BMW 5 Series Complete Workshop Service Repair Manual 2007 2008 2009 2010
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: E60 (Sedan) / E61 (Touring) Product Name: BMW 5 Series Complete Workshop Service Repair Manual 2007 2008 2009 2010 Codes Chassis Code: E60 (Sedan), E61 (Touring) 👋 Introduction Market Position Segment: Executive Sedan/Wagon Reputation: Renowned for driving dynamics, luxury, and advanced technology. Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar XF. Key Features Design: Chris Bangle's flame surfacing design language (E60/E61 generation). Technology: Introduction of iDrive infotainment, advanced driver assistance systems, and innovative powertrains. Driving Dynamics: BMW's signature RWD bias and engaging handling. 📋 Manual Details Coverage Areas Engine Options: All petrol and diesel engines for the specified years. Transmission Options: Manual and Automatic transmissions. Drivetrain Options: Rear-Wheel Drive (RWD) and xDrive (All-Wheel Drive - AWD). Body Styles: Sedan (E60), Touring/Wagon (E61). Page Count Estimated Page Count: Extensive, typically 2,000+ pages for a complete workshop manual. Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF (Assumed based on description) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions control, engine management (DME). Transmission: Manual gearbox (Getrag, ZF), Automatic transmission (ZF 6HP series), clutch, driveline components (propeller shaft, driveshafts). Brakes: Hydraulic system, ABS, DSC (Dynamic Stability Control), brake pads, rotors, calipers, parking brake. Steering: Power steering system (Hydraulic), steering gear, steering column, tie rods. Suspension: Front suspension (Double-wishbone), Rear suspension (Integral-link), shock absorbers, springs, control arms, sway bars. Electrical: Battery, charging system, starter, lighting, wiring diagrams, fuses, relays, body electronics (CAS, FRM, LCM), comfort systems. Body: Body panels, doors, hood, trunk lid, bumpers, interior trim, glass, seals, sunroof (if applicable). HVAC: Heating, ventilation, and air conditioning system, compressor, condenser, evaporator, climate control unit. Infotainment And Navigation: iDrive system, radio, CD player, navigation system, displays, control modules (CCC, CIC). Procedures Included Maintenance: Oil changes, filter replacements (oil, air, cabin), spark plug replacement, brake fluid flush, coolant flush. Troubleshooting: Diagnostic fault codes (DTCs), symptom-based troubleshooting, electrical diagnostics. Repair: Engine component repair/replacement, transmission overhaul, brake system repair, suspension component replacement, electrical component diagnosis and repair. Disassembly And Reassembly: Detailed step-by-step instructions for major component removal and installation. Specifications: Torque specifications, clearances, fluid capacities, electrical specifications. Special Tools: Identification and usage of specialized BMW tools. Technical Depth Depth: Comprehensive; covers routine maintenance to complete engine and transmission rebuilds. Diagnostic Capabilities: Advanced diagnostics, including wiring diagrams and module coding principles (though actual coding procedures may require ISTA). 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Quality: High resolution, suitable for printing individual pages or sections. Binding Type Binding: Not applicable for downloadable format; if printed, typically spiral-bound or saddle-stitched for usability. Paper Type Paper Type: Not applicable for downloadable format; if printed, would be durable, potentially gloss or matte paper. ⚙️ Engine Specifications Primary Engine Common Petrol Engines: 2.5L I6 (N52B25), 3.0L I6 (N52B30), 4.0L V8 (N62B40), 4.8L V8 (N62B48), 4.4L V8 Twin-Turbo (S63B44 - M550i). Common Diesel Engines: 2.0L I4 Turbo Diesel (N47D20), 3.0L I6 Turbo Diesel (M57D30). Performance Hp Range: 170 hp (520i/520d) to 500 hp (E60 M5 S85 V10). Torque Range: 220 lb-ft (520i) to 383 lb-ft (E60 M5). Fuel System Fuel Delivery: Electronic Port Fuel Injection (MPI) or Direct Injection (DI) depending on engine. Fuel Type: Unleaded gasoline (RON 91+), Diesel fuel (ULSD). Engine Management ECU: Digital Motor Electronics (DME) by Bosch or Continental. Engine Construction Block Material: Aluminum alloy (N52, N54, N62, S85), Cast Iron (M57). Head Material: Aluminum alloy. 