30 of the
223 complaints filed about the BMW 535XI
are about the electrical system —
13% of everything owners reported.
The worst model year for it is 2008.
Station wagon lift gate has severe wiring failures between the lift gate and body. This problem is well known throught the blog community. Broken wires cause failures, and electrical danger, to the rear lighting system that includes brake, running, back up, and turn signals. Also effected is the rear wiper, defroster, and operation access to open and close the lift gate. Tailgate failure would prohibit emergency opening and access to spare tire and fuses. I have already spent $3,000 on one harness replacement (dealer) and am looking at another $3,000 to repair (dealer) more wiring that will restore the brake/running lights on one side (failed state inpection). The internal lighting diagnostics did NOT indicate any lighting problems or warning. Broken wires could also cause failures to some or all of the entire electrical system. Very dangerous.
NHTSA complaint #11508175 — an unverified report by a vehicle owner.
The vehicle's engine caught fire approximately 13 1/2 hours after last having been driven. I parked it in my driveway at 9pm on April 15, 2022. I was alerted to a fire in the engine by my neighbor at 10:30am on April 16, 2022. The entire engine was engulfed in flames, melting all of the plastic components. It burned through my hood and affected every part of the engine. We were able to get the fire out with a garden hose before it spread to the house and my parents' two other vehicles parked next to it. No one was burned while putting out the fire, but several neighbors and family members did breathe in the toxic smoke. 911 was called and the fire department confirmed the fire was out. The driveway under the vehicle has burn damage, but we haven't moved the vehicle yet to see the extent of it. The check engine light had been on since purchase. The vehicle had been maintained by a mechanic specializing in import motors. He was unable to determine the cause of the check engine alert, and said it was a problem that BMW has with several of their models of this era. The vehicle was only covered under liability insurance, so our insurance company has not required an inspection. It has not yet been inspected by a mechanic or any other entity. The vehicle is available for inspection if requested.
NHTSA complaint #11461541 — an unverified report by a vehicle owner.
FOR OVER THE PAST YEAR, THE (SMALL) ENGINE LIGHT HAS BEEN REPEATEDLY & CONSTANTLY GOING ON/OFF. I'VE HAD SENSORS, SPARK PLUGS, TUBES & EVERYTHING UNDER THE SUN REPLACED AND HAVE TAKEN (OR TOWED IN MOST CASES) THE CAR TO MANY DIFFERENT AUTO REPAIR SHOPS FOR MULTIPLE QUOTES & REPAIRS. THE LATEST PROBLEM IS THE SMALL ENGINE LIGHT CAME ON & THE CAR WAS STUCK IN PARK AND WOULD NOT ENGAGE IN DRIVE OR REVERSE. IT WOULDN'T SHIFT. AFTER TURNING THE CAR OFF AND THEN ON AGAIN, THE ENGINE LIGHT WAS COMPLETELY GONE & THE CAR WAS FINE TO DRIVE/REVERSE. AFTER DRIVING THE CAR A FEW BLOCKS, THE ENGINE