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BMW 5-series (E60) 2004 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5-series Model Code: E60 Year: 2004 👋 Introduction Market Position Target Audience: BMW 5-series (E60) owners, independent repair shops, DIY enthusiasts Value Proposition: Provides dealership-level repair information, enabling cost savings and empowerment for vehicle maintenance Competitive Analysis Differentiation: Vehicle-specific, factory-level detail, comprehensive coverage, digital format for ease of use and portability Key Features Format Advantage: Single PDF manual, no need to flip through multiple books, print-only what is needed Content Advantage: Diagrams, illustrations, wiring schematics, and specifications for complete repair 📋 Manual Details Coverage Areas Coverage: All models and all repairs A-Z for the 2004 BMW 5-series (E60) Page Count Estimated Page Count: Extensive (implied by 'complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications') Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Compatibility: Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac 📖 Manual Coverage Systems Covered Engine Management: Engine Control System, Fuel Service Specifications, Emission Control, Ignition Starting Charging Powertrain: Engine, Lube, Intake Exhaust Cooling, Auto Transmission, Manual Transmission, Transfer Propeller Shaft, Drive Shaft, Differential, Axle Chassis: Suspension, Tire & Wheel, Brake Control, Brake, Parking Brake, Steering Column, Power Steering Electrical And Body: Electrical, Multiplex/CAN Communication, Air Condition, Suppl. Restraint System (SRS), Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter Audio/Visual, Horn, Windshield/Glass Mirror, Instrument Panel, Seat, Engine Hood/Door, Exterior & Interior Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Repair: Complete step-by-step repair instructions for all major systems Diagnostics: Troubleshooting and diagnostic procedures for various issues Wiring Schematics: Detailed wiring diagrams for all electrical systems Technical Depth Depth: Factory-level detail, suitable for dealership technicians and advanced DIYers 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within PDF for quick information retrieval Print Quality Printability: All pages printable, with option to enlarge images Binding Type Binding: Digital (PDF) - No physical binding; print as needed Paper Type Paper Type: N/A (Digital) Software Requirements Reader Requirement: Adobe PDF Reader (free online) Unzipping Requirement: Winzip or equivalent (free online) ⚙️ Engine Specifications Primary Engine Engine Options 2004 E60: Likely includes 525i (2.5L I6), 530i (3.0L I6), and 545i (4.4L V8) models for the US market. International markets may have additional diesel options. Performance Typical Horsepower Range: Approx. 184 hp (525i) to 325 hp (545i) depending on engine variant Typical Torque Range: Approx. 230 Nm (525i) to 450 Nm (545i) depending on engine variant Fuel System Fuel Delivery: Likely multi-point fuel injection (MPI) or direct injection (DI) depending on engine Engine Management ECU Type: Various Bosch Motronic or similar advanced Engine Control Units (ECUs) Cooling Cooling System Type: Pressurized liquid cooling system with electric fan 🔧 Transmission Standard Standard Transmission: Likely a 6-speed manual transmission for some models Optional Optional Transmission: 6-speed Steptronic automatic transmission with manual shift mode Features Transmission Control: Electronic transmission control (TCM) for automatic transmissions Fluid Specifications Automatic Transmission Fluid Type: Specific BMW ATF (e.g., LT-3 or equivalent) required for automatic transmissions 📐 Dimensions Exterior Wheelbase E60: Approx. 2888 mm (113.7 in) Length E60: Approx. 4841 mm (190.6 in) Width E60: Approx. 1846 mm (72.7 in) Height E60: Approx. 1469 mm (57.8 in) Weights Curb Weight Range: Approx. 