NHTSA vehicle safety data

2001 BMW 540I Recalls & Complaints

The 2001 BMW 540I has 4 NHTSA recall campaigns and 15 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized BMW dealer.

NHTSA recall and complaint data for the 2001 BMW 540I. Recall data is refreshed daily from NHTSA.

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2001 BMW 540I owner complaints

Owners have filed 15 complaints with NHTSA about the 2001 BMW 540I, describing incidents dated March 23, 2001 to March 3, 2026.

Most-cited components

Air Bags 5 complaints
Electrical System 5 complaints
Power Train 3 complaints
Steering 2 complaints
Engine 1 complaint
Exterior Lighting 1 complaint

Of the 15 complaints on file, 1 reports a crash (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11721725 · Filed March 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.
ODI #11513083 · Filed March 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…
ODI #11299247 · Filed January 14, 2020
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…

Read all 15 complaints

Inflators In Sports Steering Wheels May Explode

NHTSA #19V015000 · Air Bags — Frontal — Driver Side — Inflator Module · NHTSA notice

Reported January 14, 2019 · BMW of North America, LLC

Potentially affected: 157,549 vehicles

Repair completion: 23.18% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Owners notified March 14, 2019 · Vehicles built September 1, 2000 – July 4, 2003 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Recall group: Takata airbag inflators

DO NOT DRIVE — this recall carries a "do not drive" advisory. Contact a BMW dealer immediately.

Defect description

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.

Safety consequence

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

Manufacturer 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.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

BMW/AIR BAG CONTROL MODULE

NHTSA #03V421000 · Air Bags — Frontal — Sensor/Control Module-Inactive · NHTSA notice

Reported October 24, 2003 · BAYERISCHE MOTOREN WERKE

Potentially affected: 23,000 vehicles

Owners notified November 10, 2003 · Vehicles built January 1, 2001 – August 31, 2001 (per NHTSA)

Defect description

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.

Safety consequence

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.

Manufacturer remedy

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

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

BMW/ENGINE AUXILIARY/COOLING FAN

NHTSA #02V138000 · Engine and Engine Cooling — Cooling System — Fan · NHTSA notice

Reported May 16, 2002 · BAYERISCHE MOTOREN WERKE

Potentially affected: 1,550 vehicles

Defect description

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.

Safety consequence

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.

Manufacturer 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.

Notes

ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

BMW/ENGINE AUXILIARY/COOLING FAN

NHTSA #01V206000 · Engine and Engine Cooling — Cooling System — Fan · NHTSA notice

Reported June 21, 2001 · BAYERISCHE MOTOREN WERKE

Potentially affected: 76,469 vehicles

Owners notified September 28, 2001 · Vehicles built January 16, 2001 – June 18, 2001 (per NHTSA)

Defect description

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.

Safety consequence

Manufacturer remedy

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.

Notes

ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

try.vin has no NCAP crash-test rating on file for the 2001 BMW 540I. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

15 owner complaints have been filed with NHTSA for the 2001 BMW 540I.

Air Bags

ODI #11721725

Incident: March 3, 2026 · Filed: March 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.

Electrical System; Air Bags

ODI #11513083

Incident: November 1, 2022 · Filed: March 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.

Engine

ODI #11299247

Crash

Incident: April 12, 2014 · Filed: January 14, 2020

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

Air Bags

ODI #10990793

Incident: March 10, 2017 · 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.

Air Bags

ODI #10882005

Incident: May 1, 2016 · Filed: July 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.

Steering

ODI #10714790

Incident: March 31, 2015 · 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

Steering

ODI #10564400

Incident: January 15, 2014 · Filed: February 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

Power Train

ODI #10382233

Incident: February 6, 2011 · Filed: February 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.

Electrical System; Exterior Lighting

ODI #10331632

Incident: May 16, 2010 · Filed: May 21, 2010

3RD (HIGH) TAIL LIGHT BULB AND SOCKET OVERHEATS AND MELTS, RENDERING THE LIGHT INOPERABLE AND POSSIBLY CAUSING A FIRE HAZARD. *TR

Electrical System

ODI #10262484

Incident: March 10, 2009 · Filed: March 19, 2009

ELECTRICAL SHORT IN FAULTY THERMOSTAT CAUSED ALL WIRING TO MELT AND LEAD TO A DAMAGE OF MAIN COMPUTER. *TR

Other BMW 540I model years

Check your 2001 BMW 540I VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your BMW 540I at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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