2004 BMW 5 Series Electrical System

BATTERY CABLE - INSULATED BULKHEAD CONNECTOR

Unrepaired Recalls (1) 12V-126:79 Safety: Battery Cable - Insulated Bulkhead Connector Mar 23, 2012 OEM Code 12V-126:79 All the dealerships i contacted to fix this recall never replied to me and The battery connection has ruined my electrical components on my vehicle(Long beach BMW and Cerritos BMW California)

THE WIRE HARNESS FOR BOTH HEADLIGHTS IN THIS VEHICLE ARE COMPLETELY FRAYED. BARE COPPER WIRES CAN BE SEEING AND THE LIGHTS ARE INOPERATIVE. IN ADDITION TO NIGHT DRIVEABILITY BEING AND ISSUE, THE POTENTIAL FOR A SHORT CIRCUIT AND FIRE UNDER THE HOOD EXISTS. A CURSORY INTERNET RESEARCH SHOWS THAT THIS IS COMMON ISSUE WITH SEVERAL BMW MODEL YEARS, POTENTIALLY AFFECTING THOUSANDS OF DRIVERS.

TL* THE CONTACT OWNED A 2004 BMW 525I. WHILE THE VEHICLE WAS PARKED IN THE GARAGE, A NEIGHBOR NOTICED THAT THE VEHICLE WAS ON FIRE. THE FIRE DEPARTMENT WAS CALLED AND EXTINGUISHED THE FIRE. THE FIRE DEPARTMENT STATED THAT THE FIRE WAS DUE TO A FAULTY BATTERY CABLE. THE CONTACT STATED THAT THE VEHICLE WAS DESTROYED IN THE FIRE. THE CONTACT RECEIVED MEDICAL ATTENTION DUE TO SMOKE INHALATION. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CONTACT CALLED AN UNKNOWN LOCAL BMW DEALER, BUT THEY WERE UNABLE TO ASSIST. THE FAILURE MILEAGE WAS 160,000.

ABOUT 3 WEEKS AGO WE NOTICED IN THE FRONT PASSENGER SEAT "A MARK" THAT LOOKS LIKE A BURNT - WE THOUGHT THAT IT WAS JUST A MARK OR SOMEBODY PUT A HOT BOTTLE O CUP ON THE SEAT - BUT THIS MORNING WE TURN THE HEATING IN BOTH SEAT TO WARM UP A LITTLE BIT THEN SMELL AND SMOKE START TO COME OUT THE BURNT MARK. WE TURNED IT OFF BOTH SIDES AND OPEN THE WINDOW - NOW OUR CONCLUSION IS THE HEATING ELEMENT CAUSED THAT BURN IN THE SEAT.

MY I DRIVE OR CCC HAS MALFUNCTIONED. AT FIRST THE SCREEN WOULD TURN ON AND OFF OR FREEZE UP. FINALLY THE SCREEN WENT BLANK. THIS UNIT PROVIDE THE SAFETY INFORMATION OF THE VEHICLE. THIS UNIT ALSO PROVIDES THE COMMUNICATIONS SUCH AS BLUETOOTH AND HANDS FREE FUNCTIONS. THIS UNIT ALSO PROVIDES ALL THE SERVICE INFORMATION/ BASICALLY IT LIKE DRIVING A VEHICLE WITH OUT A BRAIN. THIS SEEMS TO BE A RECURRING PROBLEM WITH OTHER BMW OWNER.

MICRO POWER MODULE (MPM) STARTED SMOKING WHILE DRIVING, CAUSING ERRATIC ENGINE RPM, AND CAUSING SMOKE INSIDE CABIN AND BURNT ELECTRONICS SMELL. COMPLETE LOSS OF RADIO AND IDRIVE FUNCTIONALITY. MODULE IS LOCATED IN TRUNK UNDER THE SPARE TIRE. NOTIFIED BMW OF NORTH AMERICA, AND THEY JUST SAID THAT THE CAR WAS OUT OF WARRANTY AND NOTHING COULD BE DONE. I FEEL THAT THIS IS A SERIOUS DEFECT THAT COULD POSSIBLY START A FIRE. SEVERAL BMW ONLINE FORUMS HAVE DISCUSSED THIS ISSUE. OTHERS HAVE REMEDIED THE PROBLEM BY RELOCATING THE MODULE TO A HIGHER PLACE IN THE TRUNK. MOST OF WHO OWN THESE CARS DO NOT KNOW THAT THESE VEHICLES HAVE THIS VULNERABILITY. VEHICLE WAS MOVING IN THE EARLY MORNING WHEN THIS HAPPENED.

