2002 BMW 540I Problems
Owner-reported complaints filed with NHTSA, grouped by component
Data refreshed
What this page shows
Everything below is an owner-reported complaint submitted to NHTSA about the 2002 BMW 540I, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.
Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.
Reports by component
Ranked by how many owner reports name each component category
- Electrical531.3%
- Steering531.3%
- Airbags212.5%
- Engine212.5%
- Fuel system16.3%
- Exterior lighting16.3%
Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.
Each component in detail
What the reports in each category say, in the owners' own words
Electrical
Reports naming the electrical system — wiring, battery, charging, control modules, infotainment and electrical accessories.
From owner reports, verbatim
TL* THE CONTACT OWNS A 2002 BMW 540I. THE CONTACT STATED THAT IT TOOK TEN ATTEMPTS TO START THE VEHICLE. THE FAILURE OCCURRED AT LEAST THIRTY TIMES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 166,000.
AFTER STARTING UP MY CAR, THERE WAS A SLIGHT WHINE UNDER THE HOOD. I GAVE THE CAR A LITTLE BIT OF THROTTLE TO SEE IF THE WHINE WENT AWAY AND HEARD A LOUD BANG. THE CAR WAS STILL RUNNING BUT MY BATTERY LIGHT WAS ON. I NEEDED TO GET HOME, AND I THOUGHT THAT MY CAR MAY NOT START AGAIN IF I TURNED IT OFF SO I DROVE HOME. IMMEDIATELY I NOTICED THAT I DIDN'T HAVE ANY POWER STEERING. AS I DROVE MY ENGINE TEMPERATURE GOT HIGHER AND I BARELY MADE IT HOME WITHOUT OVERHEATING. A FEW DAYS LATER I LOOKED IN THE ENGINE COMPARTMENT AND SAW THAT THE POWER STEERING PUMP HAD BROKEN FREE OF THE ENGINE - THE BRACKET HAD SHEARED OFF. THAT IN TURN CAUSED THE BELT TO FALL OFF WHICH WAS TURNING THE WATER PUMP AND ALTERNATOR. I GOT ON THE COMPUTER AND LOOKED UP THE PROBLEM AND FOUND A LOT OF PEOPLE EXPERIENCING THE SAME PROBLEM, SOME DRIVING DURING THE INCIDENT. THIS IS A REAL DEFECTIVE DESIGN AND CAUSES ME TO BE CONCERNED ABOUT THE SAFETY. I HOPE NOTHING TRAGIC HAS TO HAPPEN TO SOMEONE FOR THIS TO BE CONSIDERED A RECALL. *TR
Too few reports in this category for a page of its own — they appear in the full complaint list.
Steering
Reports naming the steering system — racks, columns, power-steering assist and steering linkage.
From owner reports, verbatim
POWER STEERING PUMP MOUNTING BRACKETS BROKE OFF ( ON A POWER STEERING PUMP ITSELF), CAR THUS LOST POWER STEERING, BELT GOT OFF, IN A TURN IT WOULD HAVE BEEN A DISASTER , SOMEHOW I WAS ABLE TO STEER IT CLEAR IN A TURN. I GUESS I WAS LUCKY.
I WAS DRIVING AND MY SERPENTINE BELT FELL OFF. AFTER INSPECTION THE BRACKET FOR MY POWER STEERING PUMP BROKE AND CAUSED THE BELT TO FALL OFF. LOST POWER STEERING WHILE DRIVING. *TR
Too few reports in this category for a page of its own — they appear in the full complaint list.
Airbags
Reports naming the air-bag system — deployment behaviour, inflators, sensors and warning lights.
From owner reports, verbatim
TL* THE CONTACT OWNED A 2002 BMW 540I. WHILE THE CONTACT'S VEHICLE WAS AT A STOP SIGN, IT WAS REAR ENDED BY ANOTHER VEHICLE. THE AIR BAGS FAILED TO DEPLOY. THERE WERE NO INJURIES AND A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED AND DEEMED A TOTAL LOSS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 40,000. *BF *TR
TL* TAKATA RECALL. THE CONTACT OWNS A 2002 BMW 540I. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V318000 (AIR BAGS); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT. ...UPDATED 09/14/16 *BF UPDATED 10/18/16.*JB
Too few reports in this category for a page of its own — they appear in the full complaint list.
Engine
Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components.
