2008 BMW 535XI Electrical System Problems

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.

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...

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...

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/

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...

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

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...

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...

MY CAR CAUGHT FIRE WHILE PARKED AND NOT RUNNING.

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.

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.

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...

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

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.

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...

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. *TR

E61 WAGON, REAR HATCH: 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...

I DISCOVERED MULTIPLE SEVERED 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 REAR RIGHT TAIL LIGHT STOPPED FUNCTIONING CORRECTLY, AND THE BRAKE LIGHT, THE RUNNING LIGHT, THE REVERSE LIGHT, AND THE BLINKER STOPPED WORKING. THIS CREATED MANY POTENTIAL ACCIDENTS AS ONCOMING DRIVERS COULD NOT PROPERLY SEE ME REVERSING OR TURNING RIGHT. THERE IS AN ACTIVE RECALL FOR THE ISSUE AND BMW IS REPLACING THE REAR TAIL LIGHTS FOR VIN'S THAT THE GOVERNMENT HAS IDENTIFIED AS HAVING THE ISSUE. MY VEHICLE HAS THE ISSUE. BMW REFUSED TO REPLACED THE TAIL LIGHT THAT HAS PERMANENT LOSS OF FUNCTIONALITY. I WAS FORCED TO PAY OUT OF POCKET FUNDS FOR THE ITEM THAT HAS A RECALL AND BMW NORTH AMERICA HAS REFUSED TO ASSIST IN THIS MATTER. I SPOKE TO [XXX] AT BMW NORTH AMERICA, HE IS A CUSTOMER RELATIONS SUPERVISOR, AND HIS CONTACT INFORMATION IS IN THE BMW CASE FILE WITH ID LAST 7 DIGITS OF MY VIN. HE INDICATED THAT BMW WILL NOT...

WARNING LIGHTS CAME ON WHILE DRIVING THE CAR. WINDSHIELD WIPERS STARTED GOING ON (WITHOUT BEING TURNED ON). BRAKE AND TAIL LIGHTS FAILED INTERMITTENTLY. GAUGES ALL WENT TO ZERO INTERMITTENTLY WHILE DRIVING. SUNROOF WOULDN'T CLOSE. DROVE TO DEALER. DIAGNOSED AS ELECTRICAL SYSTEM COMPONENTS SUBMERGED IN REAR OF CAR DUE TO BLOCKED SUNROOF DRAIN. THE SAME ISSUE WAS REPAIRED A YEAR PRIOR. THIS TIME TO LIABILITY ASSUMED BY MANUFACTURER OR DEALER BECAUSE OF "OUTSIDE FORCE" (RAIN). $9,500 REPAIR ESTIMATE. APPEARS TO BE A COMMON PROBLEM/ FLAW WITH THE MODEL. DEALER DID NOT APPEAR TO DO A CHECK OF THE DRAINAGE SYSTEM WHILE CAR WAS IN FOR ROUTINE SERVICE A MONTH BEFORE THE INCIDENT. NO LOSS OF STEERING OR ENGINE WHILE DRIVING. *TR

THE REAR RAIL LIGHT WARNING STARTED FLASHING INTERMITTENTLY AND THEN REAR TAIL LIGHT PERMANENTLY FAILED. INSPECTION OF REAR TAIL LIGHT SHOWED MELTING OF PLASTIC AROUND GROUND WIRE CONNECTION TO LIGHTING ASSEMBLY AND DAMAGE TO BOTH LIGHT ASSEMBLY AND THE WIRING. QUICK INTERNET SEARCH REVEALED THAT THIS WAS A VERY COMMON PROBLEM IN BMWS DUE TO INADEQUATE CAPACITY OF GROUND WIRING. *TR

