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

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, 340-24impulse wheel 340-32wheel speed sensor 340-25, 340-30see also Brakessee also DSC (dynamic stability control)

A/C (air-conditioning)fluid 640-1see also IHKAsee also Heater

ACC (active cruise control)340-25

Acceleration sensoractive stabilizer 300-6DSC 340-25, 340-32

Accelerator pedal module (PWG)132-19

Accessory belt020-32

Acronyms, commonly used ECL-2

Activated carbon canister160-30

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 steeringsee Steering

Adaptation600-14

Adaptive headlights630-5

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-conditioningsee IHKAsee also Heating

Air distribution control servo motors (stepper motors)

640-5, 640-19

Air ducts, turbosee Turbocharger

Air filterelement 020-24housing

M54 130-13N52 131-11N54 132-11V8 133-18

Air flow sensor see Mass air flow sensor

Air quality (AUC) sensor640-4

Air spring330-13see also Electronic height control (EHC)

see also Rear suspension

Airbag system010-28, 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, 721-11

driver 320-9, 721-5, 721-20locations 721-3, 721-11passenger 721-6, 721-13, 721-21seat occupancy sensor 520-5, 721-6, 721-14

status light 721-6, 721-14thorax (side) 721-3, 721-7, 721-11, 721-22

troubleshooting 720-2warning light 721-4, 721-12

Alarm 400-4, 515-24

Alignment020-49, 300-12, 320-32specifications 320-37

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

Aluminum suspension components300-2

Amplifier650-4

Antenna515-6, 515-9, 650-5, 650-6ECL-39

Antifreeze (engine coolant)020-30, 170-7

Antilock brake systemsee ABS (antilock brake system)

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

Anti-trap protectionsunroof 540-1, 540-3window 512-5

A-pillar trim513-15

Arm, control300-2, 300-3see also Front suspensionsee 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, 240-14capacity 240-14cooler 170-3, 170-16

AUC (air quality) sensor640-4

Automatic shiftlock250-8

Automatic tailgate412-9

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, 250-1

removing / installing 240-17service 020-48, 240-12shiftlock 250-8troubleshooting 240-9, 250-2valve body 240-3see also ATF (automatic transmission fluid)

see also Torque converter

Axle joint311-1, 331-10

B

Back-up lights630-4function

automatic transmission 612-10SMG 231-8

switch manual transmission 230-4

2 INDEX

Ball jointfront tension strut 310-19swing arm 330-22

Battery020-25, 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 pedestal311-1, 311-14

Bearing, wheelfront 310-22rear 330-26

Belt020-32

Bit-serial data (BSD) interface 121-18, 600-8

Blade, wiper020-51, 611-4, 611-8

Blower640-6, 640-11

Bluetooth 650-2antenna 650-2

BMW acronyms ECL-2

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

Bodyassembly 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)

Bonnetsee Engine hood

Bootsee Trunk

B-pillar trim513-16

Brake fluid020-26, 340-5

Brake light center 630-24force display 630-4switch 340-29, 612-9

Brakes010-23, 300-1, 300-11, 340-2bleeding 340-5booster

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

caliper 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 stability control)

BSD (bit-serial data) interface 121-18, 600-8

BST (battery safety terminal)121-4, 721-9, 721-16

Bulbapplications 630-2monitoring 630-6

Bumperfront 510-3rear 510-5

Bus 130-8, 130-27, 131-8, 132-8, 240-2, 240-4, 340-25

basics 600-2, 600-7, 600-9, 600-11parameters 600-8

Bushingfront tension strut 310-1subframe 330-25

byteflight600-7

C

CA (comfort access)515-9

Cabin microfilter020-28, 640-7

California Air Resources Board (CARB)

OBD-1

Caliper300-1, 340-6, 340-13

Camberfront 320-35rear 320-36

Camshaft adjustment

see VANOS (variable camshaft timing)

sensor 120-7, 12016service M54 117-35

Camshaft timing chainM54 117-6N52 113-17, 117-51N54 113-31, 117-51tensioner

N52, N54 117-64V8 117-84

V8 113-42, 117-69see also VANOS (variable camshaft timing)

CAN130-8, 130-27, 131-8, 132-8see also Bus

Capacities, fluidA/C system 640-2ATF 240-14differential

front 311-9rear 331-2

coolant 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 memory515-8

CARB (California Air Resources Board)

OBD-1

Carbon canister, activated160-30

CAS (car access system)010-28, 010-29, 121-13, 121-14, 512-1, 512-2, 512-3, 515-4, 600-5, 630-4

