BMW 540 Recalls
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NHTSA safety recall results (34)
Recall information provided by National Highway Traffic Safety Administration
Electrical system: Starter assembly
2026-01-29
26V056000
BMW of North America, LLC (BMW) is recalling certain 2021-2023 Toyota Supra, 2022-2023 2 Series Coupe, 2021-2024 5 Series (xDrive), 2021-2022 Z4, 2022-2024 4 Series (Gran Coupe), 2021-2024 4 Series (Convertible and xDrive Convertible), 2021-2023 4 Series (Coupe), 2021-2024 3 Series, 2021-2023 X4, 2021-2024 X3 vehicles. Please see the recall report for a complete list of all models. The engine starter may overheat and catch fire due to wear on an internal component.
Fire increases the risk of injury.
Dealers will replace the engine starter, free of charge. A letter informing owners of the safety risk was mailed on March 27, 2026. Owners will receive another letter once the remedy is available. Owners may contact BMW customer service at 1-800-525-7417 or Toyota's customer service at 1-800-331-4331. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 24, 2026.
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Electrical system: Starter assembly: Relay
2025-09-22
25V636000
BMW of North America, LLC (BMW) is recalling certain 2019-2021 BMW 330i, 2019-2022 BMW Z4, 2020-2022 BMW 530i, X3, X4, Toyota Supra, 2021-2022 BMW 430i, 430i Convertible, and 2022 BMW 230i vehicles. The engine starter relay may corrode, causing the relay to overheat and short circuit.
A short circuit in the starter relay may increase the risk of a fire.
Owners are advised to park their vehicles outside and away from structures until the remedy is complete. Dealers will replace the engine starter, free of charge. Owner notification letters were mailed February 6, 2026. Owners may contact BMW customer service at 1-800-525-7417. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning November 14, 2025.
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Electrical system: Alternator/generator/regulator
2025-03-31
25V202000
BMW of North America, LLC (BMW) is recalling certain 2025 330i, 330i xDrive, 530i, 530i xDrive, 4 Series Coupe (430i, 430i xDrive), 4 Series Convertible (430i, 430i xDrive), 4 Series Gran Coupe (430i, 430i xDrive) and X3 30 xDrive vehicles. The electrical connection between the starter-generator and battery may come loose.
A loose starter-generator connection can result in an engine stall, increasing the risk of a crash. In addition, the wiring may overheat, increasing the risk of a fire.
Dealers will inspect and replace the starter-generator and positive battery cable as necessary, free of charge. Interim owner letters notifying owners of the safety risk were mailed May 28, 2025. Second letters will be sent once the remedy is available. Owners may contact BMW customer service at 1-800-525-7417.
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Air bags: air bag/restraint control module
2024-11-18
24V870000
BMW of North America, LLC (BMW) is recalling certain 2025 530i and 540i xDrive vehicles. The air bag control unit may have been manufactured incorrectly, which can result in the air bags not deploying as intended.
Air bags that do not deploy as intended during a crash increases the risk of injury.
Dealers will replace the air bag control unit, free of charge. The vehicles have not been sold from dealer inventory and therefore no owner letters will be mailed. Owners may contact BMW customer service at 1-800-525-7417.
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Electronic stability control (esc)
2024-10-01
24V739000
BMW of North America, LLC. (BMW) is recalling certain 2023-2024 X1, X5, X6, X7, XM, 530i, i5, 740i, 760i, i7, and 750e vehicles. Please see the recall report for a complete list of models and model years. The integrated brake (IB) system may malfunction and result in a loss of power brake assist or cause the Antilock Brake (ABS) and Dynamic Stability Control (DSC) systems to not function properly.
A loss of power brake assist can extend the distance required to stop the vehicle. Additionally, malfunctioning ABS and/or DSC systems can cause a loss of vehicle control. Either of these scenarios can increase the risk of a crash.
Dealers will replace the integrated brake module, free of charge. Interim owner notification letters notifying owners of the safety risk are expected to be mailed November 22, 2024. Second letters will be mailed once the parts are available. Owners may contact BMW customer service at 1-800-525-7417. Vehicles in this recall were previously repaired under recall number 24V-104 and will need to have the new remedy completed.
