The 745e replaced the four-cylinder 740e with the 2019 G11 facelift, pairing the well-regarded B58 3.0-litre inline-six with an 113 hp electric motor integrated into the ZF 8-speed automatic. Combined output is 394 hp with 600 Nm of torque, and a 12 kWh battery provides roughly 45-55 km of real-world electric range. Air suspension is standard, and the full iDrive 6 suite with gesture control is included. The B58 is one of BMW's most robust modern engines, but the PHEV layer and flagship electronics introduce meaningful complexity for used-car buyers.· more· less
Proven B58 engine, robust internalsStrong combined 394 hp performance
PHEV complexity adds failure pointsAir suspension repairs are expensive
Buy if: You charge regularly, want flagship luxury with an efficient inline-six PHEV, and can verify full recall history and HV battery health before purchase.
Avoid if: You rarely charge the car (negating the hybrid benefit), cannot budget for surprise repair bills above €2,000, or need a simpler ownership experience.
The onboard AC charger commonly fails between 3-6 years, preventing plug-in charging · more· less
The KLE (Komfort-Lade-Elektronik) is the onboard charger that converts mains AC power into DC to charge the high-voltage battery. It is widely reported as the most common failure on BMW PHEVs, including the 745e. Symptoms include 'Unable to charge' errors, a flashing red ring on the charging port, and 'Mains power too low' warnings despite a normal mains supply. The module typically fails between 3 and 6 years of age regardless of mileage. BMW dealerships charge approximately €2,000-2,500 for replacement including coding and labour. Independent specialists can source the unit and complete the work for €1,500-1,800. Without a functioning KLE the car cannot charge via plug and loses all electric driving capability, though it continues to operate as a conventional petrol vehicle. BMW has occasionally offered goodwill contributions for cars just outside warranty but most used-car buyers will bear the full cost. Specialist repair of the KLE circuit board (rather than full replacement) is emerging as a lower-cost option at around €800-1,200 through specialist firms.
Air suspension strut leak
up to €4,0002 of 7
Rubber air spring bladders crack with age, causing one corner to sag after parking · more· less
Air suspension is standard on the G11 7 Series. The rubber bladders degrade from temperature cycling and UV exposure, typically developing leaks between 80,000 and 130,000 km. Rear springs tend to fail first. Symptoms include one corner sitting lower after overnight parking, the compressor running constantly, or dashboard suspension warnings. An OEM air spring from BMW costs approximately €800-1,200 per corner installed at a dealer. Aftermarket alternatives from Arnott or Bilstein reduce the cost to around €500-700 per strut. If the compressor has been overworked due to a slow leak, it may also need replacement at €500-800. A full suspension refresh covering four struts and a compressor can reach €3,500-4,000 at a dealer. Independent specialists with rebuilt OEM struts can bring this down to around €2,000-2,500 for a full set.
High-voltage battery cell degradation
up to €10,0003 of 7
Individual cells lose capacity over time, reducing electric range below useful levels · more· less
The 12 kWh lithium-ion battery pack sits beneath the rear seats. Over time, individual cells can degrade or develop imbalances, reducing the usable electric range. BMW guarantees at least 70% capacity over the warranty period (8 years / 160,000 km in most EU markets). Once outside warranty, a full battery replacement costs approximately €8,000-10,000. Individual cell module replacements are sometimes possible at BMW or through specialist hybrid workshops for €3,000-5,000, depending on how many modules are affected. Early 745e models from 2019 are approaching the end of their 8-year warranty window from 2027 onward. A BMW dealer can read battery health data via ISTA diagnostics. Reduced range is the most common symptom; complete failure is rare. The 2020 PHEV battery recall (Samsung manufacturing debris causing short-circuit risk) affected some 2021 745Le models. Verify recall completion before purchase.
B58 water pump / thermostat housing failure
up to €1,8004 of 7
Plastic housing and electric water pump fail from heat cycling, typically after 80,000 km · more· less
The B58 engine uses an integrated electric water pump and thermostat housing with plastic components that become brittle from heat cycling. Failure typically occurs between 80,000 and 120,000 km. Symptoms include coolant warning lights, reduced cabin heating, and in severe cases engine overheating. The integrated assembly costs approximately €400-600 for the part, with labour adding another €400-600 due to accessibility in the engine bay. BMW dealers typically charge €1,400-1,800 for the complete job. Independent specialists can complete it for €800-1,200. It is standard practice to replace the water pump and thermostat together since both share the same housing. An electronic coolant bleeding procedure is required after replacement to prevent air pockets.
Electric AC compressor failure
up to €3,0005 of 7
High-voltage compressor handles both cabin cooling and battery thermal management · more· less
The 745e uses a high-voltage electric AC compressor rather than an engine-driven unit. This compressor handles both cabin air conditioning and battery pack thermal management via a shared refrigerant loop. If it fails, the battery cooling system is compromised and the car may restrict electric driving to protect the cells. OEM replacement at a BMW dealer runs approximately €2,500-3,000 including HV-rated labour and refrigerant recharge. Independent specialists with HV certification can source aftermarket units and complete the work for €1,500-2,000. The failure is not as commonly reported as the KLE issue, but becomes more likely on cars beyond 100,000 km. Symptoms include poor cabin cooling combined with reduced electric range or battery temperature warnings.