Caster320-36

Catalytic converter120-9, 180-29monitoring OBD-4

Cautions 001-2

CBS (condition based service)020-3

CCC (car communications computer)650-9

Center bearing, rear driveshaft260-1, 260-5, 260-10

INDEX 3

WARNING


Center brake light630-24

Center console513-6switch 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 ductssee Turbocharger

Charging systemtroubleshooting 121-19

Check Control020-52, 620-1

CIC (car information computer)020-7

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

Classification resistor270-4

Cleaningexterior 020-49

Climate controlsee Heatersee also IHKA

Clock121-12

Clutch200-3, 210-1fluids 200-5hydraulics 210-2mechanical 210-7switch 121-14, 210-6xDrive 200-5

Codes, faultOBD-7

Coding600-13

Coil, ignition120-4, 120-12

Coil springfront 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

Compass121-13

Component locationssee Electrical components

Compressor640-6, 640-14

Condition based service (CBS)020-2, 020-3

Connecting rod100-4

Constant velocity jointsee CV (constant velocity) joint

Consumer cutoff630-7

Continuity600-17

Control arm300-1, 300-2, 300-3, 310-2, 310-3, 310-13, 330-2, 33017

see also Front suspensionsee also Rear suspension

Control modules010-28

Convenience opening / closingwindows 512-4

Coolant (antifreeze)see Cooling systemsee also Engine coolant temperature (ECT) sensor

Coolant pump170-2, 170-16, 640-6

Cooling system100-7ATF cooler 170-3, 170-19coolant (antifreeze)

bleeding 170-9capacities 170-8level 020-30

draining / 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 cover611-10

C-pillar trim513-18

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

Crankshaft 100-4front seal

M54 119-11N52, N54 119-14V8 119-21

rear main sealM54 119-12N52, N54 119-17V8 119-24

sensor 120-6, 120-14vibration damper 117-3

Crash sensor721-4

Cruise control130-8, 131-8, 132-8active (ACC) 340-25clutch switch 210-6switch 612-5

CV (constant velocity) joint300-3, 311-1, 311-9boot 020-46, 311-6, 311-6, 331-12driveshaft 260-1, 260-5, 260-11

Cylinder headcover

M54 113-4N52, N54 113-14V8 113-39

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

D

Dashboard010-31, 513-3switches 612-8

Defogger640-2, 640-6

Diagnostic executive OBD-1

Diagnostic monitorsOBD-3

Diagnostic trouble code (DTC)see DTC (diagnostic trouble code)

Differential300-1, 300-3, 311-1, 331-1applications 331-2mounts 331-9oil 020-46, 200-8


removing / installing front 311-11rear 331-3

sealsfront 311-5, 311-15rear 331-4

4 INDEX

Digital motor electronics see DME (digital motor electronics)

Dimensions010-3

Direct injection132-8, 132-9-132-9160-2

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, 120-16crankshaft sensor 120-6, 120-14diagnostics 130-6, 131-6, 132-6, 133-6

evaporative emissions control 160-6, OBD-5

fuel supply 160-2grounds 130-6, 131-6, 132-6, 133-6, ECL-34

main relay testing M54 130-26N52 131-23N54 132-39

ME 9.2, 9.2.2 133-9MS45.1 130-8MSD80, MSD81 132-8MSV70, MSV80 131-8power supply

ME9.2, 9.2.2 133-7MS45.1 130-7MSD80, MSD81 132-7MSV70, MSV80 131-7

system voltage 130-5, 131-5, 132-5, 133-5

troubleshooting 120-9, 130-5, 131-5, 132-5

turbo 132-10see also Direct injectionsee also ECM (engine control module)see also EDK (electronic throttle control)

see also Evaporative control systemsee also Fuel injectorsee also Ignition systemsee also Mass air flow sensorsee also MILsee also Oxygen sensorsee also Secondary air injection

DMTL (detection module for tank leakage)

160-30

Dome light630-25

Door411-2check 411-2handle 400-4, 515-11hinge 411-3latch 515-14lock 400-4, 515-11panel 411-6pressure sensor 721-5, 721-12sill trim 513-15switch module 612-10

