BMW 540i recalls, complaints and VIN decoding

Air Bags › Frontal › Driver Side › Inflator Module

Model years 2000–2003

NHTSA “Do Not Drive” advisory: affected vehicles should not be driven until the recall repair is done.

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.

Consequence:

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

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.

Filed by BMW of North America, LLC

Engine and Engine Cooling › Engine

Model year 2018

BMW of North America, LLC (BMW) is recalling certain 2018 BMW 540d xDrive vehicles. The crankshaft sensor may be equipped with incorrect firmware, preventing the sensor from properly processing input from the crankshaft reluctor ring, possibly resulting in a vehicle stall. On September 12, 2018, BMW expanded the recall to a total of 5,309 vehicles including certain 2018-2019 BMW 540d xDrive, 230i M240i, M240i xDrive, X2 sDrive28i, X2 xDrive28i, X1 sDrive28i, X1 xDrive28i, 330i, 330i xDrive, 340i, 340i xDrive, 330i xDrive Gran Turismo, 530i, 530i xDrive, 540i, 540i xDrive, 530e, 530e xDrive, 640i xDrive Gran Turismo, 330e, 2019 430i Gran Coupe, 430i xDrive Gran Coupe, 440i Gran Coupe, 440i xDrive Gran Coupe, 430i, 430i xDrive, 440i, 440i xDrive, 740i, 740i xDrive, MINI Cooper, Cooper S, JCW, MINI Countryman (Cooper, Cooper All4, Cooper S, Cooper S All4, JCW All4), and MINI Clubman (Cooper, Cooper S, Cooper All4, Cooper S All4, JCW All4) vehicles.

Consequence:

A vehicle stall can increase the risk of a crash.

Remedy:

BMW will notify owners, and dealers will replace the crankshaft sensor, free of charge. The recall began September 6, 2018. Owners may contact BMW customer service at 1-800-525-7417.

Filed by BMW of North America, LLC

Air Bags › Frontal › Driver Side › Inflator Module

Model years 2002–2003

NHTSA “Do Not Drive” advisory: affected vehicles should not be driven until the recall repair is done.

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.

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.

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.

Filed by BMW of North America, LLC

Air Bags › Frontal › Sensor/Control Module-Inactive

Model year 2001

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.

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.

Remedy:

Dealers will replace the air bag control module. Owner notification began NOVEMBER10, 2003. Owners should contact BMW at 1-800-831-1117.

Filed by BMW of North America, LLC

Engine and Engine Cooling › Cooling System › Fan

Model year 2001

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.

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.

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.

Filed by BMW of North America, LLC

Engine and Engine Cooling › Cooling System › Fan

Model year 2001

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.

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.

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.

Filed by BMW of North America, LLC

Exterior Lighting › Brake Lights › Switch

Model year 2000

Vehicle description: passenger vehicles. The brake lamps in these vehicles are controlled by a switch activated by the movement of the brake pedal. This switch could fail internally, causing it to remain either in the "brake lamps off" position or in the "brake lamps on" position.

Consequence:

If this happens, the brake lamps either will not operate or will be continuously illuminated, regardless of brake pedal position.

Remedy:

Dealers will inspect and, if necessary, replace the existing brake lamp switch with an improved switch.

Filed by BMW of North America, LLC

Electrical System › 12V/24V/48V Battery › Cables

Model year 1999

Vehicle description: passenger vehicles. The thickness of the main positive electrical cable (generator to starter) insulation is less than specified, making it susceptible to being abraded or cut by the clip that secures the cable to the generator.

Consequence:

The cable insulation can be worn away, exposing the wire. The wire could contact the clip or a short circuit could occur.

Remedy:

Dealers will apply a thickness of insulating tape to the cable in the area of the clip, and install a revised clip.

Filed by BMW of North America, LLC

Engine and Engine Cooling › Cooling System

Model year 1995

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.

Consequence:

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.

Remedy:

Dealers will install a new design radiator cap to control pressure and provide greater coolant overflow in the event of overheating.

Filed by BMW of North America, LLC

Power Train › Driveline › Differential Unit

Model year 1998

Vehicle description: passenger vehicles. The differential pinion shaft within the differential case assembly was produced without the appropriate surface hardening. This can result in the shaft experiencing premature wear.

Consequence:

This condition will cause a noise from the differential and, ultimately, failure of the shaft and loss of drive.

Remedy:

Dealers will replace the entire differential assembly.

Filed by BMW of North America, LLC

Vehicle Speed Control

Model year 1995

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.

Consequence:

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.

Remedy:

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.

Filed by BMW of North America, LLC