The 2003 BMW 540i has 2 safety recalls and 7 owner complaints on file with NHTSA. The most-reported problem area is steering (2 complaints).
Recalls2safety recalls
Complaints7filed by owners
Crashes · fires0 · 0reported in complaints
Injuries · deaths0 · 0reported in complaints
2 recalls for this model year carries an NHTSA do not drive advisory. Check your VIN at nhtsa.gov/recalls.
Safety recalls
Air bags › Frontal › Driver side › Inflator module
NHTSA recall 19V015000 · Jan 14, 2019 · 157,549 vehicles · opened 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 bags › Frontal › Driver side › Inflator module
NHTSA recall 15V318000 · May 28, 2015 · 419,235 vehicles · opened 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 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, and 2003 X5 3.0i and 4.4i Sports Activity Vehicles. Please note that the 5-series and X5 vehicles are only included if they are equipped with the optional sports steering wheel. The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.
Risk: 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.
Fix: 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 recall 14V-348 in its entirety. Additionally, vehicles that have had their driver side frontal air bag replaced previously as part of a recall remedy need to have their air bag replaced under this recall as well. Note: On December 17, 2015 BMW removed the model year 2004 X5 3.0i and 4.4i Sports Activity vehicle from this recall. Those vehicles were mistakenly identified as including the air bags that are subject to this recall.
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
17mpg combined
City / highway
15 / 19 mpg
Fuel
Premium Gasoline
4.4 L · 8 cyl · Automatic (S5) · Rear-Wheel Drive · about $4,850/year to fuel
540i Sport Wagon
17mpg combined
City / highway
15 / 19 mpg
Fuel
Premium Gasoline
4.4 L · 8 cyl · Automatic (S5) · Rear-Wheel Drive · about $4,850/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
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
Fires
Injuries
Typical mileage*
Steering
2
0
0
0
—
Air bags
2
0
0
0
—
Power train
1
0
0
0
—
Electrical system
1
0
0
0
—
Engine
1
0
0
0
—
Tires
1
0
0
0
—
Service brakes, air Antilock › Abs warning light
1
0
0
0
—
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
Apr 9, 2025Air bags Air bag light coming on and off intermittently. Known recall affecting bmw 540 models around this vin number. BMW says this particular vin not affected, but if NHTSA adds vin to list, they will fix.
Mar 12, 2024Service brakes, air › Antilock › Abs warning light See attached document for complaint
Aug 10, 2017 · 175,000 milesAir bags 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 BMW DID NOT REPLACE THE PASSENGER SIDE AIRBAG WITH THIS RECALL. THIS NON-REPLACEMENT OF THE PASSENGER SIDE AIRBAG IS CONCERNING TO ME AS THE PASSENGER IS AT RISK FOR THE PROBLEMS THAT TAKATA AIRBAGS PRODUCE WHETHER DRIVER'S SIDE OR THE PASSENGER SIDE. IT IS ANATHEMA TO PROPER GOOD FAITH PERFORMANCE OF BMW AND TAKATA TO NOT REPLACE THE PASSENGER SIDE AIRBAG IN THE SAME MANNER AS THE DRIVER'S SIDE…
May 8, 2014 · 76,786 milesTires 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
Oct 3, 2014 · 130,000 milesSteering 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 ENGINE FAILURE WOULD OCCUR ALONG WITH LOSS OF POWER STEERING. *TR
Mar 1, 2012 · 31,068 milesElectrical system 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
Nov 12, 2012 · 92,000 milesPower train 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 OF MY OTHERS. WHEN I OPENED THE HOOD IT WAS OBVIOUS THAT THE SERPENTINE BELT WAS NOT ALIGNED CORRECTLY. THROUGH FURTHER OBSERVATION, IT WAS CLEAR THAT THE POWER STEERING PUMP MOUNTS WERE BROKEN. THE BROKEN MOUNTS CAUSED THE PUMP TO PUSH FORWARD AND NOT BE ALIGNED. THE BELT WAS BEING CHEWED UP IN THE PROCESS. WHILE REMOVING THE PUMP I NOTICED THAT THE BOLTS HOLDING IT IN PLACE WERE LOOSE. THESE LOOSE…
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.