2004 BMW 5 Series

On certain vehicles, the insulated bulkhead connector (used to join the two halves of the positive battery cable) may have been incorrectly installed during vehicle assembly.  Over time, the bolt connection could loosen, which would increase electrical resistance.  In addition, an incorrectly insulated bulkhead connector could allow humidity to accumulate at this location, causing current leakage.  These issues could cause the cable connection to overheat, which could result in a vehicle fire causing property damage and/or personal injury.  Correction: Dealers will inspect and, as necessary, secure the insulated bulkhead connector.  In addition, protective grease will be added to the area and the plastic battery positive terminal cover will be replaced.

On certain vehicles, a check valve in the brake vacuum pump may leak a small amount of lubricating oil.  Over time, this could result in contamination of the brake booster.  Loss of brake power assist could occur which, in conjunction with traffic, road conditions, and driver's reactions, could increase the risk of a crash causing property damage and/or personal injury.  Correction: Dealers will inspect and, if necessary, replace the brake booster and master cylinder.  Additionally, the brake vacuum line (including the check valve) will be replaced to eliminate the possibility of oil reaching the brake booster.

On certain vehicles, the front passenger seat occupant detection mat can fatigue during field usage depending on the seat configuration, vehicle geometry, manner and frequency of front passenger entry/exit.  Over time micro cracks could develop in the side flanks of the mat, which could lead to a break of the conductive path and the system will recognize a failure and with exception of head protection system the front passenger air bag will be deactivated.  The airbag On/Off lamp will be illuminated to make the occupants aware of the deactivation.   Correction: The occupant detection mat will be granted a warranty extension of 10 years.

On certain vehicles equipped with heated seats, excessive contact with the seat backrest side bolster upon entering and exiting the vehicle may damage the heating mat located in this area.  If this happened, the seated occupant may experience excessive heat in this location.  The heating mat could damage, or melt a small hole in the lower portion of the backrest's outboard side bolster.  If this were to occur, an electrical/melting smell or small amount of smoke would be noticeable.  In some cases, the small hole in the backrest's side bolster could damage the seated occupant's clothing.  In rare instances, this could lead to a minor or superficial skin injury.  Correction:  Dealers will modify the seat heating circuit for the front seat backrests.

On certain vehicles, the digital engine management control unit was not produced according to specifications.  As a result, engine stalling will occur after a short period of operation.  The vehicle may not be able to be restarted.  Also, a loss of power steering and, after repeated actuation of the brake pedal, a loss of brake power assistance will occur.  If stalling were to occur, the driver would be unable to maintain vehicle speed or accelerate.  Steering and braking, while possible, would be difficult.  Depending on traffic conditions and the driver's reactions, this could lead to a crash.  Correction:  Dealers will replace the digital engine management control unit.