TL* THE CONTACT OWNED A 2004 BMW 525I. THE CONTACT STATED THAT THE VEHICLE CAUGHT FIRE AND BLEW UP IN THE GARAGE WITHOUT WARNING. THE FIRE DEPARTMENT WAS CONTACTED AND STATED THAT THE FIRE WAS STARTED BY THE BATTERY CABLE. A FIRE REPORT WAS FILED. THE CONTACT SUSTAINED INJURIES THAT REQUIRED HOSPITALIZATION. THE VEHICLE WAS TOTALED AND THE CONTACT'S HOME WAS DAMAGED EXTENSIVELY. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS CONTACTED AND STATED THAT IT WAS NOT THEIR RESPONSIBILITY. SIX MONTHS PRIOR TO THE FIRE, THE VEHICLE WAS TAKEN TO THE DEALER (CHAPMAN BMW IN PHOENIX, AR) WHERE A RECALL REPAIR OF THE BATTERY CABLE WAS PERFORMED. THE RECALL INFORMATION WAS LOST IN THE FIRE. THE FAILURE MILEAGE WAS 160,000.

THE WIRING INSIDE THE HEADLIGHTS ARE ALL CRUMBLING AND EXPOSING THE COPPER WITHIN CREATING AN ELECTRONCAL FIRE OR SHORTING OF THE SYSTEM. THIS APPEARS TO BE VERY COMMON ON THE E60 SERIES BMW AND SHOULD BE ADDRESSED.

THE HEADLIGHT ASSEMBLY PRODUCED BY HELLA CONTAINS APPARENTLY DEFECTIVE WIRING. THE INSULATION ON THE ELECTRICAL WIRES TO THE HIGH BEAM BULBS AND THE PARKING LIGHT BULBS DETERIORATES AND CRUMBLES OFF LEAVING EXPOSED ELECTRICAL WIRES IN THE HEADLIGHT ASSEMBLY. MOVING THE WIRES DURING REMOVAL AND REPLACEMENT OF BULBS CAUSED THE INSULATION TO BREAK OFF COMPLETELY. THE PROBLEM WAS JUST DISCOVERED, BUT WAS OBVIOUSLY IN A STATE OF DECAY FOR A LONG PERIOD OF TIME.

I OWN A 2004 BMW 530 I MY DAGHTER JUST CAME BACK FRO WORK SHE PARKED THE CAR IN MY DRIVE WAY AND SHE CAME INSIDE SHE HAD DIINNER AND WE GOT READY FOR BED AT APPROXMENTLY 11PM WE GET A NOCK ON THE SIDE WINDOW WERE FROM THE POLICE DEPT SAY TO EVECUATE AND TO COME OUT NOW WHEN WE CAME OUT THE CAR WAS IN A FIRE AND THE SAINT CLOUD FL MARSHAL SAID THE FIRE START CAUSE DUE TO THE BATTERY OR THE WIRE IN THE TRUNK I CALLED BMW COPPERT OFFICE TO LET THEM KNOW AND THEY SAID THEY WILL NEED TO PICK UP THE CAR TO HAV ENGINER TO LOOK AT THE CAR WAS TOTTLED BMW AFTER THEY TOOL 40 DAY FOR EVALUATION THEY CALLED ME TODAY AND ONLY OFFERED TO PAY $5000.00 TOWARD A CERTIF USED OR NEW BMW I TOLD THEM THAT THIS WAS NOT ACCEPTABLE AND I TOLD THEM I WILL CALL YOUR COPANY AND THEY SEEM NOT TO CARE I WANT TO MAKE SURE EVERY OWNER OUT THERE NEED TO KNOW THIS CAN HAPPEN TO THEM AND THAT RECALL THAT BMW HAD BY REPLACING THE ONLY ONLY A RUBER PART ON THE RED WIRE IN THE TRUNK DOES NOT HELP PLEASE LET ME KNOW IF YOU CAN HELP ME RECOVER MY MONEY ON THE CAR.I DID NOT HAVE FULL COVERGE I ONLY HAD LIBLTY INSURANCE SO THIS DID NOT HELP I HAVE BEEN DOING MY HOMEWORK AND FOUND OUT THAT THERE HAVE BEEN 1.2 MILLION BMW RECALL AND ONLY 1 FIRE MY CAR IS THE 2ND AS I READ MORE ABOUT THE ISSUE AND ALSO FOUND SOME NEWS COMPANY SUCH NBC HAD A ARTICLE ON THIS ISSUE .