Drive axle311-1, 311-2, 311-9, 331-1, 331-10front 311-1

bearing pedestal 311-1, 311-14CV joint 300-3, 311-1, 311-9CV joint boot 020-45, 311-6removing / installing 311-2

rear 300-1, 300-3, 331-1, 331-10CV joint boot 331-12removing / installing 331-11

Drive belt020-32

Drive cycleOBD-5

Driveshaft260-1CV joint 260-1, 260-5front 260-4rear 260-5, 300-1

troubleshooting 260-2

Drivetrain200-2lubricants 200-6

DSC (dynamic stability control)010-24, 130-8, 132-8, 340-2, 340-24, 340-26

acceleration sensor 340-25, 340-32button 340-24coding 340-30control module 340-29controls 340-28faults 340-26power supply 340-27steering angle sensor 121-12, 320-8, 340-25, 340-32, 612-5, 612-7

switch 340-24wheel speed sensor 340-25, 340-30see 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 340-24see also DSC (dynamic stability control)

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

Dynamic drivesee Active stabilizer (ARS)

Dynamic stability control (DSC)see ABSsee also DSC (dynamic stability control)

E

E-box (electronics box)ECL-29

ECM (engine control module)M54 130-9, 130-27N52 131-9, 131-25N54 132-9, 132-41V8 133-9, 133-27

ECT sensorsee Engine coolant temperature (ECT) sensor

EDK (electronic throttle control)M54 130-15N52 131-13N54 132-11, 132-19V8 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 componentsECL-3antennas 650-5, 650-6, ECL-39audio and communications equipment 650-3

engine compartment ECL-44harness connectors ECL-18passenger compartment ECL-59seat ECL-64SMG ECL-67trunk ECL-68underneath vehicle ECL-72

Electrical switchessee Switches

Electrical system010-28, 600-1acronyms ECL-2component location table ECL-3component photos ECL-39engine 121-1test equipment 600-2troubleshooting 121-2, 600-15wire color codes ELE-3

Electrical test equipment600-2

Electrical wiring diagramscolor and size ELE-3diagrams ELE-9index ELE-4sample ELE-2

Electronic height control (EHC)330-4disabling 330-6faults 330-7power supply 330-5

Electronic immobilizer (EWS)515-23

INDEX 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

Emergency020-15alarm, disarming 515-25brake 020-28, 340-19flat tire indication 020-16fuel flap release 515-2jump starting 020-27panic mode 512-6, 515-25sunroof closing 540-2tire changing 020-17towing 020-18trunk lid release handle 412-1

Engineapplications 100-3basic settings 130-5, 131-5, 132-5, 133-5

belt 020-32compartment 020-19, ECL-44covers 020-21crankcase 100-4, 100-8crankshaft seals

see Crankshaftelectrical system 121-1grounds 130-6, 131-6, 132-6, ECL-34hood 410-3id tag 100-2lubrication 119-3management

see DME (digital motor electronics)

M54 010-10, 100-3N52 010-11, 100-8N54 010-14, 100-14N62, N62TU 010-16, 100-16oil 020-39, 119-3on-board diagnostics 130-6, 131-6, 132-6, 133-6, OBD-1

pulley 117-3removal / installation

M54 110-3N52, N54 110-6V8 110-8

serial number 020-13, 100-2specifications 100-3troubleshooting 170-6see also DME (digital motor electronics)

see also ECM (Engine control module)

Engine control modulesee ECM (engine control module)

Engine coolant temperature (ECT) sensor

M54 130-24N52 131-22N54 132-38V8 133-25see also Cooling system

Engine cooling fan170-3, 170-12

Engine electronics fuse carrierECL-29, ECL-30, ECL-31

Engine hood410-3service position 410-5

Engine managementsee DME (digital motor electronics)

Evaporative control system133-14, 160-7carbon canister, activated 160-30DMTL 160-30monitoring OBD-5

Evaporatortemperature sensor 640-4

EWS (electronic immobilizer)515-23

Exhaust manifold180-13

Exhaust system020-47, 180-2diagrams 180-32see also Catalytic convertersee also Oxygen sensor

Expansion tank020-30, 170-2, 170-13

Expansion valve640-14

Exteriorcleaning 020-49lights 630-3trim 510-8washing 020-51

F

Fansee Cooling systemsee also IHKA, blower

Fastenersaluminum 020-9

Fault codesee DTC (diagnostic trouble code)

Fault memoryOBD-2

F-CAN600-7

Fenderfront 410-2

Filtersair 020-24cabin microfilter 020-32, 640-17fuel 020-43oil 020-41, 020-43

Final drivesee Differential

Firing order120-2

Flat tire indication020-16

Flex-disc, rear driveshaft260-1, 260-5, 260-9

Flywheel210-14, 240-48

Foglight630-20, 630-21

Freeze-frame dataOBD-3, OBD-7

Fresh air microfilter020-28, 640-7

Front centering sleeve260-5, 260-11

Front end reinforcement300-1, 310-3

6 INDEX

Front suspension010-20, 300-2, 310-1aluminum components 300-2arms 300-1, 310-13components 310-2, 310-3ride height 320-32stabilizer bar 300-2, 310-29struts / springs 300-1, 300-2, 310-2, 310-3, 310-5

subframe 300-2, 310-2wheel bearing 310-22tension strut 300-2, 310-2, 310-3, 310-14

