2004-2010 BMW 5 Series E60/61 Service & Repair Manual

Important Safety Notice i i Foreword i v Index rea r of manual 0 General Data and Maintenance 001 Warning s and Cautions 00 3 002 Vehicl e Identification and VIN 01 0 Decoder 02 0 Symptoms and Field Observations Product Familiarization Maintenance 1 Engine 100 Engine-Genera l 13 0 110 Engin e Removal and Installation 13 1 113 Cylinde r Head Removal 13 2 and Installation 13 3 117 Camshaf t Timing Chain 16 0 119 Lubricatio n System 17 0 120 Ignitio n System 18 0 121 Battery , Starter, Alternator Fuel Injection (M54 Engine) Fuel Injection (N52 Engine) Fuel Injection (N54 Engine) Fuel Injection (V8 Engine) Fuel Tank and Fuel Pump Radiator and Cooling System Exhaust System 2 Transmission 200 Transmission-Genera l 24 0 210 Clutc h 25 0 230 Manua l Transmission 26 0 231 Sequentia l Manual Gearbox (SMG) 27 0 Automatic Transmission Gearshift Linkag e Driveshafts Transfer Case 3 Suspension, Steering and Brakes 300 Suspension , Steering and Brakes-General 310 Fron t Suspension 311 Fron t Axle Differential 320 Steerin g and Wheel Alignment 330 Rea r Suspension 331 Rea r Axle Differential 340 Brake s 4 Body 400 Body-Genera l 410 Fenders , Engine Hood 411 Door s 412 Trun k Lid, Tailgate 5 Body Equipment 510 Exterio r Trim, Bumpers 512 Doo r Windows 513 Interio r Trim 515 Centra l Locking and Anti-theft 520 Seat s 540 Sunroo f 6 Electrical System 600 Electrica l System-General 611 Wiper s and Washers 612 Switche s 620 Instrument s 630 Light s 640 Heatin g and Air-conditioning 650 Radi o 7 Equipment an d Accessories 720 Sea t Belts 721 Airba g System (SRS) ECL ELE OBD ECL Electrica l Component Locations ELE Electrica l Wiring Diagrams OBD On-Boar d Diagnostics

001-1 001 Warnings and Caution s PLEASE REA D THES E WARNING S AND CAUTION S BEFORE PROCEEDIN G WIT H MAINTENANC E AN D REPAI R WORK . WARNINGS— See also CAUTIONS • Rea d the important safet y notic e on the copyright page a t the beginning of the book . • Som e repairs may be beyond your capability. If you lack the skills, tools and equipment o r a suitable workplace for any procedure described in this manual, we suggest you leave such repair s to an authorized BM W dealer service department or other qualified shop. • I f any procedure, tightenin g torque , wear limit, specification or data presented in this manua l doe s not appear to be appropriate for a specific application, contac t the publisher or the vehicle manufacturer for clarification before using the informatio n in question. • D o not reuse an y fasteners that are worn or deformed. Man y fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes , but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips and cotte r pins . Replace these fasteners with new parts. • D o not work under a lifted car unless i t is solidly supporte d on stands designe d fo r the purpose. Do not support a car on cinder blocks, hollow tile s or other prop s that may crumble unde r continuous load . Do not work unde r a car that is supported solely by a jack. Do not work unde r the car while the engine is running. • I f you are going to work under a car on the ground, mak e sure that the ground is level. Block the wheels to keep the car from rolling. Disconnec t th e battery negative (-) termina l to prevent others from starting the car while you are unde r it. • D o not run the engin e unles s th e work area is well ventilated. Carbon monoxide kills. • Remov e rings , bracelet s and other jewelry so that they canno t cause electrical shorts, get caught in running machinery, or be crushed by heavy parts . • Tie long hai r behin d you r head . Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tool s or runnin g engines. If your hair, clothing, or jewelry were to ge t caught i n the machinery , sever e injury could result . Do not attempt to work on your car i f you d o no t feel well. You increase the dange r of injury to yourself and other s i f you ar e tired, upset or have taken medication or any other substance tha t may keep you from being fully alert. Illuminate your work area adequately but safely. Use a portabl e safety light for working inside or under the car. Make sure the bul b is enclosed b y a wire cage. The ho t filament of an accidentall y broken bul b ca n ignite spilled fuel, vapors or oil. Catch draining fuel , oil, or brake fluid in suitable containers . Do not use food or beverage containers that might mislead someon e into drinking from them. Store flammable fluids away from fire hazards. Wip e up spills at once, but do not store the oil y rags , which can ignit e and burn spontaneously. Observe good workshop practices. Wear goggles whe n you operate machine tool s or work with battery acid. Wea r glove s or other protective clothing whenever the job requires working with harmful substances . Greases, lubricants and other automotive chemicals contain toxic substances, many of which are absorbed directly throug h the skin. Rea d the manufacturer's instructions and warning s carefully. Use hand and eye protection. Avoid direct skin contact. Disconnect the battery negativ e (-) termina l whenever yo u work on the fuel system or the electrical system. D o not smoke or work near heaters or other fire hazards . Kee p an approved fir e extinguisher handy . Friction materials (such as brake pads and shoes or clutch discs) contain asbestos fibers or other friction materials . D o not create dust by grinding, sanding , or by cleaning wit h compressed air. Avoid breathing dust . Breathing any friction material dus t ca n lead to serious diseases and may result in death. Batteries give off explosive hydrogen gas during charging. Keep sparks, lighted matche s an d open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it may ignite gas trapped in the cells and cause the battery to explode. The air-conditioning system is filled with chemical refrigerant , which is hazardous. Mak e sure the system is serviced only by a trained technician using approved refrigerant recovery/recyclin g equipment, trained in related safety precautions, and familiar with regulations governing the discharge and disposal of automotive chemical refrigerants. Continued on next page • Thoroughl y read each procedur e and the WARNINGS and CXcXCxzcxz

