2002 BMW Serie 5 problems

• M57D25, 2.5 litres (150-197 hp, 2000-2010 depending on application)

  150–197 hp · M57D25, M57D25TU

  It shares the swirl flap risk of the rest of the M57 family in its automatic versions; a specialist workshop points to a final 197 hp revision as an exception, but for the earlier versions we have found no clear confirmation of whether or not they have them.^[2]

  With caution

• M57D30, first-generation 3.0 litres (177-193 hp, 1998-2006 depending on application)

  177–193 hp · M57D30

  A specialist workshop points out that the versions with an automatic gearbox have the swirl flaps that are prone to breaking, while the E53 X5 3.0d (across its whole production run) and the manual versions of the first 330d and 530d are free of them.^[2]

  With caution

Faults that affect 2002 cars

• Critical severityFrequency: CommonIntakeBroken intake swirl flapsYes: most automatic M57 and M57TU engines (330d, 530d, 535d, 730d, X3 3.0d and so on) have six metal flaps in the intake manifold that can seize, come loose and wreck a cylinder. The E53 X5 3.0d and the manual gearboxes of the first 330d/530d are free of them, according to a specialist workshop.
• High severityFrequency: CommonLubricationCrankcase ventilation (PCV) valve failureThe valve that separates oil from the crankcase gases (PCV) degrades over time, especially after 120,000-150,000 km, and can cause oil consumption, bluish smoke and a rough idle and, if ignored, foul the turbo, the EGR or the particulate filter.Appears at around 120,000 km
• Medium severityFrequency: OccasionalCylinder head and blockCracked exhaust manifoldThe M57 exhaust manifold can crack, causing loss of power, an unstable idle and a smell of exhaust fumes in the cabin; the recommended repair is to replace it with a cast one.
• Medium severityFrequency: OccasionalOtherCrankshaft pulley vibration damper failureThe M57 crankshaft vibration damper (pulley) can fail with use, warning with abnormal noises and knocking at the front of the engine before it breaks completely.
• Low severityFrequency: OccasionalIntakeFaulty air flow meter on the BMW M57 (loss of power)The air flow meter is a known fault on six-cylinder M57 diesels: over time it loses accuracy and the car pulls less. It is a cheap repair compared with the turbo or injection.Repair (garage): €100–€300

• M54B22, 2.2 litres (168-170 hp)

  170 hp · M54B22

  A long-lived engine if maintained, but expect to renew the cooling system and the CCV if there are no invoices.^[5][6][7]

  With caution

• M54B25, 2.5 litres (189-192 hp)

  192 hp · M54B25

  A long-lived engine if maintained, but expect to renew the cooling system and the CCV if there are no invoices.^[5][6][7]

  With caution

• M54B30, 3.0 litres (228-235 hp)

  231–235 hp · M54B30

  A long-lived engine if maintained, but expect to renew the cooling system and the CCV if there are no invoices.^[5][6][7]

  With caution

Faults that affect 2002 cars

• High severityFrequency: CommonCoolingThermostat and water pump failureThe M54's thermostat, housing and water pump contain plastics that become brittle and fail. If left unattended, overheating can warp the aluminium cylinder head. It is advisable to replace them together.Appears at around 129,000 km
• High severityFrequency: CommonCoolingCracked expansion tank and coolant leakThe plastic expansion tank degrades over the years and eventually cracks. It is cheap compared with the cost of overheating an M52/M54, and age matters more than mileage.
• Medium severityFrequency: CommonLubricationCracked crankcase ventilation valve (CCV) and oil consumptionThe M54's CCV valve (oil separator) is made of plastic and cracks with age: oil then gets into the intake, consumption rises and a rough idle and smoke appear. It is the engine's most frequently cited weak point.Appears at around 96,000 km
• Medium severityFrequency: CommonLubricationOil leak from the valve cover gasketThe M54's valve cover is made of plastic and, over the years, warps and stops sealing: oil leaks, a burning smell, oily spark plugs and misfires appear. It is replaced together with the gasket.
• Medium severityFrequency: OccasionalOtherWorn VANOS O-ringsThe seals in the VANOS (variable valve timing) system harden with heat and synthetic oil: the engine loses power below 3,000 rpm and the idle becomes rough. It is fixed with a seal kit.Appears at around 129,000 km

• High severityFrequency: OccasionalBrakesABS module failure on the BMW 5 Series E39According to the owner reports collected by fiches-auto.fr (317 for the 1995-2003 5 Series), there are 16 cases of ABS module failure.
• Medium severityFrequency: OccasionalSuspensionPremature wear of the front arm bushes on the BMW 5 Series E39According to the owner reports collected by fiches-auto.fr (317 for the 1995-2003 5 Series), there are 16 cases of front arm bushes with play, vibrations and vague steering, and 8 of ball joints.
• Medium severityFrequency: OccasionalElectrical systemAlternator failure and battery drain on the BMW 5 Series E39According to the owner reports collected by fiches-auto.fr (317 for the 1995-2003 5 Series), there are 13 cases of alternator failure, 7 of battery failure (one that went flat in two days) and 7 of starter motor failure.
• Low severityFrequency: CommonElectronics and infotainmentFading pixels in the instrument cluster of the BMW 5 Series E39According to the owner reports collected by fiches-auto.fr (317 for the 1995-2003 5 Series), 43 reports describe cluster pixels that gradually fade out.
• Low severityFrequency: OccasionalElectrical systemElectric window failure on the BMW 5 Series E39According to the owner reports collected by fiches-auto.fr (317 for the 1995-2003 5 Series), there are 15 cases of failed window motors, mostly on the rear windows.