Calling all high mileage xi owners (what has broken?)

I am at 205K on my 2002 325 xi. It is my work car and I put around 5k miles on it a month.
I have replaced: brakes, rotors, sensor wire, spark plugs, clutch, control arm bushings, RF control arm, RF, sway bar, front axles, valve cover gasket, exhaust gasket, struts and tires.
I am very happy with the car, all parts and labor I spent under 3,500.00$
I do get a regular oil changes monthly.

04 330XI 6SPD @ 127,000 mi:

- Motor mounts
- Transfer case mount
- Rear struts
- Inner axle boots (Leaking from the large clamp loosening over time)
- Tensioner pulley (noisy)
- Inspection II

Only minor stuff!

I purchased the car 4/11. Knew that the engine had been replaced because previous owner bottomed out on a pothole and cracked oil pan and kept driving, cracked the engine block. It had 104,272 miles (71,000 on replacement engine).
Alignment $85, air conditioning recharge $133, front struts replace and install $400; replace parking cable left; $291;replace profile gaskets/rings $58 parts; $100 labor; replace both belts $40 belts; $30 labor, $55 replace right parking brake cable; $51 cable, $105 replace crank seal; $55 replace oil filter housing gasket; $166 replace engine thermostat; $231 replace guide support deflection pulley; replace torn CV boot left axle, $165 (replaced entire left axle); tires $694, another alignment $88, drain and change transmission fluid $89, (I supplied the fluid, 1-1/2 qt Pentosin MTF-2), install coolant expansion tank; $65 for the part, $118 labor, flush radiator $69 (it's in shop for that now). Bought the car for $7500. It's a blast to drive, but is it worth the expense? I don't have a car payment, so guess that's the trade off, you have more maintenance on an older car. Forgot to mention the rack and pinion boot is torn. The estimate for that was $1200 to replace entire R&P. Will buy a boot kit and replace torn boot. I supply the parts, get them online from various places or locally at auto supply shops when possible. I found an independent mechanic who doesn't mind me supplying parts. Otherwise, the amounts above would be more like 3 times the cost.

2003 325xi

96K

Replaced:

Tires
2 Window regulators
Passenger side brake light wiring
Valve Cover Gasket
Spark Plugs
Belts
Windshield wipers & pump
Battery
Headlight bulb
Front transaxle left and right

Needs:
2 more window regulators
New rotors and pads x 4
Headlight lens x 2

200 000kms

Clutch, brakes, spindles, axels, cooling system, (full front suspension)

Originally Posted by ZemogFC3S

- expansion tank just cracked last week

Why does it seem almost everyone has replaced this so far? How/when will I know that this part failed?

I thinking about pulling the trigger on an '02 325XI, 100K.

Originally Posted by chadddada

Why does it seem almost everyone has replaced this so far? How/when will I know that this part failed?

I thinking about pulling the trigger on an '02 325XI, 100K.

Because its plastic and prone to fail. From what i've seen here is replace it along with much of the cooling system every 80k. My t-stat is failing on my newly acquired 330 with 85k so I'm doing the tank at the same time. Don't want this cracking 1000miles away from home to be bent over by a local dealer that wants $110 for the part alone.

Originally Posted by chadddada

Why does it seem almost everyone has replaced this so far? How/when will I know that this part failed?

I thinking about pulling the trigger on an '02 325XI, 100K.

As was said, this thing blows up as it ages.

You'll know that it has failed when you hear a pop and your engine overheats. Please replace it before this happens. I'm at 108k on my car and will be replacing mine in the coming weeks.

Expansion tank is just a poor design was super unhappy when I looked at all the plastic pullys...now I have to change those before I get the ess sc

Bought with 91k.

1. Sunroof kit after bits and pieces in track
2. Driver's side window regulator after cracked mount
3. Thermostat after stuck open position (included a stewart water pump to replace the oem and all hoses/expansion tank were good)
4. Front inner and outer CV's were cleaned and repacked with Mobil-1 grease. Stupid amount of vibration at around 50-60mph.
5. Two bent rims; two new tires. (Needless to say the previous owner did not avoid rough roads and the car was had for mighty cheap.)
6. Rear springs and shocks with Bilsteins. Oem were leaking bad and spring was cracked.
7. Left lower control arm with bushing.
8. All four brake pads/rotors.
9.DME housing fan


136,900 I've just finished doing:
1.4 new tires
2.Drive belt
3.A/C belt and recharge
4.VCG (second time)
5.Oil filter housing gasket
6.both front axles
7.left front control arm
8.both front wheel bearings
9.front and rear brakes (3rd time-warranty)
10.left rear bilstein shock (second time- warranty)
11.fuel filter
12.expansion tank
13.upper and lower radiator hoses
14.Emp stewart waterpump (second time- warranty as seals were weeping)
15.camshaft actuator line
16.right window regulator . . . .
17.Engine mounts

at 153,000 . . . .