DRIVING DOWN THE ROAD AND SMELLED A BURNING SMELL. TURNED OFF THE SEAT HEATER. THE SEAT FELT VERY HOT ON MY LOWER BACK. WHEN I GOT TO WORK NOTICED THAT THE LEATHER WAS BURNED THROUGH ON THE DRIVERS LEFT SIDE. YOU CAN SEE THE EXPOSED WIRING. VERY DANGEROUS. BMW WOULD NOT REPLACE. IN SEARCHING ON LINE, I SAW THAT THIS IS A COMMON SITUATION ON THE SEAT HEATER ELEMENT.

TL* THE CONTACT OWNS A 2004 BMW 525I. WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE FAILED TO RESTART UNTIL AFTER REPEATED ATTEMPTS. THE FAILURE OCCURRED WHENEVER THE VEHICLE WAS IN OPERATION. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE COMPUTERIZED SYSTEM NEEDED TO BE REPLACED. THE VEHICLE NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.

TL* THE CONTACT OWNS A 2004 BMW 525I. THE CONTACT STATED THAT THE SERVICE INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE LIGHTING WIRES WERE ZIP TIED TOGETHER AND THE CASING WAS MISSING. AS A RESULT, THE LIGHTING ASSEMBLY ON THE DRIVER AND PASSENGER SIDE WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 190,000.

THERE WAS A BURNT PLASTIC ODOR, SHORTLY AFTER THAT SMOKE CAME OUT OF THE TRUNK. A CABLE CONNECTED TO THE BATTERY CAME LOOSE WHICH CAUSE THE POWER MODULE TO BURN OUT. THERE WAS A POWER OUTAGE THROUGHOUT THE CAR, THE NOTICEABLE ONES INCLUDED; THE RADIO (NO IMAGE WAS DISPLAYED ON THE SCREEN AND NO SOUND); THE CAR ALARM WAS NOT WORKING AND THE BING SOUND ALERTING KEY IN IGNITION, SEATBELT NOT STRAPPED, ETC. WAS NOT WORKING. *TR

THERE WAS A BURNT PLASTIC ODOR, SHORTLY AFTER THAT THERE WAS SMOKE COMING OUT OF THE TRUNK. THERE WAS A CABLE CONNECTED TO THE BATTERY THAT COME LOOSE, WHICH CAUSED THE POWER MODULE TO BURNT OUT. THERE WAS POWER OUTAGE THROUGHOUT THE CAR, THE NOTICEABLE ONES INCLUDED: THE RADIO (THE SCREEN WAS COMPLETELY BLACK AND THERE WAS NO SOUND); THE CAR ALARM; AND THE BING ALERTING SOUNDS THAT GOES OFF WHEN KEY IS IN IGNITION, SEATBELTS ARE NOT STRAPPED,ETC. WERE NOT WORKING. MY TECHNICIAN CHANGE THE POWER MODULE THEN HE NOTICED THAT THE CABLE THAT CAME LOOSE ONLY DISCONNECTS WHEN THERE IS A CAR ACCIDENTS AS A PRECAUTION, JUST THE SAME WAY THE AIRBAGS DEFLATE. HE ADVISED THAT IT WAS A MANUFACTURING DEFECT THAT COULD LEAD TO AN EXPLOSION. WHEN I INFORMED BMW CENTER ABOUT THIS PROBLEM THEY SAID IT HAD NOTHING TO DO WITH A DEFECT THAT IT WAS "WEAR AND TEAR", BUT THEN AGAIN THEY DIDN'T BOTHER TO DIAGNOSE IT, THEY DIDN'T EVEN BOTHER TO TAKE A LOOK AT IT! *TR

