Model year record

1994 BMW 540i recalls & problems

The 1994 BMW 540i has 4 safety recalls and 8 owner complaints on file with NHTSA. The most-reported problem area is power train (4 complaints).

Recalls4safety recalls

Complaints8filed by owners

Crashes · fires0 · 0reported in complaints

Injuries · deaths0 · 0reported in complaints

Safety recalls

Engine and engine coolingAug 4, 1998

Cooling system

Recall 98V178000340,000 vehicles

Problem: VEHICLE DESCRIPTION: PASSENGER VEHICLES. A MALFUNCTION OR FAILURE OF A COOLANT SYSTEM COMPONENT, SUCH AS A THERMOSTAT, WATER PUMP, OR FAN BELT, CAN RESULT IN SIGNIFICANTLY INCREASED COOLANT TEMPERATURE AND SYSTEM PRESSURE. IF THE INDICATIONS OF A CRITICAL OVERHEATING CONDITION IS NOT NOTICED BY THE DRIVER, IT IS POSSIBLE THAT DAMAGE TO, OR FAILURE OF, A COOLANT SYSTEM COMPONENT COULD OCCUR.
Risk: IF A CRACK WERE TO FORM OR A SEAM WERE TO SEPARATE IN THE HEATER CORE END PIECE, HOT COOLANT COULD SUDDENLY BE EXPELLED, INCREASING THE RISK OF PERSONAL INJURY TO A VEHICLE OCCUPANT.
Fix: DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERFLOW IN THE EVENT OF OVERHEATING.

Vehicle speed controlAug 19, 1997

Vehicle speed control

Recall 97V131000410,000 vehicles

Problem: THE CRUISE CONTROL AND THROTTLE CABLES ARE ATTACHED TO THE SAME THROTTLE VALVE ACTUATING LEVER AT THE THROTTLE HOUSING. IT IS POSSIBLE THAT THE PLASTIC BUSHING ON EITHER CABLE COULD BREAK DUE TO ENVIRONMENTAL INFLUENCES COUPLED WITH VIBRATION. IF THE BUSHING BREAKS, THE OUTER CABLE HOUSING CAN SEPARATE FROM THE BUSHING. IN THIS CASE, DURING APPLICATION OF THE THROTTLE PEDAL WITHOUT CRUISE CONTROL BEING ENGAGED, THE OUTER TUBE COULD CATCH ON THE EDGE OF THE BROKEN BUSHING.
Risk: THIS COULD CAUSE THE THROTTLE VALVE TO REMAIN PARTIALLY OPEN. IT HIS WERE TO OCCUR, THE CAR MIGHT NOT DECELERATE AS EXPECTED INCREASING THE RISK OF A VEHICLE CRASH.
Fix: DEALERS WILL INSTALL A SPRING STEEL CLIP ON THE OUTER TUBE OF EACH CABLE IN THE AREA OF THE ADJUSTING SCREW AND PLASTIC BUSHING. THE CLIP IS DESIGNED TO PREVENT THE OUTER TUBE FROM DISLODGING FROM THE BUSHING.

Exterior lightingJul 1, 1996

Brake lights › Switch

Recall 96V111000180,000 vehicles

Problem: THE BRAKE LIGHT SWITCH CAN FAIL ALLOWING THE SWITCH TO REMAIN IN THE "BRAKE LIGHTS OFF" POSITION OR IN THE "BRAKE LIGHTS ON" POSITION.
Risk: IF THIS HAPPENS, THE BRAKE LIGHTS EITHER WILL NOT OPERATE OR WILL BE CONTINUOUSLY ON, REGARDLESS OF BRAKE PEDAL POSITION. FOLLOWING DRIVERS WOULD NOT BE ABLE TO DETERMINE WHETHER THE VEHICLE IS STOPPING, INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Fix: DEALERS WILL REPLACE THE EXISTING BRAKE LIGHT SWITCH WITH A NEWLY DESIGNED SWITCH.

