BMW 5 Series (E60, E61) Repair Manual: 2004-2010 - Complete Index

(1)

WARNING

Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your BMW, be sure to read 001 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

A

ABS (antilock brake system)

300-11, 340-2, 340-24 impulse wheel 340-32

wheel speed sensor 340-25, 340-30

see also Brakes

see also DSC (dynamic stability

control)

A/C (air-conditioning)

fluid 640-1

see also IHKA see also Heater

ACC (active cruise control)

340-25

Acceleration sensor

active stabilizer 300-6 DSC 340-25, 340-32

Accelerator pedal module (PWG)

132-19

Accessory belt

020-32

Acronyms, commonly used

ECL-2

Activated carbon canister

160-30

Active cruise control (ACC)

340-25

Active stabilizer (ARS)

010-22, 300-4 bleeding 310-30 commissioning 300-8 front 310-32 IPO diagram 300-5 troubleshooting 300-8 Active steering see Steering Adaptation 600-14 Adaptive headlights 630-5

Adaptive transmission control (AGS)

240-5

Advanced crash and safety management (ASCM)

720-1, 721-11

Advanced safety electronics (ASE)

720-1, 721-3

Air-conditioning see IHKA see also Heating

Air distribution control servo motors (stepper motors)

640-5, 640-19

Air ducts, turbo see Turbocharger Air filter element 020-24 housing M54 130-13 N52 131-11 N54 132-11 V8 133-18

Air flow sensor

see Mass air flow sensor Air quality (AUC) sensor

640-4

Air spring

330-13

see also Electronic height control

(EHC)

see also Rear suspension Airbag system

010-28, 400-4, 720-1, 721-1 contact spring 612-6, 721-13 control module 721-3, 721-11 crash sensor 721-4, 721-12 curtain (head protection) 721-3,

721-11

driver 320-9, 721-5, 721-20 locations 721-3, 721-11

passenger 721-6, 721-13, 721-21 seat occupancy sensor 520-5, 721-6,

721-14 status light 721-6, 721-14 thorax (side) 721-3, 721-7, 721-11, 721-22 troubleshooting 720-2 warning light 721-4, 721-12 Alarm 400-4, 515-24 Alignment 020-49, 300-12, 320-32 specifications 320-37 Alternator (generator) 121-18

bit-serial data (BSD) interface 121-18 troubleshooting 121-2, 121-19

Aluminum suspension components

300-2 Amplifier 650-4 Antenna 515-6, 515-9, 650-5, 650-6 ECL-39

Antifreeze (engine coolant)

020-30, 170-7

Antilock brake system

see ABS (antilock brake system) Anti-theft alarm (DWA)

400-4, 515-23 emergency disarming 515-25 interior protection 515-25 Anti-trap protection sunroof 540-1, 540-3 window 512-5 A-pillar trim 513-15 Arm, control 300-2, 300-3

see also Front suspension see also Rear suspension ARS (active stabilizer)

see Active stabilizer (ARS) ASCM (advanced crash and safety

management)

720-1, 721-11

ASE (Advanced safety electronics)

720-1, 721-3

ATF (automatic transmission fluid)

020-48, 200-6, 240-12, 240-14 capacity 240-14

cooler 170-3, 170-16

AUC (air quality) sensor

640-4 Automatic shiftlock 250-8 Automatic tailgate 412-9 Automatic transmission 010-19, 240-4 applications 200-3, 240-2 control module (TCM) 240-3, 340-25 cooler 170-3, 170-19 fluid leaks 240-10 gearshift 250-7 mechatronics 240-3, 240-10

neutral safety switch function 121-14, 250-1 removing / installing 240-17 service 020-48, 240-12 shiftlock 250-8 troubleshooting 240-9, 250-2 valve body 240-3

see also ATF (automatic transmission

fluid)

see also Torque converter Axle joint 311-1, 331-10

B

Back-up lights 630-4 function automatic transmission 612-10 SMG 231-8

(2)

Ball joint

front tension strut 310-19 swing arm 330-22 Battery 020-25, 121-4, 600-1 charging 121-10 checking 020-26 reconnection notes 121-12 registration 121-12 replacing 121-10 safety terminal 121-4, 721-9, 721-16 sensor 121-5 testing 121-7 troubleshooting 121-2 BC (on-board computer) 612-5, 620-1 Bearing pedestal 311-1, 311-14 Bearing, wheel front 310-22 rear 330-26 Belt 020-32

Bit-serial data (BSD) interface

121-18, 600-8 Blade, wiper 020-51, 611-4, 611-8 Blower 640-6, 640-11 Bluetooth 650-2 antenna 650-2 BMW acronyms ECL-2 BMW Assist 650-9 emblem (Roundel) 510-8 Online 650-9 TeleServices 650-9 Body assembly 010-25, 400-2 design 010-25, 400-3 dimensions 010-4, 400-2 grounds ECL-34 maintenance 020-49 technical data 010-3

Body basic module (KBM) see KBM (body basic module) Body gateway module (KGM)

see KGM (body gateway module) Bonnet

see Engine hood Boot see Trunk B-pillar trim 513-16 Brake fluid 020-26, 340-5 Brake light center 630-24 force display 630-4 switch 340-29, 612-9 Brakes 010-23, 300-1, 300-11, 340-2 bleeding 340-5 booster vacuum pump 100-13, 100-15, 100-16, 133-26, 300-11, 340-18 caliper 340-6, 340-13 components 340-9 fluid 020-26, 340-5 light switch 612-9 master cylinder 340-16 pads, calipers, rotors 340-9 pad / rotor wear 020-27, 340-9 parking brake 020-28, 340-19 rotor 340-14

troubleshooting 340-2

vacuum pump 13, 15, 100-16, 133-26, 300-11, 340-18

see also ABS (antilock brake system) see also DSC (dynamic stability

control)

