Recalls & faults: BMW E65/E66 7-Series (2002-08)

Recalls: BMW E65/E66 7-Series

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.

Recalls: BMW E65/E66 7-Series

2002-03 BMW E65/E66 7-Series: loss of power steering fluid

In March 2003, a recall was issued for BMW E65 and E66 7-Series vehicles. In these vehicles, the power steering rack hydraulic unions may not have been tightened to the correct torque during assembly – this could lead to a loss of power steering fluid and loss of power-assisted steering; the fluid could also pose a fire hazard if ignited (PRA 2003/6063).

2002-03 BMW E65/E66 7-Series: vehicle jacks not appropriately labelled

In March 2003, a recall was issued for BMW E65 and E66 7-Series vehicles because the jacks were not labelled in accordance with the mandatory standard. Specifically, the safety warning label on the vehicle’s jack used a pictogram, only and did not include specific wording regarding its safe operation (PRA 2003/6064).

2002-04 BMW E65/E66 7-Series: potential damage to seat heating elements

In February 2005, a recall was issued for BMW E65/E66 7-Series vehicles manufactured from September 2002 to June 2004. In these vehicles, mechanical loads exerted in the backrest heating for the front seats when persons ingress or egress may result in damage to the seat heating element in the backrest padding. A break in the contact line could cause the damaged area to overheat, creating a risk of minor burns (PRA 2005/7573).

BMW E65/E66 7-Series: fault seat occupancy detectors

In February 2005, a recall was issued for BMW E65/E66 7-Series vehicles because the seat occupancy detectors may intermittently be unable to reliably detect that the front seat is occupied. As a result, the front passenger’s front and side airbags and seatbelt pretensioners may not activate when required (PRA 2005/7574).

2006 BMW E65/E66 7-Series: lower rubber mounts could come loose

In July 2006, a recall was issued for BMW E65/E66 7-Series vehicles manufactured from 9 January 2006 to 26 April 2006. In these vehicles, the lower rubber mounts could come loose from the rear shock absorbers – if this occurred, wheel guidance would be lost and, depending on the driving situation, it may not be possible to control the vehicle safely (PRA 2006/8620).

2002-08 BMW E65/E66 7-Series V8: loss of power braking assistance

In October 2010, a recall was issued for BMW 7-Series models with V8 petrol engines that were available for sale prior to 30 November 2009. In these vehicles, engine oil from the brake vacuum pump may enter the brake vacuum line and potentially the brake booster. The engine oil may cause leaks in the brake booster’s internal rubber membrane which would impair the brake power assistance system – as such, an increased level of brake pedal pressure would be required to slow the vehicle (PRA 2012/13090).

Problems and faults: BMW E65/E66 7-Series

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

BMW E65/E66 735i/735Li, 745i/745Li and 750i/750Li: N62 Valve Stem Seal Failure

For BMW E65/E66 735i/735Li, 745i/745Li and 750i/750Li models produced from 2001 to 2008 with the N62 V8 engine, the engine may:

1. consume excessive amounts of oil; and
2. produce bluish-white smoke from the exhaust, particularly after idling for a few minutes or when accelerating from a stop.

This was due to the rubber valve stem seals becoming brittle over time and losing their ability to seal effectively – this enabled engine oil to leak past the seals, into the combustion chamber. To fix, the 32 individual seals had to be replaced. While the traditional “book” method required the cylinder heads to be removed, many independent specialists use a valve spring compressor tool that allows the seals to be replaced with the heads still on the engine – this significantly reduces labour costs.

BMW E65/E66 735i/735Li, 745i/745Li and 750i/750Li: N62 Coolant Leak

For BMW E65/E66 735i/735Li, 745i/745Li and 750i/750Li models produced from 2001 to 2008 with the N62 V8 engine, there may be a persistent coolant leak that typically presents as a puddle under the front of the engine. Furthermore, a “Low Coolant” warning usually appears on the iDrive screen. This coolant leak was due to the original front rubber seal on the aluminium coolant pipe (which runs through the engine’s “V” failing over time due to heat cycles. Replacing the coolant pipe requires an engine teardown. However, a common aftermarket fix involves using a collapsible, telescopic coolant pipe – this allows the old pipe to be cut out and the new one installed without removing the timing cover or intake manifold.

BMW E65/E66 735i/735Li, 745i/745Li and 750i/750Li: Alternator Bracket Oil Leak

For BMW E65/E66 735i/735Li, 745i/745Li and 750i/750Li models produced from 2001 to 2008 with the N62 V8 engine, there may be a severe oil leak that could be mistaken for an oil pan leak. For the N62 V8 engine, the alternator was mounted to a bracket that also served as an oil passage for the engine’s oil thermostat. There was a small rubber gasket behind this bracket which would eventually flatten and fail, causing significant oil loss. To fix, the alternator and bracket needed to be removed, and the rubber gasket replaced. While the gasket was inexpensive (maybe $10), labour was expensive since it required several components to be removed to gain sufficient access to the bracket bolts.