1500 kg to 1700 kg depending on engine and options Gross Vehicle Weight Rating: Vehicle specific, detailed in manual 🛡️ Safety Features Ratings NHTSA Front Impact Rating: Likely 5-star for driver and passenger based on BMW's safety reputation IIHS Top Safety Pick: High likelihood of being a Top Safety Pick for its era Active Features Stability Control: Dynamic Stability Control (DSC) as standard Traction Control: Automatic Stability Control + Traction (ASC+T) Passive Features Airbags: Frontal airbags, side-impact airbags, head protection airbags (curtain) Seatbelts: Pretensioning front seat belts, three-point rear seat belts Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system 💡 Technology Features Infotainment I Drive System: Introduction of the iDrive infotainment system with central controller and LCD screen Navigation System: Optional Professional Navigation System Driver Assistance Parking Assistance: Optional Park Distance Control (PDC) front and rear Cruise Control: Standard cruise control, optional Active Cruise Control (ACC) Connectivity Bluetooth Connectivity: Optional Bluetooth mobile phone integration Lighting Headlights: Halogen or optional Xenon Adaptive Headlights 🔧 Maintenance Service Intervals Oil Change Interval: Typically flexible service intervals (Condition Based Service - CBS) around 15,000-25,000 km or 12-24 months, depending on driving conditions and oil quality Brake Fluid Change Interval: Typically every 2 years Coolant Change Interval: Extended life coolant, often around 5 years or 100,000 km initially, then replaced more frequently Spark Plug Replacement Interval: Varies by engine, typically 60,000 - 100,000 km for iridium plugs Fluid Specifications Engine Oil Specification: BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) synthetic oil, viscosity typically 0W-30 or 5W-30 depending on climate. Refer to manual for exact grade. Coolant Specification: BMW Blue...
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BMW 5-series (E60) 2004 Service and Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5-series
Model Code:
E60
Year:
2004
👋 Introduction
Market Position
Target Audience:
BMW 5-series (E60) owners, independent repair shops, DIY enthusiasts
Value Proposition:
Provides dealership-level repair information, enabling cost savings and empowerment for vehicle maintenance
Competitive Analysis
Differentiation:
Vehicle-specific, factory-level detail, comprehensive coverage, digital format for ease of use and portability
Key Features
Format Advantage:
Single PDF manual, no need to flip through multiple books, print-only what is needed
Content Advantage:
Diagrams, illustrations, wiring schematics, and specifications for complete repair
📋 Manual Details
Coverage Areas
Coverage:
All models and all repairs A-Z for the 2004 BMW 5-series (E60)
Page Count
Estimated Page Count:
Extensive (implied by 'complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications')
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
Compatibility:
Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac
📖 Manual Coverage
Systems Covered
Engine Management:
Engine Control System, Fuel Service Specifications, Emission Control, Ignition Starting Charging
Powertrain:
Engine, Lube, Intake Exhaust Cooling, Auto Transmission, Manual Transmission, Transfer Propeller Shaft, Drive Shaft, Differential, Axle
Chassis:
Suspension, Tire & Wheel, Brake Control, Brake, Parking Brake, Steering Column, Power Steering
Electrical And Body:
Electrical, Multiplex/CAN Communication, Air Condition, Suppl. Restraint System (SRS), Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter Audio/Visual, Horn, Windshield/Glass Mirror, Instrument Panel, Seat, Engine Hood/Door, Exterior & Interior
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair:
Complete step-by-step repair instructions for all major systems
Diagnostics:
Troubleshooting and diagnostic procedures for various issues
Wiring Schematics:
Detailed wiring diagrams for all electrical systems
Technical Depth
Depth:
Factory-level detail, suitable for dealership technicians and advanced DIYers
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text within PDF for quick information retrieval
Print Quality
Printability:
All pages printable, with option to enlarge images
Binding Type
Binding:
Digital (PDF) - No physical binding; print as needed
Paper Type
Paper Type:
N/A (Digital)
Software Requirements
Reader Requirement:
Adobe PDF Reader (free online)
Unzipping Requirement:
Winzip or equivalent (free online)
⚙️ Engine Specifications
Primary Engine
Engine Options 2004 E60:
Likely includes 525i (2.5L I6), 530i (3.0L I6), and 545i (4.4L V8) models for the US market. International markets may have additional diesel options.
