Figured it was time for an update.
Friday 7/25: SA calls, but I'm in my truck driving, so I have the wife take the call. She says "OK" about a million times (typical phone conversation for her it seems) and finally says "OK, we can't pick it up until Monday anyway because we are out of town." I'm thinking, "What?"
She hangs up and says the fuel filter heater has been replaced, and they are doing a "complete software update, free of charge." That sounds suspicious to me, as I doubt replacing this heater filter requires an update. Whatever, it isn't costing me anything, so what the hell. I'm actually thinking they are trying to erase the permanently stored fault codes to cover their tracks.
Saturday 7/26: SA calls again with impeccable timing, as I'm again driving and tell the wife to take it. The story now is that the area where the dealer is located lost power, so the update was interrupted. They don't know when power will be back, but they'll have to start the update over again afterwards. Likely be Monday late morning/afternoon before the car is ready. Wife says "OK, but if it goes past noon, we'll need a loaner car." Not an issue. So what the hell, these things happen. Or do they?
Sunday 7/27: Back home from our camping trip, and I'm talking with my neighbor. His office happens to be right next to the BMW dealer, and he was at work all day on Saturday and knows nothing about a power outage. It is possible, as I've had power when my neighbor across the street didn't, so not totally implausible. But with everything else, seems quite fishy......
Monday 7/28: SA calls, and this time I can take the call. Apparently now there is a fried FRM module that needs to be replaced. "So that power outage fried the FRM Module, right?" SA says "No, it was likely faulty before. But I've got the OK for the same 80/20 deal." I say that is likely bullshit, you fried the FRM and are trying to get me to cover part of the cost. But I have no proof, and they aren't budging on it, so I say "how much?" $60. Fuck it, just fix my fucking car and be done with it! And I'm probably done with BMW Bellevue too, but I don't say that.
I'm now looking at $200 out of pocket, which in the scheme of things isn't bad considering I don't have warranty coverage. This in theory gets me the latest fuel filter heater, so not likely to be defective as previous models have been, and a new FRM module, that I likely didn't need, nor should have paid for it. But again, they are wearing me down and the fight isn't worth my time at this point.
Tuesday 7/29: I call at 3:50 PM wondering what the status is of my X5. The SA says "we just finished the paperwork, you can come pick it up." Great! Finally! In the shop 7 days for a CEL.
I go to the cashier, and read every word on the invoice before handing over my CC for the $200. The first part says:
B** "Customer states SES light on, please check.
Performing Vehicle test
1125 WB
8703 WB
1 13-32-8-575-515 Fuel strainer with heating: 133010
1 07-12-9-952-104 Hose clamp: 079510
1332551 Replacing fuel filter
1125 WB
FC: 13320012SA
65635 Fuel Filter heater (1-2, 4, 8703) interrogated fault memory and found fuel filter heating faults ran test plan and per diag code: D1330_D000000_07_001 found the fuel filter heating internally faulty. parts ordered at this time. (3 1125) removed and replaced diesel fuel filter with fuel filter heater (5 1125) cleared fault memory and road tested. fault was no longer present.
E** Failure to FRM module
Cause
6100009 SIB 65 27 08 (My notes: This SIB talks about FRM failure, but only covered under Manuf. warranty period, which I'm out of. But again, a known problem.....)
1125 WB
1 61-35-9-308-375 footwell module 3: 613020
6100710 Program without CAS
1125 WB
6100980 QUICK DELETE WITH PROG
1125 WB
6100711 PROGRAM 1ST ABORT
1125 WB
6135616 REPLACING FOOTWELL MODULE
1125 WB
6100712 PROGRAM W/O CAS
1125 WB
FC: 61380615SA
65636 FRM SHORTED INTERNALLY 2.00 (1) INSPECTED AND VERIFIED THAT THE LIGHT MALFUNCTION WARNING WAS ACTIVE. RAN A SHORT TEST TO CHECK FOR UNRESPONSIVE. (2) CHECKED SUPPLY VOLTAGE AND GROUND TO FRM MODULE, NO FAULTS WERE FOUND (3) CODED AND PROGRAMMED VEHICLE TO RESCUE FRM, PROGRAMMING FAILED. (4) PERFORMED BATTERY RESET AND ATTEMPTED TO PROGRAMMING AGAIN, PROGRAMMING FAILED. (5) REMOVED AND REPLACED FRM. (6) CODED AND PROGRAMMED TO VEHICLE. CLEARED FAULT MEMORY AND ROAD TESTED. FAULT WAS NO LONGER PRESENT."
So sections B & E deal with the fuel filter heater and the FRM module. Ok, everything should be fine now. When I walked in my SA was on the phone, so I didn't bother to stop and talk to her. Probably wasn't worth the time anyway. I walk out to the waiting area and a few minutes later my X5 pulls up. I do a quick walk around and get in the running X5. WHAT IN THE BLUE FUCK IS THAT ON THE DASH!!!!! THE GOD DAMN YELLOW CEL IS STILL ON!!!!!!!!!

I literally drive the X5 20 feet right back into the service drop off lane and go find my SA. She has to be paged, and she shows up. I say "Why is the CEL still on? That's the whole reason I brought it in." She has a look on her face like "oh shit......" She apologizes, and says she'll get with the Service Manager right away and figure out what is going on. Since it is already 4:30 PM, I know they won't get to it today. I get back the same loaner car I had (325d) and leave the dealership.
The good thing here is that the CEL was already back on before I left the dealership, not 5 miles down the road. I had meant to bring my OBD reader, but forgot it at home. But I'm certain the P203A code was back.
I'll be waiting tomorrow (day 8 in the shop) to see what they come up with this time......

So, thoughts on:
Volvo XC90
Audi Q7
Porsche Cayenne
(The wife still wants an SUV, although I'm pushing for a sedan or wagon......)
Oh, and it will be leased for a period shorter than the warranty period.