The 2002 BMW 540i has 2 NHTSA recall campaigns affecting an estimated 576,784 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 17 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
Recall campaigns
AIR BAGS19V0150002019-01-14157,549 affected
Defect
BMW of North America, LLC (BMW) is recalling certain model year 2000-2003 525i Sedan, 530i Sedan, 540i Sedan, 2001-2003 525i Sports Wagon and 540i Sports Wagon vehicles, and 2000-2004 X5 SAV 3.0i, X5 SAV 4.4i, and X5 SAV 4.6is vehicles. This recall affects certain vehicles where the original steering wheel has been…
Consequence
An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy
Owners are advised not to drive their vehicles until the vehicle has been remedied. BMW will notify owners, and dealers will inspect the vehicle for an optional sports steering wheel with an affected inflator. Dealers will replace the air bag module as necessary, free of charge. The recall began March 14, 2019. …
AIR BAGS15V3180002015-05-28419,235 affected
Defect
BMW of North America, LLC (BMW) is recalling certain model year 2002-2005 325i, 325xi, 330i, and 330xi Sedans, and 325xi and 325i Sportswagons, 2002-2006 330Ci, 325Ci, and M3 Convertibles and 325i, 330i, and M3 Coupes, 2002-2003 M5, 540i, 525i Sedan, and 530i Sedans, and 540i and 525i Sportswagons, and 2003 X5 3.0i…
Consequence
In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy
Owners are advised not to drive their vehicles until the vehicle has been remedied. BMW will notify owners, and dealers will replace the front driver air bag module, free of charge. The recall began Aug 2016. Owners may contact BMW customer service at 1-800-525-7417. Note: This recall supersedes recall 14V-348 in…
Complaints by component
ELECTRICAL SYSTEM
5
STEERING
5
AIR BAGS
2
1crashes
ENGINE
2
EXTERIOR LIGHTING
1
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
1
UNKNOWN OR OTHER
1
Total complaints17
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Tl* the contact owned a 2002 bmw 540i. While the contact's vehicle was at a stop sign, it was rear ended by another vehicle. The air bags failed to deploy. There were no injuries and a police report was filed. The vehicle was towed and deemed a total loss. The manufacturer was not notified of the…”
“Tl* the contact owns a 2002 bmw 540i. The contact stated that it took ten attempts to start the vehicle. The failure occurred at least thirty times. The manufacturer was notified of the failure. The vehicle was not diagnosed or repaired. The approximate failure mileage was 166,000.”
“Tl* takata recall. The contact owns a 2002 bmw 540i. The contact received notification of nhtsa campaign number: 15v318000 (air bags); however, the part to do the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The…”
“Power steering pump mounting brackets broke off ( on a power steering pump itself), car thus lost power steering, belt got off, in a turn it would have been a disaster , somehow I was able to steer it clear in a turn. I guess I was lucky.”
“I was driving and my serpentine belt fell off. After inspection the bracket for my power steering pump broke and caused the belt to fall off. Lost power steering while driving. *tr”
“After starting up my car, there was a slight whine under the hood. I gave the car a little bit of throttle to see if the whine went away and heard a loud bang. The car was still running but my battery light was on. I needed to get home, and I thought that my car may not start again if I turned it…”
“After starting up my car, there was a slight whine under the hood. I gave the car a little bit of throttle to see if the whine went away and heard a loud bang. The car was still running but my battery light was on. I needed to get home, and I thought that my car may not start again if I turned it…”
“After starting up my car, there was a slight whine under the hood. I gave the car a little bit of throttle to see if the whine went away and heard a loud bang. The car was still running but my battery light was on. I needed to get home, and I thought that my car may not start again if I turned it…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2002 BMW 540i as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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