BSD (bit-serial data) interface

121-18, 600-8

BST (battery safety terminal)

121-4, 721-9, 721-16 Bulb applications 630-2 monitoring 630-6 Bumper front 510-3 rear 510-5 Bus 130-8, 130-27, 131-8, 132-8, 240-2, 240-4, 340-25 basics 600-2, 600-7, 600-9, 600-11 parameters 600-8 Bushing

front tension strut 310-1 subframe 330-25 byteflight 600-7

C

CA (comfort access) 515-9 Cabin microfilter 020-28, 640-7

California Air Resources Board (CARB) OBD-1 Caliper 300-1, 340-6, 340-13 Camber front 320-35 rear 320-36 Camshaft adjustment

see VANOS (variable camshaft

timing)

sensor 120-7, 12016 service M54 117-35

Camshaft timing chain

M54 117-6 N52 113-17, 117-51 N54 113-31, 117-51 tensioner N52, N54 117-64 V8 117-84 V8 113-42, 117-69

see also VANOS (variable camshaft

timing)

CAN

130-8, 130-27, 131-8, 132-8

see also Bus Capacities, fluid A/C system 640-2 ATF 240-14 differential front 311-9 rear 331-2 coolant 170-8 fuel 160-2 manual transmission 230-4 oil 020-41, 020-43, 119-3 SMG 231-13 transfer case 270-5

Car access system (CAS) see CAS (car access system) Car information computer (CIC)

020-7

Car communications computer (CCC)

650-9

Car memory

515-8

CARB (California Air Resources Board)

OBD-1

Carbon canister, activated

160-30

CAS (car access system)

010-28, 010-29, 121-13, 121-14, 512-1, 512-2, 512-3, 515-4, 600-5, 630-4 Caster 320-36 Catalytic converter 120-9, 180-29 monitoring OBD-4 Cautions 001-2

CBS (condition based service)

020-3

CCC (car communications computer)

650-9

Center bearing, rear driveshaft

(3)

WARNING

Center brake light

630-24

Center console

513-6

switch cluster (SZM) 640-2, 640-3

Central information display (CID)

020-4, 650-10

Central locking

400-4, 515-3 button 515-7, 612-8

Charge air ducts see Turbocharger Charging system

troubleshooting 121-19

Check Control

020-52, 620-1

CIC (car information computer)

020-7

CID (central information display)

020-4, 650-10 Classification resistor 270-4 Cleaning exterior 020-49 Climate control see Heater see also IHKA Clock 121-12 Clutch 200-3, 210-1 fluids 200-5 hydraulics 210-2 mechanical 210-7 switch 121-14, 210-6 xDrive 200-5 Codes, fault OBD-7 Coding 600-13 Coil, ignition 120-4, 120-12 Coil spring front 300-1, 310-2, 310-3, 310-10 rear 300-1, 330-2, 330-8, 330-12

Combustion chamber leak test

170-6

Comfort access (CA)

515-9 antenna 515-9

Compass

121-13

Component locations see Electrical components Compressor

640-6, 640-14

Condition based service (CBS)

020-2, 020-3

Connecting rod

100-4

Constant velocity joint see CV (constant velocity) joint Consumer cutoff 630-7 Continuity 600-17 Control arm 300-1, 300-2, 300-3, 310-2, 310-3, 310-13, 330-2, 33017

see also Front suspension see also Rear suspension Control modules

010-28

Convenience opening / closing

windows 512-4

Coolant (antifreeze) see Cooling system

see also Engine coolant temperature

(ECT) sensor Coolant pump 170-2, 170-16, 640-6 Cooling system 100-7 ATF cooler 170-3, 170-19 coolant (antifreeze) bleeding 170-9 capacities 170-8 level 020-30 draining / filling 170-7 expansion tank 020-33, 170-2, 170-13 fan 170-3, 170-12 hoses 020-31 intercooler 170-21

power steering cooling loop 170-20 pump 170-1, 170-16, 640-6 pressure test 170-6 radiator 170-2, 170-11 service 020-30 thermostat 170-2, 170-7, 170-14 troubleshooting 170-5 Cowl cover 611-10 C-pillar trim 513-18 Crankcase 100-4, 100-8 breather 100-15, 130-24, 131-20, 132-37 Crankshaft 100-4 front seal M54 119-11 N52, N54 119-14 V8 119-21 rear main seal

M54 119-12 N52, N54 119-17 V8 119-24 sensor 120-6, 120-14 vibration damper 117-3 Crash sensor 721-4 Cruise control 130-8, 131-8, 132-8 active (ACC) 340-25 clutch switch 210-6 switch 612-5

CV (constant velocity) joint

300-3, 311-1, 311-9 boot 020-46, 311-6, 311-6, 331-12 driveshaft 260-1, 260-5, 260-11 Cylinder head cover M54 113-4 N52, N54 113-14 V8 113-39 M54 100-4, 113-5 N52 100-10, 113-17 N54 113-31 V8 113-42

D

Dashboard 010-31, 513-3 switches 612-8 Defogger 640-2, 640-6 Diagnostic executive OBD-1 Diagnostic monitors OBD-3

Diagnostic trouble code (DTC) see DTC (diagnostic trouble code) Differential 300-1, 300-3, 311-1, 331-1 applications 331-2 mounts 331-9 oil 020-46, 200-8 front 311-10 rear 331-2 removing / installing front 311-11 rear 331-3 seals front 311-5, 311-15 rear 331-4

(4)

Digital motor electronics

see DME (digital motor electronics) Dimensions

010-3

Direct injection

132-8, 132-9-132-9

160-2

DISA (variable intake manifold)

