2004 BMW 545I

44 complaints on file, page 1 of 3.

1. Filed Aug 29, 2026Failure Jul 14, 2026Oakland, CAUnknown or otherFire

   Vehicle suffered a catastrophic engine fire while parked due to fuel line separation under open recall 04V303000.

   NHTSA complaint 11760532
2. Filed Feb 4, 2020Failure Oct 1, 2018Hayward, CAAir bags, Seat belts

   MY CAR HAS THE PASSENGER RESTRAINT SYSTEM WARNING EVERYTIME I START MY CAR. THE AIR BAG RECALL IS BY TAKATA IS FOR THE 2003 545I MODEL. MY CAR WAS MANUFACTURED IN SEP OF 2003 WITH THOSE TAKADA AIRBAGS.

   NHTSA complaint 11306903
3. Filed Jan 19, 2020Failure Jul 19, 2019130,000 milesFort Wayne, INElectronic stability control (esc), Steering

   DYNAMIC STEERING MALFUNCTION CAUSING HAZARDOUS DRIVING CONDITIONS AT HIGHWAY SPEEDS

   NHTSA complaint 11300372
4. Filed Nov 28, 2019Failure Nov 24, 2019180,000 milesRockwell, NCElectrical system, Exterior lighting

   ELECTRICAL WIRING IN HEADLIGHTS ARE DISINTEGRATING. THE SHIELDING IS DRY ROTTING AND FLAKING OFF NEARLY EVERY WIRE IN BOTH HEADLIGHTS CAUSING THEM TO MALFUNCTION DURING DRIVING. LIGHTS WILL CUT OFF RANDOMLY. I'D IMAGINE THE WIRES ARE SHORTING OUT.

   NHTSA complaint 11282786
5. Filed Sep 8, 2019Failure Jul 16, 201997,000 milesHartland, WIEngine

   VALVE COVER GASKET LEAK, TIMING CHAIN COVER GASKET LEAK, VALVE STEM LEAK.

   NHTSA complaint 11253982
6. Filed Feb 7, 2019Failure Feb 1, 2019119,000 milesAuburn, GAElectrical system, Exterior lighting

   BARE WIRES INSIDE THE HEADLIGHT HOUSING, THESE ARE HID LIGHTS MADE BY HELLA FOR BMW THEY ARE OEM. WHEN CONTACTING BMWNA THEY SAY THAT'S NOT HOW THEY MAKE THERE LIGHTS AND BLAME HEAT AND THE CAR NOT BEING MAINTAINED AT A BMW DEALERSHIP, WELL THE REST OF THE WIRING ON THE CAR IS JUST FINE EVEN THE WIRES THAT COME IN CONTACT WITH A HIGH HEAT PRODUCING ENGINE... IT'S THE SAME EXACT ISSUE MERCEDES BENZ HAD ON THE W202 CHASSIS, WIRES THAT WOULD DEGRADE AT AN EXTREMELY FAST RATE. BUT FOR HEADLIGHTS THAT COST WELL OVER $1000 EACH. BUT MY QUESTION IS WHAT HAPPENS WHEN A FAMILY IS OUT AT NIGHT AND THERE HEADLIGHTS MALFUNCTION BECAUSE OF SOMETHING BMW KNOWS ABOUT BUT REFUSE TO TAKE RESPONSIBILITY AND SAID FAMILY HAS A WRECK AND KILLS MULTIPLE PEOPLE BECAUSE OF A KNOWN PROBLEM. THIS IS MY SECOND ATTEMPT AT GETTING SOMETHING DONE THE FIRST WAS CONTACTING BMWNA WHICH EQUALED TO INSULTING SOMEONE'S KNOWLEDGE OF ELECTRICAL COMPONENTS. ALSO THE HEADLIGHTS NO LONGER ADJUST, THE ANGEL EYES NO LONGER WORK BULBS BLOW AS SOON AS THEY ARE REPLACED AND CONSTANT WARNINGS THAT PARKING LIGHTS HAVE A MALFUNCTION. TELLING SOMEONE HEAT IS THE CAUSE MAKES AN AUTOMOTIVE COMPANY KINDA LOOK IGNORANT ESPECIALLY WHEN WIRES TOUCHING AN ENGINE ARE NOT EFFECTED BY HEAT AT ALL AND ARE STILL 100% FLEXIBLE AND HAVE NOT LOST ANY OF THE INSULATION. YOU CAN SEE SOME OF THE WIRES HAVE LIQUID ELECTRICAL TAPE USED, SHOULD ANY VEHICLE WITH 119XXX MILES HAVE SUCH AN ISSUE?

