BMW 5 Series 520d Touring Business Edition Plus common faults.

2020–2024, estate, diesel, 190 HP.

The fault list covers: B47D20 engine, ZF8HP transmission.

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5 fault write-ups. All are important. 23 recalls.

If you know the year, pick it. Faults for other years drop out of the list.

Before you buy

Known faults

5 important faults

critical4

Diesel high pressure pump: power loss and engine shutdown while driving

critical

The high pressure pump of these common rail diesels (Bosch CP4) can fail while driving. The characteristic course is not gradual: a "Drivetrain fault" message appears on the dash, and within a few seconds the power is gone, on the motorway too. Afterwards the engine often cranks but will not start.

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What makes the repair expensive: once the inside of the pump wears, metal debris travels through the rail and contaminates the entire fuel system. At that point replacing the pump is not enough: the injectors, the rails, the tank and the lines go with it. That is the difference between a "pump replacement" and a "full system replacement" quote, that is what you should ask about.

The maker started a recall for this in the United States (NHTSA 21V586000, 2014 to 2018 328d / X5 xDrive35d / 535d / 740Ld / X3 xDrive28d). The same campaign did not run in Europe, even though the same pump works in the 320d/520d/X3 20d versions that are common right across Europe. The recall does not cover these cars.

between 79,000 and 248,000 km

What to check

Ask whether there has ever been a "Drivetrain fault" message or a loss of power while driving
Ask for the service history: if the high pressure pump was replaced, check whether the injectors and the lines were replaced with it. If not, the debris may still be in the system
After a cold start listen to the engine at idle: irregular running or smoke is suspect

3 more steps in the write-up

Diesel EGR cooler: cracking, coolant in the intake, fire risk

critical

The internal fins of the exhaust gas recirculation cooler crack over time, and glycol coolant leaks into the intake, where it mixes with soot. The sticky mixture can ignite at high temperature: it can melt the plastic intake manifold and, in extreme cases, cause an engine bay fire.

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The maker recalled the 2013 to 2018 four and six cylinder diesels, roughly 800,000 cars worldwide. The first repair attempt proved insufficient, and the leak returned in several cases: the cooler fitted since 2022, from a different supplier, is the valid fix.

So "the recall was carried out" is not enough on its own: you have to check when, and which repair was done. A first round repair does not by itself rule the problem out.

The early symptoms are white, sweet smelling exhaust smoke, slowly dropping coolant, and a rough idle.

It shows up on diesels built between 2013 and 2018. The earlier M57 is not covered by the recall.

between 108,000 and 222,000 km

What to check

Check the level in the expansion tank, and ask whether it has needed topping up
After a cold start watch the exhaust: persistent white smoke and a sweet smell mean the coolant is burning
Ask for the service book and find the EGR cooler recall entry: Check the date too

2 more steps in the write-up

B47 diesel: the timing chain stretches on the early model years

critical

On the early model years the timing chain of the B47 stretches faster than intended. The chain tensioner compensates for the stretch for a while and then no longer can: the chain jumps, the valve timing goes off, and in a severe case engine damage follows. The first sign is a rattling, clacking noise on a cold start that goes quiet after one to three seconds. On the B47 the chain sits at the front of the engine, not at the rear as on its predecessor, the N47. The replacement is therefore considerably less, between 1,200 and 1,800 euro, against 2,000 to 2,500 euro on the N47; if the chain has already jumped, the repair can run up to 4,500 euro. The risk is highest on units built before the end of 2015, with a reported rate of 3 to 5 per cent. 2016 was better but cases remained, and between July and December 2016 an improved chain tensioner was phased in. After mid-2016 the problem is rare, below one per cent. The engine has been in almost every four-cylinder diesel BMW since 2014, from the 1 Series to the 5 Series and from the X1 to the X4. The build date therefore says more here than the model.

above 120,000 km1,200–4,500 EUR

What to check

Start the engine cold and listen for the rattling noise in the first seconds
Ask for the build date, because units built before the end of 2015 are the risky ones
Ask whether the chain or the tensioner has been replaced, and ask for the invoice

2 more steps in the write-up

B47 / B57 diesel: particulate filter and turbo on short trips

critical

The B47 replaced the N47, and the maker fixed the timing chain problem. The two remaining risks on this modern diesel depend on how the car was used.

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The first is the particulate filter. On short urban trips the regeneration cannot finish, and the filter clogs. The second is the turbo. With extended oil change intervals its bearings wear.

On this engine the service history and the type of use tell you more than the odometer. On a 200,000 km car driven on motorways and serviced often, the filter and the turbo can be in better shape than on a 90,000 km city-only car.

Where turbo wear leads in the worst case: a runaway engine. If the turbo shaft seal fails, engine oil enters the intake on the compressor side. A diesel burns that too, and this is different from a petrol engine: a diesel controls torque with the quantity of fuel injected, and it has no throttle. Once the engine runs on its own oil, cutting the injection and switching off the ignition will not stop it. The revs climb on their own until the engine destroys itself for lack of lubrication.

If this happens while driving, turning the key does not help. The only thing that works is cutting off the air: cover or plug the intake, or discharge a dry powder extinguisher into the intake tract. On a manual car you can also stall it: hold the parking brake and the brake pedal, select a high gear, and release the clutch quickly so the drivetrain chokes the engine.

