1994 BMW 540i recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-19. Recalls apply to specific VINs — run your VIN to confirm.
4 safety recalls, most serious first
1. Vehicle Speed Control
What's wrong, in plain English: A vehicle part that may fail. THE CRUISE CONTROL AND THROTTLE CABLES ARE ATTACHED TO THE SAME THROTTLE VALVE ACTUATING LEVER AT THE THROTTLE HOUSING. IT IS POSSIBLE THAT THE PLASTIC BUSHING ON EITHER CABLE COULD BREAK DUE TO ENVIRONMENTAL INFLUENCES COUPLED WITH VIBRATION. IF THE BUSHING BREAKS, THE OUTER CABLE HOUSING CAN SEPARATE FROM THE BUSHING. IN THIS CASE, DURING APPLICATION OF THE THROTTLE PEDAL WITHOUT CRUISE CONTROL BEING ENGAGED, THE…
What could happen: THIS COULD CAUSE THE THROTTLE VALVE TO REMAIN PARTIALLY OPEN. IT HIS WERE TO OCCUR, THE CAR MIGHT NOT DECELERATE AS EXPECTED INCREASING THE RISK OF A VEHICLE CRASH.
The fix: DEALERS WILL INSTALL A SPRING STEEL CLIP ON THE OUTER TUBE OF EACH CABLE IN THE AREA OF THE ADJUSTING SCREW AND PLASTIC BUSHING. THE CLIP IS DESIGNED TO PREVENT THE OUTER TUBE FROM DISLODGING FROM THE BUSHING.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1994 540I.
- Book a repair at any authorized BMW dealer. Quote NHTSA campaign 97V131000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: VEHICLE SPEED CONTROL
Summary: THE CRUISE CONTROL AND THROTTLE CABLES ARE ATTACHED TO THE SAME THROTTLE VALVE ACTUATING LEVER AT THE THROTTLE HOUSING. IT IS POSSIBLE THAT THE PLASTIC BUSHING ON EITHER CABLE COULD BREAK DUE TO ENVIRONMENTAL INFLUENCES COUPLED WITH VIBRATION. IF THE BUSHING BREAKS, THE OUTER CABLE HOUSING CAN SEPARATE FROM THE BUSHING. IN THIS CASE, DURING APPLICATION OF THE THROTTLE PEDAL WITHOUT CRUISE CONTROL BEING ENGAGED, THE OUTER TUBE COULD CATCH ON THE EDGE OF THE BROKEN BUSHING.
Consequence: THIS COULD CAUSE THE THROTTLE VALVE TO REMAIN PARTIALLY OPEN. IT HIS WERE TO OCCUR, THE CAR MIGHT NOT DECELERATE AS EXPECTED INCREASING THE RISK OF A VEHICLE CRASH.
Remedy: DEALERS WILL INSTALL A SPRING STEEL CLIP ON THE OUTER TUBE OF EACH CABLE IN THE AREA OF THE ADJUSTING SCREW AND PLASTIC BUSHING. THE CLIP IS DESIGNED TO PREVENT THE OUTER TUBE FROM DISLODGING FROM THE BUSHING.
Notes: OWNER NOTIFICATION IS EXPECTED TO BEGIN BY THE END OF OCTOBER 1997. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-800-831-1117. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
2. Visibility (wipers / glass)
What's wrong, in plain English: You may not be able to see the road clearly. THE REMOTE ACTIVATION DEVICE CAN CLOSE WINDOWS AND SUNROOF FROM A DISTANCE GREATER THAN THE MAXIMUM (6 METERS) PERMITTED BY FMVSS NO.118, "POWER OPERATED WINDOW SYSTEMS."
What could happen: CONSEQUENCE OF NON-COMPLIANCE: THIS COULD ALLOW WINDOWS OR SUNROOFS TO BE CLOSED ON AN ARM OR NECK OF AN INDIVIDUAL WHEN THE REMOTE DEVICE OPERATOR IS NOT WITHIN THE IMMEDIATE VICINITY.
The fix: REPLACE THE INSIDE REAR VIEW MIRROR WHICH HAS THE ACTIVATION RECEIVER WITH ONE WHOSE RECEIVER WILL CONTROL THE DOOR LOCKING AND THEFT ALARM, BUT WILL NOT PERMIT REMOTE OPERATION OF THE WINDOWS AND SUNROOF.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1994 540I.
- Book a repair at any authorized BMW dealer. Quote NHTSA campaign 94V017000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
Summary: THE REMOTE ACTIVATION DEVICE CAN CLOSE WINDOWS AND SUNROOF FROM A DISTANCE GREATER THAN THE MAXIMUM (6 METERS) PERMITTED BY FMVSS NO.118, "POWER OPERATED WINDOW SYSTEMS."
Consequence: CONSEQUENCE OF NON-COMPLIANCE: THIS COULD ALLOW WINDOWS OR SUNROOFS TO BE CLOSED ON AN ARM OR NECK OF AN INDIVIDUAL WHEN THE REMOTE DEVICE OPERATOR IS NOT WITHIN THE IMMEDIATE VICINITY.
