The BMW 3-Series Mk5 saloon, which is also known as the E90, and the E91 Touring estate, were pretty controversial when launched in 2004. Not only did they have the room-dividing ‘flame surface’ styling penned by head stylist Chris Bangle but they also featured the company’s iDrive multimedia control system, which took everyone a while to get used to.
Still, under the futuristic skin lay some mechanical bits that were somewhat more conventional, which means that if yoyo own one today you shouldn’t have too many fears about getting under the bonnet and fixing the odd niggling issue. There’s not only a printed Haynes 3-Series manual to help you along, but you can also buy the online manual, which means it’ll be with you on your phone or tablet whenever you need it.
And if you use Haynes to help you sort out any annoying problems with your 3-Series, then you’ll save hundreds on garage labour costs along the way.
What recalls has the BMW 3 Series Mk5 been subject to?
The BMW 3 Series has seen the inside of BMW dealerships for recall work on a number of occasions.
The first was because of a faulty connector in the blower regulator wiring loom. The affected almost 280,000 cars.
Then a faulty positive battery cable forced 311,848 cars back to dealerships. A faulty power steering box caused 701 examples to return to dealers, then 1756 cars were recalled because of faulty wiring for the side airbags and seatbelt pretensioners.
Incorrect connections for the side airbags in convertible models caused another recall, then 287 cars were recalled because the brake servo could fail, lengthening braking distances.
An out-of-spec propshaft universal joint affected 10989 3-Series models, and had to be replaced, and 2954examples were recalled to have faulty variable valve timing VANOS units replaced.
What common problems does the BMW 3 Series have?
The BMW 3 Series fitted with diesel engines can suffer a problem that causes it to emit a droning noise at all speeds. This is down to a damaged exhaust flexible pipe.
A number of owners have also reported an issue that affects cars with manual gearboxes, because the clutch can seize.
A dead battery can also afflict the BMW 3-Series, but it isn’t the battery’s fault, because a faulty fuel filter heater drains it.
There have also been reports of the front axle of the 3-Series creaking and clunking as you go over speed bumps and suchlike. It’s faulty anti-roll bar bushes that are the cause.
And finally, some models fitted with the six-cylinder diesel can be prone to an issue in which the engine misfires and judders, then stalls as you’re driving along.
Does the BMW 3 Series Mk5 have an exhaust drone?
Yes, a prevalent exhaust drone can affect the BMW 3-Series, and it doesn’t really matter which engine is fitted because the issue can affect all versions.
The reason is that the exhaust flexible pipe can be prone to damage, and you’ll know when it’s happened because there will be a prominent droning noise, no matter whether the car is driving along or when it’s just idling and stationary.
The only solution is to replace the exhaust flexible pipe, which is a procedure covered in depth in the Haynes 3-Series manual, so just read up beforehand, gather together the required tools and replacement parts, and off you go, making sure you raise the car safely and set it on axle stands to begin with.
Is the BMW 3 Series prone to clutch seizure?
The BMW 3-Series can suffer an issue that causes its clutch to seize up.
The source of the fault is likely the dual-mass flywheel, which can be faulty, and the way to fix the issue is to remove and replace the clutch assembly, including the flywheel.
The clutch replacement procedure is featured in the Haynes 3-Series manual, and will require you to remove the gearbox beforehand, so make sure you read the procedure thoroughly, because it isn’t going to be the work of a moment, and you’ll want to get it right first time.
The good news is that by doing the job yourself, you’ll save yourself hundreds if not thousands of pounds in workshop labour charges.
Why won’t your BMW 3 Series Mk5 start?
Silence. It certainly isn’t golden when you press the start button in your BMW 3-Series only to be greeted by it. In fact, it’s pretty soul-destroying.
The battery is clearly flat, but what’s caused that to happen? First thing to do is to plug in a fault code reader (click here for our test of the best fault code readers you can buy in 2023).
If it generates the code 4B1C, 19228, 4B1B or 19227, then you can be pretty sure that the fault lies with the fuel filter heater.
So, the next job is to replace the fuel filter and the fuel filter heater, and while you’re doing so, remove the battery from the vehicle and place it on charge.
The fuel filter and fuel filter heater are both located underneath the vehicle, so you’ll need to raise the rear of your 3-Series and set it on axle stands, then remove some underbody protection to get to the affected components.
To see how to disconnect the battery in your BMW 3-Series, just watch our FREE video below.
What’s that creaking noise from your BMW 3 Series?
You buy a BMW because you want a classy-feeling car that will also make you look good. But a creaking noise from the front end over every bump is going to tarnish that impression somewhat. But that’s what some 3-Series owners have been subjected to.
This tends to happen more when the temperature is low, and is down to faulty anti-roll bar bushes.
The good news is it’s a relatively simple job to carry out, so just follow the instructions in the Haynes 3-Series manual about how to remove the anti-roll bar, then replaces the old bushes with new ones (part number: 31 30 6 778 064), which have been upgraded to avoid the fault occurring again.
Then follow the procedure for how to refit the anti-roll bar to the vehicle.
Has your BMW 3 Series Mk5 suddenly conked out?
‘Cough’. What was that? ‘Hiccup’. There it is again. ‘Splutter’. What is that? And then your engine dies. You pull over to the side of the road and flick on the hazards. What’s the problem?
Once you’ve got the car back home, you need to plug in a fault code reader. This might display the codes 3F40, 48A9, 250900, 276B00, 3F30 or 3F31, all of which indicate an issue with the fuel rail pressure sensor.
Then you need to check the fuel rail pressure sensor connector to make sure there’s no corrosion or short circuit. If this is fine, then the issue lies with the sensor itself, so you’ll then have to remove the old sensor and replace it with a new one, all of which is covered in depth in the Haynes 3-Series manual, so just read up and you’ll soon be back on the road.
