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2004 BMW 545I

Owner reports · Recalls · Investigations

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What owners reported most

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When problems were reported

Mileage at the reported incident

38 reports with mileage · 6 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Air Bags. Review the 18 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 12 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

1 crash reports3 fire reports3 injury reports

Electrical System complaints

12 reports
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180,000 miles · Nov 28, 2019
Electrical SystemExterior 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 ODI #11282786

119,000 miles · Feb 7, 2019
Electrical SystemExterior 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…

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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 ODI #11174913

174,250 miles · Aug 21, 2017
Electrical 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/ BASIC…

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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 ODI #11018755

220,000 miles · Aug 11, 2016
Air BagsElectrical SystemEngine

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 ODI #10895079

92,000 miles · Dec 8, 2015
Electrical SystemExterior 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 L…

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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 ODI #10808948

91,636 miles · Dec 9, 2014
Air BagsElectrical SystemInjury

I RECENTLY PURCHASED A 2004 BMW 545I. ON THE SECOND TIME HAVING A PASSENGER IN THE CAR, WHILE DRIVING DOWN THE HIGHWAY, I WAS ALERTED BY A CHIME AND MESSAGE THAT THE PASSENGER SIDE AIRBAG / SAFETY RESTRAINT SYSTEM HAD FAILED. ALSO NOTICED WAS THAT WHEN TURNING ON THE DRIVER'S SEAT HEATER, THE SEAT GOT VERY HOT IN ONE PARTICU…

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I RECENTLY PURCHASED A 2004 BMW 545I. ON THE SECOND TIME HAVING A PASSENGER IN THE CAR, WHILE DRIVING DOWN THE HIGHWAY, I WAS ALERTED BY A CHIME AND MESSAGE THAT THE PASSENGER SIDE AIRBAG / SAFETY RESTRAINT SYSTEM HAD FAILED. ALSO NOTICED WAS THAT WHEN TURNING ON THE DRIVER'S SEAT HEATER, THE SEAT GOT VERY HOT IN ONE PARTICULAR SPOT- ON THE LEFT SIDE NEAR MY HIP (HOT ENOUGH THAT I RECEIVED A MINOR BURN ON MY LEG THROUGH A PAIR OF JEANS). I CONTACTED BMW CUSTOMER SERVICE ABOUT THE PROBLEM, AS I WAS MADE AWARE THAT THERE WERE RECALLS ON OTHER MODELS FOR THE SAME REASONS, AND WAS TOLD THAT THERE WERE NO OPEN RECALLS FOR EITHER ISSUE ON MY MODEL. THE REPRESENTATIVE SIMPLY EXPLAINED THAT THE VEHICLE WAS OUT OF WARRANTY AND THAT FIXING THE ISSUES WOULD BE AT MY EXPENSE. I BELIEVE THAT THESE ARE VERY SERIOUS DEFECTS THAT COULD AFFECT MY SAFETY AND THE SAFETY OF MY PASSENGERS. *TR

NHTSA ODI #10663024

123,760 miles · Aug 20, 2014
Electrical SystemUnknown Or Other

ODOMETER WAS ROLLED BACK TO 89,151. HTTP://SFBAY.CRAIGSLIST.ORG/SBY/CTO/4622086070.HTML SELLER'S AD: I HAVE THIS BM. IN GREAT SHAPE AND SUPER CLEAN IN AND OUT V8 89300 MILES ALL,POWER IN SIDE NAVIGATION ,CD STEREO SUNROOF LEATHER SEATS MORE INFO PLEASE CALL ME OR EMAIL ME THANKS. SE HABLA SPANOL[XXX] INFORMA…

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ODOMETER WAS ROLLED BACK TO 89,151. HTTP://SFBAY.CRAIGSLIST.ORG/SBY/CTO/4622086070.HTML SELLER'S AD: I HAVE THIS BM. IN GREAT SHAPE AND SUPER CLEAN IN AND OUT V8 89300 MILES ALL,POWER IN SIDE NAVIGATION ,CD STEREO SUNROOF LEATHER SEATS MORE INFO PLEASE CALL ME OR EMAIL ME THANKS. SE HABLA SPANOL[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10626504

29,000 miles · Dec 16, 2013
Electrical SystemElectronic Stability Control (esc)Vehicle Speed Control

