Recalls & faults: BMW E60 5-Series sedan (2003-10)

Recalls: BMW E60 5-Series sedan

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the number of recalls should not be taken as an indicator of a model’s reliability or its safety more generally.

Recalls: BMW E60 5-Series sedan

2002-04 BMW E60 5-Series sedan: damage to seat heating element

In February 2005, a recall was issued for BMW E60 5-Series sedans manufactured from September 2002 to June 2004. In these vehicles, mechanical loads exerted in the backrest heating for the front seats when persons ingress or egress may result in damage to the seat heating element in the backrest padding. A break in the contact line could cause the damaged area to overheat, creating a risk of minor burns (PRA 2005/7573).

BMW E60 5-Series sedan: front seat occupancy detectors

In February 2005, a recall was issued for BMW E60 5-Series sedans because the seat occupancy detectors may intermittently be unable to reliably detect that the front seat is occupied. As a result, the front passenger’s front and side airbags and seatbelt pretensioners may not activate when required (PRA 2005/7574).

2006 BMW E60 5-Series sedan: loss of wheel guidance

In July 2006, a recall was issued for BMW E60 5-Series sedans manufactured from 9 January 2006 to 26 April 2006. In these vehicles, the lower rubber mounts could come loose from the rear shock absorbers – if this occurred, wheel guidance would be lost and, depending on the driving situation, it may not be possible to control the vehicle safely (PRA 2006/8620).

Pre-2009 BMW E60 5-Series V8: reduced brake power assistance

In October 2010, a recall was issued for models with BMW E60 5-Series vehicles with V8 petrol engines that were available for sale prior to 30 November 2009. In these vehicles, engine oil from the brake vacuum pump may enter the brake vacuum line and potentially the brake booster. The engine oil may cause leaks in the brake booster’s internal rubber membrane which would impair the brake power assistance system – as such, an increased level of brake pedal pressure would be required to slow the vehicle (PRA 2012/13090).

2008-09 BMW E60 5-Series Diesel: diesel fuel filter heater could short circuit

In September 2011, a recall was issued for 5-Series sedans with turbo-diesel engines that were available for sale from 20 August 2008 to 12 June 2009. In these vehicles, moisture may enter the diesel fuel filter heater at the electric contacts, causing the heater to short circuit – this could result in the short-term discharge of the starter battery such that the vehicle may not start. However, the short-circuit could also lead to an engine fire when the vehicle was switched off. Note that the diesel fuel filter heat unit only operated at temperatures below -1 degree Celsius (PRA 2011/13091).

2003-10 BMW E60 5-Series sedan: fire in luggage compartment

In March 2012, a recall was issued for BMW E60 sedans that were available for sale from 1 March 2003 to 31 July 2010. In these vehicles, the battery cover may not have been correctly clipped to the floor panel due to an assembly error – this could cause loosening and possible overheating of the positive terminal cable connection which could, in turn, result in a fire in the luggage compartment even if the engine was not running (PRA 2012/13082).

2009 BMW E60 5-Series Diesel: diesel fuel filter heater could short circuit

In August 2013, a recall was issued for BMW E60 5-Series vehicles with turbo-diesel engines that were available for sale from 1 August 2009 to 30 November 2009. In these vehicles, an internal short-circuit may occur in the area of the electric contacts of the diesel fuel filter heating unit. At worst, an electrical short-circuit may occur in the diesel fuel filter heater which could could a vehicle fire. Please note, however, that the diesel fuel filter heater unit only operated at temperatures below -1 degree Celsius. For the VINs of the recalled vehicles, please see PRA 2013/13591.

2009-10 BMW E60 5-Series Sedan: camshaft timing unit bolts could break

In November 2023, recall campaign 0011520700 was issued for 2009-10 BMW E60 5-Series Sedans. In these vehicles, the bolts connecting the variable camshaft timing unit (BMW’s ‘VANOS’) to the engine may break. If this occurred, the vehicle’s ‘limp home’ safety mode may be activated, the engine warning light may illuminate and the vehicle may lose motive power. A loss of motive power while driving could increase the risk of a collision and injury to vehicle occupants and other road users. For the VINs of the recalled vehicles, please see REC-005810.