100-11

Distributive functions

010-28

Diversity antenna

650-5, 650-6, ECL-39

DME (digital motor electronics)

applications 100-3, 120-4, 130-2, 131-2, 132-2, 133-2 basic settings 130-5, 131-5, 132-5, 133-5 camshaft sensor 120-7, 120-16 crankshaft sensor 120-6, 120-14 diagnostics 130-6, 131-6, 132-6, 133-6

evaporative emissions control 160-6, OBD-5

fuel supply 160-2

grounds 130-6, 131-6, 132-6, 133-6, ECL-34

main relay testing M54 130-26 N52 131-23 N54 132-39 ME 9.2, 9.2.2 133-9 MS45.1 130-8 MSD80, MSD81 132-8 MSV70, MSV80 131-8 power supply ME9.2, 9.2.2 133-7 MS45.1 130-7 MSD80, MSD81 132-7 MSV70, MSV80 131-7 system voltage 130-5, 131-5, 132-5, 133-5 troubleshooting 120-9, 130-5, 131-5, 132-5 turbo 132-10

see also Direct injection

see also ECM (engine control module) see also EDK (electronic throttle

control)

see also Evaporative control system see also Fuel injector

see also Ignition system see also Mass air flow sensor see also MIL

see also Oxygen sensor see also Secondary air injection DMTL (detection module for tank

leakage) 160-30 Dome light 630-25 Door 411-2 check 411-2 handle 400-4, 515-11 hinge 411-3 latch 515-14 lock 400-4, 515-11 panel 411-6 pressure sensor 721-5, 721-12 sill trim 513-15 switch module 612-10 Drive axle 311-1, 311-2, 311-9, 331-1, 331-10 front 311-1 bearing pedestal 311-1, 311-14 CV joint 300-3, 311-1, 311-9 CV joint boot 020-45, 311-6 removing / installing 311-2 rear 300-1, 300-3, 331-1, 331-10 CV joint boot 331-12 removing / installing 331-11 Drive belt 020-32 Drive cycle OBD-5 Driveshaft 260-1 CV joint 260-1, 260-5 front 260-4 rear 260-5, 300-1 troubleshooting 260-2 Drivetrain 200-2 lubricants 200-6

DSC (dynamic stability control)

010-24, 130-8, 132-8, 340-2, 340-24, 340-26 acceleration sensor 340-25, 340-32 button 340-24 coding 340-30 control module 340-29 controls 340-28 faults 340-26 power supply 340-27

steering angle sensor 121-12, 320-8, 340-25, 340-32, 612-5, 612-7 switch 340-24

wheel speed sensor 340-25, 340-30

see also ABS (antilock brake system) DTC (diagnostic trouble code)

020-9, 120-9, 130-6, 131-6, 132-6, 600-13, OBD-7

table OBD-8

DTC (dynamic traction control)

switch 340-24

control)

DWA (anti-theft alarm) see Anti-theft alarm (DWA) Dynamic drive

see Active stabilizer (ARS) Dynamic stability control (DSC)

see ABS

control)

E

E-box (electronics box)

ECL-29

ECM (engine control module)

M54 130-9, 130-27 N52 131-9, 131-25 N54 132-9, 132-41 V8 133-9, 133-27

ECT sensor

see Engine coolant temperature

(ECT) sensor

EDK (electronic throttle control)

M54 130-15 N52 131-13 N54 132-11, 132-19 V8 133-13, 133-19

EHC (electronic height control) see Electronic height control (EHC) EKP (fuel pump module)

160-9

Electric cooling fan

170-3, 170-12

Electric steering lock (ELV)

320-10

Electrical components

ECL-3

antennas 650-5, 650-6, ECL-39 audio and communications equipment

650-3

engine compartment ECL-44 harness connectors ECL-18 passenger compartment ECL-59 seat ECL-64

SMG ECL-67 trunk ECL-68

underneath vehicle ECL-72

Electrical switches see Switches Electrical system

010-28, 600-1 acronyms ECL-2

component location table ECL-3 component photos ECL-39 engine 121-1

test equipment 600-2 troubleshooting 121-2, 600-15 wire color codes ELE-3

Electrical test equipment

600-2

Electrical wiring diagrams

color and size ELE-3 diagrams ELE-9 index ELE-4 sample ELE-2

Electronic height control (EHC)

330-4 disabling 330-6 faults 330-7 power supply 330-5

Electronic immobilizer (EWS)

(5)

WARNING

Electronic outer door handle module (TAGE)

400-4, 515-6, 515-9, 515-10, 515-11

Electronics box

ECL-29

ELV (electric steering lock)

320-10 Emblem, BMW (Roundel) 510-8 Emergency 020-15 alarm, disarming 515-25 brake 020-28, 340-19 flat tire indication 020-16 fuel flap release 515-2 jump starting 020-27 panic mode 512-6, 515-25 sunroof closing540-2 tire changing 020-17 towing 020-18

trunk lid release handle 412-1

Engine applications 100-3 basic settings 130-5, 131-5, 132-5, 133-5 belt 020-32 compartment 020-19, ECL-44 covers 020-21 crankcase 100-4, 100-8 crankshaft seals see Crankshaft electrical system 121-1 grounds 130-6, 131-6, 132-6, ECL-34 hood 410-3 id tag 100-2 lubrication 119-3 management

see DME (digital motor

electronics) M54 010-10, 100-3 N52 010-11, 100-8 N54 010-14, 100-14 N62, N62TU 010-16, 100-16 oil 020-39, 119-3 on-board diagnostics 130-6, 131-6, 132-6, 133-6, OBD-1 pulley 117-3 removal / installation M54 110-3 N52, N54 110-6 V8 110-8 serial number 020-13, 100-2 specifications 100-3 troubleshooting 170-6

see also DME (digital motor

electronics)

see also ECM (Engine control

module)