🔧 Transmission Standard Type: 6-speed Manual or 6-speed Automatic (ZF 6HP series). Optional Type: 7-speed SMG III (Sequential Manual Gearbox) for E60 M5. Features Automatic Features: Steptronic (manual shifting mode), Adaptive Transmission Control (ATC). AWD System: xDrive (Active all-wheel drive system with variable torque distribution). Fluid Specifications Automatic Transmission Fluid: BMW ATF ETL-800 or equivalent (e.g., Pentosin ATF1). Manual Transmission Fluid: SAE 75W-90 GL-4 or GL-5 synthetic gear oil (e.g., Castrol Syntrans). 📐 Dimensions Exterior Length: E60 Sedan: ~190.6 in; E61 Touring: ~191.1 in Width: E60/E61: ~72.4 in Height: E60 Sedan: ~57.7 in; E61 Touring: ~57.4 in Wheelbase: E60/E61: ~116.4 in Weights Curb Weight Range: 3,600 - 4,200 lbs (approx.) Gross Vehicle Weight Rating: Varies by model, consult specific vehicle VIN. Cargo Trunk Volume: E60 Sedan: ~14.0 cu ft; E61 Touring: ~20.6 cu ft (expandable) 🛡️ Safety Features Ratings NHTSA Ratings: Generally good, with 5-star ratings in frontal and side impact tests for most configurations (check specific year/model). IIHS Ratings: Typically Top Safety Pick awards for the period. Active Features Electronic Stability Control: Dynamic Stability Control (DSC) with traction control. Anti Lock Brakes: Anti-lock Braking System (ABS). Brake Assist: Brake Assist System (BAS). Passive Features Airbags: Frontal airbags, side airbags, curtain airbags (head protection). Seatbelts: 3-point inertia-reel seat belts with pretensioners and load limiters. Child...
E60 Sedan: ~14.0 cu ft; E61 Touring: ~20.6 cu ft (expandable)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Generally good, with 5-star ratings in frontal and side impact tests for most configurations (check specific year/model).
IIHS Ratings:
Typically Top Safety Pick awards for the period.
Active Features
Electronic Stability Control:
Dynamic Stability Control (DSC) with traction control.
Anti Lock Brakes:
Anti-lock Braking System (ABS).
Brake Assist:
Brake Assist System (BAS).
Passive Features
Airbags:
Frontal airbags, side airbags, curtain airbags (head protection).
Seatbelts:
3-point inertia-reel seat belts with pretensioners and load limiters.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
System Name:
iDrive (CCC - Car Communication Computer or CIC - Car Information Computer on later models)
Features:
Navigation, Radio (AM/FM/Satellite), CD/DVD player, Bluetooth connectivity, USB/Aux input.
Driver Assistance
Available Systems:
Adaptive Cruise Control (ACC), Head-Up Display (HUD), Lane Departure Warning (LDW), Active Steering, Parking Assistant.
Connectivity
Telematics:
BMW ConnectedDrive (may require subscription or specific hardware).
Lighting
Headlights:
Xenon Adaptive Headlights with LED angel eyes (standard on many models).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000-15,000 miles or 12-24 months, as indicated by Condition Based Service (CBS) system.
Brake Fluid Interval:
Every 2 years, regardless of mileage.
Coolant Interval:
BMW long-life coolant, typically changed at major service intervals or as indicated by CBS.
Spark Plug Interval:
Approximately 60,000 - 100,000 miles, depending on engine variant and plug type.
Fluid Specifications
Engine Oil Spec:
BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) synthetic oil, viscosity typically 0W-30 or 5W-30 depending on climate and engine.
Coolant Spec:
BMW Blue (Ethylene Glycol based) or BMW Pink/Purple (Glycerol based) long-life coolant.
Power Steering Fluid:
Pentosin CHF 11 S or CHF 202 (Green hydraulic fluid).
Known Issues
Common Problems E60 E61:
Oil cooler gasket leaks, VANOS solenoid issues, CCV system failures (crankcase ventilation), water pump failure (especially electric pumps on later models), alternator pulley bearing failure, valve stem seal wear, rear shock mount failure, ABS/DSC sensor issues, iDrive system glitches.
Maintenance Considerations:
Regularly check for oil leaks, listen for unusual engine noises, ensure proper cooling system function, and monitor battery health.
📚 Vehicle History
Brand Heritage
Legacy:
BMW (Bayerische Motoren Werke AG) has a long history of producing performance-oriented luxury vehicles.
Model Evolution
Generation:
E60 (Sedan) and E61 (Touring) generation, replacing the E39.
Production Years Covered:
2007, 2008, 2009, 2010 model years.
Facelift:
Mid-cycle facelift introduced for the 2008 model year (LCI - Life Cycle Impulse) with styling and technology updates.
Production
Manufacturing Location:
Primarily Dingolfing, Germany, with some assembly possibly in other BMW global plants.
🏆 Awards & Recognition
Recognitions
Past Awards:
Consistently received accolades for its handling, ride comfort, and technology from automotive publications like Car and Driver, MotorTrend, and Edmunds during its production run.
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