Oil filter housing gasket leak
up to €9006 of 7
Gasket hardens from heat exposure, causing oil weep or coolant seepage around the housing · more· less
The oil filter housing gasket and the adjacent plastic coolant vent hose are known weak points on B58 engines. Both degrade from engine heat, typically showing symptoms between 60,000 and 100,000 km. The primary source of leaks near the oil filter housing is often the brittle plastic coolant vent hose rather than the gasket itself. Symptoms include visible oil residue on the engine block or a slight burning oil smell. Independent mechanics charge approximately €400-600 for gasket replacement including the coolant hose. BMW dealers typically quote €700-900. The repair itself is straightforward if caught early, but ignoring a leak can lead to oil dripping onto hot exhaust components.
12V battery drain and DC-DC converter stress
up to €1,2007 of 7
The 12V system relies on a DC-DC converter from the HV battery; failures cause no-start conditions · more· less
The 745e has no traditional alternator. Instead, a DC-DC converter steps down voltage from the high-voltage battery to maintain the 12V system. If the SME (Safety Management Electronics) detects a fault and opens the HV contactors, the DC-DC converter can no longer charge the 12V batteries. This means simply driving the car will drain the 12V system because nothing is replenishing it. Symptoms include a dead 12V battery after short trips, multiple warning messages on startup, or a complete no-start condition. A 12V battery replacement costs €200-300 (AGM type required). If the DC-DC converter itself fails, replacement runs €800-1,200 at an independent specialist. Cars that sit for extended periods without being plugged in are particularly vulnerable since the HV battery slowly depletes, eventually leaving insufficient voltage for the DC-DC converter to maintain the 12V system. A quality trickle charger is recommended for cars not driven weekly.
Robust engine, but PHEV complexity and flagship electronics demand attention
The B58 inline-six is one of BMW's most reliable modern engines and avoids the turbo coolant line and valve stem seal issues found in the N63 V8 of the 750i. However, the plug-in hybrid system introduces its own set of risks: the KLE charging module is a known weak point, the HV battery is approaching warranty expiry on early cars, and the electric AC compressor handles critical battery thermal management. Air suspension is standard on all G11 7 Series models and represents the largest potential single repair cost. Cars with complete BMW service history, confirmed recall completions, and documented battery health data are significantly lower-risk purchases.
Service history
Complete BMW dealer or authorized specialist records essential. Verify oil changes and hybrid system checks at correct intervals.
Tires
Check tread depth, age (date codes), and uneven wear patterns. Rear tires wear faster due to weight distribution and xDrive torque split.
Cold start
Start the car completely cold. The engine may not start immediately if the HV battery has charge (normal PHEV behavior). Force engine start via sport mode.
Test drive
Minimum 30 minutes including motorway speeds. Test both electric-only mode and combined power mode.
Specific for this vehicle
Test plug-in charging before purchase
Connect the car to a Type 2 charger or household socket. Watch for 'Unable to charge' errors, flashing red ring on the port, or 'Mains power too low' messages. KLE failure is the most common PHEV issue.
Request HV battery health report from BMW dealer
BMW ISTA diagnostics can read cell voltages and state-of-health. Look for balanced cell voltages and capacity above 70%. Ask how much real-world electric range the owner achieves.
Check air suspension for sag after overnight parking
Ideally view the car after it has sat overnight. All four corners should be level. Uneven ride height indicates a leaking strut or failing compressor.
+ 4 more checksShow less
Listen for compressor noise under the car
A constantly running suspension compressor indicates an air leak somewhere in the system. The compressor is located under the boot floor area.
Verify all recalls completed via BMW VIN check
Key recalls: PHEV battery cell contamination (2020-2021), integrated brake system weld defect (2021), starter motor fire risk (2021-2022). Contact BMW with VIN.
Check for oil residue around the oil filter housing
Inspect the B58 engine bay for oil weeping around the oil filter housing area. Minor seepage is common but active dripping indicates a gasket replacement is needed.
Test all electrical systems thoroughly
Check iDrive for freezes or reboots, test gesture control, verify all parking sensors, check rear camera feed, and test the driver-assistance systems.
Integrated brake system (IBS) weld defect causing loss of ABS/brake assist (2021 models)Critical - verify completed
Starter motor magnetic switch wear causing overheating / fire risk (starters manufactured Jul 2020-Jul 2022)Verify completed
Seat belt warning system ECU software error (2020 models)Verify completed
Rear camera display settings retention (may not show rear view in reverse)Verify completed
The 745e has been subject to several recalls including two critical safety items (HV battery fire risk and brake system weld defect). Contact a BMW dealer with the VIN to verify all recalls have been completed. The HV battery recall is particularly important for 2020-2021 models.
Warranty Status
Factory warranty (3 years from Nov 2016 with 2+1)Expired on all used 745e models
HV battery warranty (8 years / 160,000 km)2019 models expire from 2027; 2022 models covered until 2030
Rust perforation warranty (12 years)2019 models covered until 2031
The HV battery warranty (8 years / 160,000 km, 70% capacity guarantee) is the most valuable remaining coverage. Early 2019 models will reach the 8-year limit from 2027. Verify the exact first-registration date and current battery health. BMW Extended Warranty packages are available through dealers for powertrain and electrical coverage.
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.
