Does the 2002 BMW 540I have any recalls?

Yes. NHTSA lists 2 recalls for the 2002 BMW 540I, the most recent reported on January 14, 2019 (Air bags: frontal, driver side, inflator module). Check a specific car by its VIN at nhtsa.gov/recalls.

What are the most common problems with the 2002 BMW 540I?

Owners have filed 12 complaints with NHTSA. The most frequently reported area is electrical system (5 complaints), followed by steering (5).

How many 2002 BMW 540I complaints mention a crash or fire?

1 of 12 complaints report a crash and 0 a fire; 0 injuries were reported in total. Complaints are unverified reports from owners.

2002 BMW 540I recalls and problems

2 recalls and 12 owner complaints on file with NHTSA for the 2002 BMW 540I.

recalls

owner complaints

complaints mentioning a crash

mentioning a fire

Recalls apply to specific production ranges. To see whether a particular car still has an open recall, enter its VIN at nhtsa.gov/recalls. Repairs for safety recalls are free at authorised dealers.

2002 BMW 540I recalls

Air bags: frontal, driver side, inflator module

NHTSA campaign 19V015000 · reported January 14, 2019 · BMW of North America, LLC · 157,549 vehicles potentially affected

The problem: 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 replaced with the optional sports steering wheel. The sports steering wheel has a frontal air bag inflator that may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
The risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
The fix: 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. Owners may contact BMW customer service at 1-800-525-7417.

Air bags: frontal, driver side, inflator module

NHTSA campaign 15V318000 · reported May 28, 2015 · BMW of North America, LLC · 419,235 vehicles potentially affected

The problem: 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 and 4.4i Sports Activity Vehicles. Please note that the 5-series and X5 vehicles are only included if they are equipped with the optional sports steering wheel. The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.
The risk: 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.
The fix: 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 its entirety. Additionally, vehicles that have had their driver side frontal air bag replaced previously as part of a recall remedy need to have their air bag replaced under this recall as well. Note: On December 17, 2015 BMW removed the model year 2004 X5 3.0i and 4.4i Sports Activity vehicle from this recall. Those vehicles were mistakenly identified as including the air bags that are subject to this recall.

Most reported problems

Areas named in owner complaints to NHTSA. One complaint can name several areas.

Electrical system5
Steering5
Air bags2
Engine2
Exterior lighting1
Fuel system, gasoline1
Unknown or other1

What owners report

Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.

Jan 23, 2018 · Air bags · 40,000 miles · crash reported
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 FAILURE. THE FAILURE…

Dec 9, 2016 · Electrical system · 166,000 miles
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.

Jul 22, 2016 · Air bags
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 MANUFACTURER WAS MADE AWARE…

Jun 24, 2015 · Exterior lighting · 100,000 miles
THE PLASTIC COVERS ON THE HEADLIGHTS OF MY BMW BECAME CRAZED/FROSTED. EVERY BMW OF THIS VINTAGE HAS THE SAME PROBLEM. I SHOWED THIS TO OCCUR IN 2010 AT 100,000 MILES, BUT IN FACT IT WAS A STEADY DEGRADATION OVER SEVERAL YEARS. IT'S A SAFETY ISSUE, BECAUSE THE LIGHT OUTPUT IS SIGNIFICANTLY REDUCED. CAUSING RISK AT…

May 12, 2015 · Steering · 86,000 miles
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.

540I model years compared

Year	Recalls	Complaints	Crashes	Fires
2000	2	31	1	2
2001	4	15	1	0
2002	2	12	1	0
2003	2	7	0	0

Across all years, the 2000 540I has the most complaints (31). All BMW 540I years →

Questions

Does the 2002 BMW 540I have any recalls?: Yes. NHTSA lists 2 recalls for the 2002 BMW 540I, the most recent reported on January 14, 2019 (Air bags: frontal, driver side, inflator module). Check a specific car by its VIN at nhtsa.gov/recalls.
What are the most common problems with the 2002 BMW 540I?: Owners have filed 12 complaints with NHTSA. The most frequently reported area is electrical system (5 complaints), followed by steering (5).
How many 2002 BMW 540I complaints mention a crash or fire?: 1 of 12 complaints report a crash and 0 a fire; 0 injuries were reported in total. Complaints are unverified reports from owners.

Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received January 23, 2018.