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

Fuel filler emergency release 515-2

Fuel filter020-43, 160-22, 160-29

Fuel injectionsee also Direct injectionsee also DME (digital motor electronics)

see also Fuel injectorsee also Ignition system

Fuel injectorM54 130-9, 130-18N52 131-9, 131-15N54 132-20V8 133-22

Fuel level sender160-19

Fuel pressureregulator 160-16, 160-29testing 160-17

Fuel pumpelectric 160-3, 160-19fuse 160-9high pressure 100-15, 160-24module (EKP) 160-9, 160-29see also Fuel system

Fuel railM54 130-18N52 131-15N54 132-30V8 133-22

Fuel system 160-2 monitoring OBD-5schematic 160-3, 160-4, 160-4troubleshooting 160-9

Fuel tank020-47, 160-2capacity 160-2draining 160-28evaporative control 133-14, 160-7leak detection module (DMTL) 160-30

Fuel trimOBD-5

Fuses 600-2, ECL-21engine management 130-7, 131-7, 132-7, 133-8

Fusible linksECL-21

G

Gearshiftknob 250-2

Gear shift switch (GWS)240-3, 240-6, 250-2, 250-10troubleshooting 250-3

Generatorsee Alternator (generator)

Global positioning system (GPS)650-9

Glove compartment513-10

GPS650-9

GRAV010-25, 400-2, ECL-34

Grill inserts510-8

Grounds130-6, 131-6, 132-6, 133-6, ECL-34

GT1OBD-3

Guide arm330-2, 330-18

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

H

Halogen630-9

Hand brake020-28, 340-19

Handle, door400-4, 515-11

Harness connectorsECL-18

Hazard warning switch612-9, 630-3

Headlight630-9adaptive 630-5aim 630-10automatic control 630-3beam (dip switch) 612-5bulb replacement 630-13removing / installing 630-16switch 612-8washer 611-16xenon 630-5, 630-9, 630-13see also Lights

Heatercore 640-7

temperature sensor 640-4valve 640-6

High precision injection (HPI)see Direct injection

High pressure fuel pump160-24

Hingeslubricating 020-49

Hood410-3service position 410-5

Hornbutton 320-8contact spring 612-7, 721-5

HPI (high precision injection)see Direct injection

Hydraulic fluid310-30, 320-4

I

IBS (intelligent battery sensor)121-5, 600-12

Identification platesdate of manufacture 020-13engine serial number 020-13, 100-1transmission 200-3VIN 002-1, 020-12

Identification transmitter (remote key)515-6

Idle speed control020-47M54 130-10, 130-17N52 131-10N54 132-10N62 133-13

iDrive020-4, 020-7, 020-53, 400-5controller 612-10display (CID) 650-10

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

Ignition electrical switchSTART STOP switch 612-8

Ignition interlock250-9

Ignition systemcoil 120-4, 120-12

see also Ignition coildiagnostics 120-9disabling 120-2firing order 120-2spark plugs 020-44timing 120-5troubleshooting 120-9see also DME (digital motor electronics

INDEX 7

WARNING


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

I/M (inspection / maintenance)OBD-5

Incremental sensor270-4

Indicator lights020-16, 620-1

Initializingsunroof 121-13windows 121-12, 512-13

Injectorsee Fuel injector

Inspection / maintenance (I/M)OBD-5

Instruments010-31, 400-5, 620-1car information computer (CIC) 020-7CBS display 020-6central information display (CID) 020-4

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

Intake air temperature (IAT) sensor130-14, 131-12, 132-17, 133-18

Intake manifoldM54 130-21N52 131-17N54 132-34pressure sensor 132-18V8 133-12, 133-24

Integral link300-3, 330-2, 330-21

Integrated voltage supply module (IVM)

see IVM (integrated voltage supply module)

Intelligent battery sensor (IBS)121-5, 600-12

Intercooler100-14, 132-10, 170-21

Interior010-27care 020-49lights 630-25protection (USIS) 515-25temperature sensor 640-2trim 513-12

IVM (integrated voltage supply module)

