The E60 5 Series brought controversial Bangle styling and the first iDrive system to the executive sedan segment. The 520d was added in 2005 as the fuel-efficient four-cylinder diesel option, initially with the M47 engine at 120 kW/163 hp, with a reduced-output 150 hp Fleet Edition sold alongside it, and from September 2007 with the more powerful N47 at 130 kW/177 hp. Both engines offer strong real-world fuel economy of around 5.5-6.5 L/100 km, but the N47 carries the well-documented timing chain risk that defines much of this car's ownership experience.· more· less
Excellent fuel economy for its sizeComfortable long-distance cruiser
N47 timing chain is a known riskComplex electronics age poorly
Buy if: You find a well-documented M47 pre-facelift model or a late N47 with confirmed timing chain service and complete maintenance history.
Avoid if: You cannot budget for potential engine-out timing chain repairs on the N47 or are uncomfortable with aging BMW electronics.
Price & maintenance
Used price
€5,500
median asking price, typically 260,000 km
Typical range€3,900 – €7,300
Kilometres drivenAll
Maintenance cost
€900 – €1,700/year
at 15,000 km/year
Fixed costsservice, tyres, brakes€500 – €850 /yr
Risk bufferunplanned repairs€400 – €850 /yr
Price estimates are based on German asking prices. Prices and costs vary by vehicle condition and location.
Ownership costs
Maintenance assumes 15,000 km a year. Price estimates are based on German asking prices. Prices and costs vary by vehicle condition and location.
Rear-mounted timing chain stretches, causing rattle and potential catastrophic engine damage · more· less
The N47 engine (fitted from September 2007) has a well-documented timing chain design flaw. The chain, tensioner, and guides are located at the rear of the engine against the gearbox, making replacement extremely labor-intensive. Early N47 engines built between March 2007 and January 2009 are most severely affected due to a manufacturing fault on the crankshaft sprocket. BMW partially addressed this with revised components from mid-2009, but failures continued on later cars. Symptoms start with a metallic rattle from the rear of the engine on cold start, lasting a few seconds to over 30 seconds. If ignored, the chain can skip or snap, causing pistons to strike valves and destroying the engine. Independent specialists typically charge €2,000-3,500 for chain, guides, and tensioner replacement; if the crankshaft sprocket or bearings are also damaged, costs can reach €4,000-6,000. A full engine replacement at a BMW dealer has been quoted at €8,000-12,000. This issue does not affect the M47 engine (pre-September 2007 models). Preventive replacement is recommended at 100,000-120,000 km on N47 engines that have not already been serviced.
Swirl flap detachment (M47 engine)
€500 - 4,0002 of 9
Intake manifold swirl flaps can break apart and be ingested into the engine · more· less
The M47TU2D20 engine (pre-September 2007 models) uses swirl flaps in the intake manifold that are known to deteriorate over time. The flap spindles can wear, causing the flaps to break loose and be sucked into the cylinders, resulting in scored cylinder walls, damaged pistons, and in worst cases a destroyed engine. If caught before engine ingestion, preventive removal and blanking costs around €200-500 at an independent specialist. If engine damage has occurred, repairs range from €2,500-4,000 or more depending on severity. Many owners proactively delete the swirl flaps using billet aluminum blanking plates with no significant performance loss. This is one of the first things to check on any M47-powered E60. This issue does not affect the N47 engine.
DPF clogging and regeneration failure
€500 - 1,8003 of 9
Diesel particulate filter blocks from short trips, thermostat failure prevents regeneration · more· less
Both the M47 and N47 engines are fitted with a diesel particulate filter that requires periodic regeneration through extended highway driving. Short urban trips prevent the exhaust from reaching the temperatures needed for automatic regeneration. A common compounding factor is a stuck thermostat (a known E60 weak point), which prevents the coolant from reaching the temperature threshold that triggers DPF regeneration. Symptoms include the DPF warning light, reduced power, and increased fuel consumption. Professional DPF cleaning costs €300-500. A new aftermarket DPF costs approximately €800-1,200 fitted, while an OEM unit from BMW can cost €1,500-1,800. Replacing the thermostat (€200-400) often resolves repeated regeneration failures.
