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

INDEX 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

Advanced crash and safety management (ASCM) 720-1, 721-11 Advanced safety electronics (ASE) 720-1, 721-3

Antifreeze (engine coolant) 020-30, 170-7 Antilock brake system see ABS (antilock brake system)

Air-conditioning see IHKA see also Heating

Anti-theft alarm (DWA) 400-4, 515-23 emergency disarming 515-25 interior protection 515-25

Air distribution control servo motors (stepper motors) 640-5, 640-19

Anti-trap protection sunroof 540-1, 540-3 window 512-5

Air ducts, turbo see Turbocharger

A-pillar trim 513-15

Air filter element 020-24 housing M54 130-13 N52 131-11 N54 132-11 V8 133-18

Arm, control 300-2, 300-3 see also Front suspension see also Rear suspension

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

Active steering see Steering

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

Adaptation 600-14

Aluminum suspension components 300-2

Adaptive headlights 630-5

Amplifier 650-4

Adaptive transmission control (AGS) 240-5

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

1

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 switch manual transmission 230-4

2

INDEX 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

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 100-13, 100-15, 10016, 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

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

Blower 640-6, 640-11

Bulb applications 630-2 monitoring 630-6

Bluetooth 650-2 antenna 650-2

Bumper front 510-3 rear 510-5

BMW acronyms ECL-2

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

Car communications computer (CCC) 650-9

Bushing front tension strut 310-1 subframe 330-25

CARB (California Air Resources Board) OBD-1

byteflight 600-7

Carbon canister, activated 160-30

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)

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

Bonnet see Engine hood

California Air Resources Board (CARB) OBD-1

Boot see Trunk

Caliper 300-1, 340-6, 340-13

B-pillar trim 513-16

Camber front 320-35 rear 320-36

Brake fluid 020-26, 340-5

Car access system (CAS) see CAS (car access system) Car information computer (CIC) 020-7

Car memory 515-8

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 260-1, 260-5, 260-10

INDEX 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.

Center brake light 630-24 Center console 513-6 switch cluster (SZM) 640-2, 640-3

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

Central information display (CID) 020-4, 650-10

Consumer cutoff 630-7

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

Continuity 600-17

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

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

3

4

INDEX 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

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)

Drive belt 020-32

EKP (fuel pump module) 160-9

Drive cycle OBD-5

Electric cooling fan 170-3, 170-12

Driveshaft 260-1 CV joint 260-1, 260-5 front 260-4 rear 260-5, 300-1 troubleshooting 260-2

Electric steering lock (ELV) 320-10

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 see also DSC (dynamic stability control) DWA (anti-theft alarm) see Anti-theft alarm (DWA) Dynamic drive see Active stabilizer (ARS) Dynamic stability control (DSC) see ABS see also DSC (dynamic stability control)

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) 515-23

INDEX 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.

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 closing 540-2 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 300-1, 310-3

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6

INDEX 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

Fusible links ECL-21

High pressure fuel pump 160-24

G

Hinges lubricating 020-49

Gearshift knob 250-2 Gear shift switch (GWS) 240-3, 240-6, 250-2, 250-10 troubleshooting 250-3 Generator see Alternator (generator)

FTM (flat tire monitor) 300-13, 620-1

Global positioning system (GPS) 650-9

Fuel filler emergency release 515-2

Glove compartment 513-10

Fuel filter 020-43, 160-22, 160-29

GPS 650-9

Fuel injection see also Direct injection see also DME (digital motor electronics) see also Fuel injector see also Ignition system

GRAV 010-25, 400-2, ECL-34

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

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

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

Handle, door 400-4, 515-11

Ignition coil 120-4 cover (upper engine cover) 020-22 remove / install 120-12 sleeve 113-15

Harness connectors ECL-18

Ignition electrical switch START STOP switch 612-8

Hazard warning switch 612-9, 630-3

Ignition interlock 250-9

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

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 see also DME (digital motor electronics

Hand brake 020-28, 340-19

Heater core 640-7 temperature sensor 640-4 valve 640-6 High precision injection (HPI) see Direct injection

INDEX 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.

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

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

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

Incremental sensor 270-4

K

Indicator lights 020-16, 620-1

KBM (body basic module) 512-1, 512-2, 512-3, 515-5, 630-7

Initializing sunroof 121-13 windows 121-12, 512-13

Key 515-5

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

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 tailgate 515-6, 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

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INDEX 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

OC3 (passenger seat occupancy sensor) 520-5, 721-6, 721-13

ME 9.2, ME 9.2.2 133-9 see also DME (digital motor electronics)

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

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

Oil condition sensor (OZS) 020-4, 020-39, 119-8 fault evaluation 119-9 replacing 119-10

Misfire 120-9, OBD-4

Oil seal see Crankshaft, seal

Models 010-5

On-board computer (BC) switch 020-10, 020-39, 020-40, 612-5, 620-1

MOST-bus 650-1 MS45.1 130-8 see also DME (digital motor electronics) MSD80, MSD81 132-8 see also DME (digital motor electronics) MSV70, MSV80 131-8 see also DME (digital motor 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

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

INDEX 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.

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

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

Parts 020-10

Radio 121-12, 650-1, 650-7 controls 320-8 satellite 650-3

Passenger seat occupancy sensor (OC3) 520-5, 721-6

Rain and light sensor (RLS) 630-3

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

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)

9

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 see also Crankshaft

10

INDEX

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

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

Servotronic 300-10, 320-2

Spoiler, rear 412-8

SGM (safety gateway module) 512-2, 515-4, 721-3

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

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

SRS (supplemental restraint system) 720-1 contact spring 612-5, 612-7

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

Stability control 340-2, 340-24 see also DSC (dynamic stability control)

Subframe front 300-2, 310-2, 310-3 rear 300-3, 330-2, 330-23 see also Front suspension see also Rear suspension

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

Sunroof 540-1 adjusting 540-4 emergency closing 540-2 initializing 121-13, 540-3 motor 540-7

START STOP switch 612-8

Suppressor filter (wave trap) 650-5

INDEX 11 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.

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 lock 515-20 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

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

Tandem pump 300-6 TCM (automatic transmission control module) 240-3

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

Technical data 010-3

Traction control see DSC dynamic stability control

Telematics 650-9

Traction strut 300-1, 330-2, 330-18

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

Telephone control switches 320-8

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

Swivel bearing 310-2, 310-3

Timing chain see Camshaft timing chain see also VANOS (variable camshaft timing)

Swing arm 300-3, 330-2, 330-19 ball joint 330-22

SZL (steering column switch cluster) 340-25, 612-5

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

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 wheel housing liner 410-1

12

INDEX

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

Valvetronic 010-12, 010-17, 100-11, 100-18, 133-13 motor N52 131-14 V8 133-21

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

Vibration damper, crankshaft 117-3

Turbochargers 100-14 air ducts 132-12 charge pressure sensor 132-17 intercooler 100-14, 132-10, 170-21

VTG (xDrive clutch) 200-2, 200-5,

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

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

VIN (vehicle identification number) 002-1, 020-12 Voltage and polarity 600-1 Voltage tests 600-15

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 340-25

established 1950 Automotive Reference™

BentleyPublishers .com

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-bystep 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.

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

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.

Detailed brake pad and rotor service. 340 Brakes

Learn how to reset conditionbased service (CBS) intervals. 020 Maintenance

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 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 bentley_b510_new.product.announcement.pdf