Owners have filed 17 complaints
about the 2002 BMW 540I with NHTSA between 2002 and 2018.
The largest single group is the electrical system.
Across this model's run it ranks 12 of 13 worst.
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.
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 35
Against the median year of the BMW 540I. 50 means typical for this
model; 100 means roughly double.
Severity — 30
5.9% of these complaints
involved a crash, fire, injury or death, against a national rate of
9.7%.
Early failure — 0
0% of failures with a mileage on record happened under
36,000 miles, against a national rate of
29%.
Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade:
A
B
C
D
F
ungraded
What breaks on a 2002 BMW 540I
Every complaint is filed against a part. Follow any row for the complaints about that part alone.
Steering
529.4%
Median failure at 96,000 miles
Electrical System
529.4%
Median failure at 105,000 miles
Airbags
211.8%
1 crashes, 0 fires · median 40,000 mi
Engine & Cooling
211.8%
Median failure at 114,099 miles
Other & Unspecified
15.9%
Fuel & Propulsion
15.9%
Lights
15.9%
Median failure at 100,000 miles
When it fails
Odometer readings owners gave when they filed. About half of all
complaints include one.
25,000 – 49,999 miles
214.3%
75,000 – 99,999 miles
535.7%
100,000 – 149,999 miles
321.4%
150,000+ miles
428.6%
When owners complained
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.
Feb 2002peak 3Jan 2018
Complaints that involved harm
Reports where the owner recorded a crash, a fire, an injury or a death.
at 40,000 milesGlendale Heights, ILCrash
AIR BAGS
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 FAILURE. THE FAILURE MILEAGE WAS 40,000. *BF
NHTSA complaint #11064447 — an unverified report by a vehicle owner.
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
at 40,000 milesGlendale Heights, ILCrash
AIR BAGS
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 FAILURE. THE FAILURE MILEAGE WAS 40,000. *BF
NHTSA complaint #11064447 — an unverified report by a vehicle owner.
at 166,000 milesColumbia, SC
ELECTRICAL SYSTEM
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.
NHTSA complaint #10934048 — an unverified report by a vehicle owner.
Cary, NC
AIR BAGS
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 MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT. ...UPDATED 09/14/16 *BF UPDATED 10/18/16.
NHTSA complaint #10887705 — an unverified report by a vehicle owner.
at 100,000 milesAuburn, CA
EXTERIOR LIGHTING
THE PLASTIC COVERS ON THE HEADLIGHTS OF MY BMW BECAME CRAZED/FROSTED. EVERY BMW OF THIS VINTAGE HAS THE SAME PROBLEM. I SHOWED THIS TO OCCUR IN 2010 AT 100,000 MILES, BUT IN FACT IT WAS A STEADY DEGRADATION OVER SEVERAL YEARS. IT'S A SAFETY ISSUE, BECAUSE THE LIGHT OUTPUT IS SIGNIFICANTLY REDUCED. CAUSING RISK AT NORMAL HIGHWAY SPEEDS. IN ADDITION, THE CRAZING/FROSTING RESULTS IN ADDITIONAL GLARE TO ONCOMING TRAFFIC. I ASKED ABOUT RECALLS/REPLACEMENT PROGRAM FOR THIS DEFECT AT MY LOCAL BMW DEALER; THE SERVICE TECHNICIAN DISMISSED IT AS A NORMAL AGING ISSUE. I STRONGLY DISAGREE. A CAR OF THIS PRICE, OR ANY PRICE, SHOULD HAVE HEADLIGHTS THAT LAST LONGER THAN A FEW YEARS. I REPLACE THE HEADLAMP COVERS IF THEY WERE AVAILABLE, BUT THE ONLY SOLUTION IS TO REPLACE THE ENTIRE HEADLAMP ASSEMBLY AT A COST OF $1238 FOR EACH SIDE. YES, $1238. THIS WAS A QUITE EXPENSIVE AUTO, BUT REGARDLESS OF COST, THIS SAFETY ISSUE SHOULD RESULT IN A RECALL....UPDATED 07/30/15 *BF THE DEALER INFORMED THE CONSUMER IT WAS A NORMAL AGING ISSUE. THE CONSUMER STATED THE LIGHT OUTPUT WAS SIGNIFICANTLY REDUCED. UPDATED 09/01/15.
NHTSA complaint #10730119 — an unverified report by a vehicle owner.
at 86,000 milesConcord, CA
STEERING
POWER STEERING PUMP MOUNTING BRACKETS BROKE OFF ( ON A POWER STEERING PUMP ITSELF), CAR THUS LOST POWER STEERING, BELT GOT OFF, IN A TURN IT WOULD HAVE BEEN A DISASTER , SOMEHOW I WAS ABLE TO STEER IT CLEAR IN A TURN. I GUESS I WAS LUCKY.
