Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 2 of 2 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
Electrical System. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Seats. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
0 crash reports2 fire reports0 injury reports
What owners actually said
2 reports
90,000 miles · Aug 24, 2012
Electrical SystemSeatsFire
I WENT OUT TO MY BMW 540I AND FOUND THE DRIVER'S POWER SEAT ALL THE WAY BACK IN THE HORIZONTAL POSITION. I DID NOT LEAVE IT THIS WAY, SO THIS WAS CONFUSING TO ME. WHEN I ATTEMPTED TO MOVE IT BACK UPRIGHT INTO A COMFORTABLE DRIVING POSITION, IT DID NOT RESPOND- THE SEAT WAS DEAD. I COULD NOT MOVE IT MANUALLY, EITHER. I WAS FO…
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I WENT OUT TO MY BMW 540I AND FOUND THE DRIVER'S POWER SEAT ALL THE WAY BACK IN THE HORIZONTAL POSITION. I DID NOT LEAVE IT THIS WAY, SO THIS WAS CONFUSING TO ME. WHEN I ATTEMPTED TO MOVE IT BACK UPRIGHT INTO A COMFORTABLE DRIVING POSITION, IT DID NOT RESPOND- THE SEAT WAS DEAD. I COULD NOT MOVE IT MANUALLY, EITHER. I WAS FORCED TO DRIVE THE CAR A SHORT DISTANCE TO DROP MY SON OFF AT AN ACTIVITY, SO I DECIDED TO DRIVE IT AND LEAN FORWARD WHILE DRIVING. MY PLAN WAS TO TAKE THE CAR TO MY LOCAL BMW MECHANIC LATER THAT NIGHT AND DROP IT OFF TO BE REPAIRED. MY SON AND I WERE ONLY TWO MINUTES INTO OUR DRIVE, I WAS LEANING FORWARD, AND HE SAID "DO YOU SMELL SMOKE?" I DID SMELL IT, AND WAS LOOKING AROUND TO SEE WHAT WAS WRONG. THEN MY SON SAID "DAD, YOUR SEAT IS ON FIRE!" I LOOKED DOWN, AND SAW FLAMES COMING OUT FROM UNDER MY SEAT. WE PULLED THE CAR OVER AND PUT OUT THE FIRE WITH HIS WATER BOTTLE. THE HEATED SEATS WERE NOT BEING USED, THIS HAPPENED ON JULY 19TH, DURING THE SUMMER. MY LOCAL BMW SHOP IS TELLING ME THIS IS A $3100 REPAIR. THE PART IN QUESTION THAT CAUSED THE FIRE, PER THE CLAIMS ADJUSTER, IS THE "GENERAL MODULE." I UNDERSTAND THE CAR IS 10 YEARS OLD, BUT IT SIMPLY BLOWS MY MIND THAT A CAR CAN RANDOMLY CATCH ON FIRE INTERNALLY LIKE THIS. BMW NORTH AMERICA IS NOT TAKING OWNERSHIP TO THIS SITUATION, AND HAS OFFERED NO HELP. *TR
NHTSA ODI #10472344
109,834 miles · Jul 21, 2008
Power TrainFire
ON 7/19/2008, MY 2002 BMW 540I WITH AUTOMATIC TRANSMISSION CAUGHT FIRE WHILE MYSELF AND MY WIFE DRIVING TOWARD AN EVENING PARTY. AT FIRST I SMELL SOMETHING IS BURNING THEN SEE A TINY BIT OF SMOKE. I PARKED THE CAR IN A BANK OF AMERICA PARKING LOT AND MY WIFE WENT OUT TO CHECK THE CAR, AND SHE SAW FIRE STARTED TO BURST. WE CAL…
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ON 7/19/2008, MY 2002 BMW 540I WITH AUTOMATIC TRANSMISSION CAUGHT FIRE WHILE MYSELF AND MY WIFE DRIVING TOWARD AN EVENING PARTY. AT FIRST I SMELL SOMETHING IS BURNING THEN SEE A TINY BIT OF SMOKE. I PARKED THE CAR IN A BANK OF AMERICA PARKING LOT AND MY WIFE WENT OUT TO CHECK THE CAR, AND SHE SAW FIRE STARTED TO BURST. WE CALL 911 AND WITHIN FIVE MINUTES, THE FRONT END OF THE CAR IS IN FLAME. THE LOCAL FIRE DEPARTMENT CAME THE PUT OUT THE FIRE. THE CAR IS NOW BEEN TOW TO A LOCAL SHOP AND WILL BE MOVED TO THE "TOTAL LOT" OF MY INSURANCE COMPANY. I DID A QUICK SEARCH ON THE INTERNET, AND FOUND OUT I AM NOT THE ONLY ONE. I HOPE BMW CAN FIND OUT EXACTLY WHAT CAUSE THE FIRE AND FIX THE PROBLEM. MY WIFE AND I ARE LUCKY SINCE WE GOT OUT OF CAR SOON ENOUGH. THIS IS NOT A GOOD EXAMPLE FOR BMW SUCH A LUXURY BRAND. SINCERELY, STEVE HUNG *TR
VEHICLE DESCRIPTION: DURING THE TIRE MOUNTING PROCESS ON CERTAIN PASSENGER VEHICLES BUILT WITH STANDARD (NON-SPORT) SUSPENSION AND EQUIPPED WITH CONTINENTAL CONTITOURINGCONTACT CH95 ECOPLUS TIRES, SIZE 225/65R16 95H, HAVING DOT CODES 4001, 4101, OR 4201, THE OUTER SIDEWALL SURFACE OF THE TIRES MAY HAVE BEEN CUT BY A SHARP EDGE. OPERATION OF THE VEHICLE OVER A LONG PERIOD OF TIME COULD LEAD TO A REDUCTION OF INFLATION PRESSURE.
Consequence & remedy
Consequence: CONTINUED DRIVING WITH LOW INFLATION PRESSURE IN THE TIRE COULD ULTIMATELY RESULT IN DAMAGE TO THE TIRE, AFFECT VEHICLE HANDLING AND CONTROL, AND COULD IN SOME CASES RESULT IN A VEHICLE CRASH.
Remedy: DEALERS WILL INSPECT ALL FIVE TIRES FOR A POSSIBLE CUT IN THE SIDEWALL, AND IF A CUT IS FOUND, THE TIRE WILL BE REPLACED. OWNER NOTIFICATION BEGAN DECEMBER 10, 2001. 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.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
0
No exact-year investigations in this snapshot.
2002 BMW 540IA Problems, Complaints & Recalls | Skip That Year
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