Engine control module

see ECM (engine control module) Engine coolant temperature (ECT)

sensor

M54 130-24 N52 131-22 N54 132-38 V8 133-25

see also Cooling system Engine cooling fan

170-3, 170-12

Engine electronics fuse carrier

ECL-29, ECL-30, ECL-31

Engine hood

410-3

service position 410-5

Engine management

see DME (digital motor electronics) Evaporative control system

133-14, 160-7

carbon canister, activated 160-30 DMTL 160-30

monitoring OBD-5

Evaporator

temperature sensor 640-4

EWS (electronic immobilizer)

515-23 Exhaust manifold 180-13 Exhaust system 020-47, 180-2 diagrams 180-32

see also Catalytic converter see also Oxygen sensor Expansion tank 020-30, 170-2, 170-13 Expansion valve 640-14 Exterior cleaning 020-49 lights 630-3 trim 510-8 washing 020-51

F

Fan

see Cooling system see also IHKA, blower Fasteners

aluminum 020-9

Fault code

see DTC (diagnostic trouble code) Fault memory OBD-2 F-CAN 600-7 Fender front 410-2 Filters air 020-24 cabin microfilter 020-32, 640-17 fuel 020-43 oil 020-41, 020-43 Final drive see Differential Firing order 120-2

Flat tire indication

020-16

Flex-disc, rear driveshaft

260-1, 260-5, 260-9 Flywheel 210-14, 240-48 Foglight 630-20, 630-21 Freeze-frame data OBD-3, OBD-7

Fresh air microfilter

020-28, 640-7

Front centering sleeve

260-5, 260-11

Front end reinforcement

(6)

Front suspension 010-20, 300-2, 310-1 aluminum components 300-2 arms 300-1, 310-13 components 310-2, 310-3 ride height 320-32 stabilizer bar 300-2, 310-29 struts / springs 300-1, 300-2, 310-2, 310-3, 310-5 subframe 300-2, 310-2 wheel bearing 310-22 tension strut 300-2, 310-2, 310-3, 310-14

FTM (flat tire monitor)

300-13, 620-1

Fuel filler emergency release

515-2

Fuel filter

020-43, 160-22, 160-29

Fuel injection

see also Direct injection see also DME (digital motor

electronics)

see also Fuel injector see also Ignition system Fuel injector

M54 130-9, 130-18 N52 131-9, 131-15 N54 132-20 V8 133-22

Fuel level sender

160-19 Fuel pressure regulator 160-16, 160-29 testing 160-17 Fuel pump electric 160-3, 160-19 fuse 160-9 high pressure 100-15, 160-24 module (EKP) 160-9, 160-29

see also Fuel system Fuel rail M54 130-18 N52 131-15 N54 132-30 V8 133-22 Fuel system 160-2 monitoring OBD-5 schematic 160-3, 160-4, 160-4 troubleshooting 160-9 Fuel tank 020-47, 160-2 capacity 160-2 draining 160-28 evaporative control 133-14, 160-7 leak detection module (DMTL) 160-30

Fuel trim OBD-5 Fuses 600-2, ECL-21 engine management 130-7, 131-7, 132-7, 133-8 Fusible links ECL-21

G

Gearshift knob 250-2

Gear shift switch (GWS)

240-3, 240-6, 250-2, 250-10 troubleshooting 250-3

Generator

see Alternator (generator) Global positioning system (GPS)

650-9 Glove compartment 513-10 GPS 650-9 GRAV 010-25, 400-2, ECL-34 Grill inserts 510-8 Grounds 130-6, 131-6, 132-6, 133-6, ECL-34 GT1 OBD-3 Guide arm 330-2, 330-18

GWS (gear shift switch) see Gear shift switch (GWS)

H

Halogen 630-9 Hand brake 020-28, 340-19 Handle, door 400-4, 515-11 Harness connectors ECL-18

Hazard warning switch

612-9, 630-3 Headlight 630-9 adaptive 630-5 aim 630-10 automatic control 630-3 beam (dip switch) 612-5 bulb replacement 630-13 removing / installing 630-16 switch 612-8

washer 611-16

xenon 630-5, 630-9, 630-13

see also Lights Heater

core 640-7

temperature sensor 640-4 valve 640-6

High precision injection (HPI) see Direct injection

High pressure fuel pump

160-24 Hinges lubricating 020-49 Hood 410-3 service position 410-5 Horn button 320-8 contact spring 612-7, 721-5

HPI (high precision injection) see Direct injection

Hydraulic fluid

310-30, 320-4

I

IBS (intelligent battery sensor)

121-5, 600-12

Identification plates

date of manufacture 020-13 engine serial number 020-13, 100-1 transmission 200-3

VIN 002-1, 020-12

Identification transmitter (remote key)

515-6

Idle speed control

020-47 M54 130-10, 130-17 N52 131-10 N54 132-10 N62 133-13 iDrive 020-4, 020-7, 020-53, 400-5 controller 612-10 display (CID) 650-10 Ignition coil 120-4

cover (upper engine cover) 020-22 remove / install 120-12

sleeve 113-15

Ignition electrical switch

START STOP switch 612-8

Ignition interlock

250-9

Ignition system

coil 120-4, 120-12

see also Ignition coil

diagnostics 120-9 disabling 120-2 firing order 120-2 spark plugs 020-44 timing 120-5 troubleshooting 120-9

(7)

WARNING

IHKA basics 640-2 belt 020-37 blower 640-6, 640-11 capacities 640-1 compressor 640-6, 640-14 condensation sensor 640-5 condenser 640-14 control panel 640-2, 640-9 expansion valve 640-14 fluids 640-1 housing 640-5 microfilter 020-28, 640-7 pressure sensor 640-14 refrigerant port 640-14 solar sensor 640-4 stepper motors 640-5, 640-9

see also Heater

I/M (inspection / maintenance)

OBD-5 Incremental sensor 270-4 Indicator lights 020-16, 620-1 Initializing sunroof 121-13 windows 121-12, 512-13 Injector

see Fuel injector

Inspection / maintenance (I/M)

