The 1994 BMW 540i has 4 NHTSA recall campaigns affecting an estimated 931,400 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 12 complaints with NHTSA, most often about the power train. Last updated July 5, 2026.
Recall campaigns
ENGINE AND ENGINE COOLING98V1780001998-08-04340,000 affected
Defect
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…
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.
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…
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.
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.
VISIBILITY94V0170001994-01-271,400 affected
Defect
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.
Complaints by component
POWER TRAIN:AUTOMATIC TRANSMISSION
4
ENGINE AND ENGINE COOLING:ENGINE
2
ENGINE AND ENGINE COOLING
1
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
1
INTERIOR LIGHTING
1
SEATS:FRONT ASSEMBLY:POWER ADJUST
1
SEATS:FRONT ASSEMBLY:RECLINER
1
VEHICLE SPEED CONTROL
1
Total complaints12
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“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 ,…”
“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…”
“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…”
“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…”
“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…”
“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…”
“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…”
“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,…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1994 BMW 540i as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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