Performance
Typical Horsepower Range:
Approx. 184 hp (525i) to 325 hp (545i) depending on engine variant
Typical Torque Range:
Approx. 230 Nm (525i) to 450 Nm (545i) depending on engine variant
Fuel System
Fuel Delivery:
Likely multi-point fuel injection (MPI) or direct injection (DI) depending on engine
Engine Management
ECU Type:
Various Bosch Motronic or similar advanced Engine Control Units (ECUs)
Cooling
Cooling System Type:
Pressurized liquid cooling system with electric fan
🔧 Transmission
Standard
Standard Transmission:
Likely a 6-speed manual transmission for some models
Optional
Optional Transmission:
6-speed Steptronic automatic transmission with manual shift mode
Features
Transmission Control:
Electronic transmission control (TCM) for automatic transmissions
Fluid Specifications
Automatic Transmission Fluid Type:
Specific BMW ATF (e.g., LT-3 or equivalent) required for automatic transmissions
📐 Dimensions
Exterior
Wheelbase E60:
Approx. 2888 mm (113.7 in)
Length E60:
Approx. 4841 mm (190.6 in)
Width E60:
Approx. 1846 mm (72.7 in)
Height E60:
Approx. 1469 mm (57.8 in)
Weights
Curb Weight Range:
Approx. 1500 kg to 1700 kg depending on engine and options
Gross Vehicle Weight Rating:
Vehicle specific, detailed in manual
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Likely 5-star for driver and passenger based on BMW's safety reputation
IIHS Top Safety Pick:
High likelihood of being a Top Safety Pick for its era
Active Features
Stability Control:
Dynamic Stability Control (DSC) as standard
Traction Control:
Automatic Stability Control + Traction (ASC+T)
Passive Features
Airbags:
Frontal airbags, side-impact airbags, head protection airbags (curtain)
Seatbelts:
Pretensioning front seat belts, three-point rear seat belts
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
I Drive System:
Introduction of the iDrive infotainment system with central controller and LCD screen
Navigation System:
Optional Professional Navigation System
Driver Assistance
Parking Assistance:
Optional Park Distance Control (PDC) front and rear
Cruise Control:
Standard cruise control, optional Active Cruise Control (ACC)
Connectivity
Bluetooth Connectivity:
Optional Bluetooth mobile phone integration
Lighting
Headlights:
Halogen or optional Xenon Adaptive Headlights
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically flexible service intervals (Condition Based Service - CBS) around 15,000-25,000 km or 12-24 months, depending on driving conditions and oil quality
Brake Fluid Change Interval:
Typically every 2 years
Coolant Change Interval:
Extended life coolant, often around 5 years or 100,000 km initially, then replaced more frequently
Spark Plug Replacement Interval:
Varies by engine, typically 60,000 - 100,000 km for iridium plugs
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) synthetic oil, viscosity typically 0W-30 or 5W-30 depending on climate. Refer to manual for exact grade.
Coolant Specification:
BMW Blue or Purple antifreeze concentrate, mixed with distilled water (50/50 ratio)
Known Issues
Common E60 Issues:
Oil leaks (valve cover gaskets, oil pan gaskets), cooling system issues (water pump, thermostat), VANOS solenoids, ignition coils, power steering leaks, fuel pump failures, electronic module failures (e.g., LCM, GM5).
Electrical Gremlins:
Common in early E60 models due to complex electronics; door modules, central locking, and interior lighting issues can occur.
Brake Specifications
Front Brake Type:
Ventilated disc brakes
Rear Brake Type:
Disc brakes
Tire Size
Typical Tire Sizes:
Various sizes depending on wheel option, e.g., 225/50R17, 245/40R18, 245/35R19
Wheel Bolt Pattern
Bolt Pattern:
5x120 mm
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure, focus on performance, luxury, and advanced engineering
Model Evolution
E60 Introduction:
The E60 generation replaced the E39 5-series and was produced from 2003 to 2010. The 2004 model year marks an early production year for this generation.
Production
Manufacturing Locations:
Primarily manufactured in Germany (Dingolfing plant)
🏆 Awards & Recognition
Recognitions
Car Of The Year Nominations:
While specific 'Car of the Year' awards for the 2004 model are not always prominent, the E60 generation generally received positive reviews for its driving dynamics and luxury.
Design Awards:
The E60's design was a departure from its predecessor, often praised for its modern aesthetic but also polarizing for some traditionalists.
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