OBD-5

Instruments

010-31, 400-5, 620-1

car information computer (CIC) 020-7 CBS display 020-6

central information display (CID) 020-4

Check Control 020-52, 620-1 lights dimming 630-7 service 620-2

Intake air temperature (IAT) sensor

130-14, 131-12, 132-17, 133-18 Intake manifold M54 130-21 N52 131-17 N54 132-34 pressure sensor 132-18 V8 133-12, 133-24 Integral link 300-3, 330-2, 330-21

Integrated voltage supply module (IVM)

see IVM (integrated voltage supply

module)

Intelligent battery sensor (IBS)

121-5, 600-12 Intercooler 100-14, 132-10, 170-21 Interior 010-27 care 020-49 lights 630-25 protection (USIS) 515-25 temperature sensor 640-2 trim 513-12

IVM (integrated voltage supply module) 100-19, 133-8, 133-10, ECL-32

J

Jack 020-14 Jack stands 020-15 Jump starting 020-16

K

KBM (body basic module)

512-1, 512-2, 512-3, 515-5, 630-7 Key 515-5 Key memory 515-8 Keyless entry 515-4

KGM (body gateway module)

512-3, 515-5

Knock sensor

120-8, 120-19, 130-10, 131-11, 132-11. 133-14

L

Lateral acceleration sensor

340-25

Leather upholstery

020-20

Level sender, fuel

160-19

Level sensor

see Suspension, ride height

License plate light

630-25 Lift, hydraulic 020-14 Lights bulb applications 630-2 exterior 630-3, 630-23 headlights 630-9 interior 630-7, 630-25 module 620-2 sensor 630-4 switch 612-8 taillights 630-21 troubleshooting 630-6

see also Headlight Locks

door 515-11 lubricating 020-49

single lock / double lock 515-7 rear window 515-22, 611-14 tailgate515-6, 515-20 trunk lid 515-16 Lubrication system M54 100-7 N52 100-13

oil condition sensor (OZS) 119-8 oil pressure 119-5

oil pump 119-3, 119-28

Luggage compartment see Cargo compartment see also Trunk

(8)

M

Maintenance

antifreeze (engine coolant) 020-30 automatic transmission 020-48,

240-12 battery 020-25 belts 020-32

body, hinges, locks 020-49 brake fluid 020-26, 340-5 brake pad / rotor wear 020-27,

340-14

cooling system 020-30 CV joint boot, inspecting 020-47 differential oil 020-46

engine oil 020-39

exhaust system, inspecting 020-47 exterior 020-49 filters air 020-24 cabin air 020-28, 640-7 fuel 020-43 oil 020-41

fuel tank and fuel lines 020-47 idle speed 020-47 interior 020-50 maintenance tables 020-7 oil service 020-39 oxygen sensors 020-48, 180-25 parking brake 020-28, 340-19 power steering fluid 020-42, 320-4,

320-14

recommended 020-7 seat belts 020-50

service requirements, resetting 020-6

spark plugs 020-44

suspension and steering 020-48 tables 020-10 tires 020-48 transmission 020-47, 230-2, 231-12, 240-12 underbody 020-51 wheel alignment 020-49, 320-32 wiper blade 020-51, 611-4, 611-8

see also Condition based service Malfunction indicator light (MIL)

see MIL (malfunction indicator light) Manifold, exhaust

180-13

Manifold, intake see Intake manifold Manual transmission 010-18, 200-2 applications 200-3, 230-1 fluid 020-48, 200-6, 230-2 gear ratios 230-2 gearshift 250-4 identification 200-3 removing / installing 230-10 seals 230-5

Mass air flow sensor

M54 130-14 N52 131-12 N54 132-17 secondary air 130-11 V8 133-18 Master cylinder brakes 340-16 clutch 210-4 ME 9.2, ME 9.2.2 133-9

electronics)

Mechatronics

240-3, 240-10

Memory

car memory / key memory 515-8 seat and mirror 300-10, 520-1

Microfilter

020-28, 640-7

MIL (malfunction indicator light)

020-22, 120-9, 130-6, 131-6, 132-6, 133-6, OBD-2

Mirror

memory 300-10, 515-8, 520-1 switch 520-5

outside rear view 510-2 switch 612-10 Misfire 120-9, OBD-4 Models 010-5 MOST-bus 650-1 MS45.1 130-8

electronics)

MSD80, MSD81

132-8

electronics)

MSV70, MSV80

131-8

electronics) Muffler 180-2

N

Navigation 400-5, 650-9

Neutral safety switch

function 121-14, 250-1

Normal loaded position

0-32

O

OBD (on-board diagnostics)

130-6, 131-6, 132-6, 133-6, 240-9,

OBD-1 P-codes OBD-7

plug 020-12, 130-6, 131-6, 132-6, 133-6, OBD-3

OC3 (passenger seat occupancy sensor) 520-5, 721-6, 721-13 Oil, engine 020-39, 119-3 capacity 020-41, 020-43, 119-3 changing 020-41 dipstick 020-39, 119-8 filter 020-41 level, checking 020-39, 119-8 pan M54 119-26 pressure 119-5 switch 119-7

pressure relief valve M54 119-26 pump

M54 100-7, 119-26 N52 100-11, 119-4 N54 100-15, 119-4 seal

see Crankshaft, seal

temperature sensor M54 119-8

Oil condition sensor (OZS)

020-4, 020-39, 119-8 fault evaluation 119-9 replacing 119-10

Oil seal

see Crankshaft, seal On-board computer (BC)

switch 020-10, 020-39, 020-40, 612-5, 620-1

On-board diagnostics

see OBD (on-board diagnostics) Open circuit test

121-8

ORVR (on-board refueling vapor recovery)

