2003 BMW 540i Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2003 BMW 540i

2003 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.

Front Tension Strut Bushings May Fail

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. These worn bushings should be replaced.

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2003 BMW 540i Questions

How to get the batter out it wiggles slightly doesn't come. (1 answer)

My bmw 540i still has a coolant leak, water pump I believe is the case but why (2 answers)

I've replaced radiator, alternator and now I belive my water pump needs replaced. Only had this car a year and purchased it w 108,000 now has 134,000. It seems never ending w coolant leaking problems. What causes the substantial coolant issue leaking problems for all these repairs? I heard he...

What should the cost of replacing the upper timing chain cover gasket? (1 answer)

Advised that the cost of replacing the upper timing chain cover gasket would be $1700.00. Is this a good estimate?

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2003 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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2003 BMW 540i Reviews

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.

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