100-19, 133-8, 133-10, ECL-32

J

Jack020-14

Jack stands020-15

Jump starting020-16

K

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

Key515-5

Key memory515-8

Keyless entry515-4

KGM (body gateway module)512-3, 515-5

Knock sensor120-8, 120-19, 130-10, 131-11, 132-11. 133-14

L

Lateral acceleration sensor340-25

Leather upholstery020-20

Level sender, fuel160-19

Level sensorsee Suspension, ride height

License plate light630-25

Lift, hydraulic020-14

Lightsbulb applications 630-2exterior 630-3, 630-23headlights 630-9interior 630-7, 630-25module 620-2sensor 630-4switch 612-8taillights 630-21troubleshooting 630-6see also Headlight

Locksdoor 515-11lubricating 020-49single lock / double lock 515-7rear window 515-22, 611-14tailgate 515-6, 515-20trunk lid 515-16

Lubrication systemM54 100-7N52 100-13oil condition sensor (OZS) 119-8oil pressure 119-5oil pump 119-3, 119-28

Luggage compartmentsee Cargo compartmentsee also Trunk

8 INDEX

M

Maintenanceantifreeze (engine coolant) 020-30automatic transmission 020-48, 240-12

battery 020-25belts 020-32body, hinges, locks 020-49brake fluid 020-26, 340-5brake pad / rotor wear 020-27, 340-14

cooling system 020-30CV joint boot, inspecting 020-47differential oil 020-46engine oil 020-39exhaust system, inspecting 020-47exterior 020-49filters

air 020-24cabin air 020-28, 640-7fuel 020-43oil 020-41

fuel tank and fuel lines 020-47idle speed 020-47interior 020-50maintenance tables 020-7oil service 020-39oxygen sensors 020-48, 180-25parking brake 020-28, 340-19power steering fluid 020-42, 320-4, 320-14

recommended 020-7seat belts 020-50service requirements, resetting 020-6

spark plugs 020-44suspension and steering 020-48tables 020-10tires 020-48transmission 020-47, 230-2, 231-12, 240-12

underbody 020-51wheel alignment 020-49, 320-32wiper blade 020-51, 611-4, 611-8see also Condition based service

Malfunction indicator light (MIL)see MIL (malfunction indicator light)

Manifold, exhaust180-13

Manifold, intakesee Intake manifold

Manual transmission010-18, 200-2applications 200-3, 230-1fluid 020-48, 200-6, 230-2gear ratios 230-2gearshift 250-4identification 200-3removing / installing 230-10seals 230-5

Mass air flow sensorM54 130-14N52 131-12N54 132-17secondary air 130-11V8 133-18

Master cylinderbrakes 340-16clutch 210-4

ME 9.2, ME 9.2.2133-9see also DME (digital motor electronics)

Mechatronics240-3, 240-10

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

Microfilter020-28, 640-7

MIL (malfunction indicator light)020-22, 120-9, 130-6, 131-6, 132-6, 133-6, OBD-2

Mirrormemory 300-10, 515-8, 520-1

switch 520-5outside rear view 510-2switch 612-10

Misfire120-9, OBD-4

Models010-5

MOST-bus650-1

MS45.1130-8see also DME (digital motor electronics)

MSD80, MSD81132-8see also DME (digital motor electronics)

MSV70, MSV80131-8see also DME (digital motor electronics)

Muffler180-2

N

Navigation400-5, 650-9

Neutral safety switchfunction 121-14, 250-1

Normal loaded position0-32

O

OBD (on-board diagnostics)130-6, 131-6, 132-6, 133-6, 240-9, OBD-1

P-codes OBD-7plug 020-12, 130-6, 131-6, 132-6, 133-6, OBD-3

OC3 (passenger seat occupancy sensor)

520-5, 721-6, 721-13

Oil, engine020-39, 119-3capacity 020-41, 020-43, 119-3changing 020-41dipstick 020-39, 119-8filter 020-41level, checking 020-39, 119-8pan M54 119-26pressure 119-5

switch 119-7pressure relief valve M54 119-26pump

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

sealsee Crankshaft, seal

temperature sensor M54 119-8

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

Oil sealsee Crankshaft, seal

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

On-board diagnosticssee OBD (on-board diagnostics)

Open circuit test121-8

ORVR (on-board refueling vapor recovery)

133-14

Oscilloscope diagnosischarging system 121-20ignition system 120-9

Outside door handle400-4, 515-11

Outside mirror510-2switch 612-10

Oxygen sensor020-48, 100-6, 130-8, 131-8, 132-8, 133-14, 180-25

monitoring OBD-4wide band (planar) 133-15

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

P

P-codeOBD-7

Paddle shift200-4, 231-4, 240-4

Pads020-27, 340-9

PAG oil640-1

INDEX 9

WARNING


Panic mode 512-6, 515-25

Panorama 540-1, 540-6

Parasitic draw121-9

Parking brake020-28, 340-19

Parking light630-19,

Parking lock240-6, 250-3, 250-10

Parts020-10

Passenger seat occupancy sensor (OC3)

