BMW 540 Recalls

There are currently 15 recalls for your vehicle. Change vehicle

NHTSA Vehicle Safety Recalls

  • Recall Number
    99V004000
    Recall Date
    01/04/1999
    Component
    ELECTRICAL SYSTEM:BATTERY:CABLES
    Summary

    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.

    What Owners Should Do

    DEALERS WILL APPLY A THICKNESS OF INSULATING TAPE TO THE CABLE IN THE AREA OF THE CLIP, AND INSTALL A REVISED CLIP.

  • Recall Number
    00V048000
    Recall Date
    02/17/2000
    Component
    EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH
    Summary

    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.

    What Owners Should Do

    DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE EXISTING BRAKE LAMP SWITCH WITH AN IMPROVED SWITCH.

  • Recall Number
    96V111000
    Recall Date
    07/01/1996
    Component
    SERVICE BRAKES, HYDRAULIC:SWITCHES:BRAKE LIGHT
    Summary

    THE BRAKE LIGHT SWITCH CAN FAIL ALLOWING THE SWITCH TO REMAIN IN THE "BRAKE LIGHTS OFF" POSITION OR IN THE "BRAKE LIGHTS ON" POSITION.

    Consequence

    IF THIS HAPPENS, THE BRAKE LIGHTS EITHER WILL NOT OPERATE OR WILL BE CONTINUOUSLY ON, REGARDLESS OF BRAKE PEDAL POSITION. FOLLOWING DRIVERS WOULD NOT BE ABLE TO DETERMINE WHETHER THE VEHICLE IS STOPPING, INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

    What Owners Should Do

    DEALERS WILL REPLACE THE EXISTING BRAKE LIGHT SWITCH WITH A NEWLY DESIGNED SWITCH.

  • Recall Number
    03V421000
    Recall Date
    10/24/2003
    Component
    AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE
    Summary

    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.

    What Owners Should Do

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

  • Recall Number
    17V047000
    Recall Date
    01/20/2017
    Component
    AIR BAGS:FRONTAL:DRIVER SIDE INFLATOR MODULE
    Summary

    BMW of North America, LLC (BMW) is recalling certain 2000-2002 BMW 320i, 323i, 325i, 325xi, 330i, 330xi, 323Ci, 325Ci, 330Ci, M3, 323iT, 325iT and 325xiT vehicles, 2001-2002 525i, 530i, 540i, M5, 525iT and 540iT vehicles, and 2001-2003 X5 3.0i, X5 4.4i, and X5 4.6is vehicles. These vehicles may have had a driver-side air bag module installed as replacement equipment such as after a vehicle crash necessitating replacement of the original air bag, or as a remedy part for a prior recall. These replacement modules contain an air bag inflator that may rupture due to propellant degradation occurring after long-term exposure to lower absolute humidity, temperature and temperature cycling.

    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.

    What Owners Should Do

    BMW will notify owners, and dealers will inspect the driver side air bag module, replacing it as necessary, free of charge. The recall began March 15, 2017. Owners may contact BMW customer service at 1-800-525-7417.

  • Recall Number
    18V465000
    Recall Date
    07/11/2018
    Component
    ENGINE AND ENGINE COOLING:ENGINE
    Summary

    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.

    What Owners Should Do

    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.

  • Recall Number
    01V206000
    Recall Date
    06/21/2001
    Component
    ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN
    Summary

    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.

    What Owners Should Do

    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 Number
    99V005000
    Recall Date
    01/04/1999
    Component
    POWER TRAIN:AUTOMATIC TRANSMISSION
    Summary

    VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH A 5HP24 AUTOMATIC TRANSMISSION. PREMATURE WEAR OF THE RING GEAR CAN OCCUR, LEADING TO THE LOSS OF 1ST, 2ND, 3RD, AND REVERSE GEARS.

    Consequence

    IF THIS PROBLEM OCCURS, THE CAR MAY NO LONGER OPERATE IN REVERSE, 1ST, 2ND, OR 3RD GEARS.