133-14

Oscilloscope diagnosis

charging system 121-20 ignition system 120-9

Outside door handle

400-4, 515-11 Outside mirror 510-2 switch 612-10 Oxygen sensor 020-48, 100-6, 130-8, 131-8, 132-8, 133-14, 180-25 monitoring OBD-4 wide band (planar) 133-15

OZS (oil condition sensor) see Oil condition sensor (OZS)

P

P-code OBD-7 Paddle shift 200-4, 231-4, 240-4 Pads 020-27, 340-9 PAG oil 640-1

(9)

WARNING

Panic mode 512-6, 515-25 Panorama 540-1, 540-6 Parasitic draw 121-9 Parking brake 020-28, 340-19 Parking light 630-19, Parking lock 240-6, 250-3, 250-10 Parts 020-10

Passenger seat occupancy sensor (OC3) 520-5, 721-6 Passive restraint applications 720-1, 721-2 Personalization 515-8 Pilot bearing 210-15 Pinch protection 512-5, 540-1, 540-3 Piston 100-4 Polishing 020-51 Power distribution 600-5 fuses ECL-21 Power management 600-12 Power mirror see Mirror Power steering fluid

020-43, 320-4, 320-14 cooling loop 170-20

see also Steering

Power window see Window Programming

600-14

PTFE injector seal

132-24

PWG (accelerator pedal module)

132-19 Pyrotechnic devices 400-4, 721-7, 721-14

R

R-134a 640-1

Rack and pinion

300-10 Rack boot 320-3, 320-31 Radiator 170-2, 170-11 expansion tank 020-33, 170-2, 170-13 grill 510-8

outlet coolant temperature sensor 130-25, 131-22, 132-38, 133-25

see also Cooling system Radiator grill 510-8 Radio 121-12, 650-1, 650-7 controls 320-8 satellite 650-3

Rain and light sensor (RLS)

630-3

Raising vehicle

020-14

Readiness

OBD-5

Rear main seal

M54 119-12 N52, N54 119-17 V8 119-24 Rear suspension 010-21, 300-3, 330-2 aluminum components 300-2 arms 330-2, 330-16 ball joint 330-22 control arm 300-3, 330-17 ride height 320-32 shock absorber 300-3, 330-3, 330-12 spring 300-1, 330-3, 330-8, 330-13 stabilizer bar 330-32 active 330-32, 330-34 link 330-36 strut 330-3, 330-8 subframe 300-3, 330-23 bushings 330-25 suspension arms 330-2 swing arm 300-3, 330-19 thrust rod 300-1, 330-3, 330-24 wheel bearing 330-26 carrier 330-7

see also Active stabilizer (ARS)

Rear window defogger ECL-39 relay ECL-23 switch 640-2 lock 515-22, 611-14 washer jet 611-17 wiper 611-13 Refrigerant 640-1 port 640-14 Reinforcement front end 300-2, 310-4, 311-1 Remote key 515-4

Residual heat (REST)

640-2

Restraint system

400-4, 720-1, 721-1

Reversing light switch see Back-up light switch Ride height

320-32

RLS (rain and light sensor)

630-3

Rotation rate (yaw) sensor

340-25

Rotor, brake

020-27, 340-14

Roundel

510-8

Run-on flat tire

300-14

S

SAC (self-adjusting clutch)

210-10

SAE (Society of Automotive Engineers)

OBD-1

Safety

001-1, 020-14, 400-3

Safety gateway module (SGM) see SGM (safety gateway module) Satellite radio 650-3 Scan tool 020-9, 020-12, 120-9, 130-5, 131-5, 132-6, 133-6, 600-13, OBD-3 Seal differential front 311-5 rear 331-4 manual transmission 230-5 torque converter 240-46

(10)

Seat

400-6 front 520-2

front backrest rear panel 520-8 heater control 640-7

memory 300-10, 520-1

passenger seat occupancy sensor (OC3) 520-5, 721-6 rear 520-8 switches 520-2 Seat belt 020-50 front 720-4 rear 720-6 troubleshooting 720-2

see also Airbag system Seat occupancy sensor (OC3)

520-5, 721-5

Secondary air injection

M54 130-10 N62 133-15 monitoring OBD-4 Secondary voltage 120-9 Security alarm (DWA) 400-7, 515-23 electronic immobilizer (EWS) 515-23

Self-adjusting clutch (SAC)

210-10

Sequential manual gearbox (SMG) see SMG (sequential manual

gearbox) Service 020-11 resetting 020-6 Servotronic 300-10, 320-2

SGM (safety gateway module)

512-2, 515-4, 721-3 Shift boot 513-6 Shift linkage 250-4, 250-7 troubleshooting 250-2 Shift knob 250-2 Shiftlock 231-4, 240-7, 250-8 Shock absorber front 310-2, 310-3, 310-5 rear 300-3, 330-2, 330-12 Short circuits 600-17

Side (thorax) airbag

721-3, 721-15, 721-22 Siren 515-24 Slave cylinder clutch 210-7 Sleep mode 121-6

SMG (sequential manual gearbox)

010-19, 200-3, 231-2 applications 200-3, 232-1 clutch fluid 200-6, 230-13 control module 231-5 fluid service 231-12 gear ratios 231-1 gear shift 250-7 removing / installing 231-14 Solar sensor 640-4 Sound system 650-4 antenna 650-5, 650-6 radio 650-1, 650-8 speakers 650-4 Spark plugs 020-44 Speakers 650-3 Specifications, fluid A/C system 640-1 ATF 020-47, 200-6, 240-14 differential 200-8, 311-9, 331-2 manual transmission 020-48, 200-6, 230-3 oil 020-39, 119-3 SMG 200-6 transfer case 200-7, 270-5 Speed sensor 340-25, 340-30 Splash shield 020-23 Spoiler, rear 412-8 Spring front 300-1, 300-2, 310-2, 310-3, 310-10 rear 300-1, 300-3, 330-3, 330-8, 330-12

see also Air spring

SRS (supplemental restraint system)

