Ten problems related to radiator have been reported for the 2000 BMW 540. The most recently reported issues are listed below.
Radiator failure at 42k miles. After reading significant articles related to BMW e39 radiator failures, mine followed suit. There are countless instances of the v8 models showing a consistent pattern of radiator failures which often are catastrophic and life threatening.
Radiator failure in 2000 BMW 540i at 57,000 miles.
Check coolant level light comes on. Radiator leaks, almost over heated and left me stranded. Part replaced at owners expense. Still have old radiator.
While driving coolant was leaking from the radiator. Dealership was notified, but did not resolve the problem.
Radiator failure (blocked).
Radiator failure.
BMW 2000 540i, v8, failure (cracked, loss of coolant) of upper radiator hose connector. I had 3 1/2 yrs/45,000 miles on the car. Plastic component widely known among owners to be prone to failure. Thanks to their advice on warning signs, I was able to stop under control and get repair without major incident; other unsuspecting drivers have been, and will be, less fortunate. To BMW's credit, they replaced my radiator under warranty. But this does not excuse a known design deficiency.
Radiator failure.
At 71888 miles the radiator of my BMW 540i broke because of a crack in the plastic housing around the outlet. I had read about this problem on the roadfly message board. I read that the raditors broke around the hose and they only lasted about 50,000 miles. When I read it, I wondered if I was due, about a month later, I was setting at a stop light and when the light turned green, I accelerated away from the light and as I did I saw steam coming out of the fender wells. It first I thought it was another car, but soon realized it was mine. I pulled over and called to have the car towed to the dealership. It was the radiator and the plasic housing broke around the hose. This is a serious mechanical flaw in a automobile that otherwise is pretty darn good. I don't see why BMW can just provide an all metal radiator, or beef up the plastic around the hose to restand the strain.
Common radiator failures. All at usually below 50k miles.