520-5, 721-6

Passive restraintapplications 720-1, 721-2

Personalization515-8

Pilot bearing210-15

Pinch protection512-5, 540-1, 540-3

Piston100-4

Polishing020-51

Power distribution600-5fuses ECL-21

Power management600-12

Power mirrorsee Mirror

Power steering fluid020-43, 320-4, 320-14cooling loop 170-20see also Steering

Power windowsee Window

Programming600-14

PTFE injector seal132-24

PWG (accelerator pedal module)132-19

Pyrotechnic devices400-4, 721-7, 721-14

R

R-134a640-1

Rack and pinion300-10

Rack boot320-3, 320-31

Radiator170-2, 170-11expansion tank 020-33, 170-2, 170-13grill 510-8outlet coolant temperature sensor 130-25, 131-22, 132-38, 133-25

see also Cooling system

Radiator grill510-8

Radio121-12, 650-1, 650-7controls 320-8satellite 650-3

Rain and light sensor (RLS)630-3

Raising vehicle020-14

ReadinessOBD-5

Rear main sealM54 119-12N52, N54 119-17V8 119-24

Rear suspension010-21, 300-3, 330-2aluminum components 300-2arms 330-2, 330-16ball joint 330-22control arm 300-3, 330-17ride height 320-32shock absorber 300-3, 330-3, 330-12spring 300-1, 330-3, 330-8, 330-13stabilizer bar 330-32

active 330-32, 330-34link 330-36

strut 330-3, 330-8subframe 300-3, 330-23

bushings 330-25suspension arms 330-2swing arm 300-3, 330-19thrust rod 300-1, 330-3, 330-24wheel bearing 330-26

carrier 330-7see also Active stabilizer (ARS)

Rear window defogger ECL-39

relay ECL-23switch 640-2

lock 515-22, 611-14washer jet 611-17wiper 611-13

Refrigerant640-1port 640-14

Reinforcementfront end 300-2, 310-4, 311-1

Remote key515-4

Residual heat (REST)640-2

Restraint system400-4, 720-1, 721-1

Reversing light switchsee Back-up light switch

Ride height320-32

RLS (rain and light sensor)630-3

Rotation rate (yaw) sensor340-25

Rotor, brake020-27, 340-14

Roundel510-8

Run-on flat tire300-14

S

SAC (self-adjusting clutch)210-10

SAE (Society of Automotive Engineers)

OBD-1

Safety001-1, 020-14, 400-3

Safety gateway module (SGM)see SGM (safety gateway module)

Satellite radio650-3

Scan tool 020-9, 020-12, 120-9, 130-5, 131-5, 132-6, 133-6, 600-13, OBD-3

Sealdifferential


manual transmission 230-5torque converter 240-46see also Crankshaft

10 INDEX

Seat400-6front 520-2front backrest rear panel 520-8heater control 640-7memory 300-10, 520-1passenger seat occupancy sensor (OC3) 520-5, 721-6

rear 520-8switches 520-2

Seat belt020-50front 720-4rear 720-6troubleshooting 720-2see also Airbag system

Seat occupancy sensor (OC3)520-5, 721-5

Secondary air injectionM54 130-10N62 133-15monitoring OBD-4

Secondary voltage 120-9

Securityalarm (DWA) 400-7, 515-23electronic immobilizer (EWS) 515-23

Self-adjusting clutch (SAC)210-10

Sequential manual gearbox (SMG)see SMG (sequential manual gearbox)

Service020-11resetting 020-6

Servotronic300-10, 320-2

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

Shift boot513-6

Shift linkage250-4, 250-7troubleshooting 250-2

Shift knob250-2

Shiftlock231-4, 240-7, 250-8

Shock absorberfront 310-2, 310-3, 310-5rear 300-3, 330-2, 330-12

Short circuits600-17

Side (thorax) airbag721-3, 721-15, 721-22

Siren515-24

Slave cylinderclutch 210-7

Sleep mode121-6

SMG (sequential manual gearbox)010-19, 200-3, 231-2applications 200-3, 232-1clutch fluid 200-6, 230-13control module 231-5fluid service 231-12gear ratios 231-1gear shift 250-7removing / installing 231-14

