NHTSA vehicle safety data
2002 BMW 540I Recalls & Complaints
The 2002 BMW 540I has 2 NHTSA recall campaigns and 12 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 2002 BMW 540I. Recall data is refreshed daily from NHTSA.
2002 BMW 540I owner complaints
Owners have filed 12 complaints with NHTSA about the 2002 BMW 540I, describing incidents dated October 17, 2009 to December 17, 2017.
Most-cited components
- Electrical System 5 complaints
- Steering 5 complaints
- Air Bags 2 complaints
- Engine 2 complaints
- Exterior Lighting 1 complaint
- Fuel/Propulsion System 1 complaint
Of the 12 complaints on file, 1 reports a crash (owner-reported, not verified by NHTSA).
Newest complaints
ODI #11064447 · Filed
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…
ODI #10934048 · Filed
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.
ODI #10887705 · Filed
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…
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
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.
Driver Frontal Air Bag Inflator May Rupture
NHTSA #15V318000 · Air Bags — Frontal — Driver Side — Inflator Module · NHTSA notice
Reported May 28, 2015 · BMW of North America, LLC
Potentially affected: 419,235 vehicles
Repair completion: 33.39% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)
Owners notified August 19, 2016 · Recall influenced by NHTSA's Office of Defects Investigation
Recall group: Takata airbag inflators
Defect description
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.
Safety consequence
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.
Manufacturer remedy
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.
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.
Other BMW 540I model years
Check your 2002 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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