2nd Gear Member
Join Date: Jan 2009
Location: UAE - Gulf Area
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I have 530i, 2002 with 330,000 KM now & I can remember the following problems that I think, common in booth 530 & 540:
1.Suspension problems (steering rack, bushes & arms, etc) from time to time due to the complication of the suspension system.
2.One important problem, the pixels in the cluster disappears due to a pressure problem. Few threads here provide details on this problem.
3.Taillights gets water in that can damage the light itself & some electrical modules too (like radio controller). Silicon solves this problem up to certain extent.
4.Headlights goes dull & can not be cleaned from inside. Only you can polish it from time to time, till it reaches the stage of replacement.
5.Problem with electrical seats (easily broken side-covers & clicking noises). Some solutions are explained in the BMW tips board.
I would advise you to ask about the price of the steering rack, headlights, taillights, cluster repair & radio controller before you proceed. The above info is based on experience with 530. forums experts can provide more valued advises specifically about 540.