E24 6-Series

1976-1989 / Coupe / Germany

All E24 6-Series problems All workshop issues

Critical Structural and Body

3. Windscreen Surround Corrosion

Symptoms

Bubbling paint around the windscreen edges, particularly at the lower corners. By the time paint is bubbling, the underlying metal is often perforated.

Cause

The rubber windscreen seal traps moisture against the pinch weld. The factory sealant under the glass deteriorates with age, allowing water ingress between the glass and the body. UV exposure in Australia accelerates the rubber seal degradation.

Fix

The windscreen must be removed to properly repair the surround.

Corroded metal is cut out and new metal welded in.

The windscreen is refitted with new sealant and seal.

Cost: $2,000-4,000.

This is not a job you can ignore, water entering the cabin causes further damage to the footwells and wiring.

Cost mentioned in fix

Cost: $2,000-4,000

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// More E24 6-Series problems

Other known issues

Minor Structural and Body

1. Front Subframe Mount Corrosion

The front subframe mounting points corrode from road spray and accumulated grime. In advanced cases, the mount tears away from the body under braking or over bumps, causing a complete loss of front suspension geometry.

Minor Structural and Body

2. Rear Trailing Arm Pickup Point Corrosion

The rear trailing arm mounting points weaken from corrosion, causing the rear suspension to shift under load. Symptoms include vague rear-end handling, uneven rear tyre wear, and clunking from the rear when cornering.

Common Structural and Body

4. Door Bottom Corrosion

The lower edges of the doors develop rust bubbles. In advanced cases, the door skin perforates. Paint appears to blister from the inside out.

Critical Engine, M30 (633CSi, 635CSi)

5. Timing Chain and Tensioner Wear

Rattling noise from the front of the engine on cold start, lasting 2-10 seconds until oil pressure builds. In severe cases, the rattle persists when warm. If the chain jumps teeth, the engine timing shifts and performance drops dramatically, in worst cases, valve-to-piston contact occurs.

Common Engine, M30 (633CSi, 635CSi)

6. Bosch L-Jetronic Fuel Injection Issues (Early 633CSi)

Rough idle, hesitation on acceleration, rich or lean running, poor fuel economy. The engine may start fine cold but run poorly once warm, or vice versa.

Critical Engine, M30 (633CSi, 635CSi)

7. Oil Leaks

Oil residue on the engine and components. Oil smell in the cabin from oil dripping onto the exhaust manifold. Oil spots on the garage floor.

View all 15 E24 6-Series problems