BMW E65/E66 735i/735Li, 745i/745Li and 750i/750Li: N62 engine and variable idle

In January 2006, BMW issued technical service bulletin SI B 11 02 05 for BMW E65/E66 7-Series vehicles with the N62 engine (i.e. the 735i/735Li, 745i/745Li and 750i/750Li) that were manufactured from June 2004 to February 2005. In these vehicles, the driver may experience erratic or variable idle speed for around 20 seconds after a cold start. Furthermore, the ‘check engine soon’ light may illuminate and misfire faults may be logged in the DME (e.g. FC 2742, 2743, 2744, 2745, 2746, 2748, 2749 and 274E).

According to the service bulletin, this condition was due to incorrect tolerances and geometry of the ‘Valvetronic’ intermediate levers causing uneven cylinder filling during the transitional cold start period (60 seconds after start-up) when the Valvetronic system was switching from the initial 6 mm to a minimum 0.3/0.8 mm valve lift.

To fix, the Valvetronic intermediate levers were to be replaced.

BMW E65/E66 7-Series: Mechatronic Unit and ZF Transmission Faults

BMW E65/E66 7-Series vehicles equipped with the 6-speed ZF automatic transmission have been reported to experience:

1. “harsh” or “clunky” gear shifts (particularly the 2-1 downshift);
2. gear hunting; and/or
3. the transmission entering “Limp Mode.”

These symptoms were often due to failure of:

1. internal rubber seals (the “bridge seal” and “mechatronic sleeves”) which would flatten or crack, leading to a loss of hydraulic pressure;
2. deterioration in the transmission fluid over time; or
3. in some cases, failure of electronic solenoids within the Mechatronic unit, which could wear out or become clogged with fine metal debris.

Initial steps to address these symptoms included replacing the transmission fluid, filter (integrated into the pan), and the rubber bridge/sleeve seals. If these didn’t fix the problem, the solenoids within the Mechatronic unit may need to be replaced, or the unit may need to be refurbished. The two items below detail technical service bulletins that were related to the ZF transmission.

BMW E65/E66 7-Series: ZF transmission faults

In December 2008, BMW issued technical service bulletin SI B24 01 08 for BMW E65/E66 7-Series vehicles with N62TU or N73 engines and ZF automatic transmissions that were manufactured from March 2005 to October 2006. In these vehicles, the ‘Transmission’ warning light may illuminate and the transmission enter its fail safe mode. Furthermore, fault code 4F81 (‘ratio monitoring, clutch A’) may be logged in the EGS control module, as well as 507B/507C (‘parking gear sensor implausible’) or 507D (‘parking gear incorrectly disengaged’). The service bulletin attributed these faults to:

• A low transmission fluid level; or
• An internal transmission pressure leak caused by a defective adapter seal between the transmission housing and the Mechatronic unit.

If the Mechatronic adapter seal was found to be defective (i.e. cracks or seal damage), it was to be replaced.

BMW E65/E66 7-Series: ZF transmission sealing sleeve seepage

In March 2010, BMW issued technical service bulletin SI B 24 08 06 for BMW E65/E66 7-Series vehicles with ZF six-speed 6HP19/21 or 6HP26/28 transmissions that were manufactured up to April 2008. In these vehicles, transmission fluid seepage may be visible in the area of the transmission oil pan; the service bulletin attributed this condition to the tightness of the Mechatronic sealing sleeve’s O-ring. Only if a visible leakage trace indicated a substantial loss of transmission fluid was the Mechatronic sealing sleeve (part no. 24 34 7 588 725) to be replaced.

Other problems and faults: BMW E65/E66 7-Series

• If the engine pings under light throttle loads, has a high idle or falters when cold, a software update may be required to fix.
• The transmission may intermittently go into fail-safe mode and exhibit unusual shift behaviour due to errors with the controller area network (CAN) bus system.
• For models fitted with the 4.8-litre V8 petrol engine, the right side (cylinders 1-4) valve cover or oil filler cap could break in cold weather due to a build-up of ice in the vent hose or valve.
• If the key is left in the ignition overnight, the battery may be drained and the vehicle may fail to start.
• Where fitted, the night vision display may malfunction due to a damaged wiring harness (near headlights).
• The automatic headlights may not turn off when exiting a tunnel or parking garage due to a miscommunication between the sensor and headlight module.
• The universal garage door opener may not accept a code from a different source (new transmitter or new owner) if the batteries in the transmitter are low.