Most common 2004 BMW 525i problems
Share of the 84 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
BMW 525i complaints by model year
Best 525i years: 2001. Years to avoid: 2004, 2007, 2006. Compare all years →
NHTSA defect investigations
Federal safety investigators have looked into a possible defect involving the 2004 BMW 525i:
BMW airbag light illumination
BMW is conducting a safety recall campaign on approximately 200,000 my04 through my06 subject vehicles built through 11/30/05 to correct the front passenger seat air bag occupant detection mat. The specific vehicles included in the recall aremy04- 06/ 5-series with standard and sport seats, my04-06/ x3-series and my06/ 3-series with sport seats.
What 2004 BMW 525i owners say
Air bags all 33 →
Tl* the contact owns a 2004 BMW 525i. The contact stated that the passenger restraint system, fault in passenger restraint system affecting air bag, and belt tensioner/belt force limiter warning lights were continuously illuminated. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and informed the contact about NHTSA campaign number: 08V384000 (air bags); however, the statute of limitation surpassed and the vehicle was no longer eligible for the repairs. The approximate failure mileage was 118,000.
Tl* the contact owns a 2004 BMW 525i. While driving at an unknown speed, the "passenger restraint system fault" message displayed and the passenger side air bag sensor illuminated. The vehicle was taken to an independent mechanic who diagnosed that the passenger side air and restraint systems were faulty. The vehicle was repaired, but the failure recurred. The manufacturer was notified. The vehicle was not diagnosed or repaired again. The manufacturer was not notified. The failure mileage was 47,000.
Electrical system all 21 →
I was driving on my way to work and started smelling something burning. All electrical warning lights started lighting up the dash and then displays go blank. Passenger compartment was filling up with smoke coming from under glove box. I pulled over and called fire department. We disconnected battery and took to BMW. They said micro-processor located in spare tire storage area had shorted out due to water. I don't carry coolers and don't leave my trunk open when it rains. How did water get there. Bulletins show that sunroof drains get clogged and water gets into trunk and shorts out electrical. Service bulletin says if this happens, customer pay but move electrical to where it can't get wet. So BMW knows it's a problem and can cause a fire but doesn't care to cover repair. Now I'm stuck with $1000 repair for micro-processor just to be able to tell what else is burned up. …
Tl* the contact owned a 2004 BMW 525i. The contact stated that the vehicle caught fire and blew up in the garage without warning. The fire department was contacted and stated that the fire was started by the battery cable. A fire report was filed. The contact sustained injuries that required hospitalization. The vehicle was totaled and the contact's home was damaged extensively. The dealer was not contacted. The manufacturer was contacted and stated that it was not their responsibility. Six months prior to the fire, the vehicle was taken to the dealer (chapman BMW in phoenix, ar) where a recall repair of the battery cable was performed. The recall information was lost in the fire. The failure mileage was 160,000.
Seats
Literally a couple weeks ago my drivers side seat caught on fire burning a very deep hole through to the front of the seat and burning a hole in my jacked then burning my skin. Immediately I notified BMW who was extremely accommodating even helping me schedule a repair appointment.. Then the dealership closest to me called me and told me they didn't do recalls and they couldn't assist me. After BMW north America authorized this. I had an extra vehicle until last week when my daughter brought our BMW x3 to college with her. They highly suggested we not use the vehicle until its repaired the seat heater keeps intermittently going off and won't turn off and then it starts burning . I've been afraid of driving it because of the frightening burning smell. I wouldn't be writing u if I wasn't between a rock and a hard place by BMW . …
I started my car and turned the seat heater on low. Approx 5 mins later, smoke started coming out of the dash because the seat heater had burned two holes in the leather and smoke had circulated in my car. I stopped the car, turned it off, and turned it back on and the smoke cleared. I had contacted my local dealer and BMW na in dec 2012 because I felt the seat heaters were getting too hot - the drivers seat registered 132 degrees at that time. The dealer told me there was nothing wrong with the seat heater and BMW na never responded, outside the standard form email telling me they would get back to me. Today, the seat heater finally burned through the leather and I was fortunate not to have been burned.
2004 BMW 525i engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 2.5L 6-cyl | 6-speed automatic | RWD | 19 / 28 / 22 |
| 2.5L 6-cyl | 6-speed manual | RWD | 17 / 26 / 20 |
EPA ratings. Class: Midsize car.
Frequently asked questions
Is the 2004 BMW 525i a good car?
Based on 84 owner complaints filed with NHTSA, the 2004 525i rates avoid: 2.5× as many complaints as a typical year of the 525i at the same age. It is one of the 525i years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 BMW 525i?
The air bags — 33 complaints, 39% of all complaints for this model year, most often about frontal. Next are the electrical system (21) and seats (16).
How many recalls does the 2004 BMW 525i have?
NHTSA lists no recalls for the 2004 BMW 525i. You can still confirm with your VIN using our VIN recall check.
What are the best and worst years of the BMW 525i?
The best years by complaints, compared at the same age, are 2001. Years to avoid or approach with caution: 2004, 2007 and 2006. See the full BMW 525i years comparison.
At what mileage do 2004 BMW 525i problems happen?
The median mileage reported in complaints is about 90,000 miles; 21% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.