VisibilityJan 27, 1994

Power window devices and controls

Recall 94V0170001,400 vehicles

Problem: THE REMOTE ACTIVATION DEVICE CAN CLOSE WINDOWS AND SUNROOF FROM A DISTANCE GREATER THAN THE MAXIMUM (6 METERS) PERMITTED BY FMVSS NO.118, "POWER OPERATED WINDOW SYSTEMS."
Risk: CONSEQUENCE OF NON-COMPLIANCE: THIS COULD ALLOW WINDOWS OR SUNROOFS TO BE CLOSED ON AN ARM OR NECK OF AN INDIVIDUAL WHEN THE REMOTE DEVICE OPERATOR IS NOT WITHIN THE IMMEDIATE VICINITY.
Fix: REPLACE THE INSIDE REAR VIEW MIRROR WHICH HAS THE ACTIVATION RECEIVER WITH ONE WHOSE RECEIVER WILL CONTROL THE DOOR LOCKING AND THEFT ALARM, BUT WILL NOT PERMIT REMOTE OPERATION OF THE WINDOWS AND SUNROOF.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Fuel economy

540i

17mpg combined

City / highway	15 / 21 mpg
Fuel	Premium Gasoline

4 L · 8 cyl · Automatic 5-spd · Rear-Wheel Drive · about $4,850/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Typical mileage*
Power trainAutomatic transmission	4	—
Engine and engine coolingEngine; Engine › Gasoline	4	—
SeatsFront assembly › Recliner; Front assembly › Power adjust	2	—
Vehicle speed control	1	—
Interior lighting	1	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Power train › Automatic transmission
WHEN SHIFTING INTO REVERSE, THERE IS A HESITATION BEFORE TRANSMISSION SHIFTS IN. HESITATION TIME IS INCREASING. ALSO, WHEN STEPPING ON PEDAL FOR AGGRESSIVE ACCELERATION OR PASSING, VEHICLE HESITATES, THEN "CLUNKS" VIOLENTLY INTO GEAR. MECHANICS HAVE STATED THAT IT IS A COMMON PROBLEM THAT THEY SEE WITH THIS VEHICLE AND TRANSMISSION. SOLUTION IS TO REPLACE WITH A BRAND NEW TRANSMISSION(PARTS COST $5000.00).NOTHING DONE YET TO REMEDY PROBLEM DUE TO INCREDIBLE COST. ALSO, SHIFT LEVER SAFETY BUTTON NO LONGER WORKS, ALLOWING VEHICLE TO BE ACCIDENTALLY SHIFTED OUT OF DRIVING GEAR INTO OTHER GEARS. MECHANIC STATED THAT INTERNAL PIN BROKE AND THE WHOLE SHIFT LEVER HAS TO BE REPLACED WITH A PARTS…
Jul 1, 2002 · 82,000 miles
Power train › Automatic transmission
I BOUGHT A BMW 540I IN 1996 USED AT 45,000 MILES FROM A DEALERSHIP. WHEN SHIFTING INTO REVERSE TRANSMISSION WOULD BE DELAYED TEMPORARILY BEFORE ENGAGING. NOW I WAS NOT INFORM THE OF THE TECHNICAL BULLETIN AND DUE TO POOR TRANSMISSION FLUID, NOW AT 90,000 MILES THIS CAR WOULD NOT GO INTO REVERSE , SHIFTER WOULD SLIDE, AND CAR WOULD NOT MOVE. NOW THERE IS A IDENTICAL EXPERIENCE WITH AN OTHER CONSUMER CASE# 889281 WITH THE NHTSA. MY CAR HAS BEEN IN FOR OTHER RECALLS NOW I WOULD LIKE TO KNOW IF THEY FAILED TO DO THERE PART AND IN MAKING SURE THAT THE TRANSMISSON PROBLEM FLUID OR OTHER TECHNICAL PROBLEMS WAS TO BE TAKEN CAR OF BY THE DEALERSHIP BEFORE IT BECAME AN ISSUE. *AK
Sep 8, 2003 · 90,000 miles
Engine and engine cooling › Engine
