BMW 5 Series Touring (2004 – 2010) Review

Very thin windscreen glass cracks easily when hit by stones.

Check PAS fluid level regularly. Steering rack may leak fluid unnoticed out of end seal and into track rod end gaiter. Seems to be a Europe-wide shortage of parts to correct this.

Self levelling rear suspension prone to failurre after around 4 years and/or around 80k miles.

Wiring connection between car and tailgate fails. Best fixed independently because BMW dealers have been known to quote £2,000 to repair it.

DPFs and car converters tend to need replacing at 120,000 - 130,000 miles. Cost is £1,500 - £2,000.

Some cases of brake pipe corrosion on cars just 6 years old.

Significant numbers of high pressure fuel pump failures on 530i and 535i in the USA. See link: www.n54tech.com/forums/showthread.php?t=14650 BMW initially "blamed" "ethanol" or "poor quality" gasoline in the U.S. for these failures. In fact, BMW HPFP failures are well documented in Germany (even with their "superior quality" gasoline), Australia, Asia, South Africa, etc. Some of these countries have never used ethanol in any of their gasoline..... HPFP Part Numbers 1. 13-51-7-537-320 2. 13-51-7-585-655 3. 13-51-7-592-881 4. 13-51-7-596-123 5. 13-51-7-594-943 6. 13-51-7-613-933 7. XX-XX-X-XXX-402 8. 13-51-7-616-170 9. 13-51-7-616-446.

Another case of wiring problems to the reversing lights in the rear hatch becaude the cables supplying the power get crimped by the wire guide when the hatch is closed. (See above.)

E60/61 petrol models can develop electrical failure in three different areas simultaneously: fan blower in the cabin; mirror demisters and rear window demister. This can be solved by simply unclipping the 'Intelligent Battery Controller ' cable connected to the battery, then reconnecting. It's part of the problem listed above at 10-802012 and 31-8-2012.

Rear suspension arm balljoint failure on 120k mile E61 525i Touring leading to collapse of nearside rear suspension. From the photo it looks like a wear and tear problem that should have been picked up in the car's last MoT. May have been due to the weight of loads carried.

Fault with high pressure fuel pump of petrol models can lead to stalling without warning and does not show up on BMW diagnostics. This led to a voluntary recall on 26-10-2010 on 2007-2010 5-Series E60s and E61s in the USA so is an acknowledged fault, but no recall in the UK.

Failed turbo in 61k mile 2010 E61 520d auto, probably due to failure to idle from super-hot. BMW generously offered £1,000 towards £1,800 replacement bill.

Another complaint of rear suspension arm balljoint failure, this on a 130k mile 2004 E61 530D Touring. This is becoming quite a serious safety issue and owners should report the failures to VOSA. However, very difficult to blam BMW for failures on what are now 10 year old cars. Owners shoud have the rtear suspension of their E61 Tourings independently inpected, especially if they are considering towing or carrying heavy loads.

EGR, DPF and turbo problem with 50k mile 4 year old E61 BMW 520D Touring. Total bill £2,676 including £270 + VAT for diagnostics.

Reader reported total electrical failure of his 2009 BMW 525D. Insurance Assessor's report: "The vehicle suffered an electrical failure of an unidentified module mounted in the vehicle's boot. Thius caused an electrical short circuit, causing the earth wire in the body wiring loom to heat up. This has melted the plastic insulation of the earth wire and adjacent wires." Total repair cost estimated at £10,414.28. (See E60 entry 31-8-2012 for an hilarious account (some swearing) of a ridiculous design deficiency of E60/E61 5-Series whereby the battery is sited directly beneath the one-way rear cabin vent flap so if the one way flap fails water is forced through it onto the battery: http://www.liveleak.com/view?i=af8_1346299893. There was a recall: R/2012/039: http://www.vosa.gov.uk/vosa/apps/recalls/searches/expand.asp?uniqueID=39ADAE6B50B53351802579CA0037A982&freeText=Blank&tx=/)