2004 BMW Serie 7 problems

• M57D30TU, first revision 3.0 litres (201-272 hp, 2001-2006)

  201–272 hp · M57D30TU

  A BMW specialist workshop places this revision among those that generally have the swirl flaps prone to breaking.^[2]

  With caution

• M57D30TU2, second revision 3.0 litres, aluminium block (204-286 hp, 2004-2010)

  204–286 hp · M57D30TU2

  A specialist workshop expressly names the 231 hp E90 330d/330xd and the twin-turbo 335d/535d among the versions with swirl flaps; it points to only a final 197 hp revision of the 325d/525d as an exception.^[2]

  With caution

Faults that affect 2004 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

• N62B36 3.6 naturally aspirated 272 hp (735i, 2001-2005)

  272 hp · N62B36

  It is the oldest N62 and the 6 Series guide places coolant loss mainly on the older examples; check the hoses and level before buying.^[5][6]

  With caution

• N62B44 4.4 naturally aspirated 320-333 hp (545i, 645Ci, 745i, X5 4.4i; 2001-2006)

  320–333 hp · N62B44

  A 100,000 km test of a 745i recorded no engine defects, but the sources cite coolant loss from hoses (Gebrauchtwagenberater and Auto Bild) and, to a lesser extent, valve stem seals (Auto Bild): both points need checking.^[6][7][8]

  With caution

Faults that affect 2004 cars

• Medium severityFrequency: CommonCoolingN62 coolant loss from hoses and the pipe between the cylinder banksOn the N62 V8, coolant loss from cracked hoses or pipes is typical, especially on the earliest units. Replacing them is laborious: the hose between the banks means removing a good part of the engine.
• Medium severityFrequency: OccasionalLubricationN62 blue smoke and oil consumption from hardened valve stem sealsOn the N62 V8, the valve stem seals can harden with age and cause oil consumption with blue smoke. It is not a widespread fault: several German guides describe the engine as solid.

• Medium severityFrequency: OccasionalSuspensionWear of the front suspension arms and bushesAccording to testimonies collected by fiches-auto.fr, the 7 Series E65's front suspension arms, bushes, bearings and ball joints appear in 8 of 64 testimonies. No mileage or cost is given.
• Low severityFrequency: OccasionalBodywork and interiorPaint degradation on door handles and bodywork corrosionAccording to testimonies collected by fiches-auto.fr, 5 of 64 owners of the 7 Series E65 cite paint degrading on the door handles and spots of rust, as well as misting of the headlights.
• Low severityFrequency: RareElectronics and infotainmentiDrive CCC unit failure and infotainment equipment faults (sat nav, CD, radio, speakers)According to testimonies collected by fiches-auto.fr, the iDrive CCC unit and other infotainment equipment (sat nav, CD changer, radio, speakers, DVD player) are among the faults cited for the 7 Series E65. The entry gives no individual figures or costs.