FaultScore

BMW 535I fuel system problems

146 of the 722 complaints filed about the BMW 535I are about the fuel system — 20% of everything owners reported. The worst model year for it is 2009.

146

Complaints

20%

Share of all complaints

3

Crashes

2

Fires

Fuel & Propulsion complaints by model year

2008 535I 15 10.3%

Median failure at 60,000 miles

2009 535I 42 28.8%

Median failure at 70,000 miles

2010 535I 34 23.3%

Median failure at 62,500 miles

2011 535I 35 24.0%

Median failure at 78,000 miles

2012 535I 15 10.3%

Median failure at 93,500 miles

2013 535I 3 2.1%

Median failure at 3,100 miles

2014 535I 1 0.7%

Median failure at 4,500 miles

2015 535I 1 0.7%

What owners said

2013 BMW 535I Albertson, NY Fire

FUEL/PROPULSION SYSTEM

My 2013 BMW 535i (VIN [XXX] ) caught fire spontaneously while parked, turned off, and unoccupied on 11/18/2025 in Westbury, NY. A passerby saw smoke and called 911. Nassau County Police and the Westbury Fire Department responded. Firefighters informed me at the scene that the fire was mechanical in origin. The vehicle was completely off and had been parked for about 20 minutes. I was not in or near the car. The fire originated under the hood. This matches known fire patterns in BMW 5-series models from this generation involving electrical/engine components, even though my VIN shows no open recalls. The previous owner did not register the car, so any recall notices may not have reached them. The vehicle is a total loss. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11700387 — an unverified report by a vehicle owner.

2012 BMW 535I Peachtree City, GA

FUEL/PROPULSION SYSTEM

BMW N63 Engine Powertrain Issues 2012 535i The N63 engine, utilized in various BMW models including the 2012 535i, has been subject to multiple customer complaints regarding premature timing chain wear and other powertrain-related issues. This led BMW to introduce a "Customer Care Package," detailed in Technical Service Bulletin (TSB) B110614, to address the concerns reported by multiple owners and noted by the National Highway Traffic Safety Administration (NHTSA) under ID Number 11016414. A primary cause of the issue is accelerated timing chain wear. The N63 engine's design features timing chains that are prone to stretching prematurely. This stretching can disrupt the precise timing of the engine's valves, leading to a cascade of problems. As a consequence, owners have reported a variety of symptoms, including the illumination of the "drivetrain malfunction" warning light, noticeable engine noise, excessive vibration, and potentially catastrophic engine failure. The "drivetrain malfunction" message, in particular, is a frequently cited indicator of this underlying powertrain problem. To address these widely reported issues, the N63 Customer Care Package was implemented. This service bulletin instructs authorized BMW technicians to perform a series of diagnostic tests. The main objective is to detect if the timing chains have stretched beyond acceptable tolerances. If excessive wear is confirmed, the TSB provides a detailed procedure for the necessary repairs. This often involves replacing the timing chains and related components to restore proper engine function. Beyond the core timing chain replacement, the Customer Care Package also includes several proactive and preventative measures. Technicians are instructed to check and potentially replace other components, such as fuel injectors and boost solenoids, which may have been impacted or contributed to the engine's performance issues. Furthermore, the service includes reprogramming the vehicle's software

NHTSA complaint #11696232 — an unverified report by a vehicle owner.

2011 BMW 535I Schenectady, NY

FUEL/PROPULSION SYSTEM

My car suddenly shut off when I came to a stop at a red light while on a busy state route. The information cluster then began to read “Fuel supply” and “Battery Discharge” My car would not turn back on and still has not turned back on since and it's been over a month now. According to the OBD results, the fuel pump and injectors were somehow seized and therefore have caused the car to become inoperable. I was forced to spend over $1000 just to get my car out of the police tow yard and towed to my home because I could not afford the cost of the repairs needed. The NHSTA website states that there is a recall on both the fuel system and the electrical system for my exact vehicle, but according to my Vin search results, there are 0 recalls. That doesn't make sense. I had just got my new inspection done maybe a month prior to my car breaking down.

NHTSA complaint #11651226 — an unverified report by a vehicle owner.

2010 BMW 535I Greenwood, SC

FUEL/PROPULSION SYSTEM

Consistent fuel pump error code 2AAF

NHTSA complaint #11645545 — an unverified report by a vehicle owner.