MAIN PROBLEM: VEHICLE EXHIBITS HIGHLY UNSAFE TENDENCIES OF TURNING OFF RANDOMLY, LEAVING THE DRIVER WITH NO POWER, NO FUNCTIONING GAUGES, NO FUNCTIONING LIGHTS, AND MORE. CAUSE: FAULTY ALTERNATOR AND VOLTAGE REGULATOR. SCENARIO: ON 12/21/2012, A 2004 BMW 545I VEHICLE WITH APPROXIMATELY 29,000 MILES ON ITS ODOMETER IS TRA…

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MAIN PROBLEM: VEHICLE EXHIBITS HIGHLY UNSAFE TENDENCIES OF TURNING OFF RANDOMLY, LEAVING THE DRIVER WITH NO POWER, NO FUNCTIONING GAUGES, NO FUNCTIONING LIGHTS, AND MORE. CAUSE: FAULTY ALTERNATOR AND VOLTAGE REGULATOR. SCENARIO: ON 12/21/2012, A 2004 BMW 545I VEHICLE WITH APPROXIMATELY 29,000 MILES ON ITS ODOMETER IS TRAVELING ON A HIGHWAY DRIVING 70MPH, HIGHWAY IS FLAT AND SPEED IS CONSTANT WITH VERY LIGHT TRAFFIC. WITHOUT WARNING, CAR COMPLETELY TURNS OFF, ALL GAUGES (SPEED, TACHOMETER, AND FUEL) REVERT TO "0" POSITION, RADIO TURNS OFF, LIGHTS TURN OFF, CAR IMMEDIATELY SLOWS AND HAS NO PROPULSION POWER NOR SPEED CONTROL AT ALL. BRAKE PEDAL WAS NOT DEPRESSED, STEERING REVERTED TO A VERY FIRM FEELING. ABOUT 10 SECONDS OF COASTING LATER, THE VEHICLE'S ELECTRONICS RESUME OPERATION. MULTIPLE INCIDENTS WERE TO OCCUR BETWEEN 12/21/2012 AND 1/29/2013 TO VARYING DEGREES OF SEVERITY. ON 1/29/2013, THE VEHICLE FAILED IN A SIMILAR CAPACITY THREE TIMES ON A 21 MILE JOURNEY. ON 1/30/2013, VEHICLE FAILED TWICE. ON 1/31/2013, THE BMW 545I VEHICLE IS AT AN AUTHORIZED BMW DEALER. IT IS DETERMINED THE ALTERNATOR AND VOLTAGE REGULATOR ARE DEFECTIVE. ELECTRICAL POWER WAS NOT CONSISTENTLY BEING GENERATED NOR ALLOCATED TO VITAL VEHICLE COMPUTERS. THESE INTERRUPTIONS IN POWER SUPPLIES, WHICH LAST APPROXIMATELY 7-10 SECONDS, ARE REFERRED TO AS BROWN-OUTS AND THEY VARY IN DEGREE OF SEVERITY. THE MAJOR CASES INCAPACITATED THE ENTIRE VEHICLE, SHUTTING DOWN ALL GAUGES, LIGHTS, AND CRITICAL SAFETY SYSTEMS. ON 2/1/2013, THE BMW 545I WAS DELIVERED BACK TO THE OWNER WITH THE ALTERNATOR AND VOLTAGE REGULATOR REPLACED. THE MILEAGE OF THE VEHICLE AT THE TIME OF REPAIR WAS ONLY 33,426. NOTE: BMW DEALER NOTED THIS WAS A COMMON PROBLEM ON MANY OF THE 5-SERIES MODELS IN THE 2004 AND UP YEAR RANGE. *TR

NHTSA ODI #10556154

71,487 miles · Sep 9, 2013
Air BagsElectrical SystemEngine

CUSTOM ORDERED 545I IN 2004 AS STILL ORIGINAL/EXISTING OWNER. HAVE HAD REPEATED ELECTRICAL ERRORS ON I DRIVE "DYNAMIC DRIVE FAILURE PROCEED WITH CAUTION AS THE STEERING HAS BEEN EFFECTED AND SEE YOUR BMW AUTHORIZED REP," "ELECTRICAL FAILURE SEE YOUR BMW AUTHORIZED REP. IMMEDIATELY PROCEED WITH CAUTION, "PASSENGER RESTRAINT FAU…

