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BMW 540IModel year report

2002 BMW 540I Problems

Complaints
12filed with NHTSA
Median mileage
98,000miles, 10 complaints with mileage
Recalls
22 do-not-drive
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
16 mpgcombined, 4.4L 8-cyl RWD · 14 city / 21 hwy

Sources: NHTSA records for the 2002 BMW 540I (complaints, recalls, investigations), EPA fuel economy. Report an error

NHTSA recorded 12 consumer complaints for the 2002 BMW 540I. The part named most often is electrical system, with 5 complaints (42% of the total), followed by steering (5) and air bags (2). 10 of the complaints include a mileage, and 20% of those were filed for vehicles with under 50,000 miles; the median is 98,000 miles. Of all complaints, 1 involved a crash, according to the filers. NHTSA lists 2 recall campaigns (2 marked do-not-drive) and 13 technical service bulletins for this model year. Electrical system complaints overlap with 3 technical service bulletins filed under the same part. Steering complaints overlap with 1 technical service bulletin filed under the same part.

This model year has fewer than 25 complaints on record, so the numbers below can change a lot with a few new reports.

Which parts are reported most

Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.

Example complaints

Electrical system: “After starting up my car, there was a slight whine under the hood. I gave the car a little bit of throttle to see if the whine went away and heard a loud bang. The car was still running but my battery light was on. I needed to get home, and I thought that my car may not start again if I turned it off so I drove home. Immediately I noticed that I didn't have any power steering. As I drove my engine temperature got higher and I barely made it home without overheating. …”

NHTSA complaint #10556285, filed 2013-12, 151,345 miles

Steering: “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.”

NHTSA complaint #10715825, filed 2015-05, 86,000 miles

Air bags: “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 mileage was 40,000.”

NHTSA complaint #11064447, filed 2018-01, 40,000 miles

Engine: “I was driving in stop and go traffic when I noticed the steering felt a little stiffer than usual. After about 5 miles and better flowing traffic I pulled into a restaurant for dinner when my upper radiator hose exploded. I pulled into a stall and opened the hood to inspect what happened. The hose was very apparent and after further investigation I noticed the power steering pumps pulley at a very sharp angle compared to linear with the serpentine belt. I can only assume that from the bracket on the pump breaking, it caused a chain reaction of events. …”

NHTSA complaint #10478241, filed 2012-10, 76,854 miles

Mileage when problems were reported

20% of the 10 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 76,854 and 130,000 miles.

0%0–100%10–2520%25–500%50–7530%75–10030%100–15020%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (10 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 98,000 miles.

Complaints by year filed

Fewer than 15 complaints, too few for a reliable trend.

20022010201220132015320162018
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Fuel economy and running cost

EPA ratings for each 2002 BMW 540I version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).

VersionEngineTransmissionCityHwyComb.Fuel / yr
540i RWD4.4L 8-cyl5-speed automatic162218$4,550
540i RWD4.4L 8-cyl6-speed manual142116$5,150
540i RWD4.4L 8-cyl5-speed automatic141916$5,150
540i Sport Wagon RWD4.4L 8-cyl5-speed automatic141916$5,150

Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.

Recalls and investigations

Recall details for the 2002 BMW 540I → · Check a VIN at nhtsa.gov/recalls

Technical service bulletins

TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 13 on record; the latest 10 are shown.

See all 13 bulletins →

Other model years of the BMW 540I

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
20245—3—28—Too new
20236—1—27—Too new
20226—1—27—Not enough data
2021938,3506—26—Not enough data
20191216,6001—24—Not enough data
2018318,1502—24Not compared (fewer than 3 comparable model years)Rising
20172020,5001—24—Rising
2003792,0002—17—Not enough data
20021298,0002—16—Not enough data
20011589,0004—16—Stable
20003191,0002—16Not compared (before 2008)Rising
19992270,0001—16—Stable
19982650,9141—18Not compared (before 2008)Falling
19972776,3500—18Not compared (before 2008)Stable
19951080,2502—18—Not enough data
1994887,0004—17—Not enough data

All BMW 540I model years · Best and worst years by complaints

Frequently asked questions

How many NHTSA complaints does the 2002 BMW 540I have?

NHTSA recorded 12 consumer complaints for the 2002 BMW 540I as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2002 BMW 540I is reported most often?

Electrical system is named most often, in 5 complaints (42% of the total), followed by steering with 5.

Has the 2002 BMW 540I been recalled?

NHTSA lists 2 recall campaigns for this model year, 2 of them with a do-not-drive advisory. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2002 BMW 540I get?

The EPA rates the 2002 BMW 540I (540i, 4.4L 8-cyl) at 16 mpg combined, 14 city and 21 highway, with an estimated annual fuel cost of $5,150 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2002 BMW 540I reported?

Among the 10 complaints that include a mileage, the median is 98,000 miles and the middle half falls between 76,854 and 130,000 miles; 20% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Fuel economy is from the EPA and DOE (fueleconomy.gov).

Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.