    What Owners Should Do

    DEALERS WILL REPLACE THE AUTOMATIC TRANSMISSION.

  • Recall Number
    15V318000
    Recall Date
    05/28/2015
    Component
    AIR BAGS:FRONTAL:DRIVER SIDE INFLATOR MODULE
    Summary

    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.

    What Owners Should Do

    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 Number
    98V178000
    Recall Date
    08/04/1998
    Component
    ENGINE AND ENGINE COOLING:COOLING SYSTEM
    Summary

    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.

    What Owners Should Do

    DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERFLOW IN THE EVENT OF OVERHEATING.

  • Recall Number
    02V138000
    Recall Date
    05/16/2002
    Component
    ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN
    Summary

    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.

    What Owners Should Do

    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.

  • Recall Number
    01V352000
    Recall Date
    11/26/2001
    Component
    TIRES:SIDEWALL
    Summary

    VEHICLE DESCRIPTION: DURING THE TIRE MOUNTING PROCESS ON CERTAIN PASSENGER VEHICLES BUILT WITH STANDARD (NON-SPORT) SUSPENSION AND EQUIPPED WITH CONTINENTAL CONTITOURINGCONTACT CH95 ECOPLUS TIRES, SIZE 225/65R16 95H, HAVING DOT CODES 4001, 4101, OR 4201, THE OUTER SIDEWALL SURFACE OF THE TIRES MAY HAVE BEEN CUT BY A SHARP EDGE. OPERATION OF THE VEHICLE OVER A LONG PERIOD OF TIME COULD LEAD TO A REDUCTION OF INFLATION PRESSURE.

    Consequence

    CONTINUED DRIVING WITH LOW INFLATION PRESSURE IN THE TIRE COULD ULTIMATELY RESULT IN DAMAGE TO THE TIRE, AFFECT VEHICLE HANDLING AND CONTROL, AND COULD IN SOME CASES RESULT IN A VEHICLE CRASH.

    What Owners Should Do

    DEALERS WILL INSPECT ALL FIVE TIRES FOR A POSSIBLE CUT IN THE SIDEWALL, AND IF A CUT IS FOUND, THE TIRE WILL BE REPLACED. OWNER NOTIFICATION BEGAN DECEMBER 10, 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 Number
    94V017000
    Recall Date
    01/27/1994
    Component
    VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
    Summary

    THE REMOTE ACTIVATION DEVICE CAN CLOSE WINDOWS AND SUNROOF FROM A DISTANCE GREATER THAN THE MAXIMUM (6 METERS) PERMITTED BY FMVSS NO.118, "POWER OPERATED WINDOW SYSTEMS."

    Consequence

    CONSEQUENCE OF NON-COMPLIANCE: THIS COULD ALLOW WINDOWS OR SUNROOFS TO BE CLOSED ON AN ARM OR NECK OF AN INDIVIDUAL WHEN THE REMOTE DEVICE OPERATOR IS NOT WITHIN THE IMMEDIATE VICINITY.

    What Owners Should Do

    REPLACE THE INSIDE REAR VIEW MIRROR WHICH HAS THE ACTIVATION RECEIVER WITH ONE WHOSE RECEIVER WILL CONTROL THE DOOR LOCKING AND THEFT ALARM, BUT WILL NOT PERMIT REMOTE OPERATION OF THE WINDOWS AND SUNROOF.

  • Recall Number
    97V131000
    Recall Date
    08/19/1997
    Component
    VEHICLE SPEED CONTROL
    Summary

    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.

    What Owners Should Do

    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.

  • Recall Number
    98V142000
    Recall Date
    06/22/1998
    Component
    POWER TRAIN:DRIVELINE:DIFFERENTIAL UNIT
    Summary

    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.

    What Owners Should Do

    DEALERS WILL REPLACE THE ENTIRE DIFFERENTIAL ASSEMBLY.

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