This is not common, and it can happen on any turbo diesel, not only on this engine. On this engine the turbo bearing and seal wear. The warning signs are blue smoke under acceleration, an unexplained drop in oil level, and an oily charge air pipe.

What to check

Ask how the car was used: short daily trips or longer runs?
Read the fault codes for particulate filter regeneration and differential pressure
On a longer test drive watch the power delivery and the smoke under load

5 more steps in the write-up

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ZF 8HP automatic: mechatronics unit and connector sleeve leak

expensive

The ZF eight speed automatic (BMW Steptronic 8HP family) has two faults, and you can feel both.

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The first is the mechatronics unit: the valve body and the control electronics in one. If the solenoids or the pressure regulation weaken, the gearbox jerks, the D/R engagement is delayed, it logs a gear ratio fault code, and finally drops into limp mode (often staying in 2nd or 3rd).

The second, and often misdiagnosed, is the connector sleeve of the mechatronics unit: the O-ring of the plastic sleeve ages, and ATF leaks from the side of the housing, exactly where the wiring harness enters. This is easy to mistake for a rear crankshaft seal. The trail starts from the driver's side of the housing, not from the clutch side.

On cars built in 2023 there was also a separate safety recall for a welding fault in the mechatronics unit. That is not the same as the wear related sleeve and the valves.

Check the fluid level, the area around the sleeve and the fault codes first; do not accept a "full gearbox replacement" quote straight away.

above 120,000 km

What to check

On the test drive watch for delayed D/R engagement, a jerk when shifting, and limp mode (a stuck gear)
Look at the driver's side of the gearbox housing where the wiring harness enters: an ATF trail from the sleeve is suspect
Do not confuse it with a rear crankshaft seal leak: the direction of the trail decides

3 more steps in the write-up

Official recall23 recallsShow

The manufacturer fixes these for free at a franchised dealer. Ask with the VIN whether it was done.

Most recent: 31 August 2026

SR/02525/26Safety recallFire31 August 2026 · EU Safety Gate

Water may enter the starter motor and cause damage. As a result, the engine may no longer start, or the starter motor may short-circuit or remain continuously activated. This could cause local overheating of the starter motor or thermal overload of surrounding components and lead to a vehicle fire, including when the ignition is switched off. The product does not comply with the Regulation on the approval and market surveillance of motor vehicles and their trailers, and of systems, components and separate technical units intended for such vehicles.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 31/08/2026

We could not check this: model year. The authority's notice

SR/02180/26Safety recallFire7 July 2026 · EU Safety Gate

The RSW22 starter with reinforced water tightness (RWT) may experience increased abrasion of the magnetic contact, causing deposits to build up at the lowest point inside the relay. These deposits may increase relay contact resistance, leading to starting failures or short circuits. If a short circuit occurs, either when attempting to start the vehicle or while driving due to vibration-related movement of the deposits, it could cause a thermal event and increase the risk of fire. The product does not comply with the Regulation on the approval and market surveillance of motor vehicles and their trailers, and of systems, components and separate technical units intended for such vehicles.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 07/07/2026

We could not check this: model year. The authority's notice

SR/00551/26Safety recallFire30 January 2026 · EU Safety Gate

The failure concerns the RSW22 starter, type RWT (reinforced for watertightness). Increased abrasion of the magnetic contact can lead to the formation of deposits at the lowest point of the relay interior. This in turn can increase the resistance of the relay contact, causing accidental ignition or even short circuits, possibly leading to a thermal reaction and fire. The product does not comply with the Regulation on the approval and market surveillance of motor vehicles and their trailers, and of systems, components and separate technical units intended for such vehicles.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 30/01/2026

We could not check this: model year. The authority's notice

SR/00568/26Safety recallFire30 January 2026 · EU Safety Gate

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 30/01/2026

We could not check this: model year. The authority's notice

SR/00584/26Safety recallFire30 January 2026 · EU Safety Gate

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 30/01/2026

We could not check this: model year. The authority's notice

A12/01930/23Safety recallInjuries29 June 2021 · EU Safety Gate

The propellant in the driver airbag can deteriorate due to high humidity and temperature variations. In the event of an accident in which the airbag deploys, this could result in fragments from the inflator casing coming loose and injuring the vehicle’s occupants. The product does not comply with the Regulation on the approval and market surveillance of motor vehicles and their trailers, and of systems, components and separate technical units intended for such vehicles.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 29/06/2021

We could not check this: model year. The authority's notice

A12/1233/17Safety recallInjuries30 August 2017 · EU Safety Gate

The front safety belts may have a faulty locking mechanism.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 30/08/2017

We could not check this: model year. The authority's notice

A12/0882/17Safety recallInjuries12 June 2017 · EU Safety Gate

Owing to a defect in the ball head of the brake pedal, the brake lights may be permanently activated, even during driving, without any error warning being shown. This might have an impact on road users following the vehicle.

Remedy: Type of economic operator taking notified measure(s): Manufacturer Category of measure(s): Recall of the product from end users Date of entry into force: 12/06/2017

We could not check this: model year. The authority's notice

A12/00068/19Safety recallInjuriesno date · EU Safety Gate

The press-in force of the counterbalance shaft’s bearing shells may not have met the specifications, which could cause the counterbalance shaft to become loose. As a result, the engine could be damaged and locked in motion, increasing the risk of an accident.