2002 BMW 540i Problems

RepairPal has identified the most common problems with the 2002 BMW 540i as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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8
Known Problems

Leaks are known to develop in the cooling system. It is common to see more than one part recommended for repair/replacement due to overlapping labor and the use of many plastic parts in the system.

Engine oil leaks commonly develop from both valve cover gaskets, intake manifold, and PCV plate after about 60,000 miles.

The blower final stage fan resistor is known to fail. Symptoms are the heater fan speed varies regardless of the setting, the fan will not turn off when the car is switched off, or the fan will not switch on at all.

The rear lower ball joints may wear causing alignment and tire wear issues as a result of the excessive play in these joints. Our technicians tell us a 4wheel alignment should be performed after ball joint replacement.

A fluid leak may develop from one or more power steering hose. When a leak is being repaired, it is not uncommon for multiple hoses to be replaced.

The front thrust rod bushingsalso referred to as tension strut bushingsare known to fail occasionally. The oil-filled rubber mounts weaken and crack over time, causing a mushy road feel and shuddering in the steering wheel when going over bumps.

A creak or squeak can be heard from the top of the front or rear doors. This noise is most noticeable when the windows are fully up. The noise is caused by the decay of the flocking material on the door seals. New door seals, Teflon tape, special lube, or a combination of all of these may be needed to eliminate the noise.