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

I

NDEX

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 Warningsand 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, 340-24impulse wheel 340-32wheel speed sensor 340-25, 340-30

see also

Brakes

see also

DSC (dynamic stabilitycontrol)

A/C (air-conditioning)

fluid 640-1

see also

IHKA

see also

Heater

ACC (active cruise control)

340-25

Acceleration sensor

active stabilizer 300-6DSC 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, 300-4bleeding 310-30commissioning 300-8front 310-32IPO diagram 300-5troubleshooting 300-8

Active steering

see

Steering

Adaptation

600-14

Adaptive headlights

630-5

Adaptive transmission control (AGS)

240-5

Advanced crash and safetymanagement (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 020-24housingM54 130-13N52 131-11N54 132-11V8 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, 721-1contact spring 612-6, 721-13control module 721-3, 721-11crash sensor 721-4, 721-12curtain (head protection) 721-3,721-11driver 320-9, 721-5, 721-20locations 721-3, 721-11passenger 721-6, 721-13, 721-21seat occupancy sensor 520-5, 721-6,721-14status light 721-6, 721-14thorax (side) 721-3, 721-7, 721-11,721-22troubleshooting 720-2warning light 721-4, 721-12

Alarm

400-4, 515-24

Alignment

020-49, 300-12, 320-32specifications 320-37

Alternator (generator)

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

Aluminum suspension components

300-2

Amplifier

650-4

Antenna

515-6, 515-9, 650-5, 650-6ECL-39

Antifreeze (engine coolant)

020-30, 170-7

Antilock brake system

see

ABS (antilock brake system)

Anti-theft alarm (DWA)

400-4, 515-23emergency disarming 515-25interior protection 515-25

Anti-trap protection

sunroof 540-1, 540-3window 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 safetymanagement)

720-1, 721-11

ASE (Advanced safety electronics)

720-1, 721-3

ATF (automatic transmission fluid)

020-48, 200-6, 240-12, 240-14capacity 240-14cooler 170-3, 170-16

AUC (air quality) sensor

640-4

Automatic shiftlock

250-8

Automatic tailgate

412-9

Automatic transmission

010-19, 240-4applications 200-3, 240-2control module (TCM) 240-3, 340-25cooler 170-3, 170-19fluid leaks 240-10gearshift 250-7mechatronics 240-3, 240-10neutral safety switch function 121-14,250-1removing / installing 240-17service 020-48, 240-12shiftlock 250-8troubleshooting 240-9, 250-2valve body 240-3

see also

ATF (automatic transmissionfluid)

see also

Torque converter

Axle joint

311-1, 331-10

B

Back-up lights

630-4functionautomatic transmission 612-10SMG 231-8switch manual transmission 230-4

2I

NDEX

Ball joint

front tension strut 310-19swing arm 330-22

Battery

020-25, 121-4, 600-1charging 121-10checking 020-26reconnection notes 121-12registration 121-12replacing 121-10safety terminal 121-4, 721-9, 721-16sensor 121-5testing 121-7troubleshooting 121-2

BC (on-board computer)

612-5,620-1

Bearing pedestal

311-1, 311-14

Bearing, wheel

front 310-22rear 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

650-2antenna 650-2

BMW acronyms

ECL-2

BMW

Assist 650-9emblem (Roundel) 510-8Online 650-9TeleServices 650-9

Body

assembly 010-25, 400-2design 010-25, 400-3dimensions 010-4, 400-2grounds ECL-34maintenance 020-49technical 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 630-24force display 630-4switch 340-29, 612-9

Brakes

010-23, 300-1, 300-11, 340-2bleeding 340-5boostervacuum pump 100-13, 100-15,100-16, 133-26, 300-11, 340-18caliper 340-6, 340-13components 340-9fluid 020-26, 340-5light switch 612-9master cylinder 340-16pads, calipers, rotors 340-9pad / rotor wear 020-27, 340-9parking brake 020-28, 340-19rotor 340-14troubleshooting 340-2vacuum pump 100-13, 100-15, 100-16, 133-26, 300-11, 340-18

see also

ABS (antilock brake system)

see also

DSC (dynamic stabilitycontrol)

BSD (bit-serial data) interface

121-18, 600-8

BST (battery safety terminal)

121-4, 721-9, 721-16

Bulb

applications 630-2monitoring 630-6

Bumper

front 510-3rear 510-5

Bus

130-8, 130-27, 131-8, 132-8, 240-2,240-4, 340-25basics 600-2, 600-7, 600-9, 600-11parameters 600-8

Bushing

front tension strut 310-1subframe 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 320-35rear 320-36

Camshaft

adjustment

see

VANOS (variable camshafttiming)sensor 120-7, 12016service M54 117-35

Camshaft timing chain

M54 117-6N52 113-17, 117-51N54 113-31, 117-51tensionerN52, N54 117-64V8 117-84V8 113-42, 117-69

see also

VANOS (variable camshafttiming)

CAN

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

see also

Bus

Capacities, fluid

A/C system 640-2ATF 240-14differentialfront 311-9rear 331-2coolant 170-8fuel 160-2manual transmission 230-4oil 020-41, 020-43, 119-3SMG 231-13transfer 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 ResourcesBoard)

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, 180-29monitoring OBD-4

Cautions

001-2

CBS (condition based service)

020-3

CCC (car communications computer)

650-9

Center bearing, rear driveshaft

260-1, 260-5, 260-10

I

NDEX

3

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 Warningsand 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.

Center brake light

630-24

Center console

513-6switch cluster (SZM) 640-2, 640-3

Central information display (CID)

020-4, 650-10

Central locking

400-4, 515-3button 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, 210-1fluids 200-5hydraulics 210-2mechanical 210-7switch 121-14, 210-6xDrive 200-5

Codes, fault

OBD-7

Coding

600-13

Coil, ignition

120-4, 120-12

Coil spring

front 300-1, 310-2, 310-3, 310-10rear 300-1, 330-2, 330-8, 330-12

Combustion chamber leak test

170-6

Comfort access (CA)

515-9antenna 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

100-7ATF cooler 170-3, 170-19coolant (antifreeze)bleeding 170-9capacities 170-8level 020-30draining / filling 170-7expansion tank 020-33, 170-2, 170-13fan 170-3, 170-12hoses 020-31intercooler 170-21power steering cooling loop 170-20pump 170-1, 170-16, 640-6pressure test 170-6radiator 170-2, 170-11service 020-30thermostat 170-2, 170-7, 170-14troubleshooting 170-5

Cowl cover

611-10

C-pillar trim

513-18

Crankcase

100-4, 100-8breather 100-15, 130-24, 131-20,132-37

Crankshaft

100-4front sealM54 119-11N52, N54 119-14V8 119-21rear main sealM54 119-12N52, N54 119-17V8 119-24sensor 120-6, 120-14vibration damper 117-3

Crash sensor

721-4

Cruise control

130-8, 131-8, 132-8active (ACC) 340-25clutch switch 210-6switch 612-5

CV (constant velocity) joint

300-3, 311-1, 311-9boot 020-46, 311-6, 311-6, 331-12driveshaft 260-1, 260-5, 260-11

Cylinder head

coverM54 113-4N52, N54 113-14V8 113-39M54 100-4, 113-5N52 100-10, 113-17N54 113-31V8 113-42

D

Dashboard

010-31, 513-3switches 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, 331-1applications 331-2mounts 331-9oil 020-46, 200-8front 311-10rear 331-2removing / installingfront 311-11rear 331-3sealsfront 311-5, 311-15rear 331-4