BMW 5 Series Touring (2004 – 2010) Review

SEE ALSO www.honestjohn.co.uk/carbycar/bmw/5-series-e60-2003/ FOR MORE EXTENSIVE LIST

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.

6-5-2011: DPFs and car converters tend to need replacing at 120,000 - 130,000 miles. Cost is £1,500 - £2,000.

6-5-2011: Some cases of brake pipe corrosion on cars just 6 years old.

3-2-2012: 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.

13-2-2013: 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.)

4-1-2014: 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.

9-1-2014: 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.

10-1-2014: 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.

13-1-2014: 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.

26-1-2014: 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.

17-6-2014: EGR, DPF and turbo problem with 50k mile 4 year old E61 BMW 520D Touring. Total bill £2,676 including £270 + VAT for diagnostics.

20-9-2016: 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=/)

08-02-2005 R/2005/022 BMW E46, E53, E60, E61, E65, SERIES 3, 5, 7 AND X5 the bearings of the fuel injection pump may fail build dates 30-11-2004 to 31-01-2005

May 2007 TSB: SI B 61 28 06 General Electrical Systems May 2007 Technical Service. This Service Information bulletin supersedes S.I. B61 28 06 dated January 2006. [NEW] designates changes to this revision SUBJECT: ELV Warning in Instrument Cluster MODEL E90, E91, E92 (3 Series) E60, E61 (5 Series) E63, E64 (6 Series). SITUATION: The ELV (Electronic Steering Lock) check control warning illuminates in the instrument cluster and in some cases, engine start is inhibited. Diagnostics reveals fault code A0AA in the CAS (Car Access System) and prompts a control unit replacement. CAUSE: Low voltages in the vehicle electrical system when cranking/starting the engine. PROCEDURE [NEW]: This problem has been integrated into DIS diagnostics. Follow diagnostics and relevant test plan using DIS V49.0 or later.

1-10-2010: Worldwide recall of 350,000 BMW 5-Series, 6-Series and 7-Series and Rolls Royce Phantoms fitted with V-8 or V-12 engines because of a leak from the power assistance to the brakes. Affects 10,500 car s in the UK. Owners will be notified by post.

26-10-2010: Woodcliff Lake, NJ: BMW of North America has notified the US Environmental Protection Agency (EPA) of its intent to conduct a voluntary recall of some model year 2007-2010 BMWs equipped with twin-turbo inline six-cylinder engines, all of which feature BMW’s High Precision Injection direct fuel injection system. It has also asked for approval from the California Air Resources Board to conduct this action. Affected vehicles may experience a failure of the high-pressure fuel pump. Symptoms include long-crank engine starting times along with the illumination of the “Service Engine Soon” light. In certain cases, the driver may experience reduced engine performance in a Safe Mode accompanied by a tone and the illumination of the “Engine Malfunction” light. Based on the individual service history of the vehicle, the action will entail replacement of the high-pressure fuel pump and/or a software update. Approximately 130,000 vehicles are potentially affected with about 40,000 expected to require a new high pressure fuel pump. Affected BMW models include MY 2007–2010 335i models, MY 2008–2010 135i, 535i and X6 xDrive35i Sports Activity Coupes and MY 2009 – 2010 Z4 Roadster sDrive35i. In a separate action, BMW has notified the National Highway Traffic Safety Administration (NHTSA) that it will voluntarily recall approximately 20,800 MY 2008 X5 Sports Activity Vehicles equipped with normally-aspirated inline six-cylinder engines to replace the low-pressure fuel pump. In this case, should the fuel pump experience a failure, the engine will stop running and the driver will lose power assist for the steering and brakes although both the steering and the brakes remain operational.

27-3-2012: BMW is recalling 109,000 previous generation UK 5 Series and 6 Series models because of a potential electrical problem. The problem could cause a fire in the boot, but no injuries or accidents related to the fault have been reported and the recall is precautionary. All type of 5 Series and 6 Series are affected, including saloon , touring, coupe and M models. Build dates are March 2003 to July 2010. According to BMW the battery cable in the boot could be mounted incorrectly, resulting in malfunctions, problems with starting the car, or in extreme cases some scorching or, possibly, a fire. There’s no reason to panic, though, because BMW says that only 1% of cars checked so far have shown the fault. If you own the E60/E61 BMW 5 Series, built from 2003 to 2012, or the E63 6 Series, built from 2004 to 2011, then your car may be affected. BMW is working with the DVLA to gather details of current BMW 5 Series and 6 Series owners, so you should expect a letter withing the next few weeks. You will be expected to take the car to a local dealer for a fix to be undertaken, which will take around 30 minutes. There is no charge for this. If you own a current generation F10 5 Series or 6 Series there is no need to worry, these models are built with different wiring and are not at risk. (R/2012/039: http://www.vosa.gov.uk/vosa/apps/recalls/searches/expand.asp?uniqueID=39ADAE6B50B53351802579CA0037A982&freeText=Blank&tx=/)

31-3-2012 Canada: BMW 5 Series 2004 to 2010; BMW 6 Series 2004 to 2010: 16,748 units. On certain vehicles, the insulated bulkhead connector (used to join the two halves of the positive battery cable) may have been incorrectly installed during vehicle assembly. Over time, the bolt connection could loosen, which would increase electrical resistance. In addition, an incorrectly insulated bulkhead connector could allow humidity to accumulate at this location, causing current leakage. These issues could cause the cable connection to overheat, which could result in a vehicle fire causing property damage and/or personal injury. Correction: Dealers will inspect and, as necessary, secure the insulated bulkhead connector. In addition, protective grease will be added to the area and the plastic battery positive terminal cover will be replaced.

24-5-2012: UK Recall R/2012/039: BMW 5-Series, 5-Series Touring, M5 Saloon, M5 Touring, 6-Series Coupe, 6-Series Convertible, M6 Coupe, M6 Convertible & Alpina: Risk of Fire: The positive battery cable, routed from the vehicle battery to the engine bay, consists of one cable in the luggage compartment and one cable in the underbody. Both cable are connected by a screw connection and covered by a plastic cover. In single cases the plastic cover may have been fitted incorrectly during the vehicle production. Over time, an incorrectly fitted cover could cause the screw connections to come loose, leading to an increased resistance, also humidity may affect the connection and cause high resistance and drop in current. This can lead to the vehicle not starting and in extreme cases the connection could over heat leading to the possibility of a fire in the luggage area. Remedial Action: The clips on the battery will be checked the cover replaced and sealed.

15-4-2014: Worldwide recall of 489,000 BMW cars with six-cylinder 2.5 and 3.0 litre petrol engines of which less than 3,000 are in the UK. These are: N51 (1991-1995), N52 (from 2005) and the N55 6-cylinder petrol turbo (from 2009). The screws for the housing of the adjustment unit of the variable camshaft timing (Vanos) for the intake and exhaust camshafts could potentially become loose or break. An engine warning lamp ‘should ’ appear in such circumstances, but if drivers experience any loss of power they should contact their BMW dealer immediately.

9-4-2015: BMW has initiated a 'quality enhancement recall' on 2.0 litre N47 diesel engines. They are currently working their way through cars manufactured in 2007 and 2008, but owners need to contact their dealer themselves to request the work. Reader's 123d currently in for the work which at minimum involves replacing the timing chain, guide and tensioners.