RoadVitals

2001 BMW 540I

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

NHTSA has issued a “do not drive” advisory affecting this model year.

Campaign 19V015000. Confirm whether your specific vehicle is covered using its VIN before acting on this.

Check your VIN on NHTSA.gov
Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
15
Latest Mar 3, 2026
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
4
Latest Jan 14, 2019
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
0
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
1

Overview

Our database contains 15 NHTSA owner-reported complaints for the 2001 BMW 540I, most frequently naming the electrical, airbags and steering categories. 4 safety recalls have been issued covering this model year; and 13 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

  • Electrical529.4%
  • Airbags529.4%
  • Steering211.8%
  • Transmission211.8%
  • Exterior lighting15.9%
  • Engine15.9%
  • Powertrain (other)15.9%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

4 campaigns cover this model year

View all 4

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
19V015000NHTSA advisory: do not drive

AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

Jan 14, 2019
157,549 units potentially affected
The defect: 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 steering wheel has been replaced with the optional sports steering wheel. The sports steering wheel has a frontal air bag inflator that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
The risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
The 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 March 14, 2019. Owners may contact BMW customer service at 1-800-525-7417.
BMW of North America, LLCView on NHTSA.gov
03V421000

AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE

Oct 24, 2003
23,000 units potentially affected
The defect: 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 COMPONENTS.
The risk: 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 RESTARTED.
The remedy: DEALERS WILL REPLACE THE AIR BAG CONTROL MODULE. OWNER NOTIFICATION BEGAN NOVEMBER10, 2003. OWNERS SHOULD CONTACT BMW AT 1-800-831-1117.
BAYERISCHE MOTOREN WERKEView on NHTSA.gov
02V138000

ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

May 16, 2002
1,550 units potentially affected
The defect: 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.
The risk: 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.
The 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 WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-800-831-1117.
BAYERISCHE MOTOREN WERKEView on NHTSA.gov

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

View all 15
Airbags
Filed Mar 3, 2026

The contact owns a 2001 BMW 540i. The contact received notification of NHTSA Campaign Number: (17V047000 (AIR BAGS) and would like to be removed from the recall distribution list. The local dealer and manufacturer were contacted.

NHTSA ID
11721725
Incident
Mar 3, 2026
AirbagsElectrical
Filed Mar 21, 2023

The contact owns a 2001 BMW 540I. The contact stated that the dealer had previously performed an unknown air bag recall repair; however, the failure occurred a year after the recall repair was performed. The contact stated that while the vehicle was parked and turned off, an explosion was heard. The contact entered the vehicle and noticed that the passenger's side air bag had deployed, which shattered the front windshield. The air bag and an unknown warning light were illuminated. The driver's side air bag deployed a month later. The contact stated that there was no impact to the vehicle that could have caused the air bags to deploy. Additionally, the vehicle made an abnormal sound after it was turned off. The vehicle also needed to be jumpstarted daily due to the battery failing to retain a charge. The dealer was made aware of the failure; however, the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 105,000.

NHTSA ID
11513083
Incident
Nov 1, 2022
Mileage
105,000 mi
Engine
Filed Jan 14, 2020
Crash reported

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 EXPENSIVE. I WAS LUCKY IN THAT I REPLACED MINE AT 140,000 MILES

NHTSA ID
11299247
Incident
Apr 12, 2014
Mileage
145,000 mi
Airbags
Filed May 21, 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 SERVICE RECORDS FOR THIS VIN SHOW THAT THE "AIRBAG CONTROL UNIT" WAS REPLACED 6/22/04. HOWEVER, THE OPEN NHTSA RECALL CAMPAIGN ON THIS VEHICLE NOTES THAT THE INFLATOR MAY HAVE BEEN REPLACED PREVIOUSLY BUT THAT THE INFLATOR THAT WAS REPLACED STILL NEEDS TO BE INSPECTED AT THIS TIME AS IT MAY BE FAULTY.

NHTSA ID
10990793
Incident
Mar 10, 2017
Mileage
156,000 mi
Airbags
Filed Jul 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.

NHTSA ID
10882005
Incident
May 1, 2016
Mileage
75,000 mi
Steering
Filed May 5, 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 1997-2003 BMW 540I'S. *TR

NHTSA ID
10714790
Incident
Mar 31, 2015
Mileage
130,000 mi
Steering
Filed Feb 14, 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 HAPPENING TO MY VEHICLE FOR THE SECOND TIME. OTHER OWNERS REPORT MULTIPLE INSTANCES AS WELL. *TR

NHTSA ID
10564400
Incident
Jan 15, 2014
Mileage
89,000 mi
Powertrain (other)
Filed Feb 10, 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.

NHTSA ID
10382233
Incident
Feb 6, 2011
Mileage
73,263 mi

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

B510819

ELECTRICAL SYSTEM; VISIBILITY:POWER WINDOW DEVICES AND CONTROLS

The basic conditions for initializing the power windows are not met.

B160623

ENGINE AND ENGINE COOLING; 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: pressure value too low CDA594 - Message (- 0x33E) missing, receiver DME, transmitter TFE

B653423

ELECTRICAL SYSTEM; EQUIPMENT

Customers may state that the alarm system (DWA) is not active after locking their unoccupied vehicle. Depending on the vehicle’s equipment and settings, no acoustic or optical confirmation (folding the mirrors/blinking confirmation) is noticeable. Additionally, the red anti-theft alarm LED in the interior mirror does not briefly flash every 2 seconds, indicating the alarm is armed.

B013118

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

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

AIR BAGS; AIR BAGS: AIR BAG/RESTRAINT CONTROL MODULE

TAKATA CLASS ACTION SETTLEMENT. CUSTOMER SUPPORT PROGRAM. FRONT DRIVER SIDE AIRBAG MODULES.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

BMW 540I by model year
YearComplaintsRecallsInvestigationsIssue Index
2025100—
2024510—
2023500—
2022301—
2021851—
2020350—
2019111052.2
2018292055.4
2017201144.8
2003720—
2002122044.3
2001Viewing154056.6
2000312051.3
1999221036.1
1998261038.8
1997270038.2
1996000—
1995102050.2
1994840—
1993010—
1992010—
1991010—
1990010—
1989010—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.