EGR valve and cooler fouling
€300 - 8004 of 9
Exhaust gas recirculation valve seizes from carbon buildup, reducing power and efficiency · more· less
Carbon deposits from exhaust gases gradually clog the EGR valve and cooler, particularly on cars used predominantly for short trips or city driving. Symptoms include rough idle, reduced power, increased smoke, and error codes. The EGR cooler recall that BMW issued over internal coolant leaks covers later four-cylinder diesels, not this generation. Cleaning the EGR valve costs around €150-250 at an independent shop. Full replacement of the EGR valve is approximately €300-500. If the EGR cooler is also affected, total costs rise to €500-800. Treat a clogged EGR valve or cooler here as maintenance rather than as an open campaign.
CCC/iDrive system failure
€250 - 1,0005 of 9
Car Communications Computer fails causing screen blackouts, navigation loss, and constant reboots · more· less
The E60 was one of the first BMW models to feature the iDrive system, controlled on cars with the relevant option packages by the CCC (Car Communications Computer); other E60s use the simpler M-ASK head unit instead, so establish which one the car has before pricing a repair. BMW's own removal procedure takes the CCC out from behind the middle instrument-panel trim, not from the boot. The unit is prone to failure from heat cycling and capacitor degradation, causing symptoms such as screen going blank, system rebooting in loops, navigation freezing, or complete loss of audio and climate controls. Water ingress through deteriorating boot seals is a separate E60 problem that damages the modules stored back there, so check both areas. Specialist CCC repair services in Europe charge around €200-400 for refurbishment and return. A refurbished replacement unit costs approximately €400-600 fitted. BMW dealer replacement with coding runs €800-1,000. Check trunk for signs of moisture and test all iDrive functions thoroughly during any pre-purchase inspection.
Turbocharger failure
€1,500 - 2,5006 of 9
Turbo vane mechanism or bearings fail, often accelerated by poor oil maintenance · more· less
Both the M47 and N47 turbochargers can fail, though this is less common than timing chain or DPF issues. These are variable-turbine-geometry units, so there is no wastegate to blame: BMW's N47 material is explicit that the VNT turbo does not need one, and what sticks instead is the variable vane mechanism. The most frequent cause is oil starvation from blocked oil feed pipes or extended service intervals. Symptoms include excessive smoke, loss of power, whining noises, and oil in the intercooler piping. A remanufactured turbo fitted by an independent specialist costs approximately €1,500-2,000. A new genuine turbo from BMW costs €2,000-2,500 fitted. Always check turbo shaft play and listen for unusual whining during test drives. Oil should be changed every 10,000-15,000 km or at least annually, not at BMW's extended 25,000 km interval.
Boot lid wiring loom failure
€150 - 6007 of 9
Wires in the trunk lid hinge area break from repeated flexing, causing tail light faults · more· less
The wiring harness that passes through the rubber grommet at the trunk lid hinge is subjected to constant bending every time the boot is opened. Over time, the wires fracture inside their insulation, causing intermittent or permanent failure of tail lights, license plate lights, trunk release, and rear parking sensors. This is extremely common on E60 models over 10 years old. BMW offers a repair wiring set (part number 61119118817). An independent mechanic can splice and repair the broken wires for €150-250. A full harness replacement at BMW costs €400-600. This is almost guaranteed to need attention at some point during ownership.
Dual mass flywheel wear (manual gearbox)
€1,200 - 2,0008 of 9
DMF develops excessive play causing rattling on startup and shutdown, usually replaced with clutch · more· less
Manual-gearbox E60 520d models use a dual mass flywheel that wears over time, producing a distinctive rattling noise at idle, during engine startup, and especially at shutdown. This is a wear item but failure timing varies widely from 80,000 to 200,000 km depending on driving style. City driving with frequent clutch engagement accelerates wear. Replacement is typically done together with the clutch, as labor overlap makes this economical. A clutch and DMF kit from LuK or Sachs costs approximately €400-600 for parts, with labor of €600-800 at an independent shop. Total cost ranges from €1,200 to €2,000 depending on parts quality and workshop. This only applies to manual gearbox cars; automatic transmission models are not affected.
Front thrust arm bushing deterioration
€300 - 7009 of 9
Rubber bushings crack and deteriorate causing vague steering and clunking over bumps · more· less
The E60 front suspension uses hydraulic thrust arm bushings that degrade with age and mileage, typically becoming noticeable between 80,000 and 120,000 km. Symptoms include a vague, imprecise feeling in the steering, clunking or knocking sounds over speed bumps, and uneven tire wear. BMW recommends that once the bushing is replaced a second time, the entire control arm should be replaced instead. Replacement of both thrust arm bushings costs approximately €300-500 at an independent shop with quality aftermarket parts. Using OEM BMW parts and a dealer, costs reach €500-700. This is a common MOT failure point in countries with annual vehicle inspections.
