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2003 BMW 540I

2 recalls, 9 complaints - 15 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
157,549 vehicles affected
Manufacturer: BMW of North America, LLC
15V318000 May 28, 2015
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
Defect Description
BMW of North America, LLC (BMW) is recalling certain model year 2002-2005 325i, 325xi, 330i, and 330xi Sedans, and 325xi and 325i Sportswagons, 2002-2006 330Ci, 325Ci, and M3 Convertibles and 325i, 330i, and M3 Coupes, 2002-2003 M5, 540i, 525i Sedan, and 530i Sedans, and 540i and 525i Sportswagons, ... Read more
Consequence
In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with 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 replace the front driver air bag module, free of charge. The recall began Aug 2016. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall supersedes... Read more
419,235 vehicles affected
Manufacturer: BMW of North America, LLC

Complaint Statistics

9 total complaints

Top Reported Components

ComponentComplaints
STEERING2
AIR BAGS2
POWER TRAIN1
ELECTRICAL SYSTEM1
ENGINE1
TIRES1
SERVICE BRAKES1
AIR BAGS Apr 9, 2025
Incident date: Apr 9, 2025
Hello. I am following up with the previous safety report I submitted for my vehicle. I just received an updated repair estimate citing the parts that will need replaced (pdf attached). I also confirmed with the service advisor that the functionality of the safety restraint system may be impacted by ... Read more
SERVICE BRAKES Aug 9, 2024
Incident date: Mar 12, 2024
Was driving on the highway, when the vehicle popped up the message and it caused either the emergency brake or the automatic collision detection brake to engage. It turned of when I applied gas. The brake issues remain, when I restarted the vehicle after 15 minutes of being off, no brake error was d... Read more
AIR BAGS May 25, 2019
Incident date: Aug 10, 2017
TAKATA RECALL - THE BMW 2003 540I THAT I OWN, HAS A DRIVER'S SIDE AIRBAG AND A PASSENGER SIDE AIRBAG. I COMPLIED WITH THE BMW RECALL FOR THE TAKATA AIRBAG REPLACEMENT SYSTEM THAT TO MY DISSATISFACTION, REPLACED ONLY THE DRIVER'S SIDE AIRBAG. I AM REGISTERING THIS COMPLAINT TO NOTIFY NHTSA THAT B... Read more
TIRES Nov 25, 2014
Incident date: May 8, 2014
DRIVER'S SIDE, REAR TIRE EXPLODED, WHILE DRIVING ON HIGHWAY 5 IN CALIFORNIA, CAUSING $5,500 DAMAGE TO THE REAR BODY OF THE CAR. BOTH THE REPAIR FACILITY AND DISCOUNT TIRE FOUND THE OTHER 3 TIRES TO HAVE DEFECTS RENDERING THEM UNSAFE TO DRIVE. *TR
STEERING Oct 6, 2014
Incident date: Oct 3, 2014
STARTED THE CAR AND BEGAN TO DRIVE OUT OF DRIVEWAY WHEN I HEARD A NOISE IN THE ENGINE. SHUT DOWN ENGINE AND POPPED THE HOOD- FOUND DRIVE BELT SHREDDED BECAUSE POWER STEERING PUMP SNAPPED AND LET LOOSE INTO TENSION PULLEY- LUCKILY I WAS NOT AT SPEED AND BELT DID NOT FAIL- OTHERWISE CATASTROPHIC ENGI... Read more
ENGINE Oct 6, 2014
Incident date: Oct 3, 2014
STARTED THE CAR AND BEGAN TO DRIVE OUT OF DRIVEWAY WHEN I HEARD A NOISE IN THE ENGINE. SHUT DOWN ENGINE AND POPPED THE HOOD- FOUND DRIVE BELT SHREDDED BECAUSE POWER STEERING PUMP SNAPPED AND LET LOOSE INTO TENSION PULLEY- LUCKILY I WAS NOT AT SPEED AND BELT DID NOT FAIL- OTHERWISE CATASTROPHIC ENGI... Read more
ELECTRICAL SYSTEM Feb 17, 2013
Incident date: Mar 1, 2012
BMW E39 540I POSSIBLE DEFECTIVE BLOWER MOTOR RESISTOR (CLIMATE CONTROL FAN RESISTOR) WITH HEATSINK.. AFFECTS "AUTO" FAN.. VERY NOTICEABLE IN THE LONG RUN.. KNOWN PROBLEM.. MANY DO NOT LAST PAST 50,000KM.. SEE HTTP://WWW.BIMMERFEST.COM/FORUMS/SHOWTHREAD.PHP?T=143393 FOR REPLACEMENT.. *TR
POWER TRAIN Nov 19, 2012
Incident date: Nov 12, 2012
DRIVING HOME ONE EVENING, I NOTICED A BINDING FEELING BEING TRANSMITTED THROUGH THE DRIVE-TRAIN, DRIVE-ABILITY DID NOT SEEM TOO AFFECTED, OTHER THAN THE ODD BIND BEING FELT. THE NEXT MORNING UPON START-UP, THE CAR BEGAN MAKING A LOUD, RPM SENSITIVE WHINING NOISE. I SHUT THE CAR OFF AND DROVE ONE O... Read more
STEERING Nov 19, 2012
Incident date: Nov 12, 2012
DRIVING HOME ONE EVENING, I NOTICED A BINDING FEELING BEING TRANSMITTED THROUGH THE DRIVE-TRAIN, DRIVE-ABILITY DID NOT SEEM TOO AFFECTED, OTHER THAN THE ODD BIND BEING FELT. THE NEXT MORNING UPON START-UP, THE CAR BEGAN MAKING A LOUD, RPM SENSITIVE WHINING NOISE. I SHUT THE CAR OFF AND DROVE ONE O... Read more

EPA Fuel Economy, 2003 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) 15.0 19.0 17.0 Premium $4,550

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, 2003 BMW 540I

15 manufacturer communications from 8 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

ComponentBulletins
140000 AIR BAGS5
110000 ELECTRICAL SYSTEM3
350000 EQUIPMENT2
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL1
140100 AIR BAGS: AIR BAG/RESTRAINT CONTROL MODULE1
060000 ENGINE AND ENGINE COOLING1
070000 FUEL SYSTEM, GASOLINE1
133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS1
B510819 Jan 16, 2024
110000 ELECTRICAL SYSTEM
The basic conditions for initializing the power windows are not met.
B510819 Jan 16, 2024
133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
The basic conditions for initializing the power windows are not met.
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
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
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
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
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
140000 AIR BAGS
TAKATA CLASS ACTION SETTLEMENT. CUSTOMER SUPPORT PROGRAM. FRONT DRIVER SIDE AIRBAG MODULES.
B011618 Jan 1, 2019
140100 AIR BAGS: AIR BAG/RESTRAINT CONTROL MODULE
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
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
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
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.

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 (current) 2 9
2002 2 17 View
2001 4 18 View
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

Other BMW Models

Model Recalls Complaints
X5 223 4,349 View
X3 155 2,661 View
330I 122 1,050 View
X6 110 293 View
328I 108 3,743 View
M3 95 550 View
325I 83 1,809 View
Z4 83 1,439 View