FaultScore report
Owners have filed 28 complaints about the 1998 BMW 540I with NHTSA between 1999 and 2021. The largest single group is the engine & cooling. Across this model's run it ranks 10 of 13 worst.
FaultScore 37/100
Higher is worse. Measured against the other years of the BMW 540I.
How this is worked out28
Complaints
0
Crashes reported
0
Fires reported
1
Injuries reported
52,936 mi
Median mileage at failure
Half of reported failures happened before this
6%
Failed under 36,000 miles
Inside a typical bumper-to-bumper warranty
The letter says how bad. This says what kind — whether this year drew an unusual number of complaints, unusually dangerous ones, or failures that arrived unusually early.
Click any bar to open that year's report.
Every complaint is filed against a part. Follow any row for the complaints about that part alone.
Median failure at 38,288 miles
Median failure at 36,000 miles
Median failure at 51,488 miles
Median failure at 33,224 miles
NHTSA files every complaint against a named sub-assembly, not just a system. This is the difference between knowing it was "the engine" and knowing which part of it — the list to hand a mechanic.
Odometer readings owners gave when they filed. About half of all complaints include one.
A spike years after the car went on sale usually means a part wearing out on schedule across the whole fleet — the kind of pattern no single owner can see from inside their own car.
Reports where the owner recorded a crash, a fire, an injury or a death.
AIR BAGS
While stopped (engine still running) at a gas station, the driver side airbag and driver side side curtain airbag both went off. The battery disconnect feature was also triggered. Very lucky I wasn't driving when this occurred.
NHTSA complaint #11418089 — an unverified report by a vehicle owner.
In the owners' own words, exactly as filed with NHTSA.
AIR BAGS
While stopped (engine still running) at a gas station, the driver side airbag and driver side side curtain airbag both went off. The battery disconnect feature was also triggered. Very lucky I wasn't driving when this occurred.
NHTSA complaint #11418089 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
WHITE STEAM WAS COMING FROM UNDER THE HOOD ONTO THE FRONT WINDSHIELD. THE STEAM WAS FOGGING THE WINDSHIELD, AND CAUSING POOR VISIBILITY WHILE DRIVING 50-55 MPH. CONSUMER WAS ABLE TO GET THE VEHICLE TO A REPAIR SHOP. DEALER INFORMED THE CONSUMER THAT THE UPPER NECK CONNECTOR OF THE RADIATOR HOSE BROKE.
NHTSA complaint #10109039 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
2ND CATASTROPHIC RADIATOR FAILURE. NOT A LEAK, THE NECK BREAKS OFF CAUSING IMMEDIATE LOSS OF COOLING. 1ST RADIATOR AT 45K, 2ND AT 92K. BASED ON OTHER'S EXPERIENCES, THIS IS VERY COMMON FOR THIS MODEL (AND EVEN LONGER LIFE THAN MANY). CAUSES LOSS OF VISION DUE TO AMOUNT OF STEAM RELEASED. LESS EXPERIENCED DRIVER MAY HAVE DIFFICULTY CONTROLLING VEHICLE TO GET TO SIDE OF ROAD QUICKLY TO SHUT DOWN. NO WAY TO PREDICT THE FAILURE. SAME ISSUE WITH EXPANSION TANK. BOTH FAILURES ARE ON PLASTIC PARTS.
NHTSA complaint #10105896 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
I WAS DRIVING DOWN A BUSY STREET ONE EVENING AND AS I CAME TO A LIGHT, SMOKE STARTED COMING OUT OF MY HOOD. FORTUNATELY IT WAS IN THE EVENING AND TRAFFIC WAS LIGHTER THAN USUAL. I PULLED INTO A PARKING LOT OFF THE SIDE OF THE ROAD. HAVING KNOWN OTHERS THAT THIS HAS HAPPENED TO, I FIRST CHECKED THE RADIATOR AND SURE ENOUGH, THERE WAS A LARGE CRACK DOWN THE SIDE OF THE HOUSING. I HAD THE CAR TOWED HOME AND PURCHASED A NEW RADIATOR FROM BMW OF SEATTLE THE FOLLOWING MORNING. THE NEW RADIATOR WAS ABOUT $200, A FEW HOURS OF MY OWN LABOR AND A FEW MORE HOURS DETAILING THE ENGINE PAY AND HEADLIGHTS WHICH HAD RADIATOR FLUID ALL OVER THEM. ALSO FROM THE EXPERIENCE OF OTHERS WHO OWN E39 BMW 540S, I FULLY EXPECT THIS TO HAPPEN AGAIN IN THE NEXT 50K MILES. I ALSO EXPECT THE EXPANSION TANK TO GO WITHIN THE NEXT FEW MONTHS.