   NHTSA complaint 11174913
7. Filed Jun 7, 2018Failure Oct 5, 2017Bellingham, WAOccupant classification, Air bags, Seat belts

   IN 10/17 I BOUGHT THE ABOVE VEHICLE FROM PRIVATE OWNER. FROM THE TIME I STARTED DRIVING IT TO CURRENTLY, THE CONTROL DISPLAY HAS BEEN SHOWING A PASSENGER AIRBAG AND/ORSEATBEIT WARNING. THE CURRENT WARNING READS: "PASS. RESTRAINT SYSTEM. FAULT IN PASSENGER-RESTRIANT SYSTEM AFFECTING AIRBAG, BELT TENSIONER OR BELT FORCE LIMITER." THE DISPLAY BETWEEN THE SPEEDOMETER AND TACHOMETER SHOWS A RED AIRBAG SYMBOL AND A RED FASTEN SEATBELT SYMBOL, WHICH DO NOT GO OFF WITH OPERATION OF VEHICLE. THESE 2004/2005 BMW 545I HAD A NHTSA SAFETY RECALL (08V384000) BUT CERTAIN VINS, INCLUDING MINE WERE NOT INCLUDED. I CANNOT UNDERSTAND WHY, BECAUSE CLEARLY NOT KNOWING WHETHER YOUR AIRBAG & BELT TENSIONER & BELT FORCE LIMITER ARE WORKING PROPERLY IS A SAFETY ISSUE. I AM NOT THE ONLY ONE WITH THIS CONCERN, PLEASE SEE AT LEAST 10 OTHER PEOPLE LISTING THIS PROBLEM WITH "WWW.CARPROBLEMZOO.COM" UNDER BMW 545 I SEATBELT PROBLEMS. MY MECHANIC HAS TRIED SEVERAL TIMES TO RESET THESE WARNINGS, BUT THEY ALWAYS COME BACK. NHTSA'S JOB IS TO PROTECT CAR OWNERS RE REAL SAFETY CONCERNS; I ASK THAT YOU PLEASE DO THIS. HOW WOULD YOU LIKE TO HAVE A PASSENGER IN THE FRONT SEAT AND NOT KNOW IF AIRBAGS AND SEATBELTS WILL OPERATE PROPERLY IN THE EVENT OF A CRASH?20 THANK YOU. *JS *JS

   NHTSA complaint 11100379
8. Filed May 19, 2018Failure Jun 5, 2017190,000 milesClear Spring, MDAir bags

   SAME PROBLEM EVERYONE ELSE HAS WITH PASSENGER SIDE AIR BAG MALFUNCTION. $1500+ REPAIR, BUT WILL DO IT AGAIN, AS IT IS FAULTY PARTS. SOMEONE SITS DOWN IN THE PASSENGER SEAT TOO HARD, AND IT SETS OFF THE WARNING.

   NHTSA complaint 11096844
9. Filed Aug 24, 2017Failure Jul 24, 201715,000 milesSunnyvale, CAAir bags, Electronic stability control (esc), Steering

   TAKADA RECALL. MY CAR'S MAKE CRACKING NOISE OR GROANED NOISES AS SOME OTHER E60 OWNERS DESCRIBED. THE NOISES SOUNDED AS THE CAR START ROLLING AT LOW SPEED WHETHER GO STRAIGHT OR TURN A LITTLE TO LEFT OR RIGHT. IT'S HAPPENED EVERY TIME. THE AIRBAG LIGHT COME ON DURING DRIVE AND IT IS OFF WHEN I SHUT OFF THE ENGINE. THE NEXT TIME I START THE CAR IS STILL REMAIN STAYED ON, AND IT'S GOES OFF DURING DRIVE. THE STEERING WHEEL SEEMS NOT FIRM UNLIKE E39 IS MORE FIRM. I FOUND A FORUM WHERE THE E60 OWNERS HAD SIMILAR PROBLEM AND THE DEALER SOLVED THE PROBLEMS I MENTIONED ABOVE BY JUST REPLACE THE TAKATA AIRBAG AND MAYBE AN UPDATE OF SOFTWARE INVOLVED. IN CONCLUSION TO MY COMPLAINT REGARDING TAKADA AIRBAG THE BMW SHOULD OPEN A RECALL FOR MY CAR OR ADD MY CAR TO THE RECALL LIST AS IT'S NOT SAFE FOR ME AND MY FAMILY. PLEASE HELP, THANK YOU.