2012 BMW 535I at 119,000 miles Blythewood, SC

FUEL SYSTEM, GASOLINE

The contact owns a 2012 BMW 535I. The contact stated while driving approximately 50–55 MPH, the engine overheated and the vehicle shutoff. The engine warning light was illuminated. The vehicle was restarted. The contact continued to drive to her residence. The contact stated that the failure was related to NHTSA Campaign Number: 16V746000 (Fuel System, Gasoline). The vehicle was towed to an independent mechanic, who determined that the failure was due to the fuel pump and the water pump. The water pump and fuel pump were replaced. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 119,000. The VIN was not available.

NHTSA complaint #11609875 — an unverified report by a vehicle owner.

2011 BMW 535I Accokeek, MD

FUEL/PROPULSION SYSTEM

BMW REFUSES TO TAKE RESPONSIBILITY OF CONSEQUENTIAL ISSUES CAUSED MY FAULTY FUEL PUMP RECALL AND IS TRYING TO CHARGE ME 21000 to fix. Engine reads maximum drivetrain output drive moderately

NHTSA complaint #11590623 — an unverified report by a vehicle owner.

2011 BMW 535I San Francisco, CA

FUEL/PROPULSION SYSTEM

Been fixing an unknown issue due to fuel presure, loss of engine power and car gets extra hot but doesn’t over heat, I have fixed the issue more on 2 different occasions. I didn’t pass the smog text so that’s when I was told to check for any recalls, now the issues returned with same problems and probably won’t pass smog again. I have all recorded from all the years of maintenance and I’m very diligent on on time maintenance or if theirs is any kind of malfunction. I’m now addressing the situation to you as I believe that there’s something wrong that’s beyond my control. I’ve also encountered other people with same vehicle with similar issues.

NHTSA complaint #11588254 — an unverified report by a vehicle owner.

2009 BMW 535I at 70,000 miles Queens, NY

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

The contact owns a 2009 BMW 535I. The contact stated that while driving at an undisclosed speed, the vehicle vibrated violently with a message displayed to, "Check Engine – Engine Power Reduced”. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed failures with the spark plugs and ignition coil. The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the independent mechanic, who diagnosed failures with the valve cover gasket and upper radiator hose. The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the independent mechanic, who diagnosed failures with the evaporative leak detection assembly, water pump, and high-pressure fuel pump. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure but did not assist. The failure mileage was 70,000.

NHTSA complaint #11557928 — an unverified report by a vehicle owner.

2015 BMW 535I Brooklyn, NY

FUEL/PROPULSION SYSTEM

Recently purchase this vehicle from BMW of Greenwich. Drive it less than 200 miles - the odometer at the time of purchase had 55,000 miles, the engine looked perfect upon visual inspection. The fax report had a failed emissions inspection in the record and a second inspection days latter as apassed. I detected burnt smell coming from the engine, and immediately stopped driving it and called the vendor. The vendor has the car towed to their facility and it is there being (hopefully) repaired. I used my own computerized diagnostics tool, that showed error HO2S 12 Heater Control Circuit Specifics: Engine code P0141 – 02 Sensor Heater Circuit Malfunction (Bank 1- Sensor 2) Downstream What does that mean?   Heated oxygen sensors contain heating elements to help them get to operating temperature quickly in order to minimize the amount of time spent before they can provide feedback to the powertrain control module. Sensor two is downstream of the catalytic converter ensures the catalytic converter is operating efficiently by monitoring the air-fuel  This fault alters fuel burning and compromises the efficiency of the engine, compromising fuel efficiency . Now - There is no reason why a sensor this important be faulty, and therefore, it is my opinion that my new car could have gone in flames with me and my family inside. I have been reding on the internet that these sensors are prone to failure, what in my perspective could be part of planned obsolescence, which is an outright scam to swindle owners out of their money. If i am worng on the planned obsolescence perspective, I am certainly right of this being a very serious defect, that should be corrected immediately. I request that you investigate and request the manufacturer to recall these vehicles, as they present a grave risk to life and property.  

NHTSA complaint #11495474 — an unverified report by a vehicle owner.

2010 BMW 535I at 71,835 miles Howard Beach, NY Crash

FUEL/PROPULSION SYSTEM

I was told by BMW that the high pressure fuel pump for these vehicles are under warranty for 100,000 miles or 10 years. I just purchased the vehicle to not only drive from new jersey to New York and shut down. Since then it caused an accident and the used dealer is just ignoring everything. I was also told there’s an electric water pump class action suit and also something with the trunk leaking. Now I do know that a vehicle is not supposed to be sold without recalls being stated and fixed. I’m already paid 10k for the car and then 1k for a starter . The vehicle is in the body shop having body repair due to the engine shutting down. If the engine shuts down it displays fuel pump malfunction and within 20-30 mins will start again. The BMW 535i has 96,000 miles on it and I don’t think it’s fair that I should be penalized for someone not following thru with repairs let alone having an accident on my insurance now. I’m asking please just help get the vehicle running again and all future service will absolutely be done through BMW. That’s how I handled my Mercedes’ and plan so with this vehicle. I’m a single father that just took a severe beating financially and had to sell the Mercedes’ and thought buying a BMW was a good choice being I had a similar issue with Mercedes’ and they honored the repair due to the amount of time owned and still being in the mileage range of the defective part. Please help . Email-[XXX] Cell- [XXX] [XXX] Thank you in advance INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA complaint #11469497 — an unverified report by a vehicle owner.

