basic conditions for initializing the power windows are not met.
B160623
Dec 20, 2023
070000 FUEL SYSTEM, GASOLINE
Engine will crank but not start. There is no communication with the integrated fuel module (TFE) whendiagnosing with ISTA. The following two fault codes will be stored in the DME: 032B43 - Low fuel pressure system, electric fuel pump: pre
B160623
Dec 20, 2023
060000 ENGINE AND ENGINE COOLING
Engine will crank but not start. There is no communication with the integrated fuel module (TFE) whendiagnosing with ISTA. The following two fault codes will be stored in the DME: 032B43 - Low fuel pressure system, electric fuel pump: pre
B653423
Nov 22, 2023
350000 EQUIPMENT
Customers may state that the alarm system (DWA) is not active after locking their unoccupied vehicle. Depending on the vehicle??A?A?s equipment and settings, no acoustic or optical confirmation (folding the mirrors/blinking confirmation) i
B653423
Nov 22, 2023
110000 ELECTRICAL SYSTEM
Customers may state that the alarm system (DWA) is not active after locking their unoccupied vehicle. Depending on the vehicle??A?A?s equipment and settings, no acoustic or optical confirmation (folding the mirrors/blinking confirmation) i
B013118
Apr 1, 2019
140000 AIR BAGS
TAKATA AIR BAG RECALL-RELATED SHORT-TERM ALTERNATE TRANSPORTATION AND CONSEQUENTIAL REPAIRS This Service Information bulletin supersedes SI B01 31 18 dated October 2018.
B013118
Apr 1, 2019
140000 AIR BAGS
TAKATA AIR BAG RECALL-RELATED SHORT-TERM ALTERNATE TRANSPORTATION AND CONSEQUENTIAL REPAIRS This Service Information bulletin supersedes SI B01 31 18 dated October 2018.
B011618
Jan 1, 2019
140100 AIR BAGS: AIR BAG/RESTRAINT CONTROL MODULE
TAKATA CLASS ACTION SETTLEMENT. CUSTOMER SUPPORT PROGRAM. FRONT DRIVER SIDE AIRBAG MODULES.
B011618
Jan 1, 2019
140000 AIR BAGS
TAKATA CLASS ACTION SETTLEMENT. CUSTOMER SUPPORT PROGRAM. FRONT DRIVER SIDE AIRBAG MODULES.
B650916
Nov 1, 2018
350000 EQUIPMENT
Radio / Navigation / Head Unit Identification Guide
B011618
Oct 1, 2018
140000 AIR BAGS
For the above-referenced vehicles with driver?s side airbag modules, BMW of North America, LLC (?BMW NA?) will provide a Customer Support Program as outlined in the Takata Settlement Customer Support Program Overview attachment. This ?comp
B011618
Oct 1, 2018
110000 ELECTRICAL SYSTEM
For the above-referenced vehicles with driver?s side airbag modules, BMW of North America, LLC (?BMW NA?) will provide a Customer Support Program as outlined in the Takata Settlement Customer Support Program Overview attachment. This ?comp
B080119
Feb 1, 2018
140000 AIR BAGS
In an effort to improve the completion rate on Takata air bag recall affected vehicles; BMW NA has expanded the BMW Ultimate Rewards platform to include a new Recall Support page. This page will allow IRFs to check their customers VINs for
B122917
Dec 1, 2017
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
SERVICE ACTION: PROGRAM DME: The incorrect dataset could be programmed into DME 5.2.1 control module.
SIB-63-02-01
Aug 1, 2010
120000 EXTERIOR LIGHTING
BMW: PROCEDURE FOR DETERMINING AND REPLACING INCANDESCENT AND HALOGEN LIGHT BULBS UNDER WARRANTY. *RM
SIB-32-04-07
Jun 1, 2010
016000 STEERING:ELECTRIC POWER ASSIST SYSTEM
BMW: A NEW TECHNICAL PROCESS HAS BEEN CREATED FOR BMW TO IDENTIFY CAUSES OF STEERING COMPLAINTS WITH A WIDE RANGE OF MODELS. *RM
SIB-32-04-07
Jun 1, 2010
015000 STEERING:HYDRAULIC POWER ASSIST SYSTEM
BMW: A NEW TECHNICAL PROCESS HAS BEEN CREATED FOR BMW TO IDENTIFY CAUSES OF STEERING COMPLAINTS WITH A WIDE RANGE OF MODELS. *RM
SIB-16-02-09
Dec 1, 2009
072100 FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
BMW VEHICLES: FUEL LEVEL SENSOR REPAIRS. WHERE IT IS NECESSARY TO REPLACE THE RIGHT OR THE LEFT SIDE FUEL LEVEL SENSOR DUE TO A FAILURE, THE ENTIRE PUMP AND HOUSING OR DELIVERY UNIT (SUCTION JET ASSEMBLY) DO NOT NEED TO BE REPLACED AS WEL
BMW 540I - All Years Overview
Complete safety history for the BMW 540I across all model years (1989, 2024).
38
Total Recalls
340
Total Complaints
0
Investigations
11
Reported Crashes
8
Reported Fires
0
Reported Deaths
BMW 540I - Year by Year
Compare recalls and complaints across model years. Click any year to see full details.
| Year | Recalls | Complaints | |
|---|---|---|---|
| 2025 | 0 | 1 | View |
| 2024 | 1 | 10 | View |
| 2023 | 0 | 7 | View |
| 2022 | 0 | 7 | View |
| 2021 | 5 | 13 | View |
| 2020 | 5 | 3 | View |
| 2019 | 1 | 14 | View |
| 2018 | 2 | 57 | View |
| 2017 | 1 | 33 | View |
| 2003 | 2 | 9 | View |
| 2002 | 2 | 17 | View |
| 2001 (current) | 4 | 18 | |
| 2000 | 2 | 36 | View |
| 1999 | 1 | 29 | View |
| 1998 | 1 | 28 | View |
| 1997 | 0 | 31 | View |
| 1995 | 2 | 15 | View |
| 1994 | 4 | 12 | View |
| 1993 | 1 | 0 | View |
| 1992 | 1 | 0 | View |
| 1991 | 1 | 0 | View |
| 1990 | 1 | 0 | View |
| 1989 | 1 | 0 | View |