   NHTSA complaint 11019448
10. Filed Aug 21, 2017Failure Jul 21, 2017174,250 milesHudson, MIElectrical system

    MY I DRIVE OR CCC HAS MALFUNCTIONED. AT FIRST THE SCREEN WOULD TURN ON AND OFF OR FREEZE UP. FINALLY THE SCREEN WENT BLANK. THIS UNIT PROVIDE THE SAFETY INFORMATION OF THE VEHICLE. THIS UNIT ALSO PROVIDES THE COMMUNICATIONS SUCH AS BLUETOOTH AND HANDS FREE FUNCTIONS. THIS UNIT ALSO PROVIDES ALL THE SERVICE INFORMATION/ BASICALLY IT LIKE DRIVING A VEHICLE WITH OUT A BRAIN. THIS SEEMS TO BE A RECURRING PROBLEM WITH OTHER BMW OWNER.

    NHTSA complaint 11018755
11. Filed Aug 10, 2017Failure Jun 3, 2017106,590 milesWest Lafayette, INAir bags, Electronic stability control (esc), Engine and engine cooling

    I CAME BACK FROM MY SUMMER HOLIDAY, AND RESTARTED MY CAR. A LOT OF WARNINGS APPEARS ON THE ODOMETER. ABOUT ENGINE, AIRBAGS, STEERING, TIRE PRESSURE, AND SEAT BELT. (I HAVE CHECKED THE TIRE PRESSURE, IT IS NORMAL. AND I ALWAYS LOCK THE SEAT BELT BEFORE DRIVING). IN ADDITION, THE NAVIGATION SCREEN AND RADIO DIED. FURTHERMORE, THE CAR LOSE ELECTRICITY AFTER IT SHUTS DOWN. AFTER MORE THAN 3 HOURS OF SHUT DOWN, IT WON'T HAVE ENOUGH POWER TO RE-IGNITE. I CHECK ON NHTSA WEBSITE THAT THERE ARE THREE RECALL ISSUES THAT MY CAR WAS INCLUDED, AND RELATED TO THE ISSUES I AM REPORTING RIGHT NOW. ABOUT AIR BAGS (08V384000), ENGINE (12E029000), AND ELECTRICAL SYSTEM (12V126000). BUT I CANNOT FIND OUT ANY INFORMATION BY MY VIN NUMBER ON NHTSA. IT IS A USED CAR, I AM NOT SURE WHETHER THE FORMER USER RESPONDED THE RECALL BEFORE. EVEN IF THIS CAR WAS RECALLED BEFORE, I DON'T KNOW WHETHER IT WAS FIXED PROPERLY, AND THE SIMILAR ISSUES WOULD NOT HAPPEN AGAIN.

    NHTSA complaint 11015508
12. Filed Feb 10, 2017Failure Feb 8, 2017Mesa, AZAir bags

    AIRBAG LIGHT IS ON. I AM VERY SURE THAT IT IS THE FLOOR MAT PRESSURE SENSORS FOR THE AIRBAG SYSTEM.

    NHTSA complaint 10953822
13. Filed Aug 11, 2016Failure Mar 14, 2016220,000 milesTheodore, ALAir bags, Electrical system, Engine

    DRIVE MODERATELY KEEPS POPPING UP AN SERVICE ENGINE AFTER GETTING BMW TO CHECK IT AN FIX IT ALSO IT WON'T CRANK SOMETIMES BUT THE BATTERY AN ALTERNATOR IS BRAND NEW BUT AFTER IT SIT FOR HOURS IT FINALLY CRANK UP, MAYBE IT'S AN SECURITY ISSUE BUT IT'S UNNECESSARY

    NHTSA complaint 10895079
14. Filed May 16, 2016Failure May 13, 2016140,000 milesCincinnati, OHEngine

    TL* THE CONTACT OWNS A 2004 BMW 545I. WHILE DRIVING 65 MPH, THE VEHICLE OVERHEATED. THE CONTACT STATED STATED THAT THE PUMP COOL PIPE WAS MAKING THE VEHICLE OVERHEAT. THE CONTACT STATED THAT THE VEHICLE WAS DIAGNOSED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 140,000.

    NHTSA complaint 10865210
15. Filed May 10, 2016Failure Apr 28, 201691,200 milesBrooklyn, NYAir bags

    NOT TOO LONG AGO I HAD MY CAR PARKED ON A STREET ON A SUNNY DAY. I GOT IN THE VEHICLE AND STARTED IT AND RECEIVED A MESSAGE ON MY IDRIVE SAYING THAT THERE IS A PASSENGER RESTRAINT SYSTEM MALFUNCTION AND A AIRBAG LIGHT ALONG WITH THE SEATBELT LIGHT LIT UP ON THE DASH. DEALER SAYS THAT THERE IS NO RECALL FOR THIS ISSUE YET ONLINE I'VE READ THAT MY MODEL DOES IN FACT HAVE A RECALL FOR THIS ISSUE.