MALFUNCTION/REDUCE SPEED LIGHT CAME ON, THE POWER WAS DRASTICALLY REDUCED & I ALMOST GOT HIT BY A DUMP TRUCK. IN 2008, I BOUGHT MY BMW BRAND NEW BECAUSE I WANTED NO CAR ISSUES BECAUSE I AM NOT A MECHANIC. EVERY SINCE I BOUGHT THIS CAR I HAVE HAD NOTHING BUT REPEATED & DIFFERENT ISSUES THAT NO MECHANIC CAN IDENTIFY. AND IT ALL STARTED WITH THE HIGH-PRESSURE FUEL PUMP WHICH WAS REPLACED THREE TIMES (HPFP). AFTER THE THIRD HPFP WAS REPLACED, AND THE CAR WAS IN THE SHOP LITERALLY FOR THREE MONTHS STRAIGHT, I GOT A LAWYER INVOLVED AND BMW CORP APOLOGIZED & SAID I COULD HAVE A CHOICE OF: 1/ GETTING A DIFFERENT CAR THAT THEY PICKED OUT (A 535I NOT THE XI I BOUGHT BECAUSE OF SNOW AND ICE CONDITIONS) 2/ THEY CUT ME A CHECK FOR A FEW THOUSAND AND TOLD ME TO SHUT UP AND I COULD NEVER SPEAK OF WHAT HAPPENED OR BE PART OF FUTURE LAWSUITS OR CLASS ACTIONS. I'VE NEVER FELT SAFE DRIVING MY 2008 BMW (116K MILES ON IT OVER 12.5 YEARS) EVERY BMW OWNER THAT BOUGHT A BMW BETWEEN THE RANGE OF YEARS KNOWS EXACTLY WHAT I AM TALKING ABOUT RE: THE CONSTANT AND NEVER-ENDING ISSUES THAT ALL START WITH THE HPFP & ESCALATE FROM THERE. REPAIR SHOPS CAN'T FIX THE ISSUES & BMW COVERS UP. NHTSA HASN'T DONE ANYTHING ABOUT THIS MASSIVE BMW ISSUE AFFECTING THE VAST MAJORITY OF OWNERS. JUST GOOGLE IT!
NHTSA complaint #11279664 — an unverified report by a vehicle owner.
KNOWN SAFETY CONCERN DUE TO BROKEN WIRING IN E61 WAGON HATCH WIRING. SEE THIS THREAD: HTTPS://5SERIES.NET/FORUMS/E61-TOURING-DISCUSSION-4/TAILGATE-WIRING-HARNESS-REPLACEMENT-72751/
NHTSA complaint #11161148 — an unverified report by a vehicle owner.
WEDNESDAY JULY 25TH, 2018, AS I WAS GETTING READY TO LEAVE WORK, I STARTED MY CAR WHICH WAS PARKED IN MY COMPANY'S UNDERGROUND GARAGE AND THE INTERIOR BECAME ENGULFED WITH SMOKE. I TURNED THE CAR OFF AND GOT OUT TO CHECK THE ENGINE. THERE WAS NO SMOKE COMING FROM THE UNDER THE HOOD OF THE CAR. I GOT BACK INTO THE CAR AND STARTED IT AGAIN AND MORE SMOKE ENTERED INTO THE CAR. I TURNED THE CAR OFF AND WENT BACK TO MY OFFICE TO CALL AAA. APPROXIMATELY 20-30 MINUTES LATER I WENT BACK TO THE CAR AND IMMEDIATELY SMELLED SMOKE IN THE GARAGE. AS I APPROACHED THE CAR IT WAS COMPLETELY FILLED WITH SMOKE BUT I COULD TELL THAT THE BOTH THE BACK AND FRONT WINDOW SHIELDS AND THE SUNROOF WERE SCORCHED. MY KEY FOB DID NOT WORK SO I HAD TO OPEN THE CAR WITH THE KEY. WITH THE DOOR OPEN THE THICK SMOKE ESCAPED AND THEN I WAS ABLE TO SEE THE DAMAGE TO THE CAR AS A RESULT OF A FIRE. I HAVE ATTACHED SOME PICTURES SO YOU CAN SEE. I DID SOME RESEARCH AND FOUND THAT THERE HAVE BEEN SOME INSTANCES WHERE THIS HAS HAPPENED TO OTHER BMW OWNERS IN THE PAST AND THAT THIS WAS A COURSE OF ACTION TO TAKE IN LETTING YOU KNOW.
NHTSA complaint #11113836 — an unverified report by a vehicle owner.
INSULATION ON WIRING INSIDE HEADLIGHT ASSEMBLY HAS FALLEN OFF EXPOSING BARE WIRES. THIS WAS DISCOVERED WHEN REPLACING BULBS. DISCUSSION BOARDS ON WEB HAVE MANY OWNERS REPORTING SIMILAR PROBLEMS. BMW DOES NOT
NHTSA complaint #11088894 — an unverified report by a vehicle owner.