Problems and faults: BMW E60 5-Series Sedan

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

BMW E60 520d: N47 timing chain failure

For 2.0-litre N47 four-cylinder turbo-diesel engines manufactured between March 2007 and March 2011, excessively sharp teeth on the crankshaft sprocket could damage, or break, the timing chain. Please note that in the event of breakage, catastrophic engine damage could result and the primary symptom of timing chain damage was a loud ticking noise from the rear end of the engine. For these engines, two situations applied:

• For models manufactured before May 2009, the timing chains, camshaft sprocket and crankshaft required replacement. Of these, the crankshaft had to be replaced because the sprocket was welded to it and the engine also had to be removed because the timing chains were positioned at the rear of the engine, Due to the cost of repair, some owners opted to replace the engine instead.
• For models manufactured from May 2009 to March 2011, the crankshaft did not require replacement since the design of the crankshaft sprockets had been changed. The timing chains and timing guides, however, still required replacement.

BMW E60 530d: M57D30 swirl flaps

For E60 530d models with the M57D30 engine (automatic transmissions only), the swirl flap mechanism in the inlet manifold consisted of butterfly valves within each individual inlet tract. These butterfly valves were secured to an actuating rod via two small screws and, over time, these screws could become loose. If this occurred, the screws could be drawn into the cylinder and cause significant damage to the piston, cylinder head and valves. If a screw were to pass through the exhaust valve, it could then damage the turbocharger. As a result of this problem, a common modification is to remove the swirl flaps and replace them with blanking plates. From 2004 to 2007, BMW introduced larger diameter spindles (made from plastic) and larger screws, though these engines were not immune to failure. Around 2006, it is understood that plastic swirl flaps were introduced to reduce the likely extent of damage.

BMW E60 525i and 530i: M54 VANOS failure

For the M54 engine, the VANOS units may fail due to deterioration of the VANOS piston seal O-rings which are made from Buna (a material with limited temperature resistance). Over time, the O-rings harden and shrink, causing them to lose their functional characteristics – this can cause symptoms such as a loss of power below 3000 rpm, surging around 3000 rpm, a louder idle and rough running.

The piston O-rings lies under and provides support to a Teflon piston seal ring. Replacing the O-rings requires the Teflon seals to be removed for access. Since the Teflon seals cannot be removed from the piston seal groove without damaging it, the Teflon and O-ring seals must be replaced simultaneously. For greater longevity, the Buna O-rings can be replaced with O-rings made from Viton.

The VANOS unit had two piston seals with O-rings, while each piston had two O-ring sizes to provide hydraulic sealing in two VANOS cylinders of different sizes and an additional, smaller O-ring that was used to seal off a piston bearing. It is understood that the O-ring for this cap was also made from Buna and deteriorated in the same manner as the piston seal O-rings.

For more information about the M54 engine, please see BMW M54 and S54 engines.

BMW E60 5-Series: M54, N52, N52K, N62 and N62TU engine deposits

In February 2008, BMW issued technical service bulletin SI B 13 01 07 for E60 5-Series Sedans with M54, N52, N52K, N62 and N62TU engines. In these vehicles, deposits in the injection and induction system may cause driveability complaints and the ‘Service Engine Soon’ light to be illuminated. This condition could be caused by:

• Deposits at the fuel injector’s tip which affected fuel flow and the air/fuel mixture ratio. Symptoms included hesitation or stumble during acceleration or loss of power; poor fuel efficiency; increased HC and CO emissions; and, the ‘Service Engine Soon’ lamp to illuminate due to misfire faults;
• Carbon deposits at the valves and on the intake manifold ports absorbing fuel during the warm-up phase, causing a leaner air/fuel mixture. Carbon deposits (or build-up) could also disturb the mixture flow at low throttle conditions and/or idle speeds. Symptoms of carbon deposits included a loss of power; unstable and/or rough idle; increased HC, CO and NOx emissions; and, the ‘Service Engine Soon’ lamp to illuminate due to intermittent misfire faults; and,
• Combustion Chamber Deposit Interference (CCDI) when there was contact between carbon deposits on the piston crown and the cylinder head. The noise created by this contact may be misdiagnosed as a ping, knock or other mechanical failure. CCDI occurs first as a cold start noise that can fade as the engine reaches operating temperature. As deposits build, there is an increase in compression temperature that may cause pre-ignition detonations. Symptoms include knocking, pining, poor acceleration, increased NOx emissions and engine idle speed surges.

BMW E60 525i and 530i: M54 engine and cold climates

In February 2009, BMW issued technical service bulletin SI B11 08 03 for BMW E60 5-Series Sedans with the M54 engine. In these vehicles, extremely cold climate conditions could cause moisture to accumulate and freeze in the:

• Engine oil separator;
• Hose to oil dipstick guide tube; or,
• Orifice in the dipstick guide tube.