2012 BMW 535I at 90,000 miles Bakersfield, CA

FUEL SYSTEM, GASOLINE

The contact owns a 2012 BMW 535I. The contact stated that while driving at 20 MPH, the vehicle stalled as the drivetrain malfunction warning message flashed on the instrument panel. The contact stated that the vehicle failed to start up after multiple attempts. The contact had a friend replace the battery; however, the failure persisted. The contact then had the vehicle towed to a dealer where they diagnosed the vehicle with a defective fuel pump. Upon investigation, the contact discovered NHTSA Campaign Number: 16V746000 (Fuel System, Gasoline) which she linked to the failure. The manufacturer was notified and informed her that there were no recalls on the vehicle. The vehicle was not repaired and remained in the possession of the dealer. The failure mileage was approximately 90,000.

NHTSA complaint #11442812 — an unverified report by a vehicle owner.

2012 BMW 535I Townsend, DE

FUEL/PROPULSION SYSTEM

While driving car stalled, dropped speed and engine warning light came on. Fuel pump was needed. Had to have car towed obtained a rental for 11 days. Fuel pump out of stock. Immediately after fuel pump was replaced less than two weeks the thermostat had to be replaced. Another tow and another rental. I need to be compensated for stress aggravation and loss of use. Repairs and car rental and tow cost over $3500

NHTSA complaint #11432548 — an unverified report by a vehicle owner.

2012 BMW 535I at 97,000 miles Redding, CA

FUEL SYSTEM, GASOLINE

The contact owns a 2012 BMW 535i. The contact stated while driving 70 MPH, the vehicle stalled without warning. The contact waited approximately 5-10 minutes before restarting the vehicle. The contact stated that the failure persisted soon after the initial failure. The contact had not taken the vehicle to a dealer for assistance. The manufacturer had yet to be notified of the failure. Upon investigation, the contact linked the failure to NHTSA Campaign Number: 16V746000 (Fuel System, Gasoline) however, the vehicle was not included in the recall. The vehicle was not repaired. The failure mileage was approximately 97,000.

NHTSA complaint #11430482 — an unverified report by a vehicle owner.

2011 BMW 535I Rio Rico, AZ

FUEL/PROPULSION SYSTEM

While driving on the highway my car turned off suddenly. car was towed to home After checking possible causes we found out that even the fuel gauge in the instruments cluster was displaying a large amount of fuel ( 1/2 tank) actually it was empty. We put two gallons of gasoline then car start up again but fuel gauge still showing half of tank

NHTSA complaint #11427066 — an unverified report by a vehicle owner.

2011 BMW 535I Rio Rico, AZ

FUEL/PROPULSION SYSTEM

while driving on the highway the car turned off suddenly. Car was towed to home after checking possible causes we found out the even the THE FUEL GAUGE IN THE INSTRUMENT CLUSTER WAS displaying a large amount of fuel ( 1/2 tank) actually it was empty . We did put 2 gallons of gasoline than car start up again but the fuel gauge still showing half of tank.

NHTSA complaint #11424497 — an unverified report by a vehicle owner.

2009 BMW 535I South Elgin, IL

FUEL/PROPULSION SYSTEM

The car stop running completly when I was wainting at the stop light An anounsmemt came out in my dash saying that I have to repleaced the fuel pump I know that there was a recall abuot this problem but I never got any notice or letter from bmw

NHTSA complaint #11423416 — an unverified report by a vehicle owner.

2010 BMW 535I at 120,000 miles Port Washington, NY

FUEL SYSTEM, GASOLINE

TL* THE CONTACT OWNS A 2010 BMW 535I. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 20-25 MPH, THE VEHICLE LOSS MOTIVE POWER. THE CONTACT COASTED AND MANUALLY STEERED THE VEHICLE TO THE SIDE OF THE ROADWAY. THE CONTACT STATED THAT THE FUEL PUMP WARNING LIGHT WAS ILLUMINATED. THE CONTACT HAD THE VEHICLE TOWED TO RALLYE BMW (1 BRUSH HOLLOW RD, WESTBURY, NY 11590, (516) 226-7947) WHO HAD REPLACED AN UNKNOWN PART HOWEVER, APPROXIMATELY A WEEK LATER THE FAILURE RECURRED WITH THE SAME WARNING LIGHT ILLUMINATED. THE CONTACT RETURNED THE VEHICLE TO THE SAME DEALER AND THE FUEL PUMP WAS REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.

