2006 BMW 530XI Electrical System Problems

The insulation on the internal wiring of the headlight (left and right) have fallen off the wiring leaving sections of conductor exposed creating shorts in the lighting system. This is a known problem in the BMW community (owners and BMW) since at least 2011. This is due to the use of bio-degradable wiring by BMW that breaks down prematurely. Replacement headlight assemblies (high intensity discharge Xenon) are over $1,000 each. Both halogen high beam lights are inoperable which reduces driver vision at night on suburban roadways. Re-wiring with correctly specified wiring is possible but requires specific skills and experience. This is a known problem which BMW has hoped would go away as few of their cars of this age are on the road. This risk assessment driven policy should not shield BMW from fully addressing their failures in material selection which impact safe use of their cars.

Inside headlight wiring insulation became brittle and falls off leading to potential shorts and equipment failure. Additional wiring throughout engine compart shows similar degradation and failure. Split wire housing to protect wires from engine heat also show signs of decay, exposing wires to excess heat and inducing failure of insulation. This is not a turbocharged engine and has lower engine compartment temperatures. This problem started 7-8 years ago and has gotten worse.

STALLS OUT, SKIPS, HESITATES, ETC., PCV VALVE RECALL THIS OCCURS WHEN DRIVING THE CAR ON STREETS, HIGHWAYS ETC., WHEN DRIVING THE CAR. *TR

Mileage: 137,000

DEGRADATION OF HEADLIGHT WIRING. WIRE INSULATION IS FLAKING, CRACKING, AND INTERNAL CONDUCTOR WIRES ARE EXPOSED. CAUSES INTERMITTENT HEADLIGHT ISSUES AS WIRING SHORTS DURING DRIVING.

Mileage: 180,000

AFTER A RECENT HEAVY RAIN THE VEHICLE ELECTRICAL DASHBOARD INSTRUMENTS WERE ERRATIC, THE REAR HATCH OPENING/CLOSING MECHANISM FAILED, AND ULTIMATELY THE REAR AIR SUSPENSION FAILED WITH THE CAR SITTING ON THE REAR BOTTOMING STOPS CAUSING DIFFICULTY IN CONTROLLING THE VEHICLE DUE TO THE SEVERE BOUNCING. FURTHER INVESTIGATION REVELED STANDING WATER IN THE SPARE TIRE AND BATTERY/ELECTRICAL AREAS AT THE REAR OF THE CAR.

Mileage: 98,600

THE WIRING HARNESS INSIDE THE HEADLIGHTS IS CRUMBLING AWAY CAUSING LIGHTS TO INTERMITTENTLY NOT WORK. THE WIRES SPARK WHEN THEY TOUCH TOGETHER. THIS IS A FIRE HAZARD.

Mileage: 109,000

TL* THE CONTACT OWNED A 2006 BMW 530XI. WHILE DRIVING APPROXIMATELY 25 TO 30 MPH, THE VEHICLE HAD AN ABNORMAL ODOR. THE CONTACT PULLED THE VEHICLE OVER AT A FUEL STATION, OPENED THE TRUNK, AND NOTICED FLAMES. THE FIRE WAS EXTINGUISHED BY A PATRON. A POLICE REPORT WAS NOT FILED. THE VEHICLE WAS DESTROYED AND TOWED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBERS: 12V126000 (ELECTRICAL SYSTEM) AND 08V384000 (AIR BAGS). THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 93,000. UPDATED 11/02/16*LJ *TR

Mileage: 93,000

RECALL CAMPAIGN NO. 12V-126: BATTERY CABLE INSULATED BULKHEAD CONNECTOR THE ISSUE INVOLVES A BATTERY CABLE BOLT CONNECTION IN THE TRUNK. SPECIFICALLY, THIS BOLT CONNECTION IS SECURED TO THE TRUNK FLOOR PANEL BY AN INSULATED BULKHEAD CONNECTOR. THE INSULATED BULKHEAD CONNECTOR MAY HAVE BEEN INCORRECTLY ATTACHED TO THE TRUNK FLOOR PANEL. OVER TIME, THIS CAN LEAD TO A LOOSENING OF THE BOLT CONNECTION AND CAUSE AN OVERHEATING CONDITION - EXACTLY SAME THING HAPPEND TO ME

Mileage: 90,000

TL* THE CONTACT OWNS A 2006 BMW 530XI. THE CONTACT STATED THAT SMOKE EMITTED INTO THE VEHICLE FROM THE REAR WITHOUT WARNING. THE CONTACT WAS ABLE TO PULL THE VEHICLE OVER AND NOTICED FLAMES COMING FROM THE TRUNK OF THE VEHICLE. THE CONTACT WAS ABLE TO EXTINGUISH THE FLAMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 12V126000 (ELECTRICAL SYSTEM). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE. PARTS DISTRIBUTION DISCONNECT.

