Hi All , I had the Dreaded HPFP failure on the way back from up north last night. This seems to be the Bane of the n54 motor.
The SA told me that 4 other 535is came in today with the exact same symptoms and exact same diagnosis. That is saying something, I don't live in a HUGE city any more, Bham is not all that large and there are not many 535i's ( only been out 9-12 months).

If you need symptoms of the impending issue:
Long to crank from cold start
loss of power at speed
Horrid engine vibration between 1500rbm-3000rpm
Exhaust sounds like Garbage truck or Ricer fart can
Possible Limp home mode ( mine did not have this come up)

I wanted to start a list of 535 owners that have had theirs replaced ( so may have had multiple replacements like the E90's).
Include Date and date of Cars manufacture ( on inside of drivers side door) to see how wide spread this is in the E60' s or if it is concentrated to a certain build date.

The E60 WERE NOT included on the HPFP recall that the 1's and 3's got, even though it is the same motor. The part thankfully was in stock for all 5 that failed this weekend and covered under warranty.

Kinda odd they went down like that at one time... The dealer suggested first cold weather for the area... I say high ethanol content in gas...

I've had that engine malfunction warning twice now. The first time the dealer replaced the fuel injector on the #1 cylinder. The second time it happened the car had about 3400 miles on it. It coded for the #3 fuel injector, HPFP, turbocharger charge-air pressure too low and misfire at low tank fill level. Dealer did nothing this time as they could not get the car to do it again. They admitted that they really don't know what is causing this only that a lot of 535's are experiencing the problem. I had to laugh at the misfire at low tank fill level code. I have never run the car lower than 1/4 tank.
It has not happened again yet. I only have 4100 miles now.

Just turned my '08 535i for 3rd time with 3460 miles.
Hesitation, sputtering as if engine is missing and engine malfunction light comes on.
Dealer originally thought problem was related to xs ehtanol so they drained
gas, cleaned fuel pump and injectors. When problem returned, they replace
injector #1 and said problem was likely to return...which it has.
Keep me informed of what your dealership does...Thanks.

:o :( :unsure:

No problems so far for me at all...03/08 build (for reference)

Low Coolant at like 3500 miles, but that's it so far for me. Only at 5k miles though.

Knock on wood

I had a Second HPFP failure in under 1500 miles since the first one was replaced... :(

wow, are you getting the SW update?

wanted to bring back this thread. My 08 535 is in at my dealer right now for this problem. 4300 miles, and monday am, unusually long cranking time, later in the day jumping out into traffic, hesitation in revs, then the car fell on it's face (from an acceleration standpoint) and had a heavy misfire. A restart cleared it. After that, any heavy throttle would get it to recur. Of course the dealer has not yet been able to duplicate the problem, and won't do anything until they can. Asked if i've ever ran out of gas.....
no of course.
We'll see what they can figure out.

ask your SA how they know it is NOT an HPFP? Symptoms would suggest it is, so it would be interesting to see what they think is the problem then.

The misfire and high revs could have been logged into your DME, wonder if they scanned it to see what codes have been thrown. :think: Certain codes are tell tale signs of an HPFP, aside from the driver complaints/symptoms.

Yeah, this happened to me 2 saturdays ago. Had to wait 2hrs for roadside to tow me. Dealer took the car and was done on monday. Actually seems to pull harder now than before. But man i was on the highway when it just shut off, not fun at all. I was pissed, just bought the car in november! Still, everytime i think i feel my car hesitate, i think its going to happen again. Also the dealer told me the fuel pumps are now warrentied for 10yrs!