    NHTSA complaint 10864301
16. Filed Mar 16, 2016Failure Jul 9, 201563,000 milesArroyo Seco, NMAir bags

    THE AIR BAG WARNING CAME ON IN THE INFORMATION CENTER ABOUT A MALFUNCTION ON THE PASSENGER SIDE. DEALER SAID SENSOR WOULD NEED REPLACEMENT.

    NHTSA complaint 10850047
17. Filed Mar 15, 2016Failure Jun 8, 2015181,500 milesStephens City, VAAir bags, Seat belts

    TL* THE CONTACT OWNS A 2004 BMW 545I. WHILE THE VEHICLE WAS PARKED, THE AIR BAG AND PASSENGER SEAT BELT WARNING LIGHTS ILLUMINATED. THE FAILURE OCCURRED CONSTANTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FRONT PASSENGER SEAT AIR BAG OCCUPANT DETECTION MAT FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 181,500.

    NHTSA complaint 10849866
18. Filed Dec 8, 2015Failure Nov 16, 201592,000 milesSherman, CTElectrical system, Exterior lighting

    PASSENGER SIDE HEADLIGHT ASSEMBLY WIRE "JACKET" IS BRITTLE AND FLAKING OFF, CAUSING MALFUNCTIONS IN PARKING LAMP "HALO" DUE TO EXPOSED COPPER WIRES. ALSO, HIGH-BEAM HALOGEN LIGHT WIRING HAS EXPOSED COPPER WIRING. WIRES GET HOT TO THE TOUCH AND CAUSE A "PASSENGER PARKING LAMP MALFUNCTION" TO APPEAR INSIDE THE CAR. PROBLEM SEEMS LIKE IT IS A FIRE HAZARD TO SAY THE LEAST. MANY ONLINE FORUM MEMBERS HAVE EXPRESSED THE SAME ISSUE. I ATTEMPTED TO CONTACT BOTH THE HEADLIGHT ASSEMBLY MANUFACTURER, HELLA, AS WELL AS THE CAR MANUFACTURER, BMW OF NORTH AMERICA; BOTH COMPANIES DID NOT TAKE RESPONSIBILITY. PROBLEM EXPANDS OVER MANY MODELS FOR SEVERAL YEARS. PLEASE INVESTIGATE. I HAVE EVEN HEARD OF HEADLAMPS CATCHING FIRE, CAUSING SUBSTANTIAL DAMAGE TO THE VEHICLE. EVEN IF THE CONSUMER DECIDED TO PURCHASE A NEW HEADLIGHT ASSEMBLY FOR ~$1,500, THE WIRING WILL LIKELY STILL CAUSE THE SAME ISSUE A FEW YEARS DOWN THE ROAD. THE HEADLAMP BULBS ARE HIGH VOLTAGE XENON GAS BULBS THAT HAVE OVER 20K VOLTS FEEDING THEM. THIS IS A HUGE SAFETY ISSUE!

    NHTSA complaint 10808948
19. Filed Nov 16, 2015Failure Nov 1, 201581,520 milesTampa, FLAir bags

    TL* THE CONTACT OWNS A 2004 BMW 545I. WHILE DRIVING VARIOUS SPEEDS, THE AIR BAG WARNING INDICATOR ILLUMINATED CONTINUOUSLY. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 08V384000 (AIR BAGS). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 81,520. ....UPDATED 12/30/15 *BF UPDATED 2/23/2016*JS *CN

    NHTSA complaint 10790684
20. Filed Oct 27, 2015Failure Sep 18, 2015122,000 milesKeller, TXPower train, Seat belts1 injured

    THIS TRANSMISSION IS SLIPPING AGGRESSIVELY. IT HAPPENS ON UP-SHIFT 1-2 AND DOWNSHIFT 2-1. IT HAPPENS LIKE 4 TO 5 TIMES IN A WEEK. ALSO SOMETIMES I GET A BIG SLAM ON BOTH UP-SHIFT AND DOWNSHIFT... WHEN THIS HAPPENS, THE TRANSMISSION MALFUNCTION ERROR MESSAGE POPS UP AND REDUCES MY MOVEMENT TO SAFE-MODE, UNLESS I SHUT THE ENGINE OFF AND RESTART THE ENGINE. IF YOU TAKE TIME TO GO ON BMW FORUMS AND BLOGS, EVERYONE COMPLAIN ABOUT THIS ISSUE WITH THIS 5 SERIES... PLEASE DO SOMETHING.. THE PASSENGER AIRBAG RESTRAINT ERROR POPS UP EVEN WHEN SOMEONE IS NOT SEATING ON THE PASSENGER SIDE.. THIS NEEDS TO BE LOOKED INTO.. ALMOST EVERY BMW OWNER HAS THIS PASSENGER ISSUE...

    NHTSA complaint 10786374