Depending on the position of the crankcase ventilation valve when this occurred, the following may occur:

• High crankcase pressures (stuck closed) resulting in valve cover leakage and/or breakage; or,
• An oil hydro-lock condition (stuck open) which could result in engine damage.

To fix, the crankcase ventilation valve, hoses and dipstick guide hoses were to be replaced; a new insulated style of oil separator and hoses were also introduced.

BMW E60 525i and 530i (N52): ticking noise from camshaft lifters

In September 2009, BMW issued technical service bulletin SI B11 09 07 for E60 525i and 530i Sedans with N52 engines that were produced prior to 31 November 2008. In these vehicles, an occasional ticking or rattling noise from the camshaft hydraulic lifters (HVA) may occur during cold engine starts. It is understood that the ticking was caused by an insufficient quantity of air-free oil for the HVA elements. To fix, however, the twelve (12) exhaust camshaft hydraulic valve lifters needed to be replaced (part no. 11 33 7 605 330).

A revised cylinder head was phased into production from 1 October 2008 and fully implemented on 31 November 2008, as per the following casting numbers –

• N51 (B30): 7588277.01;
• N52 (B30): 7588273.01; and,
• N52K (B30): 7588271.01.

BMW E60 5-Series: N52/N54 VANOS faults

In October 2010, BMW issued technical service bulletin SI B11 02 08 for E60 5-Series Sedans with N52, N52K and N54 engines produced from March 2005.In these vehicles, the ‘Service Engine Soon’ (MIL) lamp may illuminate and be accompanied by a reduction in engine performance/performance; this may occur after driving with the engine at normal operating temperature. If the ignition is cycled, the engine then usually performs normally. Furthermore, the following fault codes are stored in the DME:

• 2A82 VANOS intake – stiff; jammed mechanically;
• 2A87 VANOS exhaust – stiff; jammed mechanically; or,
• 3100 Boost-pressure control, deactivation – boost pressure build up prohibited (N54 engine only).

These VANOS faults may be caused by insufficient oil pressure supply to the inlet VANOS adjustment unit. To effectively move the camshafts to the target positions in the specified time and under all engine conditions, sufficient oil pressure supply to the VANOS control pistons was required. When engine operation required that the VANOS quickly advance or retard the intake or exhaust camshaft, fault 2A82 or 2A87 may occur if the camshaft is ‘late’ or does not reach the target position. In this situation, engine power may be reduced and a check control message be displayed.

According to the service bulletin, a mechanical restriction or electrical failure of the VANOS solenoid and/or the electrical circuit could cause insufficient oil supply to the VANOS assemblies.

Depending on the diagnosis, both VANOS solenoids may need to be replaced (as well as the engine oil and filter). If there was excessive wear to the camshaft bearing ledge, the camshaft hook ring seals and the affected camshaft bearing ledge would require replacement.

BMW E60 540i, 545i and 550i: N62 engine and variable idle

In January 2006, BMW issued technical service bulletin SI B 11 02 05 for BMW E60 540i, 545i and 550i vehicles with the N62 engine that were manufactured from June 2004 to February 2005. In these vehicles, the driver may experience erratic or variable idle speed for around 20 seconds after a cold start. Furthermore, the ‘check engine soon’ light may illuminate and misfire faults may be logged in the DME (e.g. FC 2742, 2743, 2744, 2745, 2746, 2748, 2749 and 274E).

According to the service bulletin, this condition was due to incorrect tolerances and geometry of the ‘Valvetronic’ intermediate levers causing uneven cylinder filling during the transitional cold start period (60 seconds after start-up) when the Valvetronic system was switching from the initial 6 mm to a minimum 0.3/0.8 mm valve lift.

To fix, the Valvetronic intermediate levers were to be replaced.

BMW E60 5-Series: ZF transmission faults

In December 2008, BMW issued technical service bulletin SI B24 01 08 for E60 5-Series Sedans with N52K or N54 engines and ZF automatic transmissions that were manufactured prior to February 2008. In these vehicles, the ‘Transmission’ warning light may illuminate and the transmission enter its fail safe mode. Furthermore, fault code 4F81 (‘ratio monitoring, clutch A’) may be logged in the EGS control module, as well as 507B/507C (‘parking gear sensor implausible’) or 507D (‘parking gear incorrectly disengaged’). The service bulletin attributed these faults to:

• A low transmission fluid level; or
• An internal transmission pressure leak caused by a defective adapter seal between the transmission housing and the Mechatronic unit.