TO WHOM IT MIGHT CONCERN. MY BMW 540I WAS DIAGNOSED FOR COMPRESSION LOSS BY THE LOCAL BMW AUTHORIZED DEALER. ACCORDING TO THE DEALER, THE CAUSE IS EXTENDED SULFUR CONTENT USED IN THE US GASOLINE. THE SULFUR CAUSES A CHEMICAL REACTION WITH THE USED ENGINE BLOCK ALLOY (NIKASIL) AND ERODES PREMATURELY. CURRENT MILEAGE IS 99'000 MILES. THIS IS FAR BELOW ANY SERVICE LIFE EXPECTANCY STANDARD FOR A QUALITY MAKE/BRAND CAR (ENGINE). BMW WANTS TO HOLD THEIR CUSTOMERS RESPONSIBLE FOR DAMAGE CAUSED BY A DESIGN FLAW. BMW MISSED TO PROPERLY TEST AND EVALUATE THIS CAR PRIOR TO EXPORTING IT INTO THE US MARKET. BMW CONFESSES TO THE PROBLEM BY EXTENDING THE ORIGINAL WARRANTY FROM 4 TO 6 YEARS. I FEEL THAT…
Dec 30, 2002 · 87,000 miles
Engine and engine cooling › Engine › Gasoline
THIS IS THE SECOND ENGINE FOR THIS CAR, THE FIRST WAS REPLACED AT 38,228MI ... THIS ENGINE WAS REPLACED WITH THE SAME DEFECTIVE ENGINE THAT WAS ORIGINALLY IN THE CAR, NOT THE NEWER BLOCKS ... THIS WILL BE THE THIRD ENGINE IN 142,00MI AND I AM GETTING NO HELP HERE ... VERY DISAPPOINTING ... I WANT SATISFACTION ... I SHOULD NOT BE ON A THIRD ENGINE, PERIOD!!!*AK
May 26, 2002
Engine and engine cooling › Engine
BMW WITH M60B30 AND M60B40 V'8 FROM 93-95 ENGINES HAVE BEEN KNOWN TO SUFFER DAMAGE TO THE CYLINDER BORES FROM EXCESSIVE AMOUNTS OF SULPHER IN US FUELS. THE BLOCKS WERE MADE OF NIKASIL. THE PROBLEM REPRESENTS ITSELF AS AN EXCESSIVELY HIGH IDLE WHICH MY CAR HAS. BMW INITIATED AN ENGINE WARRANTY, COVERING ALL INTERNAL LUBRICATED PARTS, WHICH INCLUDES THE SHORT BLOCK FOR 100,000, OR 6 YEARS. I TOOK MY CAR TO BE CHECKED AND THIS IS WHEN I DISCOVERED( BASED ON A COMPRESSION TEST) IT HAS THE PROBLEM BMW KNEW ABOUT. THE PROBLEM IS MY CAR IS MORE THAN 6 YEARS OLD WITH LESS THAN 100,000.00 MILES BMW WILLNOT REPAIR MY PROBLEM ALLTHOUGH THEY ACKNOWLEDGE IT EXISTS. I HAVE AN EXTENDED WARRANTY ON THE CAR…
Jun 6, 2001
Power train › Automatic transmission
AT 85,000 MILES WHEN SHIFTING INTO REVERSE TRANSMISSION WOULD BE DELAYED TEMPORARILY BEFORE ENGAGING. DEALER NOTIFIED MANUFACTURER, WHO INFORMED CONSUMER THAT VEHICLE WAS OUT OF ITS WARRANTY, AND NOT COVERED UNDER A RECALL. *AK CONSUMER STATES TRANSMISSION MALFUNCTIONED BECAUSE MANUFACTURERE DID NOT INFORM HIM OF THE TECHNICAL BULLETIN AND DUE TO POOR TRANSMISSION FLUID, FINALLY AT 92642 VEHICLE WOULD NOT GO IN TO REVERSE, SHIFTER WOULD SLIDE, BUT CAR WOULD NOT MOVE. *SLC
Nov 1, 2000
Vehicle speed control
SPEED SENSOR FAILED, CAUSING FAILURE OF TRANSMISSION, CANNOT CHANGE GEARS.PLEASE PROVIDE FURTHER INFORMATION. *AK
Apr 26, 2000
Seats › Front assembly › Recliner
DRIVERS SEAT "ROCKS". IF IN AN ACCIDENT I FEAR THE SEAT WILL DETATCH AND DRIVER WILL DIE. NEW SEAT RAILS WILL FIX BUT BMW WILL NOT PAY.*AK
Jan 8, 2000

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.