Complaints by model year
Each bar is one model year. The most recent years are still collecting complaints.
NHTSA ODI complaints (public domain) · updated 23 Oct 2026
Year by year
| Model year | Complaints | Recalls |
|---|---|---|
| 2002 | 2 | 1 |
| 2001 540iA | 7 | 3 |
| 2000 | 8 | 0 |
| 1999 540iA | 10 | 2 |
| 1998 | 3 | 1 |
| 1997 | 12 | 0 |
| 1996 | 0 | 0 |
| 1995 | 0 | 1 |
| 1994 | 0 | 1 |
| 1993 | 0 | 1 |
| 1992 | 0 | 1 |
| 1991 | 0 | 1 |
| 1990 | 0 | 1 |
| 1989 | 0 | 1 |
A model year gets its own page when it has enough data for at least three sections
Most common problems
- Engine and engine cooling26
- Power train6
- Electrical system2
- Air bags2
- Suspension1
- Structure1
- Service brakes, hydraulic1
- Seats1
NHTSA ODI complaints, all model years
Recalls
8 campaigns cover the 540iA.
ON CERTAIN PASSENGER VEHICLES, A MICROPROCESSOR IN THE AIR BAG CONTROL MODULE, WHICH ACTIVATES THE FRONT AIR BAGS, THE SIDE AIR BAGS, THE FRONT SEAT SAFETY BELT PRETENSIONERS, AND THE BATTERY SAFETY TERMINAL, MAY HAVE A MALFUNCTION THAT COULD LEAD TO AN UNINTENDED ACTIVATION OF ONE OR MORE OF THESE COMPONENTS.
ON CERTAIN PASSENGER VEHICLES, THE ENGINE AUXILIARY/COOLING FAN OPERATION, INCLUDING VARIABLE SPEED, IS ELECTRONICALLY CONTROLLED. FAILURE OF THE FAN MOTOR CAN CAUSE THE ELECTRICAL CIRCUITRY OF THE FAN CONTROL UNIT TO OVERLOAD AND FAIL, CAUSING THE FAN TO STOP OPERATING.
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.
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE ENGINE AUXILIARY/COOLING FAN OPERATION, INCLUDING VARIABLE SPEED, IS ELECTRONICALLY CONTROLLED. FAILURE OF THE FAN MOTOR CAN CAUSE THE ELECTRICAL CIRCUITRY OF THE FAN CONTROL UNIT TO OVERLOAD AND FAIL, CAUSING THE FAN TO STOP OPERATING.
VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH A 5HP24 AUTOMATIC TRANSMISSION. PREMATURE WEAR OF THE RING GEAR CAN OCCUR, LEADING TO THE LOSS OF 1ST, 2ND, 3RD, AND REVERSE GEARS.
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE THICKNESS OF THE MAIN POSITIVE ELECTRICAL CABLE (GENERATOR TO STARTER) INSULATION IS LESS THAN SPECIFIED, MAKING IT SUSCEPTIBLE TO BEING ABRADED OR CUT BY THE CLIP THAT SECURES THE CABLE TO THE GENERATOR.
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 POSSIBLE THAT DAMAGE TO, OR FAILURE OF, A COOLANT SYSTEM COMPONENT COULD OCCUR.
VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE DIFFERENTIAL PINION SHAFT WITHIN THE DIFFERENTIAL CASE ASSEMBLY WAS PRODUCED WITHOUT THE APPROPRIATE SURFACE HARDENING. THIS CAN RESULT IN THE SHAFT EXPERIENCING PREMATURE WEAR.
NHTSA recalls