NHTSA complaint #11413933 — an unverified report by a vehicle owner.

2008 BMW 535I at 97,000 miles Deltona, FL

FUEL/PROPULSION SYSTEM

HPFP IS GOING BAD ENGINE LIGHT COMES ON LONG CRANK START

NHTSA complaint #11397808 — an unverified report by a vehicle owner.

2010 BMW 535I at 128,000 miles Philadelphia, PA

FUEL/PROPULSION SYSTEM

SEVERAL TIMES I WAS PLACED IN PERIL WHILE TRAVELING AT HIGH RATES OF SPEED THEN THE CAR STALLS ON US HIGHWAY 95. THERE WERE ALSO TIMES WHEN THE CAR STALLED WHILE DRIVING LESS THAN 35MPH. WHEN THIS HAPPENS I HAVE NO REAL CONTROL TO STEER THE WHEEL, NO PRIOR WARNING OR ISSUES WITH THE CAR TO INDICATE IT WOULD STALL. IT IS EXTREMELY TRAUMATIZING. TRAUMATIZING! MESSAGE OF "FUEL PUMP MALFUNCTION. MODERATE DRIVING POSSIBLE". CAR STALLS WHILE IN MOTION WHETHER IT IS 20MPH OR 65MPH. INITIAL MALFUNCTION IN JULY WAS AFTER 1HR OF DRIVING THEN SEVERAL TIMES AFTER THAT PERIODICALLY AS THE CAR ISN'T DRIVEN OFTEN DUE TO STAY AT HOME RESTRICTIONS. THE ISSUE COULD NOT BE DUPLICATED AT TWO AUTO MECHANIC SHOPS, IN FACT BY THE TIME THE TOW TRUCK ARRIVED, THE CAR STARTED AND WAS ABLE TO BE DRIVEN ONTO THE TRUCK. THERE IS NO PATTERN OF DRIVING BEHAVIOR OR MESSAGES BETWEEN FAILURE / STALL AND AS MONTHS WENT ON, THE TIME BETWEEN STALL AND INABILITY TO START THE CAR SHORTENED FROM DRIVING1HR TO DRIVING 10 MINUTES. BMW OF THE MAIN LINE REPLACED THE FUEL PUMP, FUEL FILTER AND STALL AND ERROR ISSUE REMAINS. WIRING TO FUEL PUMP ISSUE POSSIBLE. THERE ARE SEVERAL OPEN COMPLAINTS ON THE EXACT SAME ISSUE. MODEL YEAR 2010 SHOULD BE INCLUDED IN THE RECALL FOR 535I XDRIVE HTTPS://WWW.NHTSA.GOV/VEHICLE/2010/BMW/5%252520 SERIES/4%252520DR/RWD%25252F4WD#COMPLAINTS HTTPS://WWW.NHTSA.GOV/VEHICLE/2010/BMW/5%252520SERIES/4%252520DR/RWD%25252F4WD#COMPLAINTS WIRING ISSUE DETECTED AND MAY BE PART OF THE RECALL NHTSA RECALL NO. : 16V-746. IF THE FUEL PUMP BECOMES INOPERATIVE, A NO-START CONDITION OR, IN RARE CASES, A STALLING CONDITION WITHOUT THE ABILITY TO RESTART THE VEHICLE COULD OCCUR. STARTED JULY AND DEGRADED SEPTEMBER, OCTOBER, NOVEMBER THEN FINALLY DECEMBER. $$$$ IN REPAIR COSTS THAT DID NOT RESOLVE THE "FUEL PUMP MALFUNCTION. MODERATE DRIVING POSSIBLE" MESSAGE. HELP

NHTSA complaint #11387031 — an unverified report by a vehicle owner.

2010 BMW 535I at 150,000 miles Riverside, CA

FUEL/PROPULSION SYSTEM

RECEIVING P0087 LOW PRESSURE FUEL, CAR GOES INTO DRIVETRAIN MALFUNCTION. FIX IS REPLACING HIGH PRESSURE FUEL PUMP.

NHTSA complaint #11375976 — an unverified report by a vehicle owner.

Other BMW 535I problems