Model year record

2001 BMW 540i recalls & problems

The 2001 BMW 540i has 4 safety recalls and 15 owner complaints on file with NHTSA. The most-reported problem area is electrical system (6 complaints).

Recalls4safety recalls

Complaints15filed by owners

Crashes · fires1 · 0reported in complaints

Injuries · deaths0 · 0reported in complaints

1 recall for this model year carries an NHTSA do not drive advisory. Check your VIN at nhtsa.gov/recalls.

Safety recalls

Air bagsJan 14, 2019

Frontal › Driver side › Inflator module

Recall 19V015000157,549 vehiclesopened after NHTSA action (ODI)

NHTSA advisory: do not drive affected vehicles until repaired.

Problem: 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.
Risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Fix: 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.

Air bagsOct 24, 2003

Frontal › Sensor/control module-inactive

Recall 03V42100023,000 vehicles

Problem: 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.
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.
Fix: DEALERS WILL REPLACE THE AIR BAG CONTROL MODULE. OWNER NOTIFICATION BEGAN NOVEMBER10, 2003. OWNERS SHOULD CONTACT BMW AT 1-800-831-1117.

Engine and engine coolingMay 16, 2002

Cooling system › Fan

Recall 02V1380001,550 vehicles

Problem: 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.
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.
Fix: 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.

Engine and engine coolingJun 21, 2001

Cooling system › Fan

Recall 01V20600076,469 vehicles

Problem: 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.
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.
Fix: 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.

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

18mpg combined

City / highway	16 / 22 mpg
Fuel	Premium Gasoline

4.4 L · 8 cyl · Automatic 5-spd · Rear-Wheel Drive · about $4,550/year to fuel

540i

16mpg combined

City / highway	14 / 21 mpg
Fuel	Premium Gasoline

4.4 L · 8 cyl · Manual 6-spd · Rear-Wheel Drive · about $5,150/year to fuel

540i

16mpg combined

City / highway	14 / 19 mpg
Fuel	Premium Gasoline

4.4 L · 8 cyl · Automatic (S5) · Rear-Wheel Drive · about $5,150/year to fuel

540i Sport Wagon

16mpg combined

City / highway	14 / 19 mpg
Fuel	Premium Gasoline

4.4 L · 8 cyl · Automatic (S5) · Rear-Wheel Drive · about $5,150/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	Crashes	Typical mileage*
Electrical systemIgnition; Wiring	6	0	49,063 mi
Air bagsSide/window	5	0	105,000 mi
Power trainAutomatic transmission	3	0	73,263 mi
Steering	2	0	—
Exterior lighting	1	0	—
Engine	1	1	—

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

Recent owner complaints

Air bags
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.
Mar 3, 2026
Air bags
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…
Nov 1, 2022 · 105,000 miles
EngineCrash
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
Apr 12, 2014 · 145,000 miles
Air bags
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.
Mar 10, 2017 · 156,000 miles
Air bags
POSSIBLE TAKATA INFLATOR: AT FIRST THE PASSENGER AIRBAG LIGHT CAME ON OCCASIONALLY AND NOW THE PASSENGER AIRBAG LIGHT IS ON ALL AT THE TIME.
May 1, 2016 · 75,000 miles
Steering
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
Mar 31, 2015 · 130,000 miles
Steering
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
Jan 15, 2014 · 89,000 miles
Power train
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.
Feb 6, 2011 · 73,263 miles

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