From owner reports, verbatim
AFTER STARTING UP MY CAR, THERE WAS A SLIGHT WHINE UNDER THE HOOD. I GAVE THE CAR A LITTLE BIT OF THROTTLE TO SEE IF THE WHINE WENT AWAY AND HEARD A LOUD BANG. THE CAR WAS STILL RUNNING BUT MY BATTERY LIGHT WAS ON. I NEEDED TO GET HOME, AND I THOUGHT THAT MY CAR MAY NOT START AGAIN IF I TURNED IT OFF SO I DROVE HOME. IMMEDIATELY I NOTICED THAT I DIDN'T HAVE ANY POWER STEERING. AS I DROVE MY ENGINE TEMPERATURE GOT HIGHER AND I BARELY MADE IT HOME WITHOUT OVERHEATING. A FEW DAYS LATER I LOOKED IN THE ENGINE COMPARTMENT AND SAW THAT THE POWER STEERING PUMP HAD BROKEN FREE OF THE ENGINE - THE BRACKET HAD SHEARED OFF. THAT IN TURN CAUSED THE BELT TO FALL OFF WHICH WAS TURNING THE WATER PUMP AND ALTERNATOR. I GOT ON THE COMPUTER AND LOOKED UP THE PROBLEM AND FOUND A LOT OF PEOPLE EXPERIENCING THE SAME PROBLEM, SOME DRIVING DURING THE INCIDENT. THIS IS A REAL DEFECTIVE DESIGN AND CAUSES ME TO BE CONCERNED ABOUT THE SAFETY. I HOPE NOTHING TRAGIC HAS TO HAPPEN TO SOMEONE FOR THIS TO BE CONSIDERED A RECALL. *TR
I WAS DRIVING IN STOP AND GO TRAFFIC WHEN I NOTICED THE STEERING FELT A LITTLE STIFFER THAN USUAL. AFTER ABOUT 5 MILES AND BETTER FLOWING TRAFFIC I PULLED INTO A RESTAURANT FOR DINNER WHEN MY UPPER RADIATOR HOSE EXPLODED. I PULLED INTO A STALL AND OPENED THE HOOD TO INSPECT WHAT HAPPENED. THE HOSE WAS VERY APPARENT AND AFTER FURTHER INVESTIGATION I NOTICED THE POWER STEERING PUMPS PULLEY AT A VERY SHARP ANGLE COMPARED TO LINEAR WITH THE SERPENTINE BELT. I CAN ONLY ASSUME THAT FROM THE BRACKET ON THE PUMP BREAKING, IT CAUSED A CHAIN REACTION OF EVENTS. FIRST THE BRACKET BROCKET PUTTING THE PUMP AT A STEEP ANGLE N FORCING THE BELT TO GO OFF TRACK WHICH THEN CAUSED ALL THE OTHER ACCESSORIES TO BE DISABLED INCLUDING THE WATER PUMP WHICH OVERHEATED THE CAR. *TR
Too few reports in this category for a page of its own — they appear in the full complaint list.
Fuel system
Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.
From owner reports, verbatim
THERE IS A CONSTANT FUEL LEAK UNDER THE VEHICLE CAUSING ENGINE CHECK LIGHT TO ILLUMINATE.*AK
Too few reports in this category for a page of its own — they appear in the full complaint list.
Exterior lighting
Reports naming headlights, tail lights, turn signals and other exterior lighting.
From owner reports, verbatim
THE PLASTIC COVERS ON THE HEADLIGHTS OF MY BMW BECAME CRAZED/FROSTED. EVERY BMW OF THIS VINTAGE HAS THE SAME PROBLEM. I SHOWED THIS TO OCCUR IN 2010 AT 100,000 MILES, BUT IN FACT IT WAS A STEADY DEGRADATION OVER SEVERAL YEARS. IT'S A SAFETY ISSUE, BECAUSE THE LIGHT OUTPUT IS SIGNIFICANTLY REDUCED. CAUSING RISK AT NORMAL HIGHWAY SPEEDS. IN ADDITION, THE CRAZING/FROSTING RESULTS IN ADDITIONAL GLARE TO ONCOMING TRAFFIC. I ASKED ABOUT RECALLS/REPLACEMENT PROGRAM FOR THIS DEFECT AT MY LOCAL BMW DEALER; THE SERVICE TECHNICIAN DISMISSED IT AS A NORMAL AGING ISSUE. I STRONGLY DISAGREE. A CAR OF THIS PRICE, OR ANY PRICE, SHOULD HAVE HEADLIGHTS THAT LAST LONGER THAN A FEW YEARS. I REPLACE THE HEADLAMP COVERS IF THEY WERE AVAILABLE, BUT THE ONLY SOLUTION IS TO REPLACE THE ENTIRE HEADLAMP ASSEMBLY AT A COST OF $1238 FOR EACH SIDE. YES, $1238. THIS WAS A QUITE EXPENSIVE AUTO, BUT REGARDLESS OF COST, THIS SAFETY ISSUE SHOULD RESULT IN A RECALL....UPDATED 07/30/15 *BF THE DEALER INFORMED THE CONSUMER IT WAS A NORMAL AGING ISSUE. THE CONSUMER STATED THE LIGHT OUTPUT WAS SIGNIFICANTLY REDUCED. UPDATED 09/01/15. *JB
Too few reports in this category for a page of its own — they appear in the full complaint list.
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.
Elsewhere on this vehicle
Data sources
- NHTSA Office of Defects Investigation — owner-reported complaints and the components recorded on them
Data on this page last refreshed .