NHTSA complaint #10715825 — an unverified report by a vehicle owner.
at 96,000 milesDenver, CO
STEERING
I WAS DRIVING AND MY SERPENTINE BELT FELL OFF. AFTER INSPECTION THE BRACKET FOR MY POWER STEERING PUMP BROKE AND CAUSED THE BELT TO FALL OFF. LOST POWER STEERING WHILE DRIVING.
NHTSA complaint #10704846 — an unverified report by a vehicle owner.
at 151,345 milesFayetteville, NC
STEERING
AFTER STARTING UP MY CAR, THERE WAS A SLIGHT WHINE UNDER THE HOOD. I GAVE THE CAR A LITTLE BIT OF THROTTLE TO SEE IF THE WHINE WENT AWAY AND HEARD A LOUD BANG. THE CAR WAS STILL RUNNING BUT MY BATTERY LIGHT WAS ON. I NEEDED TO GET HOME, AND I THOUGHT THAT MY CAR MAY NOT START AGAIN IF I TURNED IT OFF SO I DROVE HOME. IMMEDIATELY I NOTICED THAT I DIDN'T HAVE ANY POWER STEERING. AS I DROVE MY ENGINE TEMPERATURE GOT HIGHER AND I BARELY MADE IT HOME WITHOUT OVERHEATING. A FEW DAYS LATER I LOOKED IN THE ENGINE COMPARTMENT AND SAW THAT THE POWER STEERING PUMP HAD BROKEN FREE OF THE ENGINE - THE BRACKET HAD SHEARED OFF. THAT IN TURN CAUSED THE BELT TO FALL OFF WHICH WAS TURNING THE WATER PUMP AND ALTERNATOR. I GOT ON THE COMPUTER AND LOOKED UP THE PROBLEM AND FOUND A LOT OF PEOPLE EXPERIENCING THE SAME PROBLEM, SOME DRIVING DURING THE INCIDENT. THIS IS A REAL DEFECTIVE DESIGN AND CAUSES ME TO BE CONCERNED ABOUT THE SAFETY. I HOPE NOTHING TRAGIC HAS TO HAPPEN TO SOMEONE FOR THIS TO BE CONSIDERED A RECALL.
NHTSA complaint #10556285 — an unverified report by a vehicle owner.
at 151,345 milesFayetteville, NC
ELECTRICAL SYSTEM
AFTER STARTING UP MY CAR, THERE WAS A SLIGHT WHINE UNDER THE HOOD. I GAVE THE CAR A LITTLE BIT OF THROTTLE TO SEE IF THE WHINE WENT AWAY AND HEARD A LOUD BANG. THE CAR WAS STILL RUNNING BUT MY BATTERY LIGHT WAS ON. I NEEDED TO GET HOME, AND I THOUGHT THAT MY CAR MAY NOT START AGAIN IF I TURNED IT OFF SO I DROVE HOME. IMMEDIATELY I NOTICED THAT I DIDN'T HAVE ANY POWER STEERING. AS I DROVE MY ENGINE TEMPERATURE GOT HIGHER AND I BARELY MADE IT HOME WITHOUT OVERHEATING. A FEW DAYS LATER I LOOKED IN THE ENGINE COMPARTMENT AND SAW THAT THE POWER STEERING PUMP HAD BROKEN FREE OF THE ENGINE - THE BRACKET HAD SHEARED OFF. THAT IN TURN CAUSED THE BELT TO FALL OFF WHICH WAS TURNING THE WATER PUMP AND ALTERNATOR. I GOT ON THE COMPUTER AND LOOKED UP THE PROBLEM AND FOUND A LOT OF PEOPLE EXPERIENCING THE SAME PROBLEM, SOME DRIVING DURING THE INCIDENT. THIS IS A REAL DEFECTIVE DESIGN AND CAUSES ME TO BE CONCERNED ABOUT THE SAFETY. I HOPE NOTHING TRAGIC HAS TO HAPPEN TO SOMEONE FOR THIS TO BE CONSIDERED A RECALL.
NHTSA complaint #10556285 — an unverified report by a vehicle owner.