001-2 Warning s and Cautions WARNINGS (continued ) • D o not expose any par t o f the A/C system to high temperature s such as open flame. Excessiv e heat increase s syste m pressure and may cause th e system to burst. • Som e aerosol tire inflators are highly flammable. Be extremely cautious when repairin g a tire that may have been inflate d usin g an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repai r area. Inflat e and deflate the tire at least four times befor e breaking th e bead from the rim . Completely remov e the tire from the ri m before attempting an y repair. • Car s covered by this manua l ar e equipped wit h a supplementa l restraint system (SRS ) that automaticall y deploy s airbag s an d pyrotechnic seat bel t tensioner s in case o f a frontal or side impact. These ar e explosive devices. Handle d improperly or without adequate safeguards , the y can be accidently activate d and cause seriou s injury . • Th e ignition system produce s hig h voltage s tha t can be fatal. Avoid contact with exposed terminals an d us e extreme car e when working on a car with the engine runnin g o r the ignitio n switched ON. • Plac e jack stands only at locations specified by the manufacturer. The vehicle lifting jack supplied with the vehicle is intended for tire changes only . Use a heavy duty floor jack to lif t vehicle before installing jack stands . See 020 Maintenance. • Batter y acid (electrolyte) can cause sever e burns. Flus h contact area with water, then seek medica l attention . • Aeroso l cleaners and solvents may contain hazardou s or deadly vapors and are highly flammable . Us e only i n a well ventilated area. Do not use on hot surfaces (engines , brakes , etc.). • Du e to risk of personal injury , be sure the engine is cold before beginning work on the cooling system . CAUTIONS— See also WARNINGS • I f you lack the skills, tools and equipment, o r a suitable workshop for any procedure described in this manual, leave such repairs to an authorized BMW dealer or other qualified shop. • BM W is constantly improving it s cars and sometimes these changes, bot h in parts and specifications, are made applicable to earlier models . Any part numbers liste d in this manua l ar e for reference only. Check with your authorized BMW dealer parts department for the latest information. • Befor e starting a job, mak e certai n tha t you hav e the necessary tools and parts on hand. Read all the instructions thoroughly, and do not attempt shortcuts. Use tools appropriate t o the work and use only replacement parts meeting BMW specifications. • Us e pneumatic an d electric tools onl y to loosen threade d parts and fasteners. Do not use these tool s to tighten fasteners, especially on light alloy parts . Us e a torque wrench to tighten fasteners to the tightening torqu e specification listed. Be mindful of the environment an d ecology. Before you drain the crankcase, fin d out the prope r wa y to dispose of the oil. D o not pour oil onto the ground , dow n a drain, or into a stream, pon d or lake. Dispos e of waste in accordance wit h federal, state an d local laws . The control module for the anti-lock brak e system (ABS) canno t withstand temperatures from a paint-drying booth or a heat lam p in excess of 203° F (95° C). D o not subject to temperatures in excess of 185°F (85° C) for more than two hours . Before doing an y electrical welding on cars equipped with ABS, disconnect the battery negativ e (- ) termina l (groun d strap) and the ABS control modul e connector . Make sur e ignition is switched OFF befor e disconnecting battery. Label batter y cables befor e disconnecting. On some models , battery cables are not color coded . Disconnecting th e battery may erase fault code(s) stored in control module memory. Usin g special BMW diagnostic equipment, check for fault codes prior to disconnecting th e batter y cables. If the malfunction indicator light (MIL) is illuminated, see OBD On-Boar d Diagnostics at the bac k of this manual. (This light may be identified as the Check Engin e ligh t or the Service Engin e Soon light.) I f any othe r syste m fault s ar e detecte d (indicated by a n illuminated warning light), see an authorized BM W dealer . If a normal or rapid charger is used to charge battery, disconnec t the battery remov e it from the vehicle in order to avoid damagin g the vehicle. Do not quick-charge the batter y (fo r boost starting) for longe r than one minute . Wai t at least on e minut e befor e boosting the battery a second time . Connect an d disconnect a battery charger only with the battery charger switched OFF. Sealed or "maintenance free " batteries shoul d be slow-charged only, at an amperage rat e that is approximately 10 % of the battery's ampere-hour (Ah ) rating . Do not allow battery charging voltag e to exceed 16.5 volts. If the battery begins producin g ga s o r boiling violently, reduce the charging rate . Boosting a sulfated battery a t a high charging rat e can cause an explosion. Do not use steel fasteners on engine components mad e of aluminum-magnesium alloy . Use aluminum fasteners only. Test fasteners for aluminum compositio n wit h magnet. Replace aluminu m bolt s each time they are loosened. Follo w torque instructions, including angl e of rotation specifications, when installin g aluminum fasteners .