Remedy: REPLACE THE INSIDE REAR VIEW MIRROR WHICH HAS THE ACTIVATION RECEIVER WITH ONE WHOSE RECEIVER WILL CONTROL THE DOOR LOCKING AND THEFT ALARM, BUT WILL NOT PERMIT REMOTE OPERATION OF THE WINDOWS AND SUNROOF.
Notes: SYSTEM: EQUIPMENT; ELECTRIC POWER ACCESSORIES; WINDOWS. VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH REMOTE ACTIVATION DEVICES FOR DOOR LOCKING AND THEFT ALARM ARMING. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME AND FREE OF CHARGE OR THE REMEDY DOES NOT CORRECT THE DEFECT OR NONCOMPLIANCE, PLEASE CONTACT BMW SERVICE CENTER AT 1-201-573-2100. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
3. Brakes
What's wrong, in plain English: Anything that slows the car down. Treat brake recalls as urgent. THE BRAKE LIGHT SWITCH CAN FAIL ALLOWING THE SWITCH TO REMAIN IN THE "BRAKE LIGHTS OFF" POSITION OR IN THE "BRAKE LIGHTS ON" POSITION.
What could happen: IF THIS HAPPENS, THE BRAKE LIGHTS EITHER WILL NOT OPERATE OR WILL BE CONTINUOUSLY ON, REGARDLESS OF BRAKE PEDAL POSITION. FOLLOWING DRIVERS WOULD NOT BE ABLE TO DETERMINE WHETHER THE VEHICLE IS STOPPING, INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
The fix: DEALERS WILL REPLACE THE EXISTING BRAKE LIGHT SWITCH WITH A NEWLY DESIGNED SWITCH.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1994 540I.
- Book a repair at any authorized BMW dealer. Quote NHTSA campaign 96V111000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH
Summary: THE BRAKE LIGHT SWITCH CAN FAIL ALLOWING THE SWITCH TO REMAIN IN THE "BRAKE LIGHTS OFF" POSITION OR IN THE "BRAKE LIGHTS ON" POSITION.
Consequence: IF THIS HAPPENS, THE BRAKE LIGHTS EITHER WILL NOT OPERATE OR WILL BE CONTINUOUSLY ON, REGARDLESS OF BRAKE PEDAL POSITION. FOLLOWING DRIVERS WOULD NOT BE ABLE TO DETERMINE WHETHER THE VEHICLE IS STOPPING, INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy: DEALERS WILL REPLACE THE EXISTING BRAKE LIGHT SWITCH WITH A NEWLY DESIGNED SWITCH.
Notes: SYSTEM: BRAKES; HYDRAULIC; SWITCH; BRAKE LIGHT. VEHICLE DESCRIPTION: PASSENGER VEHICLES. OWNER NOTIFICATION: OWNER NOTIFICATION IS EXPECTED TO BEGIN AUGUST 5, 1996. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-800-831-1117. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
4. Engine
What's wrong, in plain English: Engine problems range from stalling to fire. VEHICLE DESCRIPTION: PASSENGER VEHICLES. A MALFUNCTION OR FAILURE OF A COOLANT SYSTEM COMPONENT, SUCH AS A THERMOSTAT, WATER PUMP, OR FAN BELT, CAN RESULT IN SIGNIFICANTLY INCREASED COOLANT TEMPERATURE AND SYSTEM PRESSURE. IF THE INDICATIONS OF A CRITICAL OVERHEATING CONDITION IS NOT NOTICED BY THE DRIVER, IT IS POSSIBLE THAT DAMAGE TO, OR FAILURE OF, A COOLANT SYSTEM COMPONENT COULD OCCUR.
What could happen: IF A CRACK WERE TO FORM OR A SEAM WERE TO SEPARATE IN THE HEATER CORE END PIECE, HOT COOLANT COULD SUDDENLY BE EXPELLED, INCREASING THE RISK OF PERSONAL INJURY TO A VEHICLE OCCUPANT.
The fix: DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERFLOW IN THE EVENT OF OVERHEATING.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 1994 540I.
- Book a repair at any authorized BMW dealer. Quote NHTSA campaign 98V178000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: ENGINE AND ENGINE COOLING:COOLING SYSTEM
Summary: VEHICLE DESCRIPTION: PASSENGER VEHICLES. A MALFUNCTION OR FAILURE OF A COOLANT SYSTEM COMPONENT, SUCH AS A THERMOSTAT, WATER PUMP, OR FAN BELT, CAN RESULT IN SIGNIFICANTLY INCREASED COOLANT TEMPERATURE AND SYSTEM PRESSURE. IF THE INDICATIONS OF A CRITICAL OVERHEATING CONDITION IS NOT NOTICED BY THE DRIVER, IT IS POSSIBLE THAT DAMAGE TO, OR FAILURE OF, A COOLANT SYSTEM COMPONENT COULD OCCUR.