THE WIRING HARNESSES IN THE TAILGATE HAVE BEEN BOTH SEVERED AND OTHERWISE DAMAGED BY THE NORMAL OPERATION OF THE TAILGATE AND LIFTGLASS. THE HINGES AND WIRING TRAYS HAVE SHARP EDGES AND THE WIRE INSULATION MATERIAL SEEMS TO BE OF A PVC MATERIAL. IT APPEARS THAT THIS MATERIAL IS VULNERABLE TO FAILURE WITH ONLY REGULAR OPERATION OF THE VEHICLE, HOWEVER, THE SHARP EDGES OF THE HARNESS TRAY IN THE TAILGATE HINGES ACT AS SHEARS THAT HAVE SEVERED THE WIRES. THIS PRESENTS SEVERAL SAFETY ISSUES INCLUDING THE POTENTIAL OF FIRES FROM ELECTRICAL SHORTS, MALFUNCTIONING AND DAMAGE OF CONTROL MODULES DUE TO ELECTRICAL SHORTS, INOPERABLE REAR-DEFOGGER SYSTEM, INOPERABLE KEYFOB REMOTES FOR ENTRY AND LOCKING, LOSS OF RADIO SYSTEM INCLUDING WEATHER BAND FOR SAFETY UPDATES, ETC. THIS APPEARS TO BE NOT ONLY A COMMON PROBLEM, BUT EVERY VEHICLE IN THIS DESIGNATION HAS EITHER SUFFERED FROM THESE PROBLEMS OR IS SUSCEPTIBLE. AS NOTED IN SEVERAL BLOGSITES WHERE OWNERS AND REPAIR SPECIALISTS HAVE COMMENTED, THIS IS AN OBVIOUS DESIGN DEFECT THAT SHOULD BE ADDRESSED BY BOTH NHTSA AND THE MANUFACTURER. CLEARLY A RECALL AND MANUFACTURER-PAID REPAIR SHOULD BE IMPLEMENTED.
NHTSA complaint #11062694 — an unverified report by a vehicle owner.
BLOWER MOTOR SHORTED AND CAUSED WIDESPREAD ELECTRICAL PROBLEMS AFFECTING HEADLIGHTS AND THEIR CONTROL. A LARGE AMOUNT OF SMOKE BLEW OUT OF THE VENTS AS WELL. THE VEHICLE WAS BEING MOVED FROM THE GARAGE TO THE PARKING LOT AT A 3RD PARTY SERVICE PROVIDER.
NHTSA complaint #11043796 — an unverified report by a vehicle owner.
THIS IS THE 3RD COMPLAINT ON THE SAME VEHICLE I HAVE PLACED. THIS VEHICLE HAS BEEN IN AND OUT OF THE SHOP FOR THE LAST 8 MONTHS AND THEY HAVE FINALLY DISCOVERED THAT THE REAR OF THE VEHICLE, WHERE THE COMPUTER COMPONENTS ARE LOCATED, HAS BEEN RECEIVING WATER LEAKAGE FROM FAULTY PLUGS VIA THE SUNROOF DRAINAGE SYSTEM LEADING TO THE REAR OF THE VEHICLE. THUS CAUSING MAJOR MALFUNCTIONS SUCH AS FUEL INJECTORS, STARTERS, BATTERIES, SENSORS, AND INDICATORS THAT MAJOR TRANSMISSION MALFUNCTIONS HAVE OCCURRED WHEN WHAT IS REALLY WRONG IS THAT ALL THE COMPUTER COMPONENTS ARE DROWNING IN WATER, CORRODED AND RUSTED. THIS IS FAULTY FROM THE BMW FACTORY AND THEY KNOW THE PROBLEM EXISTS AND THEY REFUSE TO RECALL THIS MODEL VEHICLE. THIS PROBLEM CAN BE FOUND VIA THE INTERNET FROM MANY CONSUMERS EXPERIENCING THE SAME PROBLEM. I HAVE PLACED A COMPLAINT WITH BMW AND THEY HAVE DONE NOTHING. IN ONE INSTANCE I EXPERIENCED THE CRUISE CONTROL ACCELERATE ON ITS OWN AND WOULD NOT DISENGAGE WHEN THE BRAKE PEDAL WAS PRESSED. THE STEERING WHEEL ON/OFF BUTTON WAS THE ONLY WAY TO STOP THE ACCELERATION. THIS VEHICLE IS A DANGER TO DRIVE AND IS UNRELIABLE!!
