BMW 540i Repair and Maintenance

A guide to problems, costs, maintenance and repair for your BMW 540i

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

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.

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.

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ON CERTAIN PASSENGER VEHICLES, DUE TO LONG EXPOSURES TO CERTAIN ENVIRONMENTAL AND OPERATING CONDITIONS, THE MATERIAL STRUCTURE OF THE FRONT SPRING STRUT PLATE COULD BE AFFECTED. IN SOME CASES, THE STRUT PLATE COULD BEGIN TO CRACK, AND EVENTUALLY IT COULD BREAK. IF THIS OCCURRED, THE PLATE COULD...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 THE...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.

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My son's 540 is a very heavy car so, use front brake pads like water. Recently the alternator need to be replace. Just $ 500 for a rebuild one!New alternator are about $ 800.00, and we found out it is a water cool alternator......!!!!!!! With this model you need to be very carefull with no overheating the engine. Cronic problems with the cooler system. Very nice cars when they are new, bu...

The car ran beautifully for 7 years (2003-2010) ..Then everything fell apart at 85,000 miles..... radiator, water pump, power steering, hoses/belts. "Service engine soon" light - Recommendation: Sell car at 75,000 miles - and don't look back.

The E34 540i is a great car. Very comfortable and fast. Repairs are expensive. I buy all my parts online and have the dealer perform the work. If you can DIY that is to be recommended. The weak areas on this car include the cooling system (perhaps its weakest area), leaking valve cover gaskets, leaking intake gaskets, front suspension, and HVAC system. The cooling system is the big one to...

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