Radiator Problems of BMW 540 - part 1

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. First the bracket brocket putting the pump at a steep angle n forcing the belt to go off track which then caused all the other accessories to be disabled including the water pump which overheated the car.

See all problems of the 2002 BMW 540 🔎.

Radiator cracked at top hose inlet causing loss of coolant.

See all problems of the 1999 BMW 540 🔎.

The radiator neck broke off while driving at highway speed on my 1997 540i. It is a common problem with BMW by all accounts, owners, technicians and even my own previously experienced it with an 1988 735i. Plastic parts on the radiator is unacceptable, dangerous and costly. This has been a problem for more than 10 years on these expensive luxury vehicles with no resolution by BMW.

See all problems of the 1997 BMW 540 🔎.

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.

See all problems of the 2000 BMW 540 🔎.

Radiator cracked, disabling car on highway. Also caused xenon lamp failure. Replaced by dealer under warranty. This is a well known defect on BMW e-39 series cars.

See all problems of the 2001 BMW 540 🔎.

White steam was coming from under the hood onto the front windshield. The steam was fogging the windshield, and causing poor visibility while driving 50-55 mph. Consumer was able to get the vehicle to a repair shop. Dealer informed the consumer that the upper neck connector of the radiator hose broke.

See all problems of the 1998 BMW 540 🔎.

1) check coolant level warning light came on twice in 1 week. Kuni BMW conducted my factory inspection ii service only 2 months before this occured. ) radiator cracked where the upper hose enters the radiator, leaking fluid into the engine bay and ground. 3) replace the radiator. This is a well know defect on this vehicle - why doesn't BMW do something about this?.

Radiator failed on my 1999 BMW 540 at 54,700 miles. I believe this to be a safety problem that BMW needs to address. This safety problem: - disables the vehicle no matter where you are from rush hour traffic where the panic could endanger other drivers, to the middle of nowhere in the dead of winter by yourself. - steam from failed radiator blocks vision of the road, or whatever else is in the drivers side front corner of the vehicle. - failure can not be predicted by visual inspection of the radiator.

2001 BMW 540i automatic transmission; approximately 57,000 miles; radiator cracked spontaneously under normal driving conditions; significant steam resulting in obscurred view of the roadway and other vehicles; car taken to local repair center; awaiting cost estimate and full damage report.

(1) replaced water pump and accessory belts. On a forum that I read, many suggest replacing the radiator when replacing the water pump, as preventive maintenance due to the radiator's high and frequent failure. Replace the radiator as preventive maintenance?!? I would rather not. A radiator is not an oil or air filter. (2) upper neck on the radiator broke and released more than a gallon of coolant, in less than 50 feet, in the form of liquid and steam. The steam obscured vision on the drivers side of the vehicle. Luckily I was making a right-hand turn into a parking lot. (3) no repair as of yet. The failure of the radiator occurred at approximately 11:00 am. I made it home at 12:05 p. M. I called the local BMW parts department (one hour and thirty minutes away) to arrange to pay for the radiator by credit card and then have the part left with one of the salespersons, because the parts department closes at 1:00 p. M. But they no longer accept credit card purchases over the phone from in-state customers, even after practically begging. Very poor practice unless they want to loose customers. Actually immediately after I submit this I will go on-line and try to find an after-market radiator. Probably of better quality anyway. Sad but true. I encourage the release of the information contained in this questionnaire to the manufacturer of my vehicle.

Crack in radiator - needs replacement.

1. No symptoms; 2. Cracked radiator neck, that was fortunatly caught just prior to a catastrophic failure. The radiator neck broke in my hand as I was removing it. 3. Replaced radiator.

Various problems involving 1998 BMW 540ia which was brought used. BMW had been importing vehicles for sale, fitted with a radiator that had plastic ends as well as supply and return under approximately 21 p. S. I. These radiators suddenly ruptured under load while driving, causing the drivers to swerve on impulse at impact of the rupture. The radiator was likely to rupture at about 80k miles.

(1) normal driving conditions; noticed "steam" coming from under hood. 2) radiator's upper hose inlet cracked (plastic); car disabled (3) car out of warranty; no remedy from manufacturer.

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.

