2002 BMW 540i Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2002 BMW 540i

2002 BMW 540i Problems

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.

Valve Cover, Intake Manifold, PCV Plate Oil Leaks

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

Alignment/Tire Wear Issues Due to Excessive Play in Rear Lower Ball Joints

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.

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2002 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.

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2002 BMW 540i Reviews

We purchased are Bimmer in 2007 with 87,500 mls on it. A year later I replaced the alternator and the radiator. We went on one trip in it to Tampa, Fl and it handled superb. Overall we are happy with our 540i.

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