NHTSA complaint #10079183 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
PLASTIC NECK OF RADIATOR ON MY '98 BMW 540IA BROKE COMPLETELY AND SUDDENLY ON HIGHWAY. WHITE SMOKE CAME OUT UNDER THE HOOD. SAW TEMP GAUGE CLIMB UP RAPIDLY. PULLED OVER IMMEDIATELY. TOWED TO DEALERSHIP FOR REPAIR. NO ONE WAS HURT LUCKILY.
NHTSA complaint #10062384 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
MULTIPLE COOLANT DEFECTS ON THE 1998 540. THE CAR HAS NOW HAD 3 RADIATORS, 3 THERMASTATS, WATER TUBE SEALS REPLACED TWICE, AND A WATER PUMP. THE COSTS HAVE BEEN OVER $3,500. THESE LEAKS ARE NOT JUST EXPENSIVE, THEY POSE A REAL DANGER TO CAUSING PERSONAL INJURY AND DAMAGE. THE FAILURE RATE IS KNOWN TO BE VERY HIGH. HTTP://WWW.VOTATIONS.COM/ASP/SURVEYRESULTS.ASP?POLLID=66461 .
NHTSA complaint #10045871 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM
MULTIPLE COOLANT DEFECTS ON THE 1998 540. THE CAR HAS NOW HAD 3 RADIATORS, 3 THERMASTATS, WATER TUBE SEALS REPLACED TWICE, AND A WATER PUMP. THE COSTS HAVE BEEN OVER $3,500. THESE LEAKS ARE NOT JUST EXPENSIVE, THEY POSE A REAL DANGER TO CAUSING PERSONAL INJURY AND DAMAGE. THE FAILURE RATE IS KNOWN TO BE VERY HIGH. HTTP://WWW.VOTATIONS.COM/ASP/SURVEYRESULTS.ASP?POLLID=66461 .
NHTSA complaint #10045871 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING
MULTIPLE COOLANT DEFECTS ON THE 1998 540. THE CAR HAS NOW HAD 3 RADIATORS, 3 THERMASTATS, WATER TUBE SEALS REPLACED TWICE, AND A WATER PUMP. THE COSTS HAVE BEEN OVER $3,500. THESE LEAKS ARE NOT JUST EXPENSIVE, THEY POSE A REAL DANGER TO CAUSING PERSONAL INJURY AND DAMAGE. THE FAILURE RATE IS KNOWN TO BE VERY HIGH. HTTP://WWW.VOTATIONS.COM/ASP/SURVEYRESULTS.ASP?POLLID=66461 .
NHTSA complaint #10045871 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
ENGINE COOLING RADIATOR HOSE FITTING BROKE OFF. LOST ALL COOLANT ON HIGHWAY. DEALER REPLACED RADIATOR UNDER WARRANTY AND STATED IT IS COMMON FAILURE ON 540I BMW DUE TO PLASTIC PARTS NOT STONG ENOUGH TO RESIST TEMPERATURE. WELL DOCUMENTED ON PRIVATE WEB SITES.
NHTSA complaint #10039559 — an unverified report by a vehicle owner.
SUSPENSION:FRONT:WHEEL BEARING
DRIVER-SIDE FRONT WHEEL BEARING MAKES NOISE WHEN WHEEL SPINS FREELY. THIS WAS REPORTED SEVERAL TIMES TO DEALER IN PAST. DEALER REPLACED PASSENGER-SIDE FRONT BEARING ! DRIVER-SIDE BERAING STILL NOISY. WAITING FOR COMPLETE FAILURE TO PROVE DEALER WRONG. FRONT WHEEL BEARINGS ARE MARGINALLY DESIGNED FOR BMW 540I, THIS IS WELL DOCUMENTED ON VARIOUS WEB SITES OF BMW OWNERS. BEARINGS LAST 75,000 MILES!
NHTSA complaint #10039560 — an unverified report by a vehicle owner.
VISIBILITY:SUN/MOON ROOF ASSEMBLY
SUNROOF FAILED AND MOVING UP AND DOWN ON BUMPS. DEALER REPLACED SLIDING MECHANISM. STILL RATTLES AND DOESN'T FUNCTION PROPERLY. DEALER DECLINES TO FIX UNDER WARRANTY. DOOR SEALS SQUEEK. DEALER LUBRICATED THEM. SILL SQUEEK AFTER A FEW DAYS. ALL CUP HOLDERS BROKEN. DEALER REPLACED THEM.
