BMW 5 Series E60 E61 2003-2010 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E60 (Sedan), E61 (Touring/Wagon) Production Years: 2003-2010 Generation Generation Name: Fifth Generation (E60/E61) Codes Internal Platform Code: RWD/AWD platform 👋 Introduction Market Position Positioning: Premium Executive Sedan and Wagon segment, known for performance, luxury, and advanced technology. Competitive Analysis Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type Key Features Vehicle Highlights: Advanced chassis dynamics (Dynamic Drive, Adaptive Drive), iDrive infotainment system, powerful inline-6 and V8 engines, sophisticated electronics. Manual Value Proposition Value For Owner: Empowers owners with factory-level repair and maintenance knowledge, saving on dealership labor costs and ensuring proper vehicle care. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive Service, Repair, and Workshop Procedures Page Count Estimated Page Count: Hundreds (Specific count not provided, but described as extensive) Manual Type Type: Factory Service and Repair Workshop Manual Language Language: English (Implied by description and typical factory manuals) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (mechanical and electrical), Fuel System, Exhaust System, Cooling System, Lubrication System Drivetrain: Transmission (manual and automatic), Drive Shafts, Axles, Differentials, Transfer Case (if applicable) Chassis: Suspension (front and rear), Steering System, Braking System (hydraulic and ABS), Wheels and Tires Electrical: Complete Electrical System, Lighting, Instrumentation, Powertrain Control Modules (DME/ECU), Body Control Modules (BCM), Infotainment Systems, HVAC Electronics, Safety Systems Electronics (Airbags, ABS, DSC) Body And Interior: Body Panels, Doors, Windows, Seats, Trim, HVAC (mechanical components), Safety Restraint Systems (Airbags) Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Brake Pad/Rotor Replacement Diagnostics: Troubleshooting guides, Diagnostic Trouble Codes (DTCs) interpretation, Component testing procedures Repair: Component removal and installation, Sub-assembly rebuilds, Engine mechanical repairs, Transmission overhauls, Suspension component replacement, Electrical component repair/replacement Bodywork: Panel alignment, Dent repair, Rust prevention/repair procedures, Sealing and weatherstripping replacement Technical Depth Depth: Full Professional Level, covering routine maintenance to complete engine and transmission rebuilds, complex diagnostics, and electrical system troubleshooting. Diagrams: Hundreds of detailed photos and exploded diagrams for precise component identification and assembly guidance. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) Licensing Usage Rights: Lifetime Use, Unlimited Computers, No Expiry Dates Compatibility Operating Systems: Windows and macOS Compatible ⚙️ Engine Specifications Primary Engine Engine Options: Includes details for various gasoline engines such as the N52 (3.0L I6), N54 (3.0L Twin-Turbo I6), N62 (4.0L/4.4L V8), and diesel engines like M57 (3.0L I6 Diesel) Performance Horsepower Torque: Detailed specifications for horsepower and torque output for each engine variant covered. Fuel System Fuel Delivery: MPI (Multi-Point Injection) and Direct Injection (for later models/specific engines), fuel pump specifications, pressure regulator details. Engine Management ECU Details: Information on Engine Control Units (ECU/DME), sensor functions, and diagnostic procedures. Cooling System Coolant Spec: BMW Blue Coolant (G48 Ethylene Glycol based) or equivalent. Capacity typically 7.5-8.5 liters depending on engine. 🔧 Transmission Standard Manual Transmission: Details on available Getrag 6-speed manual transmissions. Optional Automatic Transmission: Details on available ZF 6-speed automatic transmissions (e.g., 6HP19, 6HP26) and potentially GM transmissions for some models. Features Transmission Control: Information on Steptronic (manual shifting mode) and electronic transmission control modules. Fluid Specifications Atf Type: Specific ATF fluids required for ZF transmissions (e.g., ZF Lifeguardfluid8 or equivalent) and manual transmission fluid specifications. 📐 Dimensions Exterior Length: E60 Sedan: Approx. 4841 mm (190.6 in); E61 Touring: Approx. 4854 mm (191.1 in) Width: Approx. 1846 mm (72.7 in) Height: E60 Sedan: Approx. 1468 mm (57.8 in); E61 Touring: Approx. 1491 mm (58.7 in) Weights Curb Weight: Varies by engine and equipment, typically from approx. 1550 kg (3417 lbs) to over 1850 kg (4079 lbs) Cargo Trunk Volume: E60 Sedan: Approx. 520 liters (18.4 cu ft); E61 Touring: Approx. 500-1700 liters (17.7-59.9 cu ft) with seats folded. 🛡️ Safety Features Ratings NHTSA Ratings: Generally received high safety ratings, including 5-star frontal and side crash test ratings from NHTSA for applicable models. Active Features Stability Control: Dynamic Stability Control (DSC) including Traction Control (TC), Cornering Brake Control (CBC), Dynamic Brake Control (DBC). Braking Assist: Anti-lock Braking System (ABS), Brake Fade Compensation, Brake Drying feature. Passive Features Airbags: Frontal airbags, side airbags, head protection system (air curtains) for front and rear occupants. Seatbelts: Pretensioners and force limiters for front seats, three-point seat belts for all seating positions. 💡 Technology Features Infotainment Idrive System: Features the first generation of BMW's iDrive infotainment controller, managing navigation, audio, climate control, and vehicle settings. Driver Assistance Adaptive Cruise Control: Optional Active Cruise Control (ACC) with Stop & Go functionality available on some models. Parking Assist: Optional Park Distance Control (PDC) and rearview camera. Connectivity Bluetooth: Optional Bluetooth connectivity for hands-free calling and audio streaming. Lighting Headlights: Standard halogen or optional Xenon Adaptive Headlights with automatic leveling...