NHTSA complaint #11012517 — an unverified report by a vehicle owner.
2010 BMW 535XI, CAUGHT FIRE IN ENGINE COMPARTMENT RESULTING IN TOTAL LOSS OF VEHICLE. VEHICLE HAS ONLY BEEN MAINTAINED AT BMW DEALERSHIP, AND CURRENT ON ALL INSPECTIONS, REPAIRS, AND MAINTENANCE. FIRE OCCURRED IN DUNCAN DOUGHNUTS DRIVE THROUGH, SLIGHT SMELL OF SMOKE WHILE AT DRIVE THROUGH LINE. WHILE RECEIVING FOOD AT WINDOW LESS THAN A MINUTE OR TWO LATER, AND WHILE IN PARK. FLAMES SHOT THROUGH HOOD AT MIDDLE OF ENGINE COMPARTMENT BY WINDSHIELD AND REAR 1/3 OF THE MIDDLE OF THE HOOD WITH INTENSE SMOKE. IMMEDIATEL REACTION WAS TO PUT IN DRIVE AND MOVED FOREWORD TO GET AWAY FROM BUILDING TO GET OUT OF DOOR AS ENGINE DIED, WE SCRAMBLED OUT OF VEHICLE. 2 EMPLOYEES IMMEDIATELY ASSISTED WITH FIRE EXTINGUISHERS, BUT ENGINE COMPARTMENT QUICKLY ENGULFED 1ST IN THE MIDDLE HOOD THEN LEFT HOOD AND EVENTUALLY THROUGH THE WHEELWELL. I HAVE ALL SERVICE RECORDS, AND HAVE HAD ALL REQUIRED REPAIRS, RECALLS AND MAINTENANCE PERFORMED EXCLUSIVELY AT BMW DEALERSHIP. THIS VEHICLE SHOULD NOT JUST CATCH FIRE AND BURN FOR NO APPARENT REASON AND WITHOUT AND WARNING LIGHTS OR INDICATORS. CLEARLY A SAFETY ISSUE HERE THAT REQUIRES FURTHER INVESTIGATION. I'M REALLY LUCKY THERE WERE NO INJURIES AND THAT THE CAR WAS STATIONARY AND NOT IN MY GARAGE, OR GOING DOWN THE HIGHWAY. GLAD THAT I WAS ABLE TO GET THE VEHICLE TO ROLL AWAY FROM THE BUILDING FAR ENOUGH TO PREVENT IT FROM CATCHING ON FIRE ALSO AND CAUSING ADDITIONAL PROPERTY DAMAGE. THIS 2010 BMW 535XI HAS ADMITTEDLY BEEN A FREQUENT FLIER AT THE BMW DEALERSHIP. IT HAS HAD THE VALVE COVERS REPLACED, CV JOINT REPLACED, , VANOS SOLENOID VALVES REPLACED, SHAFT SEAL REPLACED, REAR DIFFERENTIAL REPLACED, COOLANT PUMP REPLACED, OIL FILTER HOUSING REPLACED, FUEL INJECTORS REPLACED TWICE, BULB HOLDERS REPLACED, SIDE LIGHTS REPLACED, REPROGRAMMED ECT.
NHTSA complaint #10985883 — an unverified report by a vehicle owner.