IN JUNE 2012, I RECEIVED SERVICE FOR THE BATTERY CABLE RECALL FOR MY 2004 525I AT BEVERY HILLS BMW SERVICE CENTER. ONE WEEK AFTER MY SERVICE A SERVICE INDICATOR ON MY I-DRIVE SAID THERE WAS PASSENGER RESTRAINT/AIRBAG MALFUNCTION. THE BEVERLY HILLS BMW SERVICE DEPARTMENT DETERMINED THAT THIS SERVICE INDICATOR WAS TRIGGERED BY A MALFUNCTION OF THE BATTERY SAFETY TERMINAL WHICH HAPPENED SHORTLY <1000 MILES AFTER THE REPAIR OF THE BATTERY CABLE RECALL. THE RECALL SERVICE DONE AT BEVERLY HILLS BMW WAS RELATED TO THE MOUNTING OF THE BATTERY CABLES TO A CONNECTION IN THE MID-TRUNK, AND THE POSITIVE TERMINAL CABLE THAT CONNECTS THERE RUNS BACK TO THE RIGHT CORNER OF THE TRUNK AND CONNECTS TO THE BATTERY, COMMUNICATING DIRECTLY WITH THE BATTERY SAFETY TERMINAL. FROM WHAT I HAVE READ, THE BATTERY SAFETY TERMINAL CAN MALFUNCTION IF ANY CONNECTION TO IT IS LOOSE CAUSING AN ABRUPT CHANGE IN IMPEDANCE IN THE CIRCUIT, OR ON THE CONTRARY CAN BE CAUSED BY BLOWN FUSE RELATED TO A RAPID RISE IN VOLTAGE. ANOTHER POSSIBILITY IS THAT HEATING OF THE BATTERY CABLE (THE ISSUE THE RECALL EXISTS IN THE FIRST PLACE), COULD HAVE CAUSED THE BATTERY TERMINAL TO MALFUNCTION, THOUGH THAT DOES NOT EXPLAIN WHY THIS PROBLEM WOULD SURFACE ONLY AFTER THE REPAIR WORK. FURTHERMORE, THE BATTERY SAFETY TERMINAL IS NOT A WEARABLE PART, SO IT SEEM ILLOGICAL TO THINK THAT'S IT'S MALFUNCTION, TIMED TO THE RECALL REPAIR WAS JUST A COINCIDENCE. BMW OF BEVERY HILLS IS ATTMEPTING TO CHARGE ME FOR THE BATTERY SAFETY TERMINAL REPAIR $870.00 EVEN THOUGH THIS IS A DIRECT RESULT OF THEIR FALLED ATTEMPT TO REPAIR THE RECALL. BMW OF NORTH AMERICA WAS NOTIFIED OF THIS PROBLEM. *TR

TL* THE CONTACT OWNS A 2004 BMW 320I. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE CONTACT REPLACED THE BATTERY AND WAS ABLE TO START THE VEHICLE. THE BATTERY WAS REPLACED FOUR TIMES. THE CONTACT DISCOVERED THAT WATER ENTERED THE BATTERY COMPARTMENT, CAUSING THE FAILURE. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 12V126000 (ELECTRICAL SYSTEM:BATTERY:CABLES) BUT WAS UNAWARE IF THE VEHICLE WAS INCLUDED IN THE RECALL BECAUSE HE NO LONGER OWNED THE VEHICLE AND THE MANUFACTURER WOULD NOT PROVIDE ANY INFORMATION. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 70,000.

TL* THE CONTACT OWNS A 2004 BMW 530I. THE CONTACT STATED THAT THE PASSENGER SIDE RESTRAINT SYSTEM WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS INFORMED THAT THE PASSENGER SEAT MAT NEEDED TO BE REPLACED BECAUSE THE SENSOR WAS FAULTY. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE YET NO REPAIRS WERE PERFORMED. THE CURRENT AND FAILURE MILEAGE WAS 130,000.