002-1 002 Vehicl e Identification and VIN Decode r Some o f the informatio n in this manual applie s onl y to cars of a particular model year or range of years. For example, 2004 refers to the 2004 model year but does not necessarily matc h the calendar yea r in which the car was manufactured or sold. To be sure of the model year of a particular car, check the vehicle identification number (VIN) on the car. The VI N i s a unique sequence of 17 characters assigned by BMW to identify each individual car. When decoded, the VIN tells the country and year of manufacture; make, mode l and serial number; assembl y plant an d even some equipment specifications. The BM W VI N i s on a plate mounted on the top of the dashboard, on the driver's side where the number can be seen through the windshield. The 10t h character is the model year code. Example: 4 for 2004. For 2010, A is used. The tabl e below explains some of the codes in the VIN for 2004 through 2010 BMW E6 0 and E6 1 5 Series cars covered by this manual. Sample VIN: [WBA||NA53||5|0|4|B| VIN position 1 -3 4-7 8 9 10 11 12-17 Description Country of manufacture Vehcle code Restraint system Check digit Model year Assembly plant Serial number Decoding WBA WBS NA53 NE53 NU53 NA73 NE73 NW13 NB33 NB53 NW53 NF33 NV13 NF73 NV93 NN73 PT73 NB93 5 information BMW, AC. Munich, Germany BMW Motorsports GmbH, Munich. Germany 525i 2004 - 2005 (2003/09/0 1 to 2005/02/28) 525i 2006 - 2007 (2005/03/01 to 2007/02/28 ) 528i 2008 - 201 0 (2007/03/01 to 2009/1 2/31 ) 530i 200 4 - 2005 (2003/01/0 1 to 2005/08/27 ) 530i 2006 - 2007 (2005/03/01 to 2007/02/28 ) 535i 2008 - 2010 (2007/03/01 to 2009/12/31) 545i 2004 - 2005 (2003/09/01 to 2005/08/31) 550i 2006 - 2007 (2005/09/0 1 to 2007/02/28) 550i 2008 - 2010 (2007/03/01 to 2009/12/31) 525xi 2006 - 2007 (2005/04/0 1 to 2007/02/28 ) 528xi 2008 - 2010 (2007/03/01 to 2009/12/31) 530xi 2006 - 2007 (2005/04/01 to 2007/02/28) 535xi 2008 - 2010 (2007/03/01 to 2009/12/31) 530xi Spor t Wagon 200 6 - 2007 (2005/04/01 to 2007/02/28) 535xi Sport Wagon 2008 - 201 0 M5 Multiple restraint system 0 - 9 or X, calculated by NHTS A 4 5 6 7 8 9 A B, C 2004 2005 2006 2007 2008 2009 2010 Munich, Germany Sequential production number for specific vehicle