WIRING AND REAR DIVERSITY ANTENNA CAN BECOME WET UNDER REAR HATCH FAIRING. THIS HAS CAUSED THE COMFORT ACCESS TO WORK WITH REDUCED RANGE AND OR NOT WORK AT ALL. WIRING HARNESS ON BOTH RIGHT AND LEFT SIDE HAVE SEVERED CABLES FROM OPENING AND CLOSING REAR WINDOW PORTION OF HATCH.
NHTSA complaint #10955489 — an unverified report by a vehicle owner.
MY WIFE WAS DRIVING BMW 535 XI 2010 MODEL AND VIN NUMBER IS [XXX] ON HIGHWAY SUDDENLY "BATTERY MALFUNCTION" SHOWED; SHE WANT TO TAKES CAR ON SHOULDER BUT STEERING STOPPED WORKING. FINALLY SHE WAS ABLE TO STOP THE CAR IN ONE OF REPAIR SHOP. REPAIR SHOP TOLD THE BELT TIED WITH STEERING WAS JAMMED AND IN BROKEN CONDITION. IT WAS LIFE THREAT AND THERE IS NO SIGNAL ON THIS. BOUGHT THIS KIND OF EXPENSIVE CAR AND THERE IS NO SAFETY. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
NHTSA complaint #10948369 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2008 BMW 535XI. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE OVERHEATING WARNING INDICATOR ILLUMINATED. THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT PULLED OVER AND THE VEHICLE WAS RESTARTED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE ELECTRIC WATER PUMP FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 135,000.
NHTSA complaint #10927425 — an unverified report by a vehicle owner.
I PURCHASED MY CERTIFIED PRE-OWNED 2008 BMW 535XI SPORTS WAGON FROM CONCORD BMW ON 09.01.2015 WITH 81,759 MILES ON IT. ON DECEMBER 15, 2015 I WAS TRAVELING AT FREEWAY SPEED WHEN THE REAR AIR SPRINGS FULLY COLLAPSED. I BROUGHT THE VEHICLE TO CONCORD BMW'S SERVICE DEPARTMENT THAT VERY SAME DAY TO DETERMINE WHAT CAUSED THE FAILURE. ON DECEMBER 17, 2015 I RECEIVED AN EMAIL REPAIR ESTIMATE FROM BMW CONCORD SERVICE ADVISOR JOEY TIONGSON FOR $24,188.17 (I PURCHASED THE USED VEHICLE FOR $17,400.00).THE DIAGNOSIS WAS THAT CLOGGED SUNROOF DRAINS ALLOWED WATER TO TRAVEL DOWN THE FRAMEWORK OF THE VEHICLE AND FLOOD ALL THE ELECTRONIC MODULES. TIMING OF THIS INCIDENT IS SUCH THAT MID-DECEMBER 2015 PRODUCED THE FIRST RAINFALL IN OUR AREA DUE TO CALIFORNIA DROUGHT. MY CAR WAS NOT EXPOSED TO ANY SIGNIFICANT WATER PRIOR TO THESE FIRST RAINS. I BELIEVE THAT THIS IS A MANUFACTURE DEFECT AND THAT THIS VEHICLE WAS SOLD TO ME WITH THIS PRE-EXISTING CONDITION OF WHICH I WAS NEVER ADVISED. MY RESEARCH AFTER THIS INCIDENT INDICATES THAT OTHER BMW OWNERS HAVE HAD SIMILAR PROBLEMS BUT NOT TO THIS MAGNITUDE. BMW HAS ALSO ISSUED SERVICE BULLETINS ADVISING DEALERSHIPS OF THIS PROBLEM.
NHTSA complaint #10873239 — an unverified report by a vehicle owner.