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Steering: Linkages: Knuckle: Spindle: Arm
2024-09-24
24V714000
BMW of North America (BMW) is recalling certain 2024-2025 530i xDrive, 540i xDrive, 2024-2025 i5 eDrive40, i5 M60 xDrive, 2025 i5 xDrive40, 2024 740i xDrive, 760i xDrive, 750e xDrive, i7 eDrive50, i7 xDrive60, and i7 M70 xDrive vehicles. The steering spindle may break requiring a greater steering effort to control the vehicle.
A sudden increase in required steering effort increases the risk of a crash.
Dealers will replace the steering spindle's double universal joint, free of charge. Owner notification letters were mailed November 22, 2024. Owners may contact BMW Customer Service at 1-800-525-7417.
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Service brakes, hydraulic: Antilock/traction control/electronic limited slip: Control unit/module
2024-09-17
24V697000
BMW of North America (BMW) is recalling certain 2023-2024 X1, 2024-2025 X5, 2025 X6, 2023-2025 X7, 740i, 760i, 2024 XM, 530i, 540i, i7, 750e, X2, 2024-2025 i5, 2024 Rolls Royce Spectre, 2025 MINI Countryman S ALL4, JCW Countryman ALL4, and 2025 MINI Hardtop 2 Door (Cooper, Cooper S) vehicles. Please refer to the recall report for the complete list of models. The welds in the servomotor of the integrated brake control module may break, causing a loss of power brake assist and rear brake function. In addition, the Antilock Brake System (ABS) and Dynamic Stability Control (DSC) system may not function.
A loss of brake power assist or rear brake function can result in extended stopping distance. A loss of ABS or DSC can cause a loss of vehicle handling and control. Either of these scenarios can increase the risk of a crash.
Dealers will replace the integrated brake system, free of charge. Owner notification letters were mailed November 13, 2024. Owners can contact BMW Customer Service at 1-800-525-7417.
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Engine and engine cooling: Exhaust system: Emission control: Gas recirculation valve (egr valve)
2024-08-07
24V588000
BMW of North America, LLC. (BMW) is recalling certain 540d xDrive vehicles that were previously repaired under recall number 22V-614. The exhaust gas recirculation (EGR) cooler may leak internally, causing coolant to mix with diesel engine soot, which could result in smoldering particles and a melting intake manifold.
An EGR valve with smoldering particles and a melting intake manifold increases the risk of an engine fire.
Dealers will inspect and replace the EGR module and the intake manifold as necessary, free of charge. Owner notification letters were mailed October 7, 2024. Owners may contact BMW customer service at 1-800-525-7417.
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Electronic stability control (esc)
2024-02-11
24V104000
BMW of North America, LLC. (BMW) is recalling certain 2023-2025 BMW, MINI, and Rolls-Royce vehicles. Please see the recall report for a complete list of models and model years. The integrated brake (IB) system may malfunction and result in a loss of power brake assist or cause the Antilock Brake (ABS) and Dynamic Stability Control (DSC) systems to not function properly.
A loss of power brake assist can extend the distance required to stop the vehicle. Additionally, malfunctioning ABS and/or DSC systems can cause a loss of vehicle control. Either of these scenarios can increase the risk of a crash.
Dealers will replace the integrated brake system, free of charge. Owner notification letters were mailed between June and December 2024. Owners may contact BMW customer service at 1-800-525-7417 or Rolls Royce customer service at 1-877-877-3735.
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Electrical system: Adas: Driver monitoring: Camera/sensor
2023-10-17
23V700000
BMW of North America, LLC (BMW) is recalling certain 2023-2024 740i, 740i xDrive, 760i xDrive, i7 eDrive50, i7 xDrive60, i7 M70, 2024 750e xDrive, 530i, 530i xDrive, i5 eDrive40, and i5 M60 vehicles. The ground connection to the steering wheel may not have been attached correctly, resulting in an inoperative hands-on detection system.
An inoperative hands-on detection system may fail to detect when the driver's hands are not on the steering wheel and therefore not engage the emergency stopping assistant system, increasing the risk of a crash.
Dealers will inspect and reattach the ground connection as necessary, free of charge. Owner notification letters were mailed December 8, 2023. Owners may contact BMW customer service at 1-800-525-7417.