BMW 540i Repair and Maintenance

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

No_car_image
Get a Repair Estimate
Guaranteed by certified locations nationwide. Learn more
Get a Repair Estimate For Your BMW 540i
RepairPal estimates are guaranteed at over 1,700 quality certified locations nationwide. Learn more

BMW 540i Problems

Engine Oil Leaks

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

Multiple Parts May be Recommended to Correct Coolant Loss

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.

Blower Final Stage Fan Resistor May Fail

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.

See More Problems (10)

BMW 540i Recalls

Driver's Front Air Bag Defective

In a crash that deploys the driver's front air bag, the inflator of the air bag can rupture, causing metal debris to strike vehicle occupants. Dealers will replace the front driver's air bag module free of charge to correct the concern.

Recall 04V183000
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...
Recall 03V421000
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...

See More Recalls (12)

BMW 540i Reviews

Purchased a 2001 540I 6sp Manual w/Sports Suspension in 09. Car had 128,000. It now has 191,000. It's the 2nd best car I've ever owned. My best was an 89 BMW 535I 5 speed manual. The car is a blast to drive. Would NEVER own a BMW without a true manual transmission. Corners like a dream and the ride is as smooth as silk. It's the closest thing to owning an M5. The only difference is the 1...
my 2001 540i M sport has 155 plus thousand miles and runs like a dream- Change the oil religiously/every 5 k miles regardless with Castrol synthetic oil- 8 qts- worth it..Changed wheels and tires to continental high speed ,z rated tires-6 speed manual on its second clutch,third radiator,new timing chain, new coils, invest a couple of grand and the car is good good for a qtr. million miles--shif...
I bought a 2000 a year ago with 145K. Despite 16 MPG (city) I would buy it again! Great Car! (Nice "Classic" look) - Fantastic ride. (Do wish the steering was a little more responsive like the 2003 M5, and that the interior was not so cheap or dated) I did have to make some repairs to it: Replaced Radiator and reserve tank (Apx $150) - For some reason they don't last that long in thes...

See More Reviews (21)