FAILURES OF MULTIPLE WIRES/ELECTRICAL COMPONENTS IN THE TAILGATE/REAR WINDOW WIRING HARNESSES. 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 AND HAS COST OVER $2000 SO FAR. I'M WORRIED ABOUT DRIVING THIS CAR AS IT IS THE MAIN TRANSPORTATION FOR MY CHILDREN AND THEIR FRIENDS.I DISCOVERED IT WHEN THE REMOTE LOCK/UNLOCK USING THE KEY FOBS FAILED, THE TRUNK INOPERABLE AND UNCLOSEABLE, THE RADIO STOPPED WORKING, THE LIGHTS IN THE REAR OF THE CAR STAYED ON PERMANENTLY AND I HAD TO DRIVE HOME ONE NIGHT WITH THE TRUNK WIDE OPEN BECAUSE THE WIRING HAD STOPPED WORKING AND IT COULD NOT BE CLOSED. AS I INVESTIGATED I FOUND MANY BROKEN GROUND WIRES, ALONG WITH SEVERAL OTHERS WITH BROKEN INSULATION, SOME WITH BROKEN COPPER STRANDS ETC. I HAVE ALREADY HAD THE RIGHT AND LEFT WIRE HARNESSES REPLACED AT AN INDEPENDENT DEALER FOR ABOUT $2200. THIS IS A SAFETY ISSUE AND I'M WORRIED THAT MORE WILL COME. *TR

Mileage: 151,000

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. CENTRAL LOCKING MECHANISM FAILS. IF THERE WERE TO BE AN ACCIDENT AND/OR INTERIOR FIRE ESCAPING THE VEHICLE WOULD BE DIFFICULT 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. *TR

Mileage: 102,000

TL* THE CONTACT OWNS A 2006 BMW 530XI. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR DIAGNOSIS WHERE THE POWER SUPPLY AND BATTERY WERE REPLACED. AFTER THE REPAIR WAS PERFORMED, THE CONTACT NOTICED THAT THE INSTRUMENT PANEL AND OTHER GAUGES BECAME INOPERATIVE. THE VEHICLE WAS NOT REPAIRED FOR THE MOST RECENT FAILURES. THE MANUFACTURER ISSUED A RECALL FOR THE 2007-2011 MODEL YEAR VEHICLES UNDER NHTSA CAMPAIGN ID NUMBER: 13V044000 (ELECTRICAL SYSTEM) BUT NOT FOR THE 2006 MODEL. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

Mileage: 80,000

BMW IS RECALLING 200,000 MY 2006 3 SERIES SPORT SEAT, MY 2004-2006 5 SERIES STANDARD AND SPORT SEAT, AND MY 2004-2006 X3 PASSENGER VEHICLES. DEPENDING ON THE MANNER AND FREQUENCY OF THE FRONT PASSENGER'S ENTRY AND EXIT, SMALL CRACKS HAVE DEVELOPED IN THE MAT. IF THIS OCCURS, THE FRONT PASSENGER AIR BAGS, WITH THE EXCEPTION OF THE HEAD PROTECTION SYSTEM, WILL BE DEACTIVATED AND THE AIR BAG WARNING LAMP AS WELL AS THE PASSENGER AIR BAG "ON-OFF" LAMP WILL BE ILLUMINATED. CONSEQUENCES: IN THIS SITUATION THE FRONT PASSENGER AIR BAGS WILL NOT DEPLOY EVEN IF A SUFFICIENTLY SEVERE ACCIDENT WOULD OCCUR AND OCCUPANT PROTECTION PROVIDED BY THE SYSTEM WOULD NOT BE POSSIBLE. REMEDY: DEALERS WILL REWORK THE FRONT PASSENGER SEAT SENSOR MAT SO THAT EXTERNAL FORCE APPLICATION TO THE SEAT DOES NOT CAUSE A CRACK TO THE MAT. THE RECALL BEGAN ON NOVEMBER 6, 2008. BMW WILL ALSO EXTEND THE WARRANTY ON THESE VEHICLES TO 10 YEARS FROM FIRST REGISTRATION WITHOUT ANY MILEAGE LIMIT. OWNERS MAY CONTACT BMW AT 1-800-525-7417. I HAVE CONTACTED BMW AND THEY SAY MY VIN IS NOT PART OF THIS RECALL, HOWEVER I AM EXPERIENCING THE SAME ISSUE AS THE RECALLED VEHICLES. I AM WORRIED ABOUT PASSENGER SAFETY! PLEASE HELP! *TR