Solar sensor 640-4

Sound system650-4antenna 650-5, 650-6radio 650-1, 650-8speakers 650-4

Spark plugs020-44

Speakers650-3

Specifications, fluidA/C system 640-1ATF 020-47, 200-6, 240-14differential 200-8, 311-9, 331-2manual transmission 020-48, 200-6, 230-3

oil 020-39, 119-3SMG 200-6transfer case 200-7, 270-5

Speed sensor340-25, 340-30

Splash shield020-23

Spoiler, rear412-8

Springfront 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)720-1contact spring 612-5, 612-7

Stability control340-2, 340-24see also DSC (dynamic stability control)

Stabilizer baractive 300-4front 300-3, 310-2, 310-3, 310-29

link 34rear 300-1, 300-3, 330-32

link 330-36see also Active stabilizer

START STOP switch612-8

Starter121-13troubleshooting 121-2, 121-13see also CAS (car access system) module

Static damage600-3

Steering 010-22, 020-43, 300-1, 300-10, 320-1active 300-11, 320-3angle sensor 121-12, 300-7, 320-8, 340-25, 340-32, 612-5, 612-6, 612-7

bleeding 320-12column 300-10, 320-10

memory 300-10removing / installing 320-11switch cluster (SZL) 612-5trim 513-112

fluid 020-42, 320-4, 320-14cooling loop 170-20

lock 320-10pump 320-14rack 300-10, 310-2, 320-2, 320-23

boot 320-31spindle 320-13tie rod 320-2, 320-30troubleshooting 320-6wheel 320-8, 721-120

switches 320-8, 612-2

Steering column switch cluster (SZL)612-5

Steering column300-10, 320-2

Steering knuckle300-2, 310-2, 310-3, 310-20

Stepper motors640-5, 640-9

Steptronic 240-3gearshift 250-7

Stop light switch612-9

Strutbrace 310-4front 300-1, 300-3, 310-5tension 300-2traction 300-1

Subframefront 300-2, 310-2, 310-3rear 300-3, 330-2, 330-23see also Front suspensionsee also Rear suspension

Sunroof540-1adjusting 540-4emergency closing 540-2initializing 121-13, 540-3motor 540-7

Suppressor filter (wave trap)650-5

INDEX 11

WARNING


Suspension020-48, 300-1aluminum components 300-2front 300-1, 310-2, 310-3ride height 320-32rear 300-3, 330-3see also Front suspensionsee also Rear suspension

Swing arm300-3, 330-2, 330-19ball joint 330-22

Switchesback-up lights 230-4blower 640-2brake lights 612-9center console switch cluster (SZM) 640-2, 640-3

central locking 612-8child safety (rear window) 612-10clutch 121-14cruise control 612-5door switch module 612-10DSC (DTC) 340-24hazard warning 612-8headlight dimmer 612-5horn 320-8iDrive controller 612-10ignition switch (START STOP) 612-8light 612-8mirror 612-10oil pressure 119-7rear window defogger 640-2, 640-6refrigerant pressure sensor 640-4, 640-14

seat control 520-2START STOP 612-8steering column switch cluster (SZL) 612-5

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

Swivel bearing310-2, 310-3

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

T

TAGE (electronic outer door handle module)

400-4, 515-10, 515-11

Tailgate412-5aligning 412-6automatic 412-9gas strut 412-6lock 515-20rear window lock 515-22, 611-14release button 612-10removing / installing 412-5service position 412-5trim 513-20

Taillights630-4, 630-21

Tandem pump300-6

TCM (automatic transmission control module)

240-3

Technical data010-3

Telematics 650-9

Telephonecontrol switches 320-8

Temperature sensorevaporator 640-4interior 640-2outside 640-4vent flap 640-4

Tension strut, front suspension300-1, 300-2, 310-2, 310-3, 310-14bushing 310-18

Thermostat170-2, 170-7, 170-14

Thorax (side) airbag 721-3, 721-15, 721-22

Throttle housingsee EDK (electronic throttle control)

Thrust rod 300-1, 330-3, 330-24

Thrust arm, front suspension300-2

Tie rod320-2, 320-29

Tightening torques020-10

Tilt sensor515-24

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

Tire300-13changing 020-17inflation 020-13, 020-48pressures 020-16

monitor (FTM, TPM) 020-16, 300-13rotating 020-48

Toefront 320-33rear 320-36

Toolsspecialty tool suppliers 020-12

Torque converter 240-8oil seal 240-46removing / installing 240-46

Torque plate240-48

Towing020-18

TPM (tire pressure monitor)300-15

Traction controlsee DSC dynamic stability control

Traction strut300-1, 330-2, 330-18

Transfer case200-2, 200-5, 270-1capacity 270-5control module 270-3lubricant 200-6, 270-5removing / installing 270-6service 270-5see also xDrive

