I have a 2004 5 series with the 6 spd manual. In 1st, 2nd and 3rd gear if the engine hits 4000 RPM or higher the engine shutters and the car lurches. I took it to the dealer and they duplicated the problem (not hard as it happens every time), however they didn't have a fix. Their only suggestion was to only use Chevron gas, which I thought was a joke. However, desperate for any fix I tried this for a few months with no noticeable improvement. Has anyone else experience this with their manuals?

 

I also have a 2004 525i 6 sp manual.
I am not exactly sure what your concern is. Are u saying that after 4000 rpm in 1,2,3 gear, the car hesitates to accelerate? or r u experiencing some pause and all of sudden the car just jumps out?
Since mine is a 525, I never expected too much power from it, but my car feels pretty smooth in all gears in all rpm.

 

My E60 had a similar problem just before I traded it for my E61. There is a SIB out there apparently involving programming of the DME that addresses this issue in the 04 models.

 

The clutch is not as smooth as it was once, dont know why, a mechanic said that there could be an air bubble

rj

 

not with a BMW, but I had a VW Jetta 2 with the 16 valve engine and I had something that sounds very similar. I was also told it was bad gas, put in some injector cleaner and stuck to a major brand and it went away within a few tanks. I can't remember if I also changed the fuel filter for sure, but I believe I did.

When this was happening my car literally felt like it was going to shake apart. It does sound similar to what you're describing (perhaps insufficient fuel or air).

 

The car hesitates to accelerate. Rather than a smooth arc of acceleration, the engine sort of pulsates at 4000 rpm and above in those gears. I haven't had it above 4000 in 4, 5, or 6, but it may happen there as well.

 

Thanks. I made another service appt for the beginning of July. I'll mention this and see if they have any thoughts.

 

No such problems at 23K miles, but if the dealer was not concerned, then I'd assume it is something temporary. That's better than having them tear it apart on a wild goose chase with the meter running...

 

it could be in the Software. my 05 545 did not have any such issue. i did how mostly before that point for fuel economy.

 

I have a '05 545i manual and this has never happened to me...Your dealer telling you about Chevron is of course a bunch of typical BS that they try and throw at you.

Since you're in SoCal, I can recommend taking it to two independent BMW specific repair shops that I always use that are very highly respected and VERY fair priced. One is the M-Shop located in L.A. and the other is SouthBay Independent in Gardena. Both have BMW master mechanics and are very honest people. I go to SouthBay Independent since it's sorta close to where I reside.