Full Professional Level, covering routine maintenance to complete engine and transmission rebuilds, complex diagnostics, and electrical system troubleshooting.
Diagrams:
Hundreds of detailed photos and exploded diagrams for precise component identification and assembly guidance.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Printable (single pages or entire manual)
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
Licensing
Usage Rights:
Lifetime Use, Unlimited Computers, No Expiry Dates
Compatibility
Operating Systems:
Windows and macOS Compatible
⚙️ Engine Specifications
Primary Engine
Engine Options:
Includes details for various gasoline engines such as the N52 (3.0L I6), N54 (3.0L Twin-Turbo I6), N62 (4.0L/4.4L V8), and diesel engines like M57 (3.0L I6 Diesel)
Performance
Horsepower Torque:
Detailed specifications for horsepower and torque output for each engine variant covered.
Fuel System
Fuel Delivery:
MPI (Multi-Point Injection) and Direct Injection (for later models/specific engines), fuel pump specifications, pressure regulator details.
Engine Management
ECU Details:
Information on Engine Control Units (ECU/DME), sensor functions, and diagnostic procedures.
Cooling System
Coolant Spec:
BMW Blue Coolant (G48 Ethylene Glycol based) or equivalent. Capacity typically 7.5-8.5 liters depending on engine.
🔧 Transmission
Standard
Manual Transmission:
Details on available Getrag 6-speed manual transmissions.
Optional
Automatic Transmission:
Details on available ZF 6-speed automatic transmissions (e.g., 6HP19, 6HP26) and potentially GM transmissions for some models.
Features
Transmission Control:
Information on Steptronic (manual shifting mode) and electronic transmission control modules.
Fluid Specifications
Atf Type:
Specific ATF fluids required for ZF transmissions (e.g., ZF Lifeguardfluid8 or equivalent) and manual transmission fluid specifications.
📐 Dimensions
Exterior
Length:
E60 Sedan: Approx. 4841 mm (190.6 in); E61 Touring: Approx. 4854 mm (191.1 in)
Width:
Approx. 1846 mm (72.7 in)
Height:
E60 Sedan: Approx. 1468 mm (57.8 in); E61 Touring: Approx. 1491 mm (58.7 in)
Weights
Curb Weight:
Varies by engine and equipment, typically from approx. 1550 kg (3417 lbs) to over 1850 kg (4079 lbs)
Cargo
Trunk Volume:
E60 Sedan: Approx. 520 liters (18.4 cu ft); E61 Touring: Approx. 500-1700 liters (17.7-59.9 cu ft) with seats folded.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Generally received high safety ratings, including 5-star frontal and side crash test ratings from NHTSA for applicable models.
Active Features
Stability Control:
Dynamic Stability Control (DSC) including Traction Control (TC), Cornering Brake Control (CBC), Dynamic Brake Control (DBC).
Braking Assist:
Anti-lock Braking System (ABS), Brake Fade Compensation, Brake Drying feature.
Passive Features
Airbags:
Frontal airbags, side airbags, head protection system (air curtains) for front and rear occupants.
Seatbelts:
Pretensioners and force limiters for front seats, three-point seat belts for all seating positions.
💡 Technology Features
Infotainment
Idrive System:
Features the first generation of BMW's iDrive infotainment controller, managing navigation, audio, climate control, and vehicle settings.
Driver Assistance
Adaptive Cruise Control:
Optional Active Cruise Control (ACC) with Stop & Go functionality available on some models.
Parking Assist:
Optional Park Distance Control (PDC) and rearview camera.
Connectivity
Bluetooth:
Optional Bluetooth connectivity for hands-free calling and audio streaming.
Lighting
Headlights:
Standard halogen or optional Xenon Adaptive Headlights with automatic leveling and cornering function.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically Long-Life Service Interval: Up to 15,000 miles or 24 months, depending on driving conditions and oil quality. Oil Service indicator on dash prompts for service.
Brake Fluid Interval:
Typically every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Spec:
BMW Longlife-01 (LL-01) or BMW Longlife-04 (LL-04) for diesel engines. Viscosity grades like 0W-30, 5W-30, 5W-40 depending on engine and climate.
Brake Fluid Spec:
DOT 4.
Known Issues
Common Problems:
Valve cover gasket leaks (N52/N54), Oil pan gasket leaks, Water pump failure (electric on later models), Ignition coil and spark plug issues (especially N54), VANOS solenoid issues, Fuel injector issues (N54 direct injection), Rear main seal leaks, ABS/DSC module failures, HVAC blower motor resistor failure, Control arm bushings, Differential seal leaks.
Filter Part Numbers
Oil Filter:
Examples: Mann-Filter HU 816 Z, Mahle OX 157/1 De (specific to engine variant)
Air Filter:
Examples: Mann-Filter C 35154, Mahle LX 1306/1 (specific to engine variant)
📚 Vehicle History
Brand Heritage
Heritage Context:
BMW has a long-standing reputation for engineering excellence, performance, and luxury in the executive segment.
Model Evolution
E60 E61 Development:
Introduced as a significant redesign from the E39 generation, featuring advanced electronics, new engine options (including twin-turbo and V8s), and a focus on handling dynamics. Design influenced by Chris Bangle.
Production
Manufacturing Locations:
Primarily manufactured in Dingolfing, Germany. Some assembly may have occurred in other BMW facilities globally.
🏆 Awards & Recognition
Recognitions
Automotive Awards:
While specific awards vary by year and region, the 5 Series is consistently recognized for its driving dynamics, build quality, and luxury features by automotive journalists and publications globally.
Ratings
Consumer Reports Ratings:
Ratings vary, with some model years noted for strong performance and handling but potential for higher than average maintenance costs, particularly with advanced electronics and turbocharged engines.
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