1.Another vcg or valve cover because of an ongoing leak at the rear passenger side firewall (3rd time).
2. oil filler canister for power steering system and flush
3. Both front Bilstein strut assemblies with mounts.
4. Fluid flush and fill for tranny, front diff., rear diff., and transfer case
5. Another set of brakes (4th time) . .
6. Steering rack leaking a bit just below the double universal joint.
7. Intake camshaft position sensor
8. both front tie rod assemblies
9. both front endlinks
10. headlight washer pump ( still doesn't work)

Still love this car

02 330xi 127K. I traded my bike for it a few months ago.

Very little to no maintenance records came with so I have done:
ET, WP, fan clutch, belts, thermostat
both front axles, front diff fluid change
FCABs, RCABs, end links, rear strut mounts
did front pads while front end was apart
OFHG, VCG
factory HK amp failed
remove fabric from a,b and c pillars then sand a paint

Items that I plan on doing sooner rather than later:

DISA
trans flush
possibly batt or alternator
steering rack boot
rear diff fluid change
PS fluid change

Purchased a 2003 325xi Touring in February with 146,500 miles.
Since then:
VCG- DIY
Front pads and rotors- DIY
Fuel Pump- DIY (failed on the freeway)
Front Drivers side axle- Indy shop $380

now getting ready to hit 150,000 miles next week....

'04 325xi with 101k miles. Bought it new

Broken Sunroof clips, drivers side window regulator, window switch, wiper motor, battery.

Maintenance

New Cooling System hoses Stewart Water Pump
New Pulleys and Belts
New Coils
New 02 Sensors
New CPS sensors
Vanos Repair with Beisan rings
New Coils and Plugs
VCG, Crankcase vent and hoses
Eibach Lowering Springs , Koni shocks upgraded bushings and rear support
New Rotors and Brakes
SS brake lines
18 inch wheels Continental Tires
New drivers side seat cover
New Center Console and Euro tray cup holder replacement
New shift knob
New FCABs and Control Arms
Both front axles completely rebuilt

Did most myself with the help of the forums and saved a ton of money!
The cars needs constant maintenance to keep it running well. All the money was well spent as the car rides on rails in the worst weather the Northeast dishes out.

Planning on doing a headlight update and Dynavin nav system next. Haven't replaced the cooling system reservoir yet, but going to take a look at it after all I'm reading.

I also regularly (every 30k or so) remove the throttle body and Intake control valve to clean them out. So far no major repairs or breakdowns, but I'm a fanatic about fluid changes.

85K - Inner CV boot leak, Coolant tank, Thermostat, water pump, Water hoses, Oil filter housing gasket leaks, Valve cover gasket, real coil springs, brakes all four. Keep in mind though E46330xi parts are expensive than a rwd.

154k bought with 116k... just replaced front driver side window regulator and motor. timing belt and water pump. brakes and oil changes. just ordered side mirror glass (currently have brown rust spots).

thinking about doing the cooling system (preventative)- is this necessary?

Originally Posted by 325xi2004

154k bought with 116k... Just replaced front driver side window regulator and motor. Timing belt and water pump. Brakes and oil changes. Just ordered side mirror glass (currently have brown rust spots).

Thinking about doing the cooling system (preventative)- is this necessary?

Yes!! Replace cooling system now!!

Originally Posted by 325xi2004

154k bought with 116k... just replaced front driver side window regulator and motor. timing belt and water pump. brakes and oil changes. just ordered side mirror glass (currently have brown rust spots).

thinking about doing the cooling system (preventative)- is this necessary?

Cooling system is more than necessary unless you desire a new engine.

Also, how'd you manage to change the timing belt?

02 330Xi, 5 spoed, 93,000 miles
Purchased 1.5 years ago with 60,000 miles

Final Stage Unit
Battery (Optima)

Preventive maintenance on cooling system:
Radiator
Expansion tank
Water pump (Stewart)
Hoses
Thermostat
Water pump pulley (switched to metal when plastic one chipped during belt
replacement)
Belts
Belt tensioner and idler pulleys

Rear rotors
Rear pads
Wear Sensor

License plate lights/lenses

Rear springs

Steering U-joint at 140k, Front axles at 145k, and sway bar bushings at 150k