Started the car and began to drive out of driveway when I heard a noise in the engine. Shut down engine and popped the hood- found drive belt shredded because power steering pump snapped and let loose into tension pulley- luckily I was not at speed and belt did not fail- otherwise catastrophic engine failure would occur along with loss of power steering.

- Kennebunk, ME, USA

I was driving appx 40mph while on a local road slightly uphill, engine shut off without warning, lost power steering and brake assist. Luckily no cars around me so I was able to barely roll over to the roadside. Car would not start again, was towed to dealership. Replaced ECU for a total cost of $2K.

- Greenwich, CT, USA

Driving home one evening, I noticed a binding feeling being transmitted through the drive-train, drive-ability did not seem too affected, other than the odd bind being felt. The next morning upon start-up, the car began making a loud, RPM sensitive whining noise. I shut the car off and drove one of my others. When I opened the hood it was obvious that the serpentine belt was not aligned correctly. Through further observation, it was clear that the power steering pump mounts were broken. The broken mounts caused the pump to push forward and not be aligned. The belt was being chewed up in the process. While removing the pump I noticed that the bolts holding it in place were loose. These loose bolts were alarming and could have resulted in the power steering pump loosening even further cause the belt to jump. In my opinion, it is completely unacceptable for this to have happened. The fact that a molded piece of aluminum would fracture and break is alarming, and the loose bolts is even worse. It is very possible that the belt could have jumped (has happened to fellow 540I drivers) which would have resulted in no power steering.

- Reston, VA, USA

The 2003 BMW 540I power steering pump spool valve was found (disassembled and judged by BMW technician) to jam at lower RPM thus causing complete loss of power steering assist, especially in reduced RPM turns off highways. On several occasions I nearly crashed into the median-wall because of it. I sent a letter to BMW but all they told me is that it would be forwarded but that I would never hear back from them again. I consider this a material/part flaw that BMW has to consider as serious and offer some form of repair/replace plan or customer-directed action as it can lead to serious crashes during turning maneuvers!

- Pittsburgh, PA, USA