I think the repair costs used to be a lot higher than they are today. I've had mine for almost 14 years, and I used to cringe when I had to get it repaired.. but the last thing I had to replace was the water pump (first time needing replacement), and it only cost me $125, which if I remember correctly, that isn't too much more than I payed when I replaced the water pump on my escort (when it was just 4 years old).
Repairs to the body are wayyyy up there tho.. I got in an accident last year, a big truck hit my drivers door and front panal of the car... Insurance wanted to total the car, repairs were estimated at $4000, but I found a place to fix it for 3,999, so they wouldn't total it
now mind you, that was just for the driver door, and a little dent in the front panal!!!!! but, if I had to weigh the money against being safe, had I been in the escort, I can guarentee you I wouldn't be here to type this to you today!!!
So, if you are looking into a BMW, the repair costs may seem higher, when you have to fork out the money, but when you consider that you hardly ever have to replace anything (I have 250,000 miles on that baby right now, and it's still purring)... and the fact that if you ever do get in an accident, you will be very safe in it. (I think the safest car is a Volvo, but I know BMW's are up there with them).
good luck in your search