Consequence: IF A CRACK WERE TO FORM OR A SEAM WERE TO SEPARATE IN THE HEATER CORE END PIECE, HOT COOLANT COULD SUDDENLY BE EXPELLED, INCREASING THE RISK OF PERSONAL INJURY TO A VEHICLE OCCUPANT.
Remedy: DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERFLOW IN THE EVENT OF OVERHEATING.
Notes: OWNER NOTIFICATION BEGAN MARCH 31, 1999. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-800-831-1117. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Useful for owners
Owner complaints filed with NHTSA
Most complained-about parts: Engine (4), Transmission / drivetrain (4), Seats (2), Lights (1), Vehicle Speed Control (1).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (8)
04/12/2006 · Engine
WHEN SHIFTING INTO REVERSE, THERE IS A HESITATION BEFORE TRANSMISSION SHIFTS IN. HESITATION TIME IS INCREASING. ALSO, WHEN STEPPING ON PEDAL FOR AGGRESSIVE ACCELERATION OR PASSING, VEHICLE HESITATES, THEN "CLUNKS" VIOLENTLY INTO GEAR. MECHANICS HAVE STATED THAT IT IS A COMMON PROBLEM THAT THEY SEE WITH THIS VEHICLE AND TRANSMISSION. SOLUTION IS TO REPLACE W…
09/09/2003 · Transmission / drivetrain
I BOUGHT A BMW 540I IN 1996 USED AT 45,000 MILES FROM A DEALERSHIP. WHEN SHIFTING INTO REVERSE TRANSMISSION WOULD BE DELAYED TEMPORARILY BEFORE ENGAGING. NOW I WAS NOT INFORM THE OF THE TECHNICAL BULLETIN AND DUE TO POOR TRANSMISSION FLUID, NOW AT 90,000 MILES THIS CAR WOULD NOT GO INTO REVERSE , SHIFTER WOULD SLIDE, AND CAR WOULD NOT MOVE. NOW THERE IS A…
01/05/2003 · Engine
TO WHOM IT MIGHT CONCERN. MY BMW 540I WAS DIAGNOSED FOR COMPRESSION LOSS BY THE LOCAL BMW AUTHORIZED DEALER. ACCORDING TO THE DEALER, THE CAUSE IS EXTENDED SULFUR CONTENT USED IN THE US GASOLINE. THE SULFUR CAUSES A CHEMICAL REACTION WITH THE USED ENGINE BLOCK ALLOY (NIKASIL) AND ERODES PREMATURELY. CURRENT MILEAGE IS 99'000 MILES. THIS IS FAR BELOW…
07/26/2002 · Engine
THIS IS THE SECOND ENGINE FOR THIS CAR, THE FIRST WAS REPLACED AT 38,228MI ... THIS ENGINE WAS REPLACED WITH THE SAME DEFECTIVE ENGINE THAT WAS ORIGINALLY IN THE CAR, NOT THE NEWER BLOCKS ... THIS WILL BE THE THIRD ENGINE IN 142,00MI AND I AM GETTING NO HELP HERE ... VERY DISAPPOINTING ... I WANT SATISFACTION ... I SHOULD NOT BE ON A THIRD ENGINE, PERIOD!!!…
06/15/2001 · Engine
BMW WITH M60B30 AND M60B40 V'8 FROM 93-95 ENGINES HAVE BEEN KNOWN TO SUFFER DAMAGE TO THE CYLINDER BORES FROM EXCESSIVE AMOUNTS OF SULPHER IN US FUELS. THE BLOCKS WERE MADE OF NIKASIL. THE PROBLEM REPRESENTS ITSELF AS AN EXCESSIVELY HIGH IDLE WHICH MY CAR HAS. BMW INITIATED AN ENGINE WARRANTY, COVERING ALL INTERNAL LUBRICATED PARTS, WHICH INCLUDES THE SH…
05/29/2001 · Transmission / drivetrain
AT 85,000 MILES WHEN SHIFTING INTO REVERSE TRANSMISSION WOULD BE DELAYED TEMPORARILY BEFORE ENGAGING. DEALER NOTIFIED MANUFACTURER, WHO INFORMED CONSUMER THAT VEHICLE WAS OUT OF ITS WARRANTY, AND NOT COVERED UNDER A RECALL. *AK CONSUMER STATES TRANSMISSION MALFUNCTIONED BECAUSE MANUFACTURERE DID NOT INFORM HIM OF THE TECHNICAL BULLETIN AND DUE TO PO…
04/26/2000 · Transmission / drivetrain
SPEED SENSOR FAILED, CAUSING FAILURE OF TRANSMISSION, CANNOT CHANGE GEARS.PLEASE PROVIDE FURTHER INFORMATION. *AK
02/08/2000 · Seats
DRIVERS SEAT "ROCKS". IF IN AN ACCIDENT I FEAR THE SEAT WILL DETATCH AND DRIVER WILL DIE. NEW SEAT RAILS WILL FIX BUT BMW WILL NOT PAY.*AK