003-1 003 Symptom s and Field Observations GENERAL 003- 1 0 GENERA L DAT A AN D MAINTENANCE 003- 2 1 ENGIN E 003- 5 2 TRANSMISSIO N 003-1 2 3 SUSPENSION , STEERIN G AN D BRAKES. . 003-1 4 4 BOD Y 5 BOD Y EQUIPMEN T 6 ELECTRICA L SYSTE M 7 EQUIPMEN T AND ACCESSORIES . 003-17 003-18 003-19 003-24 GENERAL This repair group includes a list of symptoms, field observations, and suggested fixes for common problem s and issues found on BMW 5 Series (E60, E61) vehicles. The information is organized by sections that correspond t o th e layout of the repair manual. Additional information (when available) can be found in the repair group associated with the specifi c issue : • 0 Genera l Dat a and Maintenance • 1 Engin e • 2 Transmission • 3 Suspension , Steering and Brakes • 4 Bod y • 5 Bod y Equipmen t • 6 Electrica l System • 7 Equipmen t and Accessories This information was developed from varied sources, rangin g from professional BMW technician feedback to manufacturer-issue d technical service bulletins (TSBs). The content is intended to complement the repair information found in this repai r manual . CAUTION— • The information contained in this section is inherently dated material. It was applicable and relevant at the time this manual went to press. A/ways check BMW factory repair information at www.bmwtechinfo.com or the publisher's website at www. com for information that may supersede any information included in this section.

003-2 Symptom s and Fiel d Observations 0 GENERA L DAT A AND MAINTENANCE Topic Notes Exiting a vehicle tha t is double- locked from the outsid e Never lock a vehicle from outside the car with an someone insid e the car! In the unlikely that someon e get s double-locke d insid e th e car , the person insid e the car can exit the vehicle using the following 2-step procedure: • Pres s the central unloc k butto n to disable "double-lock" . • Pul l the door handl e twic e to open door . NOTE— • For vehicles with the factory alarm, opening the door will activate the alarm. Additional information (when available) Engine oil , toppin g up Replacing spark plugs, servic e ti p Oil residu e ma y collect on the cylinder hea d cove r near th e oi l filler cap a few days afte r topping u p or refilling the engine oil . When oi l i s added, th e filler cap is laid partially upsid e down . In this position, engine oil seeps into the area of the oil cap that is not seale d by the gasket. When the cap is reinstalled, the oil leaks fro m the unsealed are a onto the cylinder head cove r surface. If investigating an oil leak in this area, confirm that it is not oil from the cap. 020 When servicing spark plugs, a standard socket may fit too tightly into the spar k plu g bor e i n the cylinder head . If this i s the case , remov e the hea t shield insid e plu g hole (arrow) before servicing spark plugs . 020 Special tool for spark plu g removal ) Th e N5 4 engine use s a new design spar k plu g from Bosch tha t consists of a 12m m thread (compared to the 14m m design on the N52) an d a 12-point hex. The plug require s a special too l (BM W special tool part no . 83 30 0 495 560). The specia l socke t i s a thin- wall design to facilitate acces s i n the confined are a o f the N5 4 cylinder head . 020

Symptoms and Field Observations 003- 3 0 GENERA L DAT A AN D MAINTENANCE (CONTINUED ) CD § CM 2 o •a o Topic Engine oil level, checking after oil change - dynamic chec k (engine running) V8 engine A/C belt removin g and installing. A/C belt installatio n tool Notes Always perform the dynamic oil level measurement (approx . 5 minutes driving time) after an oil change. The oil level could be misinterpreted as the oil level last stored is initially displayed after an oil change. NOTE— • There is no oil level initially stored after replacing or reprogramming the engine control unit ("Oil level below min" is displayed). The correct oil level is indicated after running the engine for approx. 5 minutes. - Star t engine. - Select on-board computer function - OIL usin g rocker switch. Press BC switch in once. Oil level check begins . A clock symbol (arrow) may appear while the leve l measurement is running. NOTE— • The clock symbol appears for up to 50 seconds after starting the engine when there is no measured value or the last stored value is not within the tolerance range of the currently measured oil level. Additional information (when available) On the V8 engines, there is no tensioner on the A/C belt. To install a new belt, a special tool (BMW part # 90 88 6 641 040) is required to guide the belt onto the pulley. When installing a new battery, it must be "registered" to the vehicle to notify the vehicle power management software (engine electronics and intelligent battery sensor) that a new battery was fitted. This operatio n require s a BMW scan tool. Without new battery registration, various electrical problems as well odd electrical system behavior can occur. 020 020 121