at 151,345 milesFayetteville, NC
ENGINE
AFTER STARTING UP MY CAR, THERE WAS A SLIGHT WHINE UNDER THE HOOD. I GAVE THE CAR A LITTLE BIT OF THROTTLE TO SEE IF THE WHINE WENT AWAY AND HEARD A LOUD BANG. THE CAR WAS STILL RUNNING BUT MY BATTERY LIGHT WAS ON. I NEEDED TO GET HOME, AND I THOUGHT THAT MY CAR MAY NOT START AGAIN IF I TURNED IT OFF SO I DROVE HOME. IMMEDIATELY I NOTICED THAT I DIDN'T HAVE ANY POWER STEERING. AS I DROVE MY ENGINE TEMPERATURE GOT HIGHER AND I BARELY MADE IT HOME WITHOUT OVERHEATING. A FEW DAYS LATER I LOOKED IN THE ENGINE COMPARTMENT AND SAW THAT THE POWER STEERING PUMP HAD BROKEN FREE OF THE ENGINE - THE BRACKET HAD SHEARED OFF. THAT IN TURN CAUSED THE BELT TO FALL OFF WHICH WAS TURNING THE WATER PUMP AND ALTERNATOR. I GOT ON THE COMPUTER AND LOOKED UP THE PROBLEM AND FOUND A LOT OF PEOPLE EXPERIENCING THE SAME PROBLEM, SOME DRIVING DURING THE INCIDENT. THIS IS A REAL DEFECTIVE DESIGN AND CAUSES ME TO BE CONCERNED ABOUT THE SAFETY. I HOPE NOTHING TRAGIC HAS TO HAPPEN TO SOMEONE FOR THIS TO BE CONSIDERED A RECALL.
NHTSA complaint #10556285 — an unverified report by a vehicle owner.
at 76,854 milesKapolei, HI
STEERING
I WAS DRIVING IN STOP AND GO TRAFFIC WHEN I NOTICED THE STEERING FELT A LITTLE STIFFER THAN USUAL. AFTER ABOUT 5 MILES AND BETTER FLOWING TRAFFIC I PULLED INTO A RESTAURANT FOR DINNER WHEN MY UPPER RADIATOR HOSE EXPLODED. I PULLED INTO A STALL AND OPENED THE HOOD TO INSPECT WHAT HAPPENED. THE HOSE WAS VERY APPARENT AND AFTER FURTHER INVESTIGATION I NOTICED THE POWER STEERING PUMPS PULLEY AT A VERY SHARP ANGLE COMPARED TO LINEAR WITH THE SERPENTINE BELT. I CAN ONLY ASSUME THAT FROM THE BRACKET ON THE PUMP BREAKING, IT CAUSED A CHAIN REACTION OF EVENTS. FIRST THE BRACKET BROCKET PUTTING THE PUMP AT A STEEP ANGLE N FORCING THE BELT TO GO OFF TRACK WHICH THEN CAUSED ALL THE OTHER ACCESSORIES TO BE DISABLED INCLUDING THE WATER PUMP WHICH OVERHEATED THE CAR.
NHTSA complaint #10478241 — an unverified report by a vehicle owner.
at 76,854 milesKapolei, HI
ELECTRICAL SYSTEM
I WAS DRIVING IN STOP AND GO TRAFFIC WHEN I NOTICED THE STEERING FELT A LITTLE STIFFER THAN USUAL. AFTER ABOUT 5 MILES AND BETTER FLOWING TRAFFIC I PULLED INTO A RESTAURANT FOR DINNER WHEN MY UPPER RADIATOR HOSE EXPLODED. I PULLED INTO A STALL AND OPENED THE HOOD TO INSPECT WHAT HAPPENED. THE HOSE WAS VERY APPARENT AND AFTER FURTHER INVESTIGATION I NOTICED THE POWER STEERING PUMPS PULLEY AT A VERY SHARP ANGLE COMPARED TO LINEAR WITH THE SERPENTINE BELT. I CAN ONLY ASSUME THAT FROM THE BRACKET ON THE PUMP BREAKING, IT CAUSED A CHAIN REACTION OF EVENTS. FIRST THE BRACKET BROCKET PUTTING THE PUMP AT A STEEP ANGLE N FORCING THE BELT TO GO OFF TRACK WHICH THEN CAUSED ALL THE OTHER ACCESSORIES TO BE DISABLED INCLUDING THE WATER PUMP WHICH OVERHEATED THE CAR.
NHTSA complaint #10478241 — an unverified report by a vehicle owner.
at 76,854 milesKapolei, HI
ENGINE
I WAS DRIVING IN STOP AND GO TRAFFIC WHEN I NOTICED THE STEERING FELT A LITTLE STIFFER THAN USUAL. AFTER ABOUT 5 MILES AND BETTER FLOWING TRAFFIC I PULLED INTO A RESTAURANT FOR DINNER WHEN MY UPPER RADIATOR HOSE EXPLODED. I PULLED INTO A STALL AND OPENED THE HOOD TO INSPECT WHAT HAPPENED. THE HOSE WAS VERY APPARENT AND AFTER FURTHER INVESTIGATION I NOTICED THE POWER STEERING PUMPS PULLEY AT A VERY SHARP ANGLE COMPARED TO LINEAR WITH THE SERPENTINE BELT. I CAN ONLY ASSUME THAT FROM THE BRACKET ON THE PUMP BREAKING, IT CAUSED A CHAIN REACTION OF EVENTS. FIRST THE BRACKET BROCKET PUTTING THE PUMP AT A STEEP ANGLE N FORCING THE BELT TO GO OFF TRACK WHICH THEN CAUSED ALL THE OTHER ACCESSORIES TO BE DISABLED INCLUDING THE WATER PUMP WHICH OVERHEATED THE CAR.