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CUSTOM ORDERED 545I IN 2004 AS STILL ORIGINAL/EXISTING OWNER. HAVE HAD REPEATED ELECTRICAL ERRORS ON I DRIVE "DYNAMIC DRIVE FAILURE PROCEED WITH CAUTION AS THE STEERING HAS BEEN EFFECTED AND SEE YOUR BMW AUTHORIZED REP," "ELECTRICAL FAILURE SEE YOUR BMW AUTHORIZED REP. IMMEDIATELY PROCEED WITH CAUTION, "PASSENGER RESTRAINT FAULT PROCEED WITH CAUTION EFFECTING BELT AND BELT FORCE LIMITER, STALLING AT VERY LOW AND AS HIGH RATES OF SPEED AS HIGH AS 70 MPH WITHOUT ANY WARNING." SOMETIMES THE CAR LOGS THE ERRORS AND MANY TIMES IT DOESN'T FULLY THAT IT TAKES BMW NA'S COMPUTER TO ACCESS THE EXTENDED RAM IN THE CAR TO RETRIEVE PER BMW NA THAT THE DEALERSHIPS CAN'T. I EVEN HAVE PICTURES OF THE ERRORS THE CAR DOESN'T LOG SO THEY CLAIM THEY CAN'T DO ANYTHING. BMW ENGINEERS IN GERMANY HAVE BEEN INVOLVED AS THE CAR REFUSED TO REPROGRAM TWICE FOR THE DEALERSHIP. THIS CAR IS COMPLIANT W/ALL RECALLS PER THE DEALER AND HAS BEEN IN THE SHOP OVER 16 TIMES W/ONLY 70K MILES. THE DEALER AND BMW NA CAN'T DETERMINE THE ROOT CAUSE OF THE PROBLEMS EXCEPT TO SAY THEY THINK THEY'RE BEING TRIGGERED BY LOW VOLTAGE AND ITS HAD 3 BATTERIES AT LESS THAN 70K MILES, ISN'T DRIVEN MUCH, AND BMW NA NOR THE DEALERSHIP CAN PERMANENTLY RESOLVE THE ERRORS AND STALLING AND/OR STOP THEM. BMW NA AND THE DEALERSHIP HAVE REPLACED THE ENTIRE WIRING HARNESS AT 13K MILES, HAVE REFUSED TO TAKE THE CAR BACK AFTER SEVERAL ATTEMPTS AFTER QUALIFYING AS A LEMON UNDER THE LEMON LAW SINCE BEFORE 10K MILES AND BEEN GIVEN MULTIPLE EXCUSES FOR ALL OF THE ERRORS THEY CAN'T RESOLVE. THEY KEEP TELLING US TO BRING IT BACK EVERY TIME, BUY AN EXTENDED WARRANTY AT $6K TO CONTINUALLY SERVICE ELECTRICAL AND STALLING/RUNNING ROUGH ISSUES THEY CAN'T FIX UNDER ORIGINAL FACTORY WARRANTY. THEY'RE NOT REPORTING SERVICE TRIPS TO CARFAX AND REFUSE TO RELEASE DOCUMENTATION ON THE CAR REGARDING THE PROBLEMS TO US OR OUR ATTORNEYS. *TR

NHTSA ODI #10542730

87,000 miles · May 13, 2013
Electrical SystemEnginePower Train

VEHICLE SLIPS IN AN OUT OF 5TH AND 6TH GEAR WHEN TRAVELING AT CONSTANT 35 TO 40 MPH IN AUTO MODE AND AROUND 60 MPH IN DS MODE. NOTICEABLE OIL LEAKS AS WELL AS OCCASIONAL SMOKE FROM TAILPIPE AND VEHICLE BANGS INTO GEAR ( WHILE DOWNSHIFTING ON OCCASION) ALSO NOTICED THAT THE ELECTRICAL SYSTEM SEEMS TO CUT OUT FOR A SPLIT SECOND W…

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VEHICLE SLIPS IN AN OUT OF 5TH AND 6TH GEAR WHEN TRAVELING AT CONSTANT 35 TO 40 MPH IN AUTO MODE AND AROUND 60 MPH IN DS MODE. NOTICEABLE OIL LEAKS AS WELL AS OCCASIONAL SMOKE FROM TAILPIPE AND VEHICLE BANGS INTO GEAR ( WHILE DOWNSHIFTING ON OCCASION) ALSO NOTICED THAT THE ELECTRICAL SYSTEM SEEMS TO CUT OUT FOR A SPLIT SECOND WHILE DRIVING. HEADS UP DISPLAY AND RADIO ILLUSTRATES THIS FINDING AS THEY SHUT OFF FOR A SECOND. THE CLOCK IS ALSO BEHIND A FEW MINUTES / WEEK BECAUSE OF THIS. *TR

NHTSA ODI #10511606

Official recalls

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No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

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No exact-year investigations in this snapshot.