Engine variant determines the ownership experience
The BMW 520d E60 is fundamentally two different cars depending on the engine. The M47 (2005-2007) is the more predictable choice, with swirl flaps being the main concern and relatively affordable to address preventively. The N47 (2007-2010) is the higher-risk proposition due to the rear-mounted timing chain that can destroy the engine without warning. Both variants share E60 platform issues including aging iDrive electronics, DPF maintenance needs, and boot wiring failures. A thorough pre-purchase inspection by a BMW specialist is essential, and the timing chain status on N47 models should be the primary focus of any buying decision.
Service history
Complete BMW dealer or specialist records essential. Oil changes should be every 10,000-15,000 km, not the extended BMW interval of 25,000 km.
Cold start test
Start the engine completely cold. Listen carefully for any metallic rattling from the rear of the engine during the first 30 seconds.
Extended test drive
Drive for at least 30 minutes including highway speeds to bring the engine and gearbox up to full operating temperature.
Tire condition
Check tread depth, age (date codes on sidewall), and uneven wear patterns indicating suspension issues.
Specific for this vehicle
Identify the engine: M47 or N47
Check the engine code on the data plate or use the VIN. Models before September 2007 have the M47 (163 hp; 150 hp in the Fleet Edition), after have the N47 (177 hp). This determines which issues to prioritize.
Listen for timing chain rattle on cold start (N47)
The single most important check on post-2007 models. A metallic rattle from the rear of the engine for more than 2-3 seconds indicates chain stretch. Walk away or negotiate significant discount for repair.
Check swirl flap status (M47)
Ask whether swirl flaps have been removed or blanked. If original flaps are still fitted, budget for preventive removal. An endoscope inspection of the intake manifold can reveal flap condition.
+ 5 more checksShow less
Test all iDrive functions thoroughly
Navigate through every menu, test radio, CD, navigation, climate controls. Watch for screen flickering, rebooting, or delayed responses indicating CCC failure.
Inspect trunk for water ingress
Lift the trunk floor carpet and check for moisture, corrosion, or water stains. Water damages the battery sensor, amplifier, and the other boot-mounted electronics; the CCC itself sits behind the middle instrument-panel trim.
Check all tail lights and boot lid electrics
Operate indicators, brake lights, reverse lights, and trunk release. Intermittent failures indicate the common wiring loom breakage at the trunk lid hinge.
Check DPF regeneration status with diagnostic tool
Use a BMW diagnostic tool to check DPF soot loading and last regeneration cycle. High soot levels or very infrequent regeneration indicate clogging issues.
Test for clutch judder in traffic (manual)
Drive slowly in stop-and-go traffic. Clutch judder or vibration during engagement indicates worn dual mass flywheel.
Recalls and Technical Service Bulletins
Fuel filter heater overheating and fire risk - German campaign for four- and six-cylinder diesels produced May to November 2009, explicitly including the E60/E61 5 SeriesCritical - verify completed
Battery cable bolt connection in trunk (2003-2010 production)Verify completed
Takata airbag inflator (selected production periods)Check VIN with BMW
Contact a BMW dealer with the VIN to verify all recalls have been completed; BMW's own recall system answers by VIN, which is the only reliable check. The fuel filter heater campaign is the safety-critical one for this car. The EGR cooler recall often attached to BMW diesels does not reach this generation: the initial European campaign covered four-cylinder diesels built April 2015 to September 2016 and the expansion reached back only to August 2010, after E60 520d production ended. An Intelligent Battery Sensor fault is also widely described as a recall, but it carries no campaign number, date or market, so treat it as a known fault to test for rather than as an open action.
Warranty Status
Factory warranty (2 years)Expired on all E60 520d models
Rust perforation warranty (12 years)Expired on most, check build date
Extended warrantyNot available for cars of this age
All BMW E60 520d models are well outside their original 2-year factory warranty. No manufacturer-backed extended warranty programs are available for vehicles of this age. Third-party warranty providers may offer limited coverage, but these typically exclude pre-existing conditions and high-wear items.
Sources: Research draws on model-specific owner forums and owner communities, recall information from official authorities, German automotive press, and multiple workshop cost references cross-checked against each other.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.