Mileage: 95,000

I CONTACTED BMW NORTH AMERICA BY PHONE REGARDING A RECALL FOR THIS ISSUE. THEY TOLD ME THAT MY 2006 BMW 530XI WAS NOT INCLUDED IN THE RECALL. YET, MY CAR EXHIBITS THE EXACT PROBLEMS OUTLINED IN THE RECALL. THE FRONT PASSENGER AIR BAGS WILL BE DEACTIVATED AND THE AIR BAG WARNING LAMP, AS WELL AS THE PASSENGER AIR BAG "ON-OFF" LAMP WILL BE ILLUMINATED. THIS INCLUDES A WARNING IN IDRIVE SYSTEM STATING "PASSENGER RESTRAINT" SYSTEM ISSUE. HOW IS IT THAT OTHER 2006 5 SERIES VEHICLES WERE INCLUDED AND MY CAR WAS NOT? THE LOCAL DEALER IS SAYING THIS IS MORE THAN $1000 TO REPAIR, NOT SURE HOW THEY WOULD KNOW THAT WITHOUT SEEING THE VEHICLE. *TR

Mileage: 81,500

PASSENGER AIRBAG SENSOR. WARNING LIGHT SYSTEM FAILURE. *TR

Mileage: 72,000

A RECENT RAIN STORM FLOODED THE SPARE TIRE WELL COMPARTMENT AND FRIED ALL THE ELECTRICAL COMPONENTS STORED UNDERNEATH THE TIRE. LUCKILY I WASN'T DRIVING THE WAGON THAT DAY AND THE CAR WAS PARKED ON THE DRIVEWAY. OTHERWISE, THE CAR WOULD HAD SHUT DOWN IF IT WAS MOVING AND COULD CAUSE AN ACCIDENT (HAPPENED TO SOMEONE AS DISCUSSED IN THE BIMMER FORUM). APPARENTLY, BMW HAVE KNOWN ABOUT THIS SAFETY ISSUE AS WELL AS THE SUNROOF DRAINAGE & TIRE WELL DESIGN DEFECTS FOR QUITE SOME TIME. THEY EVEN GENERATED A TECHNICAL SERVICE/SERVICE INFORMATION BULLETIN (SIB54-06-06 & 61-13-06 ON SPECIAL ROOFS) FOR THEIR SERVICE DEPARTMENT TO USE. HOWEVER, BMW KEEPS DENYING ANY DAMAGE LIABILITY AND REFUSING TO ADMIT ANY DESIGN DEFECTS. BMW NA, PUBLIC RELATIONS AND THE SF BMW DEALERSHIP RESPONDED TO ME THAT IT IS DUE TO "EXTERNAL FACTORS" (RAINS) AND THEREBY THEY HAVE NO RESPONSIBILITY TO THE DAMAGED VEHICLE. THE SERVICE ADVISER TOLD ME THAT THE REPAIR COST WOULD RUN INTO $15K. I AM FILING THE SAID COMPLAINT AND AM SEEKING AN ATTORNEY FOR A POSSIBLE CLASS ACTION SUIT AGAINST BMW NA. *TR

Mileage: 100,500

THIS BMW 530XI WAGON SUFFERED A COMPLETE ELECTRICAL FAILURE AFTER THE SUNROOF DRAINAGE SYSTEM DRAINED RAIN WATER INTO THE COMPARTMENTS WHERE THE BATTERY, FUSES, VARIOUS WIRING HARNESSES AND COMPUTER MODULES ARE STORED. APPROXIMATELY 7 HOURS AFTER THE RAIN STORM, THE OWNER (WITH NO KNOWLEDGE OF THE IMPROPERLY DRAINED WATER) ATTEMPTED TO OPERATE THE VEHICLE. DURING THE DRIVE, THE CAR DISPLAYED TWO SYSTEM MALFUNCTIONS, FOLLOWED SHORTLY THEREAFTER BY THE MESSAGE "ELECTRONIC SYSTEM MALFUNCTION. CONTINUED DRIVING NOT POSSIBLE" AND MULTIPLE WARNING LIGHTS AND SOUNDS. THE CAR WAS PARKED IN A SAFE AREA AND LATER TOWED TO THE BMW DEALER. THE BMW DEALER CONFIRMS THAT THE SUNROOF DRAINED RAIN WATER INTO THE ELECTRONICS COMPARTMENTS, SHORTING OUT AT LEAST FOUR COMPUTER MODULES, AND DESTROYED THE BATTERY AND MULTIPLE SWITCHES, RELAYS, AND WIRING HARNESSES. CERTAIN SYSTEM COMPONENTS, INCLUDING AN AIR BAG CONTROL UNIT, SHOWED EVIDENCE OF A FIRE (PRESUMABLY DUE TO A SHORT CAUSED BY THE RAIN WATER.) THE BMW DEALER STATES THAT REPLACING ELECTRONICS MODULES AND THE BATTERY (APPROXIMATELY $4,000) ARE REQUIRED BEFORE FURTHER DIAGNOSTICS CAN BE PERFORMED TO DETERMINE IF THERE IS DAMAGE TO OTHER VEHICLE COMPONENTS. *TR