I was driving down a busy street one evening and as I came to a light, smoke started coming out of my hood. Fortunately it was in the evening and traffic was lighter than usual. I pulled into a parking lot off the side of the road. Having known others that this has happened to, I first checked the radiator and sure enough, there was a large crack down the side of the housing. I had the car towed home and purchased a new radiator from BMW of seattle the following morning. The new radiator was about $200, a few hours of my own labor and a few more hours detailing the engine pay and headlights which had radiator fluid all over them. Also from the experience of others who own e39 BMW 540s, I fully expect this to happen again in the next 50k miles. I also expect the expansion tank to go within the next few months.

While driving coolant was leaking from the radiator. Dealership was notified, but did not resolve the problem.

Without warning a crack appeared in the radiator housing causing a loss of antifreeze. Car was out of warranty. Had to replace the part. Same thing just happened again.

2nd catastrophic radiator failure. Not a leak, the neck breaks off causing immediate loss of cooling. 1st radiator at 45k, 2nd at 92k. Based on other's experiences, this is very common for this model (and even longer life than many). Causes loss of vision due to amount of steam released. Less experienced driver may have difficulty controlling vehicle to get to side of road quickly to shut down. No way to predict the failure. Same issue with expansion tank. Both failures are on plastic parts.

Radiator failure (blocked).

Multiple coolant defects on the 1998 540. The car has now had 3 radiators, 3 thermastats, water tube seals replaced twice, and a water pump. The costs have been over $3,500. These leaks are not just expensive, they pose a real danger to causing personal injury and damage. The failure rate is known to be very high. . Read more...

Radiator failure on 1999 540 touring - disables the vehicle no matter where you are from rush hour traffic where the panic could endanger other drivers, to the middle of nowhere in the dead of winter by yourself. - steam from failed radiator blocks vision of the road, or whatever else is in the drivers side front corner of the vehicle. - failure can not be predicted by visual inspection of the radiator.

Plastic neck of radiator on my '98 BMW 540ia broke completely and suddenly on highway. White smoke came out under the hood. Saw temp gauge climb up rapidly. Pulled over immediately. Towed to dealership for repair. No one was hurt luckily.

Radiator failure at 54,000 miles.

My 1997 BMW 540i 6-speed had a radiator failure at 77,500 miles. The plastic radiator connection point for the top hose snapped off. This appears to be a well know issue after speaking with BMW service techs and searching BMW internet sites. I believe that the manufacture should take care of this issue.

Radiator failure.

1997 BMW 540ia radiator failure. Upper hose connection cracked off unexpectedly, causing catastrophic dump of engine coolant. Vehicle was immediately disabled.

I own a 1997 BMW 540i. Radiator broke at plastic attachment point. Coolant leaked all over the windshield and engine. This seems to be a well known defect among owners of this car due to the plastic attachment point at the junction of the hose and the radiator.

Radiator failed at 40k miles in middle of rush hour traffic,obscuring vision while driving between many cars and then stranding car fat dangerous interchange.

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.

My 1997 BMW 540i6 radiator broke on me while driving on a highway on 5/30/03.

1997, BMW, 540i radiator failure @ 77,500 miles (detected by BMW dealer during routine service inspection); radiator replaced at my cost.

At the precise moment I fully depressed the accelerator to pass a slow-moving vehicle, causing the automatic transmission to down shift, the radiator upper neck broke off, causing complete loss of coolant. Significant steam was generated from the leak and caused a cloud behind my car that could have blocked the view of a following vehicle. I was traveling at highway speeds which minimized the steam's ability to block my view, but at lower speeds the steam may have completely blocked my view. Considering I was passing a vehicle, there was a risk that if my view was obstructed, an accident with either the vehicle being passed or oncoming traffic could have resulted. I was stranded until my temporary repairs allowed me to limp to the nearest repair facility. I understand that this is a common failure mode for this vehicle, and request an investigation be initiated.

The radiator hose connection at the top of the radiator failed completely. It is made of plastic, and split under cool weather conditions. This resulted in replacement of entire radiator, and replacement of radiator overflow container. It would appear that the use of plastic in this application resulted in heat stress over time, eventually resulting in complete failure without warning. Possible engine damage still being assessed at this time. I understand that this problem has occurred too many customers, however, the factory replacement parts appear to be exactly the same as original. Therefore, I can expect total coolant failure again in the future. This seems imprudent, and I have no response from BMW on this issue.