The 1991 BMW 535 has 2 NHTSA recall campaigns affecting an estimated 116,937 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 1 complaint with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
FEED FUEL HOSES CAN HARDEN AND "SET" OVER TIME, ALLOWING A SEEPAGE OF FUEL AT THE CONNECTION BETWEEN THE HOSE AND THE ENGINE FITTING. THE CLAMP USED TO HOLD THE HOSE TO THE FITTING IS UNABLE TO COMPENSATE FOR THE HARDENING OF THE FEED FUEL HOSE.
Consequence
FUEL SEEPAGE BETWEEN THE FEED FUEL HOSE AND THE ENGINE FITTING CAN RESULT IN FREE FUEL IN THE ENGINE COMPARTMENT, WHICH COULD RESULT IN A FIRE WHEN EXPOSED TO A SOURCE OF IGNITION.
Remedy
A REDESIGNED FEED FUEL HOSE AND HOSE CLAMP WILL BE INSTALLED TO ALLEVIATE THE FUEL SEEPAGE.
SOME OF THESE VEHICLES ARE EQUIPPED WITH A THROTTLE HOUSING ON WHICH THE THROTTLE VALVE SHAFT RETAINING NUT WAS NOT SUFFICIENTLY TIGHTENED.
Consequence
IF THE NUT WERE TO LOOSEN, MOVEMENT OF THE THROTTLE VALVECOULD BE IMPAIRED, RESULTING IN THE VEHICLE BEING UNABLE TO DECELERATE WHEN THEGAS PEDAL IS RELEASED.
Remedy
THOSE THROTTLE HOUSINGS WITH SUSPECT MANUFACTURING CODES WILL HAVE THE THROTTLE VALVE SHIFT RETAINING NUT TORQUE TESTED, AND THOSE WITH INSUFFICIENT NUT TORQUE WILL BE REPLACED.
Complaints by component
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
1
Total complaints1
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Vehicle was under recall 98178000. But owner was not notified. Vehicle broke down.towed to dealer, and was informed by mechanic that coolant system radiator cap was at fault. This had caused the problems with the water pump. Consumer was unhappy for not receiving a recall notice. *ak”
Defect investigations
InvestigationEA92017 Opened 1992-06-02 · closed 1993-03-30
HEATER CORE FAILURE
There is no summary currently available
InvestigationEA95013 Opened 1995-03-31 · closed 1996-07-15
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 BMW 535 as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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