NHTSA complaint #10039553 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
ENGINE DOESN'T REV UP ABOVE 4500 RPMS AND MISFIRES. ENGINE CHECK LIGHT ON. DEALER REPLACED ONE OF TWO CATALYTIC CONVERTERS UNDER WARRANTY. ACCORDING TO PRIVATE CLUBS ABD WEB SITES OF BMW OWNERS, 540I CAT CONVERTERS LAST 50KMILES ONLY.
NHTSA complaint #10039557 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING
ENGINE IDLES ROUGH AND STALLS WHILE DRIVING. DEALER REPLACED FAULTY CAMSHAFT SENSOR UNDER WARRANTY.
NHTSA complaint #10039555 — an unverified report by a vehicle owner.
PARKING BRAKE:CONVENTIONAL:MECHANICAL
BOTH SUN VISORS CRACKED ALONG WELD SEAM. REPLACED BY DEALER. TEMPERATURE CONTROL SWITCHE COVERS BROKEN. REPLACED BY DEALER. NOTICED THE DESIGN OF NEW COVERS IS DIFFERENT AND ELIMINATES RISK OF FAILURE. PARKING BRAKE DOESN'T HOLD. DEALER ADMITS BAD DESIN AND TRIED DIFFERENT SHOES WITHOUT SUCCESS IN PAST. DELER COULDN'T FIX, RESULTING IN SAFETY HAZARD.
NHTSA complaint #10039551 — an unverified report by a vehicle owner.
LATCHES/LOCKS/LINKAGES:TRUNK LID:LOCK
TRUNK LATCH FAILED. TRUNK STAYS OPEN. DEALER REPLECED ACTUATOR.
NHTSA complaint #10039554 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS
TECHNICIANS TOLD ME THIS WAS A COMMON PROBLEM SINCE MANUFACTURER SWITCH TO PLASTIC RADIATORS. THE UPPER HOSE FITTING BROKE OFF THE RADIATOR. *PH *JB **DIMSII IVOQ ENTRY POSTED AFTER 12/12/02 CUT OVER TO ARTEMIS**762585
NHTSA complaint #10006971 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
RADIATOR NECK SHEARED OFF WITHOUT WARNING WHILE MY WIFE WAS DRIVING ON FREEWAY. CAUSED IMMEDIATE LOSS OF COOLANT AND EMERGENCY STOP. CAR HAD TO BE TOWED.
NHTSA complaint #10002685 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM
SECOND RADIATOR FAILURE AT 56,254 MILES IN 10/19/2001 CAUSED POOR VISIBILITY. DT
NHTSA complaint #769403 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:COOLING SYSTEM
RADIATOR FAILED WITHOUT WARNING. STEAM OBSCURRED VISION. DT
NHTSA complaint #769061 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
ENGINE ENTERMITTENTLY STALLED WHEN THE CLUTCH IS DEPRESSED WHILE DRIVING AND IS RELATED TO AN INTERMITTENT LOW RMP ENGINE MALFUNCTION. YH
NHTSA complaint #551154 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR
HANDLES (2 INCIDENTS) BROKE OFF IN THE NORMAL ACTION OF OPENING THE DOOR. NOTHING EXTRAORDINARY ABOUT THE SITUATION. SEEMS A VERY CHEAP COMPONENT ON A VERY SAFETY CONSCIOUS VEHICLE.
NHTSA complaint #716738 — an unverified report by a vehicle owner.
STEERING: STEERING WHEEL/HANDLE BAR
STEERING WHEEL COLUMN ADJUSTMENT FAILS. MAKING ADJUSTMENT OF STEERING WHEEL AND VEHICLE SAFE TO OPERATE. STEERING WHEEL AND FRONT SEAT ADJUMENTS FAIL TO OPERATE FORCING OPERATOR TO DRIVE WITHOUT ABILITY TO ADJUST STEERING WHEEL OR SEAT. HAS FORCED ME TO ABANDON VEHICLE.
NHTSA complaint #712943 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
CATALYTIC CONVERTER SYSTEM FAILED.
NHTSA complaint #607204 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
DRASTIC ENGINE POWER LOSS 4-5000RPM. THIS PROBLEM IS WELL DOCUMENTED ON HTTP://WWW.BIMMER.ORG/5SERIES/MESSAGES/. DEALER HAS NO KNOWLEDGE.
NHTSA complaint #710311 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR
INTERIOR DOOR LATCH/HANDLE BROKEN AND FELL OFF OF DOOR, MUST BE OPENED FROM THE EXTERIOR. MJS
NHTSA complaint #605962 — an unverified report by a vehicle owner.