720-1

contact spring 612-5, 612-7

Stability control

340-2, 340-24

control) Stabilizer bar active 300-4 front 300-3, 310-2, 310-3, 310-29 link 34 rear 300-1, 300-3, 330-32 link 330-36

see also Active stabilizer START STOP switch

612-8

Starter

121-13

troubleshooting 121-2, 121-13

see also CAS (car access system)

module Static damage 600-3 Steering 010-22, 020-43, 300-1, 300-10, 320-1 active 300-11, 320-3 angle sensor 121-12, 300-7, 320-8, 340-25, 340-32, 612-5, 612-6, 612-7 bleeding 320-12 column 300-10, 320-10 memory 300-10 removing / installing 320-11 switch cluster (SZL) 612-5 trim 513-112 fluid 020-42, 320-4, 320-14 cooling loop 170-20 lock 320-10 pump 320-14 rack 300-10, 310-2, 320-2, 320-23 boot 320-31 spindle 320-13 tie rod 320-2, 320-30 troubleshooting 320-6 wheel 320-8, 721-120 switches 320-8, 612-2

Steering column switch cluster (SZL)

612-5 Steering column 300-10, 320-2 Steering knuckle 300-2, 310-2, 310-3, 310-20 Stepper motors 640-5, 640-9 Steptronic 240-3 gearshift 250-7

Stop light switch

612-9 Strut brace 310-4 front 300-1, 300-3, 310-5 tension 300-2 traction 300-1 Subframe front 300-2, 310-2, 310-3 rear 300-3, 330-2, 330-23

see also Front suspension see also Rear suspension Sunroof 540-1 adjusting 540-4 emergency closing540-2 initializing 121-13, 540-3 motor 540-7

Suppressor filter (wave trap)

(11)

WARNING

Suspension 020-48, 300-1 aluminum components 300-2 front 300-1, 310-2, 310-3 ride height 320-32 rear 300-3, 330-3

see also Front suspension see also Rear suspension Swing arm 300-3, 330-2, 330-19 ball joint 330-22 Switches back-up lights 230-4 blower 640-2 brake lights 612-9

center console switch cluster (SZM) 640-2, 640-3

central locking 612-8

child safety (rear window) 612-10 clutch 121-14

cruise control 612-5 door switch module 612-10 DSC (DTC) 340-24 hazard warning 612-8 headlight dimmer 612-5 horn 320-8

iDrive controller 612-10

ignition switch (START STOP) 612-8 light 612-8

mirror 612-10 oil pressure 119-7

rear window defogger 640-2, 640-6 refrigerant pressure sensor 640-4,

640-14

seat control 520-2 START STOP 612-8

steering column switch cluster (SZL) 612-5

steering wheel 320-8, 612-2 tailgate release 612-10 trunk lid release 612-10 turn signal 612-5 window 512-4, 612-10 wiper-washer 611-3, 612-5

Swivel bearing

310-2, 310-3

SZL (steering column switch cluster)

340-25, 612-5

T

TAGE (electronic outer door handle module) 400-4, 515-10, 515-11 Tailgate 412-5 aligning 412-6 automatic 412-9 gas strut 412-6 lock515-20

rear window lock 515-22, 611-14 release button 612-10 removing / installing 412-5 service position 412-5 trim 513-20 Taillights 630-4, 630-21 Tandem pump 300-6

TCM (automatic transmission control module) 240-3 Technical data 010-3 Telematics 650-9 Telephone control switches 320-8 Temperature sensor evaporator 640-4 interior 640-2 outside 640-4 vent flap 640-4

Tension strut, front suspension

300-1, 300-2, 310-2, 310-3, 310-14 bushing 310-18

Thermostat

170-2, 170-7, 170-14

Thorax (side) airbag

721-3, 721-15, 721-22

Throttle housing

see EDK (electronic throttle control) Thrust rod

300-1, 330-3, 330-24

Thrust arm, front suspension

300-2 Tie rod 320-2, 320-29 Tightening torques 020-10 Tilt sensor 515-24 Timing chain

see Camshaft timing chain

see also VANOS (variable camshaft

timing) Tire 300-13 changing 020-17 inflation 020-13, 020-48 pressures 020-16 monitor (FTM, TPM) 020-16, 300-13 rotating 020-48 Toe front 320-33 rear 320-36 Tools

specialty tool suppliers 020-12

Torque converter 240-8 oil seal 240-46 removing / installing 240-46 Torque plate 240-48 Towing 020-18

TPM (tire pressure monitor)

300-15

Traction control

see DSC dynamic stability control Traction strut 300-1, 330-2, 330-18 Transfer case 200-2, 200-5, 270-1 capacity 270-5 control module 270-3 lubricant 200-6, 270-5 removing / installing 270-6 service 270-5

see also xDrive Transmission automatic 200-4, 240-2 fluids 200-5, 231-12 identification 200-3, 200-3 manual 200-2, 230-2 pilot bearing 210-15 service 020-48 SMG 200-3, 231-1

see also Automatic transmission see also Manual transmission see also SMG (sequential manual

gearbox)

Transmission fluid cooler

170-3, 170-19 Trim BMW emblem (Roundel) 510-8 clips 513-2 cowl cover 611-10 dashboard 513-3 door panel 411-6 door sill 513-15 exterior 510-8

interior covers and trim 513-12 radiator grill 510-8

seat backrest rear panel 520-8 steering column 513-12 tailgate 513-20 trunk

inside 513-159 lid 513-18

(12)