I HAVE THREE FAULTS, 1- TRUNK OPENS RANDOMLY, 2 - RDC UNIT IN TRUNK FLOODED BECAUSE TRUNK OPENED, 3 - BATTERY DISCHARGES. I NOTICED A FEW TIMES AFTER RETURNING TO MY CAR, THE TRUNK OPENED ON ITS OWN. I ALWAYS LOCK MY CAR AND WHEN I WALK AWAY, I MAKE SURE THAT THE TRUNK IS CLOSED. WHEN I RETURN TO MY CAR, THE TRUNK IS RANDOMLY OPENED. ONE DAY, WHEN IT WAS RAINING, THIS OCCURRED AND DRENCHED MY ENTIRE TRUNK. I DRIED THE TRUNK OUT AND STARTED DRIVING THEN I NOTICED THE TPMS STARTED FAILING. AFTER CHECKING ALL THE TPMS ANTENNAS ON MY CAR, I FOUND OUT THAT THERE WAS A UNIT IN THE TRUNK. THIS UNIT WAS IN THE BASE OF THE TRUNK WITH NO VENTILATION. MY RDC UNIT WAS SUBMERGED IN WATER ALONG WITH MY BLUETOOTH SYSTEM. THE RDC UNIT FAILED AND I NOTICE THE BLUETOOTH SYSTEM HAS...

TL* THE CONTACT OWNS A 2008 BMW 535XI. THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS, THE BRAKE PEDAL WAS ENGAGED AND THE EXTERIOR BRAKE WARNING INDICATOR DISPLAYED ON THE INSTRUMENT PANEL INDICATING THE PASSENGER'S SIDE BRAKE LIGHT WAS INOPERABLE. ON A SEPARATE OCCASION BOTH THE LEFT TURN SIGNAL AND PASSENGER'S SIDE EXTERIOR BRAKE LIGHT FAILED TO OPERATE WHEN THE BRAKE PEDAL WAS ENGAGED AND A WARNING MESSAGE DISPLAYED AT THE SAME TIME. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE ELECTRICAL CONTACT ASSEMBLY WAS REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 56,000.

THE GROUND CONNECTION TO THE RIGHT REAR LIGHT ASSEMBLY FAILED. THIS RESULTED IN THE RIGHT REAR LIGHTS AND TURN SIGNAL NOT OPERATING. THE CONNECTOR TO THE WIRING HARNESS WAS MELTED AND THE TAB ON THE LAMP SOCKET HOUSING (WHERE THE CONNECTOR PLUGS IN) WAS DAMAGED. *TR

CONSUMER WRITES IN REGARDS UNRESOLVED FIRE SAFETY ISSUES WITH A 2008 BMW 535XI *TGW THE CONSUMER STATED ON FEB 14, 2012, THE BATTERY WAS REPLACED. HOWEVER, SIX DAYS LATER, A SPARK OF FIRE AND BALL OF SMOKE OCCURRED AS THE CONSUMER WAS DRIVING. THE DEALER INFORMED THE CONSUMER THE ALTERNATOR WAS FAULTY AND NEEDED TO BE REPLACED. AN INSPECTION ALSO REVEALED AN OIL LEAK. *JB THE CONSUMER STATED THE VEHICLE BURST INTO FLAMES AND EXPLODED, TOTALING THE VEHICLE. THE ENTIRE FRONT HOOD AND ENGINE COMPARTMENT WERE MELTED AND DESTROYED, AS WELL AS THE FRONT DRIVER AND PASSENGER AREAS WERE AFFECTED BY THE FIRE. THE CONSUMER AND HIS PASSENGER SUFFERED MINOR INJURIES. THE CONSUMER STATED HE HAD TAKEN THE VEHICLE TO THE DEALER IN DECEMBER 2013, AND JANUARY 2014 AFTER COMPLAINING ABOUT ELECTRICAL PROBLEMS. HE COMPLAINED OF LOW COOLANT, THE TRUNK RANDOMLY OPENING, THE KEY NOT STARTING THE VEHICLE RIGHT AWAY,...

THE WIRE HARNESS CONNECTOR TO THE RIGHT REAR LIGHTS BURNED AND MELTED OUT FOR NO REASON. THE FUSE DID NOT PROTECT THE WIRES CONNECTOR FROM BURNING. ALL THE REAR RIGHTS ARE NON OPERATIONAL. *TR