I PURCHASED A 2008 BMW 5 SERIES WAGON 9/1/2015 ON CALIFORNIA HAD ITS FIRST RAIN STORM CAUSING CATASTROPHIC FAILURE OF THE ENTIRE ELECTRICAL SYSTEM OF THE BMW RESULTING IN A COMPLETE LOSS 12/16/115. THE DRAIN LINES ARE A WELL DOCUMENTED AND A BMW SERVICE BULLETIN WAS ISSUED TO DEALERSHIPS. WHILE DRIVING ON THE HIGHWAY, I EXPERIENCED WIDESPREAD SYSTEM FAILURE, TIRE WARNINGS, TRANSMISSION FAILURE WARNINGS AND THE SUSPENSION FAILED AND THE CAR DROPPED ABOUT 6 INCHES. THE BMW DEALERSHIP GAVE US $24,188.17 REPAIR ESTIMATE FOR ALL THE ELECTRICAL COMPONENTS AND WIRING WHICH IS MORE THAN THE VALUE OF THE CAR
NHTSA complaint #10818784 — an unverified report by a vehicle owner.
THE VEHICLE OVERHEATED DUE TO WATER PUMP FAILURE. THE VEHICLE WAS TOWED TO A BMW DEALERSHIP AND THE WATER PUMP AND THERMOSTAT WERE REPLACED. SOME BMW 5-SERIES WATER PUMPS HAVE BEEN RECALLED.
NHTSA complaint #10717391 — an unverified report by a vehicle owner.
I DISCOVERED FAILURES OF MULTIPLE WIRES IN THE TAILGATE/REAR WINDOW WIRING HARNESSES. THROUGH RESEARCH ONLINE I HAVE FOUND THIS IS A COMMON PROBLEM WITH THIS VEHICLE OVER SEVERAL MODEL YEARS - SEARCH FOR BMW E61 TAILGATE WIRING PROBLEMS. THE FAILURES ARE CAUSED BY A POOR DESIGN WHERE THE WIRES ENTERING THE HINGE GUIDES (4) FOR THE GLASS AND TAILGATE ARE REPEATEDLY FLEXED AT A SHARP ANGLE UNTIL THE INSULATION, THEN THE COPPER WIRE BREAKS. SAFETY ISSUES - POSSIBLE ELECTRICAL SHORT CIRCUIT LEADING TO FIRES (HIGHEST LOAD IS FOR REAR DEFROSTER); LIGHTING FAILURES (REAR HIGH BRAKE LIGHT, LICENSE PLATE LAMPS AND OTHERS); REDUCED VISIBILITY DUE TO LOSS OF WIPER/WASHER/DEFROSTER; REAR GLASS LATCH OPENING WHILE UNDERWAY, POSSIBLY RESULTING IN LOSS OF CARGO OR INGRESS OF EXHAUST FUMES. THIS IS NOT AN EASILY REPAIRED PROBLEM. IT WOULD BE BEYOND THE CAPABILITIES OF ALL BUT A SKILLED MECHANIC WITH PROPER TOOLS. I DISCOVERED IT WHEN THE REMOTE LOCK/UNLOCK USING THE KEY FOBS FAILED. AS I INVESTIGATED I FOUND THE BROKEN WIRE, ALONG WITH SEVERAL OTHERS WITH BROKEN INSULATION, SOME WITH BROKEN COPPER STRANDS.
NHTSA complaint #10715386 — an unverified report by a vehicle owner.
THE INSULATION OF THE WIRING INSIDE THE HEADLIGHT ASSEMBLY IS CRUMBLING AND POSES A FIRE HAZARD AS THE WIRES HAVE LOST THEIR INSULATION AND CAN GET IN CONTACT WITH EACH OTHER.
NHTSA complaint #10638643 — an unverified report by a vehicle owner.
AFTER HITTING A BUMP WHEN ENTERING A DRIVEWAY, WATER SPILLED IN THE REAR CARGO AREA OF THE STATION WAGON, WATER DRAINED INTO SPARE TIRE WHEEL WELL WHERE ELECTRONIC CONTROL MODULES RESIDE SHORTING OUT MOST MAJOR CONTROLS-ANTI LOCK BRAKES, LOAD LEVELING, TRANSMISSION, TRACTION CONTROL, ETC. IT IS THE LOWEST POINT OF THE CAR'S INTERIOR.
NHTSA complaint #10567488 — an unverified report by a vehicle owner.