Mileage: 88,250

ON TUESDAY MAY 29TH WE HAD A RAIN STORM, THE NEXT DAY I GOT INTO MY VEHICLE WITH MY HUSBAND AND TWO CHILDREN TO GO TO A SOCCER GAME. FIVE MINUTES BEFORE ENTERING THE MASSACHUSETTS TURNPIKE MY VEHICLE WENT INTO TOTAL ELECTRICAL FAILURE AND MY STEERING LOCKED. LUCKILY I WAS ONLY TRAVELING AT 25MPH AND WAS ABLE TO PULL MY VEHICLE OVER. I HAD IT TOWED TO OUR LOCAL BMW DEALER WHICH FOUND THAT THE CASSETTE ON THE PANORAMIC SUNROOF TO BE DEFECTIVE....THAT CAUSED A GREAT DEAL OF WATER TO GET INTO THE VEHICLE AND GO UNDER THE SPARE TIRE IN THE REAR WHERE ALL THE ELECTRICAL IS. I PUT A COMPLAINT INTO BMW OF NORTH AMERICA BECAUSE A. THE ELECTRICAL SHOULD NOT BE PUT UNDER THE SPARE TIRE WHERE WATER COULD GET IN AND B. I WAS ABOUT TO GET ON THE TURNPIKE WHERE THE SPEED LIMIT IS 65 MPH, I AM EXTREMELY LUCKY BECAUSE IF I WAS ON THE MASS PIKE THERE COULD HAVE BEEN A TERRIBLE ACCIDENT. IT WAS 2498 TO FIX THE ISSUE, BMW WAS WILLING TO PAY HALF AND RELOCATE ALL THE ELECTRICAL TO A SAFER MORE DRYER PLACE. I AM WRITING THIS LETTER BECAUSE I FEEL THERE SHOULD BE A RECALL ON THIS ISSUE, BMW NEEDS TO RELOCATE THE ELECTRICAL COMPONENTS TO A SAFER AREA THAN UNDERNEATH THE SPARE TIRE. BMW OF NORTH AMERICA WAS EXTREMELY RUDE WHEN I TOLD THEM ABOUT THIS ISSUE, IT WAS BASICALLY "NOTHING HAPPENED TO YOU AND YOUR FAMILY, SO WE KNOW IT"S A PROBLEM, SO WE WILL PAY FOR HALF OF IT". I HOPE SOMETHING CAN BE DONE ABOUT THIS ISSUE TO SAFEGUARD OTHER BMW DRIVERS WHO HAVE SIMILAR VEHICLES. *TR

Mileage: 53,586

THE BMW VEHICLES WITH PANORAMIC MOONROOFS HAVE A KNOWN FAILURE (SEE BIMMERFEST.COM) IN THE WATER SEALS AND DRAIN CHANNELS ASSOCIATED WITH THE SUNROOF. THE ISSUE IS THAT CLOGGED LINES PRODUCE FLOODING IN THE ELECTRICAL COMPARTMENT. THIS FLOODING CAUSES TOTAL ELECTRICAL FAILURE. IN MY CASE, THE CAR WAS STOPPED AND DID NOT START AGAIN. HOWEVER, A READ OF THE MESSAGE BOARDS ASSOCIATED WITH BMWS SHOWS THAT MANY PEOPLE HAVE TOTAL FAILURE WHILE DRIVING AND THAT THE STEERING COLUMN LOCKS UP COMPLETELY. THERE IS NO ABILITY TO MANUALLY STEER A BMW ONCE THE ELECTRICAL GOES OFF. *TR

Mileage: 58,500