Troubleshooting active stabilizer 300-8 alternator 121-2, 121-19 automatic transmission 240-9 battery 121-2 brakes 340-2 charging system 121-2, 121-19 combustion chamber leak test 170-6 cooling system 170-5 driveability 130-5, 131-5, 132-5, 133-5 driveshaft 260-3 electrical 121-2, 600-15 engine management ME 9.2, ME 9.2.2 133-5 MS45.1 130-5 MSD80, MSD80 132-5 MSV70, MSV80 131-5 evaporative control 160-7 fuel system 160-9 ignition system 120-9 lights 630-6

oil condition monitor 119-9 seat belts 720-2 shift lever 250-2 starter 121-2, 121-15 steering 320-6 thermostat 170-7 Trunk lid aligning 412-2

emergency release handle 412-1 lock 515-16 release button 612-10 removing / installing 412-2 trim floor 513-19 lid 513-18 Turbochargers 100-14 air ducts 132-12

charge pressure sensor 132-17 intercooler 100-14, 132-10, 170-21 Turn signal front 630-18 rear 630-21 side 630-19 switch 612-5

U

Ultrasonic sensor (interior protection)

515-25

USIS (interior protection)

515-25 Underbody inspection 020-51 Universal joint driveshaft 260-1, 260-5 steering shaft 320-2

V

Vacuum booster brakes 340-16 Vacuum pump 100-13, 100-15, 100-16, 133-26, 300-11, 340-18 Valvetronic 010-12, 010-17, 100-11, 100-18, 133-13 motor N52 131-14 V8 133-21

VANOS (variable camshaft timing)

100-5, 100-11, 100-17 M54 117-6

N52, N54 117-65 V8 117-84

see also Camshaft timing chain Variable camshaft timing (VANOS)

see VANOS (variable camshaft

timing)

Variable intake manifold (DISA)

100-11

Vehicle data storage

620-2

Vehicle identification number (VIN)

002-1, 020-12

Ventilation microfilter

020-28

Vibration damper, crankshaft

117-3

VIN (vehicle identification number)

002-1, 020-12

Voltage and polarity

600-1 Voltage tests 600-15 VTG (xDrive clutch) 200-2, 200-5,

W

Warning lights 020-16, 620-1 Warnings 001-1

Warnings, cautions and notes

020-2 Washers 611-1 headlight 510-5, 611-16 jet 611-16, 611-17 pumps 611-18 reservoir 611-18 switch 611-3 Washing 020-51 Wastegate 100-14 Water pump

see Cooling system, coolant pump Wave trap (suppressor filter)

650-5 Waxing 020-51 Wheel alignment 020-49, 300-12, 320-32 Wheel bearing front 310-22 rear 330-30 carrier 330-3, 330-27

Wheel housing liner

410-1

Wheel hub

rear 330-29

Wheel speed sensor

340-25, 340-30 Wheels 300-13 Window anti-trap 512-5 control 512-2 features 512-1 motor 512-5 panic mode 512-6 regulator 512-12 initializing 121-12, 512-13 service 512-7 switch 512-4, 612-10 Wipers 611-1 arm front 611-4 rear 611-19 assembly front 611-10 rear 611-13 blade 020-51, 611-3, 611-18 switch 611-3 Wiring

color and size ELE-3 diagrams ELE-9 index ELE-4 sample ELE-2

X

X connectors ECL-18 xDrive 010-20, 200-5, 270-1, 340-26

see also Transfer case Xenon

630-5, 630-9, 630-13

Y

Yaw sensor

(13)

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA

Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235

http://www.bentleypublishers.com/contact-sales

BMW 5 Series (E60, E61)

Service Manual: 2004-2010

525i, 528i, 530i, 535i, 545i, 550i

Price: $149.95

Bentley Stock Number: B510

Publication Date: 2010.jun.18

ISBN: 978-0-8376-1618-6

Hardcover, 8 3/8 in. x 11 in.

Case quantity: 5

1734 pages, 2978 photos, illustrations and diagrams

The BMW 5 Series (E60, E61) Service Manual: 2004-2010

contains in-depth maintenance, service and repair information

for the BMW 5 Series from 2004 to 2010. The aim throughout has

been simplicity and clarity, with practical explanations,

step-by-step procedures and accurate specifications. Whether you’re a

professional or a do-it-yourself BMW owner, this manual helps

you understand, care for and repair your BMW.

Technical features:

• Condition based service (CBS) maintenance procedures from

replacing the cabin microfilter to checking and resetting

service intervals. This manual tells you what to do and how

and when to do it.

• Cylinder head cover gasket and crankshaft seal service

(includes removal and installation of Valvetronic motor).

• Cooling system and radiator service.

• Fuel injection and ignition system diagrams and explanations.

• Information about advanced technical features such as

Valvetronic, VANOS, twin turbochargers, DSC (dynamic

stability control), dynamic drive (active stabilizer bars), active

steering, and xDrive.

• Suspension repair procedures.

• Brakes, steering and ABS troubleshooting and repair.

• Heating and air-conditioning repair, including A/C component

replacement.

• Body and hood repairs and adjustments.

• Electrical system service, with an easy-to-use illustrated

component locator section.

• Comprehensive wiring schematics, including fuses and

grounds.

• BMW OBD II diagnostic trouble codes, SAE-defined OBD II

P-codes, as well as basic scan tool operation.

• BMW factory tolerances, wear limits, adjustments and

tightening torques.

Models and engines covered:

525i and 530i

M54 engine (2004-2005) N52 engine (2006-2007)

528i

N52K engine (2008-2010)

535i

N54 twin turbo engine (2008-2010)

545i

N62 V8 engine (2004-2005)

550i

N62 TU V8 engine (2006-2010)

Bentley technical editors removing motor cover on V8 (N62) engine.

BentleyPublishers

.com

Detailed brake pad and rotor service. 340 Brakes

bentley_b510_new.product.announcement.pdf Learn how to reset condition-based service (CBS) intervals. 020 Maintenance