NHTSA complaint #10478241 — an unverified report by a vehicle owner.
at 105,000 milesSAN Diego, CA
ELECTRICAL SYSTEM
MULTIPLE INSTANCES OF NO START. EVERY TIME THE CAR WAS TOWED TO A BMW SPECIALIST WHO OVER AND OVER AGAIN DIAGNOSED COMPLETELY DRAINED BATTERY, BUT CHARGING SYSTEM WAS OK. I HAVE JUST FOUND OUT THAT BMW HAS BEEN RECALLING 2003-2010 MODELS WITH THE EXACT SAME DEFECT.
NHTSA complaint #10453183 — an unverified report by a vehicle owner.
at 130,000 milesLOS Gatos, CA
STEERING
1. EVENTS LEADING UP TO FAILURE: I DROVE THE CAR 5MIN AND PARKED FOR 30 MINUTE LUNCH. WHEN I STARTED THE CAR, THE POWER STEERING FAILED IMMEDIATELY AND I COULDN'T TURN THE WHEEL. 2. THE FAILURE, FREQUENCY, CONSEQUENCES: POWER STEERING PUMP MOUNTING BRACKETS FRACTURED NEAR THE BOLTS THAT RETAIN THE PART TO THE CHASSIS. THE PUMP SWUNG LOOSE, ALLOWING THE BELT TO JUMP. THE TENSIONER PULLEYS WERE DAMAGED. MY MECHANIC IS UNAWARE OF OTHER INCIDENCES, THOUGH I FOUND DOCUMENTED REPORTS OF THE SAME FAILURE WITH PHOTOS AT THIS SITE: HTTP://WWW.BIMMERFEST.COM/FORUMS/SHOWTHREAD.PHP?T=323318 FORTUNATELY, THIS STEERING FAILURE HAPPENED AT NO SPEED. IF I HAD BEEN DRIVING, THE FAILURE COULD CAUSE LOSS OF STEERING, WHICH WOULD BE ESPECIALLY DANGEROUS BEFORE A TURN ON A MOUNTAIN ROAD. I COMMUTE IN THE MOUNTAINS DAILY. 3. WHAT WAS DONE TO CORRECT THE FAILURE LABOR SERVICE - ORIGINAL CHECKOUT 73.00 BELTS CAME OFF PULLEYS: BELTS CAME OFF PULLEYS: THE POWER STEERING PUMP BROKE LOOSE FROM ITS MOUNTING TABS. THE POWER STEERING SUPPLY AND RETURN HOSES ARE LEAKING, THE FAN BELTS ARE DAMAGED ,AND THE FAN BELT TENSIONER PULLEYS ARE NOISY. RECOMMEND TO REPLACE THESE ITEMS. SEE QUOTE BELOW. LABOR SERVICE - POWER STEERING PUMP 1,093.00 LABOR SERVICE - POWER STEERING SUPPLY AND RETURN HOSES AND FLUID FLUSH 534.00 LABOR SERVICE - FAN BELTS 280.00 LABOR SERVICE - TENSIONER PULLEYS 618.00.
NHTSA complaint #10349331 — an unverified report by a vehicle owner.
at 41,000 milesHarrisonburg, VA
ELECTRICAL SYSTEM
APPARENT COMPUTER MALFUNCTION CAUSED WINDOWS TO FOG UP, CLOCK TO FAIL, DIRECTIONAL SIGNALS TO FAIL AND THE ENGINE TO REFUSE TO RESTART. ALSO, THE DASH DISPLAY AND BRAKE LIGHTS REMAINED ON EVEN WITH THE IGNITION KEY REMOVED. DISCONNECTING THE BATTERY, WAITING ABOUT ONE HOUR, RECONNECTING THE BATTERY RESTORED NORMAL OPERATION.
NHTSA complaint #10318997 — an unverified report by a vehicle owner.
Santa Manica, CA
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
THERE IS A CONSTANT FUEL LEAK UNDER THE VEHICLE CAUSING ENGINE CHECK LIGHT TO ILLUMINATE.
NHTSA complaint #8003946 — an unverified report by a vehicle owner.
Santa Manica, CA
UNKNOWN OR OTHER
THERE IS A CONSTANT FUEL LEAK UNDER THE VEHICLE CAUSING ENGINE CHECK LIGHT TO ILLUMINATE.
NHTSA complaint #8003946 — an unverified report by a vehicle owner.