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BMW 7-series E65 E66 E67 E68 2004 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 7 Series Model Years Covered: 2004 Generation Generation Code: E65 (short wheelbase), E66 (long wheelbase), E67 (Protection model), E68 (Hydrogen Fuel Cell) Codes Chassis Codes: E65, E66, E67, E68 👋 Introduction Market Position Segment: Full-size Luxury Sedan Key Competitors 2004: Mercedes-Benz S-Class, Audi A8, Lexus LS, Jaguar XJ, Cadillac DTS. Competitive Analysis Differentiation: Known for advanced technology (iDrive, adaptive headlights), superior driving dynamics for its class, and luxurious interior appointments. Key Features Innovations: iDrive infotainment system, adaptive headlights (AFS), advanced electronic suspension controls, optional active roll stabilization. Vehicle Philosophy: The ultimate expression of BMW's 'Ultimate Driving Machine' philosophy, adapted for the luxury segment, emphasizing performance and technology. 📋 Manual Details Coverage Areas Primary Coverage: All 7 Series E65, E66, E67, E68 models for the 2004 model year. Page Count Estimated Page Count: 1000+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (likely PDF, searchable) 📖 Manual Coverage Systems Covered Engine Mechanical: Full rebuild procedures, component diagnostics, timing, cylinder head, pistons, crankshaft, lubrication system. Engine Management And Electrical: ECU diagnostics, sensor testing, ignition system, fuel injection, emissions control, starter, alternator, battery, wiring diagrams. Transmission Automatic: Detailed repair, overhaul, fluid changes, torque converter, shift solenoids, electronic control unit. Transmission Manual: Not applicable for 2004 7 Series which were primarily automatic. Suspension And Steering: Active roll stabilization, self-leveling suspension (ALSS), power steering system, hydraulic components, alignment specifications. Brakes: ABS, DSC (Dynamic Stability Control), brake system hydraulic components, caliper repair, rotor replacement, brake fluid specifications. Body And Chassis: Body panel removal and installation, structural repairs, door mechanisms, glass replacement, sound deadening, corrosion protection. HVAC: Climate control system, refrigerant handling, compressor, evaporator, heater core, actuators, diagnostics. Interior Trim And Accessories: Seat mechanisms, interior paneling, roof liner, dashboard components, infotainment system integration. Electrical Systems And Comfort Electronics: Complex i-bus/K-bus architecture, LCM (Light Module Control), GM (Gateway Module), PDC (Park Distance Control), central locking, power windows, lighting systems, navigation, audio. Procedures Included Preventative Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection, brake pad wear checks. Troubleshooting: Systematic diagnostic procedures for all major systems, symptom-based troubleshooting guides, fault code interpretation. Repair And Overhaul: Detailed step-by-step instructions for component removal, repair, replacement, and reassembly. Diagnostic Procedures: Specific procedures for using diagnostic tools (e.g., DIS, ISTA), reading fault memory, live data analysis, component activation tests. Wiring Diagrams: Comprehensive and specific wiring diagrams for all electrical systems, including component locations and connector pinouts. Technical Depth Depth: Complete, dealership-level technical information covering all aspects from basic maintenance to complete engine and transmission rebuilds, and advanced electronic system diagnostics. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Scan Resolution: High-resolution scans allowing for clear text and image readability. Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) Searchability Text Searchability: Searchable text content for quick access to specific topics and keywords. ⚙️ Engine Specifications Primary Engine Engine Codes 2004: N62B40 (4.0L V8), N62B44 (4.4L V8), N62B48 (4.8L V8) Performance Horsepower Range: Approx. 255 hp (4.0L) to 360 hp (4.8L) Torque Range: Approx. 295 lb-ft (4.0L) to 360 lb-ft (4.8L) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Double VANOS variable valve timing. Engine Mechanical Cylinder Block Material: Aluminum Valve Train: DOHC (Dual Overhead Camshafts), 4 valves per cylinder. Engine Maintenance Spark Plug Type: Bosch FGR7KQE0U (or equivalent) 🔧 Transmission Standard Transmission Type: 6-speed Steptronic Automatic Transmission (GA6HP26Z) Optional Optional Transmissions: N/A for 2004 model year; all models featured the 6-speed automatic. Features Shift Modes: Automatic, Manual (Steptronic sequential shifting via selector lever or steering wheel buttons). Maintenance Transmission Fluid Type: BMW ATF LT-2 (or Shell M-1375.4) Transmission Fluid Capacity Approx: 8.5 Liters (subject to torque converter fill) 📐 Dimensions Exterior Wheelbase E65: 3070 mm (120.9 inches) Wheelbase E66: 3190 mm (125.6 inches) Length E65: 5009 mm (197.2 inches) Length E66: 5180 mm (203.9 inches) Weights Curb Weight Range: Approx. 1800-1950 kg (3968-4300 lbs) Gross Vehicle Weight Rating: Varies by model and equipment, typically around 2400-2550 kg Other Wheelbase E67: 3070 mm (120.9 inches) Wheelbase E68: 3070 mm (120.9 inches) 🛡️ Safety Features Ratings NHTSA Front Impact: 5-star (for models tested) IIHS Top Safety Pick: Yes (for models tested, typically with specific equipment) Active Features Stability Control: Dynamic Stability Control (DSC) with integrated ABS, Traction Control (ASC+T). Braking System: 4-wheel ventilated disc brakes, Electronic Brake-force Distribution (EBD), Brake Assist. Lighting: Bi-Xenon Headlights with Adaptive (cornering) Headlights, front and rear fog lights. Passive Features Airbags: Frontal airbags (driver/passenger), front side-impact airbags, head protection system (curtains) for front and rear occupants. Seatbelts: 3-point inertia-reel seat belts with pretensioners and force limiters for all seating positions. Chassis Structure: High-strength steel safety cage, crumple zones. 💡 Technology Features Infotainment System Name: iDrive (first generation) Features: Central control knob and buttons, 6.5-inch or optional 8.8-inch LCD...
