1991 BMW 5 Series Recall

On certain vehicles, failure of a cooling system component such as thermostat, water pump or fan belt can result in a significant increase in coolant temperature and system pressure. Increased system pressure could result the formation of a crack or separation of a seam in the heater core end piece which would cause hot coolant to be expelled from the heater core. This hot fluid could contact car occupants resulting in possible personal injury and/or fogging of the interior window surfaces. Correction: Radiator cap will be replaced with a new design cap in order to avoid buildup of excessive pressure in the cooling system.

A failure of this component (heater and defroster) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain 318IC, 318IS, 318TI, 325I, 325IC, 325IS, 525I, 525IT, 530I, 530IT, 540I, 740I, 740IL, 840CI and M3, the cruise control and throttle cable are attached to the same throttle valve actuating lever at the throttle housing. It is possible that the plastic bushing on either cable could break causing the outer cable housing to separate from the bushing. Throttle pedal application without cruise control engagement could cause the outer tube to catch on the edge of the broken bushing resulting in the throttle valve remaining partially open. If this were to occur, the car might not decelerate as expected and a crash could occut. Correction: A spring clip will be installed on the outer tube of each cable to prevent dislodgment from the bushing.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain 325I, 325IC, 325IS, 525I, 525IT, 530I, 530IT, 535I, 540I, 735I, 735IL, 740I, 740IL and 750I, the brake light switch may fail due to a reduction of contact force on the "snap contact" system which the switch incorporates. This could cause heat induced distortion of the plastic internal switch parts in the area of the electrical contacts. This could cause the switch to remain either in the ON or the OFF position resulting in the brake lights being continuously illuminated or inoperative regardless of brake pedal operation. Correction: Switch will be replaced with on that utilizes a different contact system.

A failure of this component (lights and instruments) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain 318I, 318IS, 325I, 325IS, 525I, 525IT, 535I, 735I, 735IL, 750IL, 850I and M5, the locking tab for the airbag contact ring in the steering wheel assembly could break without warning. If this happens it is possible that the contact ring wiring could break. This would cause the readiness indicator lamp ("SRS" or "AIRBAG") to illuminate and in such a case the airbag would not be available for deployment in a frontal impact. Correction: Locking tab will be replaced with one of a different design.

A failure of this component (airbag) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain 318I, 318IC, 318IS, 325IC, 325IS, 325IX, 525I, 535I, 735I and 735IL vehicles, the fuel feed hose could harden and "set" over time due to engine compartment temperatures. If this "setting" occurs, it is possible that seepage between the hose and fitting could result because the clamp cannot provide sufficient sealing force to compensate for the hardening of the hose. Fuel seepage, in the presence of an ignition source, could result in an engine compartment fire. Correction: fuel feed hoses and associated clamps will be replaced with ones of a new design.

A failure of this component (fuel system) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain 535I, 535IA, 735IA, 735ILA vehicles, the nut which secures the throttle valve shaft may not have been tightened with sufficient torque. If the nut were to loosen, it is possible that movement of the throttle valve might be impaired. If this should occur, the vehicle might not decelerate as expected after the gas pedal is released and loos of vehicle control could result. Correction: Vehicles will be inspected and affected throttle housings with undertorqued throttle valve retaining nuts will be replaced.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain 525I and 525IA vehicles, when driven at normal engine operating temperature with an ambient temperature of 5 degrees centigrade or less, different thermal expansion rates of the throttle valve shaft and housing may impede the movement of the valve and prevent the valve from returning to the closed position. If this occurs, the vehicle will not decelerate at the usual rate after the gas pedal is released. Correction: The axial clearance of the throttle valve housing will be measured and all housing with insufficient clearance will be replaced.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain M5 vehicles, the scews attaching the wheel covers may not have been fully torqued. These screws could gradually loosen, resulting in road debris which could present a hazard to other vehicles. Correction: Loctite will be applied to the wheel cover screws to prevent their loosening.

A failure of this component (suspension) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).