2001 BMW 540i

Defect. 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.

Risk. 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.

Defect. 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.

Risk. 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.

Defect. 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.

Risk. 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.

Defect. 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.

Risk. 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.

The contact owns a 2001 BMW 540i. The contact received notification of NHTSA Campaign Number: (17V047000 (AIR BAGS) and would like to be removed from the recall distribution list. The local dealer and manufacturer were contacted.

The contact owns a 2001 BMW 540I. The contact stated that the dealer had previously performed an unknown air bag recall repair; however, the failure occurred a year after the recall repair was performed. The contact stated that while the vehicle was parked and turned off, an explosion was heard. The contact entered the vehicle and noticed that the passenger's side air bag had deployed, which shattered the front windshield. The air bag and an unknown warning light were illuminated. The driver's side air bag deployed a month later. The contact stated that there was no impact to the vehicle that could have caused the air bags to deploy. Additionally, the vehicle made an abnormal sound after it was turned off. The vehicle also needed to be jumpstarted daily due to the battery failing to retain a charge. The dealer was made aware of the failure; however, the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 105,000.

M62 V-8 ENGINES USED IN THE E-39 540 AND E-38 740 ARE NOTORIOUS FOR FAULTY TIMING CHAIN GUIDES. AT AROUND 125,000 THE PLASTIC CAN DISINTEGRATE CAUSING THE CHAIN TO SKIP A TOOTH. ONCE A TOOTH IS SKIPPED THE VALVES ARE CRUSHED AND THE ENGINE IS DESTROYED. THE COST TO REPLACE THE GUIDES IS EXTREMELY EXPENSIVE. I WAS LUCKY IN THAT I REPLACED MINE AT 140,000 MILES

TAKATA RECALL: BOTH THE MANUFACTURER (BMW NORTH AMERICA) AND THE LOCAL DEALER (UNITED BMW OF ROSWELL, GA) ARE REFUSING TO PERFORM THE INSPECTION OF THE AIR BAG INFLATOR ON THE REFERENCED VEHICLE, PER NHTSA RECALL CAMPAIGN NO. 17V-047. DEALER CLAIMS THAT NO INSPECTION IS REQUIRED SINCE MANUFACTURE'S SERVICE RECORDS FOR THIS VIN SHOW THAT THE "AIRBAG CONTROL UNIT" WAS REPLACED 6/22/04. HOWEVER, THE OPEN NHTSA RECALL CAMPAIGN ON THIS VEHICLE NOTES THAT THE INFLATOR MAY HAVE BEEN REPLACED PREVIOUSLY BUT THAT THE INFLATOR THAT WAS REPLACED STILL NEEDS TO BE INSPECTED AT THIS TIME AS IT MAY BE FAULTY.

POSSIBLE TAKATA INFLATOR: AT FIRST THE PASSENGER AIRBAG LIGHT CAME ON OCCASIONALLY AND NOW THE PASSENGER AIRBAG LIGHT IS ON ALL AT THE TIME.

THE BRACKET THAT HOLDS THE POWER STEERING PUMP ON MY 2001 BMW 540I SNAPPED ON THE TOP AND BOTTOM PIECES OF THE BRACKET RESULTING IN MY BELTS AND PULLEYS TO BE THROWN AND DESTROYED. THE REPAIR IS VERY EXPENSIVE AND TIME CONSUMING. THIS IS BECOMING A MORE AND MORE COMMON PROBLEM ON THE E39 STYLE 1997-2003 BMW 540I'S. *TR

POWER STEERING BRACKETS ON THESE CARS BREAK. HAPPENED TO ME AND THREW A BELT DURING A TURN. THIS IS AN EXTREME SAFETY HAZARD AS YOU HAVE NO POWER STEERING WHEN THE BRACKET BREAKS AND THE BELT IS THROWN. THIS IS A KNOWN ISSUE IF YOU SEARCH ON BMW FORUMS AND SHOULD BE ADDRESSED BY BMW! THIS IS HAPPENING TO MY VEHICLE FOR THE SECOND TIME. OTHER OWNERS REPORT MULTIPLE INSTANCES AS WELL. *TR

2001 BMW 540I REVERSE GEAR FAILURE ON ZF 5HP24 (A5S 440Z) TRANSMISSION. MY BMW WILL NO LONGER ENGAGE REVERSE, CAR FEELS LIKE IT IS STILL IN NEUTRAL.

3RD (HIGH) TAIL LIGHT BULB AND SOCKET OVERHEATS AND MELTS, RENDERING THE LIGHT INOPERABLE AND POSSIBLY CAUSING A FIRE HAZARD. *TR

ELECTRICAL SHORT IN FAULTY THERMOSTAT CAUSED ALL WIRING TO MELT AND LEAD TO A DAMAGE OF MAIN COMPUTER. *TR

ON MY 2001 BMW 540I WITH 84000 MILES WHEN THE CAR IS PUT INTO REVERSE IT WILL NOT REVERSE JUST FILLS LIKE IT IS IN NEUTRAL. *TR

I OWN A 2001 BMW 540I. I WILL PUT THE CAR IN DRIVE, THE CAR WILL MOVE REALLY SLOW, AS I GIVE IT A LITTLE GAS TO GO, THE CAR WILL ONLY REV UP THEN JUMP INTO GEAR. THIS WILL CAUSE A VERY STRONG JERK TO THE CAR. THE CAR ONLY HAS 70,000 MILES, I FEEL THAT IT IS MUCH TOO SOON FOR A $65,000 CAR TRANSMISSION TO GO BAD. I TOOK THE CAR TO BMW TO FIND OUT THAT I NEED TO REPLACE THE TRANSMISSION. (COST $5600) I HAVE NOT FIX THE CAR IN HOPE THAT I WILL FIND A SOLUTION FOR BMW TO FIX IT. *NM

BMW 540I ELECTRICAL PROBLEMS / DAMAGE TO INTERNAL HEATING AND ELECTRICAL EQUIPMENT. THEY POSE A HAZARD DUE TO EXTREME TEMPERATURE CHANGE IN THE CAR INTERIOR. THE HOT / AND COLD SENSATION LEAVES THE DRIVER FEELING SICK / NAUSEOUS.

VEHICLE FAILS TO START. TOWED TO DEALER. UNABLE TO LOCATE SOURCE OF PROBLEM. PLEASE PROVIDE FURTHER DETAILS.*AK

CONSUMER WAS TRAVELING 60MPH ON INTERSTATE AND SIDE/ TOP AIRBAGS EXPLODED. AFTER THEY EXPLODED, WARNING LIGHTS CAME ON AND VEHICLE LOST POWER. DEALER GAVE CONSUMER A LOANER CAR . CONSUMER'S VEHICLE WAS BEING INSPECTED.*AK