2007 BMW 530XI

VEHICLE WAS TRAVELLING 25-30 MPH ON A CITY STREET AND HIT A POTHOLE. IMMEDIATELY DRIVER HEARD A NOISE FROM THE ENGINE AREA AND CAR BEGAN SHAKING AND VIBRATING WHILE AT LOW SPEED/IDLE. SERVICE TECHNICIAN DISCOVERED THAT ALL 4 BOLTS FOR THE ENGINE MOUNT HAD SHEARED AS A RESULT OF THE IMPACT AND THE ENGINE WAS NOW HANGING FREE AND RESTING ON THE FRAME OF THE CAR. DRIVESHAFT WAS KNOCKED OUT OF ALIGNMENT AS WELL.

FRONT GLASS PANEL ON THE PANORAMIC GLASS ROOF SPONTANEOUSLY EXPLODED ON FLAT STRAIGHT STRETCH OF HIGHWAY AT 75 MPH. ALL WINDOWS WERE CLOSED, NO RADIO PLAYING, NO FORWARD TRAFFIC OR WIND TO PRODUCE AIRBORNE ROAD DEBRIS. THE ORIGINAL FACTORY ROOF WAS NOT MADE WITH LAMINATED GLASS PRODUCING A DEAFENING EXPLOSIVE SHOWER OF GLASS PIECES. PANORAMIC SUNROOF NOT COVERED UNDER REGULAR GLASS INSURANCE, REQUIRED AN EXPENSIVE AUTO CLAIM TO REPLACE.

WHILE DRIVING AT HIGHWAY SPEEDS, DASHBOARD LIT UP AND WARNED THAT COMPLETE ELECTRICAL FAILURE WAS IMMINENT. THEN VEHICLE LOST ALL POWER. HAD TO ATTEMPT EMERGENCY EXIT OF THE HIGHWAY WITHOUT ANY POWER ASSIST OF BRAKES OR STEERING. THE DIAGNOSIS WAS THAT RAINWATER FAILED TO DRAIN THRU THE SUNROOF DRAIN AND WAS ROUTED INTO THE TRUNK OF THE CAR WHERE THOUSANDS OF DOLLARS OF ELECTRONIC VEHICLE CONTROL MODULES WERE MOUNTED ON THE FLOOR UNDER THE SPARE TIRE! THIS IS AN ENGINEERING FAILURE THAT WAS WELL KNOWN TO THE MANUFACTURER AT THE TIME OF THE INCIDENT. MANUFACTURER HAS REFUSED TO ADDRESS ANY FAULT ON THEIR PART. NEWER BMWS NOW HAVE A YELLOW DECAL IN THE TRUNK WARNING THAT NO LIQUIDS ARE TO BE CARRIED IN THE TRUNK DESPITE THE FACT THAT THE TRUNK EVEN INCLUDES A RACK DESIGNED FOR TRANSPORT OF GROCERIES!! THIS IS A SERIOUS SAFETY HAZARD FOR ALL CARS DESIGNED IN THIS FASHION. .

I DISCOVERED FAILURES OF MULTIPLE WIRES IN THE TAILGATE/REAR WINDOW WIRING HARNESSES. THROUGH RESEARCH ONLINE I HAVE FOUND THIS IS A COMMON PROBLEM WITH THIS VEHICLE OVER SEVERAL MODEL YEARS - SEARCH FOR BMW E61 TAILGATE WIRING PROBLEMS. THE FAILURES ARE CAUSED BY A POOR DESIGN WHERE THE WIRES ENTERING THE HINGE GUIDES (4) FOR THE GLASS AND TAILGATE ARE REPEATEDLY FLEXED AT A SHARP ANGLE UNTIL THE INSULATION, THEN THE COPPER WIRE BREAKS. SAFETY ISSUES - POSSIBLE ELECTRICAL SHORT CIRCUIT LEADING TO FIRES (HIGHEST LOAD IS FOR REAR DEFROSTER); LIGHTING FAILURES (REAR HIGH BRAKE LIGHT, LICENSE PLATE LAMPS AND OTHERS); REDUCED VISIBILITY DUE TO LOSS OF WIPER/WASHER/DEFROSTER; REAR GLASS LATCH OPENING WHILE UNDERWAY, POSSIBLY RESULTING IN LOSS OF CARGO OR INGRESS OF EXHAUST FUMES. THIS IS NOT AN EASILY REPAIRED PROBLEM. IT WOULD BE BEYOND THE CAPABILITIES OF ALL BUT A SKILLED MECHANIC WITH PROPER TOOLS. I DISCOVERED IT WHEN THE REMOTE LOCK/UNLOCK USING THE KEY FOBS FAILED. AS I INVESTIGATED I FOUND THE BROKEN WIRE, ALONG WITH SEVERAL OTHERS WITH BROKEN INSULATION, SOME WITH BROKEN COPPER STRANDS. *TR

2007 BMW 530XI, HAS WATER LEAKING ONTO REAR FLOOR FROM ROOF DRAIN BEHIND SUNROOF. THIS ROOF DRAIN REQUIRES THE SUNROOF TO BE REMOVED, HEADLINER TO BE TAKEN DOWN AND RUBBER PIPES TO BE CHANGED IN ORDER TO ENSURE PROPER DRAINAGE. THIS IS OBVIOUSLY A DESIGN FLAW AND IS SOMETHING THAT BMW SHOULD BE COVERING THE REPAIR FEES FOR INSTEAD OF CHARGING $700 TO FIX. THE WATER IN THE CAR DAMAGES THE ELECTRONICS UNDER THE PASSENGER SEAT WHICH CAUSES SAFETY ISSUES WITH THE AIRBAGS ETC. BMW IS STATING THAT THIS IS A MAINTENANCE ISSUE WHICH SEEMS STRANGE AS I HAVE NEVER HAD TO PAY $700 TO FIX A ROOF DRAIN ON ANY OTHER VEHICLE I HAVE EVER OWNED IN THE PAST. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

THIS VEHICLE, UNLIKE ALL OTHER BMW AUTOMOBILES HAS NO ROCK GUARD IN PLACE ON THE LOWER FRONT BUMPER PROTECTING THE RADIATOR, ETC FROM ROAD HAZARDS. A ROCK WAS THROWN BY A VEHICLE IN FRONT OF ME THAT PIERCED THE CONDENSER ATTACHED TO THE FRONT OF THE RADIATOR RESULTING IN THE CAR BEING TAKEN TO A SERVICE CENTER ON A ROLL BACK. I SEE THIS AS A DESIGN FLAW, (CORRECTED ON THE 08 MODEL), THAT CAN RESULT IN DANGEROUS DRIVING SITUATIONS. *TR