TL* THE CONTACT OWNS A 2004 BMW 545I. THE CONTACT STATED THAT HE NOTICED THAT THERE WERE VARIOUS WARNING LIGHTS THAT ILLUMINATED ON THE INSTRUMENTAL PANEL. HE STATED THAT THE VEHICLES I-DRIVE WOULD MALFUNCTION CAUSING THE RADIO TO FAIL, GPS, AND HE WAS UNABLE TO MAKE PHONE CALLS FROM THE VEHICLE. THE SPEEDOMETER ALSO DISPLAYED 0 INSTEAD OF THE ACTUAL MPH THAT WAS BEING DRIVEN. THE VEHICLE WAS INSPECTED BY A DEALER AND THEY WERE UNABLE TO DIAGNOSE THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 88,000. THE VIN WAS UNAVAILABLE.

TL* THE CONTACT WOULD LIKE TO USE HIS SUBMITTED EMAIL AS THE ACTUAL COMPLAINT. OUR 2004 BMW 530I HAD THE DRIVER'S HEATED SEAT CATCH FIRE. I AM NOT GETTING MUCH HELP FROM BMW ON THIS MATTER. TO ME, THIS IS ONE HELLUVA OF AN EASY WAY TO CAUSE A MAJOR ACCIDENT. ONLY BECAUSE OF MY PARTNER'S QUICK THINKING AND TURNING OFF THE HEATER WAS SHE ABLE TO STOP THE FIRE. IT WAS HOT ENOUGH THAT IT MELTED THE FOAM (TOXIC I AM SURE) IN THE SEAT. SOMETHING LIKE THIS HAPPENING WHILE YOU ARE GOING DOWN THE ROAD IS RIGHT UP THERE WITH TOYOTA AND THEIR ACCELERATION PROBLEMS. EITHER WAY A MAJOR ACCIDENT CAN HAPPEN. NOT TO MENTION THAT A PERSON COULD BE SEVERELY BURNED. WHILE THE CAR IS OUT OF WARRANTY THIS SEAT HAS NEVER BEEN ABUSED. THE DRIVER OF THE CAR WEIGHS IN AT ABOUT 120 POUNDS. FROM CHECKING THE INTERNET THERE SEEMS TO BE A QUITE A NUMBER OF SUCH INSTANCES. THANK YOU SCOTT THE FAILURE MILEAGE WAS 60,000.

04 BMW 545 ELECTRICAL FAILURE MPM. *TR

TL* THE CONTACT OWNS A 2004 BMW 530I. THE CONTACT STATED THAT WHEN HE OPENED THE TRUNK IN THE RAIN THERE WERE SPARKS AND SMOKE EMITTING FROM THE MICROPROCESSOR (MPM), LOCATED UNDER THE SPARE TIRE WELL. AS A RESULT, THE AIR BAG SENSOR, I-DRIVE AND SEVERAL ELECTRICAL COMPONENTS ON THE VEHICLE WERE NO LONGER FUNCTIONING. THE MANUFACTURER ADVISED THE CONTACT THAT THE DEALER COULD REPAIR THE VEHICLE AT HIS EXPENSE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 74,000.

RADIO,NAVIGATION,CD,PHONE,NOT WORKING. I DRIVE IS BLINK. CAR HAS 93,000 MILES. *TR

DRIVING NORTH ON I-77 IN S.C. - TRAVELING ALONG WITH THE TRAFFIC FLOW - LEFT HAND LANE - SUDDENLY ALERT LIGHTS CAME ON THAT ABS WAS NOT OPERATING, BATTERY ALERT (HAD BATTERY INSTALLED AT DEALERSHIP) ETC.- ENGINE QUIT - DASH BOARD WENT BLANK - WAS ABLE TO GET TO THE CURB LANE (NO TURN INDICATORS) CAME TO STOP - TRIED TO RESTART -NO LUCK -WAIT MAYBE 10 MINUTES IT RESTARTED -DROVE HOME -APPROX ANOTHER 200 MILES -DEALER COULD NOT FIND ANY PROBLEM - IT COULD HAVE BEEN A DANGEROUS SITUATION IF SOMEONE PANICKED. *TR