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1990-1996 BMW 5-Series Reliability
Date Published: 2/20/08
Our reliability study for this generation BMW 5-Series includes details on average repair costs, manufacturer recalls, and everything you need to know to gauge the long-term reliability of this generation BMW 5-Series.
1990-1996 BMW 5-Series Reliability
Trouble Spots
Consumer Guide's® Auto Editors have scoured repair bulletins and questioned mechanics to search for commonly occurring problems for a particular vehicle. In some cases we also give possible manufacturer-suggested solutions. In many instances these trouble spots are Technical Service Bulletins posted by the manufacturer, however, we have our own expert looking at additional vehicle problems.
Air conditioner: Small flakes may come from the vents or a foul odor may be present when the A/C is operated. A redesigned evaporator is available to fix the problem. (1992-93)
Climate control: Fuse #20 may blow repeatedly and BMW has approved replacing the original 10-amp fuse with a 15-amp fuse. (1993-94)
Dashboard lights: The hazard flashers may begin flashing by themselves or the turn signals may flash at twice the normal speed due to condensation shorting out the circuit board. (1992-94)
Doors: If the central locking system unlocks itself after being locked or locks itself after being unlocked, the actuators could be defective or the trunk lock may need to be adjusted. (1992-93)
Oil leak: Oil and coolant leak from valley in V8 engine could be a rear main seal leaks. (1994-96)
Starter: The starter may fail because it keeps running after the engine starts. The root cause is a sticking ignition switch. The whole lock and switch must be replaced. (1992-94)
Transmission slippage: Transmission may slip and/or check-engine light may glow due to torque converter clutch (TCC) slipping and/or TCC solenoid failure. (1992-94)
Consumer Guide® Estimated Repair Costs
This table lists costs of likely repairs for comparison with other vehicles. The dollar amount includes the cost of the part(s) and labor (based on $50 per hour) for the typical repair without extras or add-ons. Like the pricing information, replacement costs can vary widely depending on region. Expect charges at a new-car dealership to be slightly higher.
Item Name Repair Cost
A/C Compressor $1,280
Alternator $610
Automatic Transmission or Transaxle $1,150
Brakes $255
Clutch, Pressure Plate, Bearing $875
Exhaust System $1,015
Radiator $710
Shocks and/or Struts $865
Timing Chain or Belt $1,920
NHTSA Recall History
1990 5-Series: Under certain conditions, front armrest may contact seatbelt buckle, damaging its release button.
1990-92 5-Series 535i: Brake lights may fail to operate, or be on continuously.
1990-94 5-Series 525i: Brake lights may fail to operate, or be on continuously.
1990-95 5-Series: Malfunction or failure of cooling system component can result in significantly increased coolant temperature and system pressure.
1990-95 5-Series 525i: Plastic bushing for cruise-control and throttle cables could break, causing throttle valve to remain partially open; car then might not decelerate as expected.
1991 5-Series 525/535: Movement of throttle valve may be impeded, preventing car from decelerating.
1991-92 55-Series 25i/535i/M5: Airbag contact-ring locking tab can break without warning, eventually causing broken wiring; airbag would then not deploy in collision, and indicator would illuminate.
1992 5-Series 525it: Airbag contact-ring locking tab can break without warning, eventually causing broken wiring; airbag would then not deploy in collision, and indicator would illuminate.
1992-94 5-Series 525it: Brake lights may fail to operate, or be on continuously.
1994 5-Series 530i/it, 540i: Brake lights may fail to operate, or be on continuously.
1994-95 5-Series 525: Double-lock mechanism can engage with key and occupants inside car.
1994-95 5-Series 530i: Plastic bushing for cruise-control and throttle cables could break, causing throttle valve to remain partially open; car then might not decelerate as expected.
1996 5-Series: In some cases, long exposure to certain environmental and operation conditions could cause front spring strut plate to begin to crack, and possibly break eventually.
1996 5-Series: On certain vehicles, environmental conditions may cause the front string strut plate to break and interfere with the front tires. Dealers will inspect and install a retaining clip.
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