003-4 Symptom s and Field Observations 0 GENERA L DAT A AND MAINTENANCE (CONTINUED ) Topic No communication wit h BMW sca n tool on DCAN . __ plug Notes Additional information (when available) Intelligent battery sensor (IBS) , service precaution s When performing diagnosis o n a vehicle with the BMW scan tool, the message "Connec t diagnostic connecto r and switch ON ignitio n (Terminal 15)! " is displayed . • D-CA N failure in vehicle. Before diagnosing D-CA N in the vehicle, try communicating wit h another vehicle . If communication cannot be established on othe r vehicle, try a different scan tool. If communication resume s o n the other vehicle, us e the following steps to diagnose DCAN . — Disconnec t vehicl e powe r supply / charger (if connected) . — Disconnec t battery. — Chec k resistanc e of D-CAN circuit across OBD socke t Pi n 6 (D_CAN_H) an d Pi n 1 4 (D_CAN__L). A good D-CA N measure s 60 ohms. The D-CAN circui t is fitted with two 12 0 ohm terminal resistors. One is fitted in wiring near OBD socket. The secon d is fitted in gateway module of vehicle (KG M or SGM) . — If resistance reading is 0 ohms, the D-CA N wires are shorte d together. Check circui t for shorts as per wiring diagram. — If resistance reading is Mega ohms , the D-CA N wiring ha s a n open circuit. Check circuit for opens as per wiring diagram . — If resistance reading is 12 0 ohms, on e o f terminal resistor s is faulty. Check resistanc e of both resistor s for an open circui t and replace as necessary . The Intelligen t Battery Senso r (IBS ) is an electronic devic e connected directly to the negative battery terminal.The IBS is very sensitive to mechanical stres s and strain. Particular attention shoul d be paid to the following points: • D o not make any additional connections at the negative terminal of the battery . • Do not modify the battery groun d cable. • D o not make any connections between the IBS and the senso r screw. • D o not use force when disconnectin g the ground terminal from the battery. • Neve r pul l on the ground cable. • D o not use the IB S as a pivot poin t to lever off the ground terminal . • D o not use the connections o f the IB S as a lever. • Us e only a torque wrench as described in the repair manua l during installation. • Do not release or tighten the sensor screw . NOTE— •A replacemen t IBS includes the ground cable. The groun d cable als o serves as a heat dissipate r for the IBS . 020, 600 121

Symptoms and Field Observations 003- 5 1 ENGIN E Topic Engine knoc k fault code s Diagnosing electri c cooling fan E-box water ingres s No crank, no start Notes Engine knoc k fault codes indicat e tha t the engin e is knocking . Detonation or knock i s an erratic form of combustion that can cause head gasket failure as well as other engine damage. Prolonge d or heavy detonation can be very damaging. Th e hammer-lik e shock waves created by detonation subject the hea d gasket, piston, rings, spark plug and rod bearings to severe overloading. As a first remedy, try highe r octan e hig h detergent fuel or switch brands . I f the faults codes continue to return, contact your authorized BMW dealer. Additional information (when available) From 03 / 2007 production vehicles : A revised power supply rela y for the electric coolant fan power supply was use d on these vehicle s Coolant fa n powe r supply rela y K9137 is located i n the bac k of the rear fuse box. Connector (B ) provides control signals for rela y activation (KLSO g from the rea r fuse box/power distribution box and local ground KL31). On cars with inoperative electri c coolant (wit h symptoms of A/C malfunction, engine overheating, or fault code 2EFE "Cooling fan activation" stored in the DME), check the power supply relay operation: Check that both B+ connections (A) are threaded on tight and free of corrosion. Check KLSO g (B+) an d KL31 (ground ) signals (B) for correc t operation. Water leak s into the E-box may cause variou s drivability complaints, loss of power or the "Service Engine Soon " lam p to illuminate while driving. Water can enter through the grommet for the ground connection X6 on the front of the E-box. If water is present, check that all drains and water channels are clear. Engine doe s not crank. Only the SRS (Supplemental Restraint System) an d re d brake lights show i n the instrumen t cluster with ignition on. FC A111 (ELV voltage supply fault) is stored in CAS (Ca r Access System). NOTE— •Asa result of a change in government requirements, the ELV was deleted on most 2007 and later models. Anti-theft protection continues to be provided by drive-away protection in EWS. Disconnect th e IB S connector (3-pi n connecto r with 2 wires) at the negative battery terminal. Follo w the white/blue and gray wires from the IB S to locate the connector . Now try startin g the vehicle. I f the vehicle starts, replace faulty IBS . 120 170, EL E 121

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2004-2010 BMW 5 Series E60/61 Service & Repair Manual

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