Transmissionautomatic 200-4, 240-2fluids 200-5, 231-12identification 200-3, 200-3manual 200-2, 230-2pilot bearing 210-15service 020-48SMG 200-3, 231-1see also Automatic transmissionsee also Manual transmissionsee also SMG (sequential manual gearbox)

Transmission fluid cooler170-3, 170-19

Trim BMW emblem (Roundel) 510-8clips 513-2cowl cover 611-10dashboard 513-3door panel 411-6door sill 513-15exterior 510-8interior covers and trim 513-12radiator grill 510-8seat backrest rear panel 520-8steering column 513-12tailgate 513-20trunk

inside 513-159lid 513-18

wheel housing liner 410-1

12 INDEX

Troubleshootingactive stabilizer 300-8alternator 121-2, 121-19automatic transmission 240-9battery 121-2brakes 340-2charging system 121-2, 121-19combustion chamber leak test 170-6cooling system 170-5driveability 130-5, 131-5, 132-5, 133-5driveshaft 260-3electrical 121-2, 600-15engine management

ME 9.2, ME 9.2.2 133-5MS45.1 130-5MSD80, MSD80 132-5MSV70, MSV80 131-5

evaporative control 160-7fuel system 160-9ignition system 120-9lights 630-6oil condition monitor 119-9seat belts 720-2shift lever 250-2starter 121-2, 121-15steering 320-6thermostat 170-7

Trunklid

aligning 412-2emergency release handle 412-1lock 515-16release button 612-10removing / installing 412-2

trimfloor 513-19lid 513-18

Turbochargers100-14air ducts 132-12charge pressure sensor 132-17intercooler 100-14, 132-10, 170-21

Turn signal front 630-18rear 630-21side 630-19switch 612-5

U

Ultrasonic sensor (interior protection)515-25

USIS (interior protection)515-25

Underbodyinspection 020-51

Universal jointdriveshaft 260-1, 260-5steering shaft 320-2

V

Vacuum boosterbrakes 340-16

Vacuum pump100-13, 100-15, 100-16, 133-26, 300-11, 340-18

Valvetronic010-12, 010-17, 100-11, 100-18, 133-13

motorN52 131-14V8 133-21

VANOS (variable camshaft timing)100-5, 100-11, 100-17M54 117-6N52, N54 117-65V8 117-84see also Camshaft timing chain

Variable camshaft timing (VANOS)see VANOS (variable camshaft timing)

Variable intake manifold (DISA)100-11

Vehicle data storage620-2

Vehicle identification number (VIN)002-1, 020-12

Ventilation microfilter020-28

Vibration damper, crankshaft117-3

VIN (vehicle identification number)002-1, 020-12

Voltage and polarity600-1

Voltage tests600-15

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

W

Warning lights020-16, 620-1

Warnings 001-1

Warnings, cautions and notes020-2

Washers611-1headlight 510-5, 611-16jet 611-16, 611-17pumps 611-18reservoir 611-18switch 611-3

Washing020-51

Wastegate100-14

Water pumpsee Cooling system, coolant pump

Wave trap (suppressor filter)650-5

Waxing020-51

Wheel alignment020-49, 300-12, 320-32

Wheel bearingfront 310-22rear 330-30

carrier 330-3, 330-27

Wheel housing liner410-1

Wheel hub rear 330-29

Wheel speed sensor340-25, 340-30

Wheels300-13

Window anti-trap 512-5control 512-2features 512-1motor 512-5panic mode 512-6regulator 512-12

initializing 121-12, 512-13service 512-7switch 512-4, 612-10

Wipers611-1arm


assembly front 611-10rear 611-13

blade 020-51, 611-3, 611-18switch 611-3

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

X

X connectorsECL-18

xDrive010-20, 200-5, 270-1, 340-26see also Transfer case

Xenon630-5, 630-9, 630-13

Y

Yaw sensor340-25

established 1950Automotive Reference™

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USATel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235http://www.bentleypublishers.com/contact-sales

BMW 5 Series (E60, E61)Service Manual: 2004-2010 525i, 528i, 530i, 535i, 545i, 550i

Price: $149.95Bentley Stock Number: B510Publication Date: 2010.jun.18ISBN: 978-0-8376-1618-6Hardcover, 8 3/8 in. x 11 in.Case quantity: 51734 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)

528iN52K engine (2008-2010)

535iN54 twin turbo engine (2008-2010)

545iN62 V8 engine (2004-2005)

550iN62 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

Documents

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