2003 Bmw 540i problems

General information about Bmw-540i
Overview of popular issues
Recalls list

The BMW E39 is the fourth generation of the BMW 5 Series range of executive cars, which was manufactured from 1995 to 2004. It was launched in the sedan body style, with the station wagon body style (marketed as "Touring") introduced in 1996. The E39 was replaced by the E60 5 Series in 2003, however E39 Touring models remained in production until May 2004.

The proportion of chassis components using aluminium significantly increased for the E39, and it was the first 5 Series to use aluminium for all major components in the front suspension or any in the rear. It was also the first 5 Series where a four-cylinder diesel engine was available. Rack and pinion steering was used for four- and six-cylinder models, the first time that a 5 Series has used this steering system in significant volumes. Unlike its E34 predecessor and E60 successor, the E39 was not available with all-wheel drive.

The high performance E39 M5 sedan was introduced in 1998, powered by a 4.9 L (302 cu in) DOHC V8 engine. It was the first M5 model to be powered by a V8 engine.

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Common 2003 Bmw 540i problems

The BMW 540i, produced in 2003, is known for several common problems that owners have reported over the years. Here are some of the most frequently mentioned issues:

Plastic DISA valve breaking and destroying the engine: The plastic DISA (Differential Intake System) valve is known to break and cause debris to enter the engine, potentially causing catastrophic damage. This issue is particularly prevalent in the M62tu engine found in the 540i.

Cluster pixel tape lifting: The instrument cluster's pixel tape may lift over time, causing the display to become distorted or fail to function properly. This can be a costly repair, as the entire cluster may need to be replaced.

Timing chain guides: The timing chain guides in the M62tu engine are known to fail, causing the timing chain to jump or break. This can lead to significant engine damage and is a costly repair. It is recommended to replace these guides proactively, especially if the vehicle has not had this service performed previously.

Oil leaks: As with many high-mileage vehicles, oil leaks become more common over time. The rocker cover gasket and oil filter cap are particularly susceptible to leaking in the BMW 540i.

Sticking valves: Early 528i models, which share some components with the 540i, are known to experience sticking valves due to running on high-sulphur petrol. While this issue is less common in the 540i, it is still worth noting as a potential problem.

Recalls: The BMW 5 Series, including the 540i, has had several recalls over the years, addressing issues such as gearbox lockups, brake light failures, and potential detachment of ball bearings from front suspension strut top mountings.

In summary, the BMW 540i, like many high-performance vehicles, has several common problems that owners should be aware of. Regular maintenance and proactive repairs can help mitigate some of these issues, but it is essential to be informed about potential problems when considering purchasing or owning a 540i.

How reliable are E39 540i?

The E39 is relatively reliable, too, with the exception of a very few known maintenance issues (e.g., I had three replacement radiators over 10 years with my last 540).

Is the BMW 540i fast?

In fact, the 2021 model is as quick as the 2017 model we last tested. The 4.7-second time to 60 is still plenty quick, however, and the 540i breezed through the quarter-mile in 13.3 seconds at 106 mph.

How many 2003 BMW 540i M Sport were made?

Only 1,265 540i M-Sport six-speed examples were produced making them significantly rarer than the M5. As expected, these renowned road machines deliver big doses of performance and a unique driving experience that make them highly sought-after as modern classics by knowledgeable enthusiasts.

What is the 540i engine?

The 2022 BMW 540i horsepower of 335 is one of the best produced by a modern sedan, thanks to a combo of a 3.0-liter BMW M TwinPower engine mated to an eight-speed sport automatic transmission and a 48V hybrid technology. It's enough power to whip up 60 mph in 4.9 seconds.

How many 2003 BMW 540i M Sport were made?

What engine came in the 540i?

3.0-liter BMW M TwinPower engine

Is the BMW 540i fast?

What is the top speed of the 2003 BMW 540i M Sport?

155 MPH, electronically limited. (only 128 MPH without sport package), electronically limited. Here's a video of what a US-spec European delivery 1999 540iA sport does in Germany, and this was with the slightly less powerful engine of that year that revs a little higher.

2003 Bmw 540i complaints

The NHTSA has received 0 complaints about various vehicle components related to the 2003 Bmw 540i.

You can leave your car complaint via the special form below.

2003 Bmw 540i recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 2 recalls for different components of the 2003 Bmw 540i.

2019-01-14

Manufacturer: BMW of North America, LLC
Park It: 1
Components: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
Summary: 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.
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. Owners may contact BMW customer service at 1-800-525-7417.

2015-05-28

Manufacturer: BMW of North America, LLC
Park It: 1
Components: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
Summary: 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.
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 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.

Additional sources

More sources of information about 2003 Bmw 540i problems:

E-39 540I common problems | BimmerFest BMW Forum

https://www.bimmerfest.com/threads/e-39-540i-common-problems.670733/

Jan 17, 2013 ... E-39 540I common problems · Behr cooling system leaking · Plastic DISA valve breaking & destroying the engine · Cluster pixel tape lifting · MID ...

Reliability of E39 540i

https://www.bimmerforums.com/forum/showthread.php?744936-Reliability-of-E39-540i

May 8, 2007 ... Anyone here own one and would they like to post their thoughts/experiences on the repairs and issues of the 540i? I don't mind fixing a BMW, I ...

BMW 530i vs 540i: Reliability, Problems & Comparison

https://www.justanswer.com/bmw/4feh9-bmw-540i-hello-i-deliberating-buying-2001-2003.html

Jan 6, 2011 ... I am deliberating between buying a 2001-2003 BMW 530i or a 2001-2003 BMW 540i. Whatever I go with will have to be a - Answered by a verified ...