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BMW 7-series E65 E66 E67 E68 2004 Service and Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
7 Series
Model Years Covered:
2004
Generation
Generation Code:
E65 (short wheelbase), E66 (long wheelbase), E67 (Protection model), E68 (Hydrogen Fuel Cell)
Codes
Chassis Codes:
E65, E66, E67, E68
👋 Introduction
Market Position
Segment:
Full-size Luxury Sedan
Key Competitors 2004:
Mercedes-Benz S-Class, Audi A8, Lexus LS, Jaguar XJ, Cadillac DTS.
Competitive Analysis
Differentiation:
Known for advanced technology (iDrive, adaptive headlights), superior driving dynamics for its class, and luxurious interior appointments.
Key Features
Innovations:
iDrive infotainment system, adaptive headlights (AFS), advanced electronic suspension controls, optional active roll stabilization.
Vehicle Philosophy:
The ultimate expression of BMW's 'Ultimate Driving Machine' philosophy, adapted for the luxury segment, emphasizing performance and technology.
📋 Manual Details
Coverage Areas
Primary Coverage:
All 7 Series E65, E66, E67, E68 models for the 2004 model year.
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, searchable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full rebuild procedures, component diagnostics, timing, cylinder head, pistons, crankshaft, lubrication system.
Engine Management And Electrical:
ECU diagnostics, sensor testing, ignition system, fuel injection, emissions control, starter, alternator, battery, wiring diagrams.
Transmission Automatic:
Detailed repair, overhaul, fluid changes, torque converter, shift solenoids, electronic control unit.
Transmission Manual:
Not applicable for 2004 7 Series which were primarily automatic.
Suspension And Steering:
Active roll stabilization, self-leveling suspension (ALSS), power steering system, hydraulic components, alignment specifications.
Brakes:
ABS, DSC (Dynamic Stability Control), brake system hydraulic components, caliper repair, rotor replacement, brake fluid specifications.
Body And Chassis:
Body panel removal and installation, structural repairs, door mechanisms, glass replacement, sound deadening, corrosion protection.
HVAC:
Climate control system, refrigerant handling, compressor, evaporator, heater core, actuators, diagnostics.
Interior Trim And Accessories:
Seat mechanisms, interior paneling, roof liner, dashboard components, infotainment system integration.
Electrical Systems And Comfort Electronics:
Complex i-bus/K-bus architecture, LCM (Light Module Control), GM (Gateway Module), PDC (Park Distance Control), central locking, power windows, lighting systems, navigation, audio.
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection, brake pad wear checks.
Troubleshooting:
Systematic diagnostic procedures for all major systems, symptom-based troubleshooting guides, fault code interpretation.
Repair And Overhaul:
Detailed step-by-step instructions for component removal, repair, replacement, and reassembly.
Diagnostic Procedures:
Specific procedures for using diagnostic tools (e.g., DIS, ISTA), reading fault memory, live data analysis, component activation tests.
Wiring Diagrams:
Comprehensive and specific wiring diagrams for all electrical systems, including component locations and connector pinouts.
Technical Depth
Depth:
Complete, dealership-level technical information covering all aspects from basic maintenance to complete engine and transmission rebuilds, and advanced electronic system diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Scan Resolution:
High-resolution scans allowing for clear text and image readability.
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper:
N/A (Digital Format)
Searchability
Text Searchability:
Searchable text content for quick access to specific topics and keywords.
⚙️ Engine Specifications
Primary Engine
Engine Codes 2004:
N62B40 (4.0L V8), N62B44 (4.4L V8), N62B48 (4.8L V8)
Performance
Horsepower Range:
Approx. 255 hp (4.0L) to 360 hp (4.8L)
Torque Range:
Approx. 295 lb-ft (4.0L) to 360 lb-ft (4.8L)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Double VANOS variable valve timing.
Engine Mechanical
Cylinder Block Material:
Aluminum
Valve Train:
DOHC (Dual Overhead Camshafts), 4 valves per cylinder.