If the Mechatronic adapter seal was found to be defective (i.e. cracks or seal damage), it was to be replaced.

BMW E60 5-Series: ZF transmission sealing sleeve seepage

In March 2010, BMW issued technical service bulletin SI B 24 08 06 for BMW E60 5-Series Sedan vehicles with ZF six-speed 6HP19/21 or 6HP26/28 transmissions that were manufactured up to April 2008. In these vehicles, transmission fluid seepage may be visible in the area of the transmission oil pan; the service bulletin attributed this condition to the tightness of the Mechatronic sealing sleeve’s O-ring. Only if a visible leakage trace indicated a substantial loss of transmission fluid was the Mechatronic sealing sleeve (part no. 24 34 7 588 725) to be replaced.

BMW E60 5-Series: active steering sensor failure

In September 2006, BMW issued technical service bulletin SI B34 05 06 for BMW E60 5-Series Sedans that were manufactured from 26 August 2005 to 28 July 2006. In these vehicles, the optical sensor in the SZL (Steering Column Switch Sensor) may fail. According to the service bulletin, a defective optical steering angle sensor could cause failure of:

• Active Steering;
• Dynamic Stability Control (DSC);
• Active Roll Stabilization (ARS);
• Adaptive Headlights (AHL);
• Active Cruise Control (ACC); and,
• The automatic turn signal reset function.

Please note that one or more systems may fail depending on the degree of damage to the optical steering angle sensor. Furthermore, the failure of DSC, ARS and Active Steering would be indicated by indicator lamps and display messages. To fix, the optical sensor in the SZL was to be replaced.

BMW E60 5-Series: squeaking when steering from left to right

In March 2009, BMW issued technical service bulletin SI B 32 07 08 for BMW E60 5-Series Sedans manufactured up to March 2006, except those with Active Steering and/or Active Roll Stabilization. In these vehicles, there may be a squeaking or squealing noise from the pinion shaft of the steering gear when the steering wheel is turned from left to right. The service bulletin attributed this condition to insufficient lubrication of the steering gear pinion shaft seal. To fix, Lubrizol treatment was to be added to the power steering fluid to lubricate the pinion shaft seal.

2007-09 BMW E60 5-Series: tail light failure

In September 2013, BMW of North America issued a recall for BMW E60 5-Series vehicles that were manufactured from 1 March 2007 to 31 December 2009. Over time, increased resistance at the tail-light electrical contact points could cause damage to the ground terminal and housing of the connector – this would result in intermittent or permanent loss of one or more rear lamp functions (i.e. tail, brake, turn-signal and reverse). As part of the recall, the rear lamp bulb carriers were to be replaced free of charge. Despite this recall being issued by BMW of North America, no equivalent recall has been issued in Australia.

Problems and faults: BMW E60 5-Series sedan

• The engine may overheat due to either an electrical problem between the electric water pump and control module or the water pump itself.
• If there is a rattling noise from the front of the engine and the ‘check engine’ light illuminates, there may be a leak in an oil line for the variable valve timing system.
• For early models, the ‘check engine’ light may illuminate and the engine may run rough due to problems with the original ignition coils; BMW subsequently replaced the original coils with Bosch units.
• For models with the 2.5-litre petrol engine, the oil condition sensor could short-circuit, causing the vehicle not to start on an intermittent basis.
• For some early models with 2.5-litre petrol engines, casting porosity in some of the cylinder heads may cause oil to leak and collect around the spark plug tube.
• The ‘electronic steering lock’ warning light may illuminate and/or the vehicle will not start if the battery was low when starting.
• The universal garage door opener may not accept a code from a different source (new transmitter or new owner) if the batteries in the transmitter are low.
• For models with steering wheel gearshift paddles, the paddles may stop working due to loose connectors terminating the electrical circuit.
• Vibrating speedometer and/or tachometer needles at idle require reprogramming.
• The pivot for the boot hydraulic lift cylinder may become loose and/or its threads may rust, requiring the cylinder to be reinstalled with sealant or the pivot to be replaced.
• For models with the 4.8-litre V8 petrol engine (i.e. the 550i), the right side (cylinders 1-4) valve cover or oil filler cap may break in cold weather due to ice buildup in the vent hose or valve.
• The ‘flat tyre’ warning light may illuminate if the sensor is not reset after a tyre is replaced.