Engine Maintenance
Spark Plug Type:
Bosch FGR7KQE0U (or equivalent)
🔧 Transmission
Standard
Transmission Type:
6-speed Steptronic Automatic Transmission (GA6HP26Z)
Optional
Optional Transmissions:
N/A for 2004 model year; all models featured the 6-speed automatic.
Features
Shift Modes:
Automatic, Manual (Steptronic sequential shifting via selector lever or steering wheel buttons).
Maintenance
Transmission Fluid Type:
BMW ATF LT-2 (or Shell M-1375.4)
Transmission Fluid Capacity Approx:
8.5 Liters (subject to torque converter fill)
📐 Dimensions
Exterior
Wheelbase E65:
3070 mm (120.9 inches)
Wheelbase E66:
3190 mm (125.6 inches)
Length E65:
5009 mm (197.2 inches)
Length E66:
5180 mm (203.9 inches)
Weights
Curb Weight Range:
Approx. 1800-1950 kg (3968-4300 lbs)
Gross Vehicle Weight Rating:
Varies by model and equipment, typically around 2400-2550 kg
Other
Wheelbase E67:
3070 mm (120.9 inches)
Wheelbase E68:
3070 mm (120.9 inches)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star (for models tested)
IIHS Top Safety Pick:
Yes (for models tested, typically with specific equipment)
Active Features
Stability Control:
Dynamic Stability Control (DSC) with integrated ABS, Traction Control (ASC+T).
Braking System:
4-wheel ventilated disc brakes, Electronic Brake-force Distribution (EBD), Brake Assist.
Lighting:
Bi-Xenon Headlights with Adaptive (cornering) Headlights, front and rear fog lights.
Passive Features
Airbags:
Frontal airbags (driver/passenger), front side-impact airbags, head protection system (curtains) for front and rear occupants.
Seatbelts:
3-point inertia-reel seat belts with pretensioners and force limiters for all seating positions.
Chassis Structure:
High-strength steel safety cage, crumple zones.
💡 Technology Features
Infotainment
System Name:
iDrive (first generation)
Features:
Central control knob and buttons, 6.5-inch or optional 8.8-inch LCD screen, navigation, radio, CD player, optional TV tuner, optional Logic7 audio system.
Driver Assistance
Cruise Control:
Standard cruise control, optional Active Cruise Control (ACC) with Stop & Go function.
Parking Assistance:
Park Distance Control (PDC) front and rear, optional rearview camera.
Connectivity
Bluetooth:
Optional Bluetooth phone integration.
Comfort Features
Seats:
Power-adjustable front seats with memory, optional heated and ventilated front seats, optional lumbar support, optional comfort seats with multiple adjustments, active comfort seats.
Climate Control:
Automatic dual-zone or quad-zone climate control, active charcoal filters.
🔧 Maintenance
Service Intervals
Oil Service:
Condition Based Service (CBS), typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil quality sensor readings.
Spark Plug Replacement:
Every 60,000 miles for most N62 engines.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or BMW Longlife-01 FE (LL-01 FE) synthetic oil, viscosity typically 5W-30 or 0W-40 depending on climate and specific engine variant.
Engine Oil Capacity:
Approx. 6.5 - 8.5 liters (depending on engine variant)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 type)
Power Steering Fluid Type:
Pentosin CHF 11S (or equivalent hydraulic fluid)
Known Issues
Common Electrical Faults:
Water ingress into LCM (Light Module Control), tailgate wiring harness fatigue, EWS (Immobilizer) issues, PDC sensor failures.
Common Engine Issues:
Oil pan gasket leaks, valve cover gasket leaks, VANOS solenoid issues, cooling system leaks (especially hoses and expansion tank), thermostat housing failure, oil separation system (CCV) issues.
Common Suspension Issues:
Failure of self-leveling rear suspension (air springs), worn control arm bushings, power steering leaks.
Common Transmission Issues:
Mechatronics unit issues, torque converter shudder, transmission control module (TCM) failure.
Common HVAC Issues:
Blend door actuator failures, HVAC blower motor issues, refrigerant leaks.
📚 Vehicle History
Brand Heritage
Brand Identity:
BMW (Bayerische Motoren Werke AG) is renowned for its focus on driving pleasure, engineering excellence, and luxury vehicles.
Model Evolution
Predecessor:
BMW 7 Series (E38)
Generation Introduction:
The E65/E66 generation debuted in 2001 (for the 2002 model year) and represented a significant departure in styling and technology from the E38.
Production
Production Period E65 E66:
2001-2008
Manufacturing Locations:
Mainly Dingolfing, Germany.
E67 E68 Purpose:
E67 was the armored/protection version, and E68 was a limited-production hydrogen fuel cell vehicle.
🏆 Awards & Recognition
Recognitions
Design Awards:
While specific awards for the 2004 model are numerous, the E65/E66 generation was widely praised for its technological advancements and luxury appointments upon release.
Ratings
Consumer Reports Reliability:
Varied, often reflecting the complexity of its advanced systems. The manual provides critical insight into maintaining this complexity.
Certifications
Oem Approval:
This manual is the OEM-equivalent document used by BMW technicians, ensuring dealership-level accuracy and detail.
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