BMW 5 Series 525 528 530 535 545 550 M5 E60 E61 Complete Workshop Service Repair Manual 2003 2004 2005 2006 2007

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E60 (Sedan), E61 (Touring/Wagon) Engine Codes Covered: N62B35, N62B40, N62B44, N62B48, S85B50 Codes Model Designations: 525i, 528i, 530i, 535i, 545i, 550i, M5 👋 Introduction Market Position Segment: Executive Luxury Sedan/Wagon Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type Key Features Platform Highlights: Advanced chassis dynamics, rear-wheel drive bias (optional xDrive all-wheel drive), sophisticated electronics, luxurious interior appointments Technological Advancements: Introduction of iDrive infotainment system, advanced driver assistance systems (optional), head-up display (optional) Target Audience Primary Audience: Owners seeking to perform their own maintenance and repairs to save costs and gain a deeper understanding of their vehicle's mechanics. 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Language: English Format: Downloadable (PDF) Delivery: Instant Email Delivery Compatibility: All PC & MAC Computers, Tablets, Smartphones Required Software: Adobe Reader (Free) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel system, intake manifold, exhaust manifold Engine Management: Engine control unit (ECU) diagnostics, ignition system, fuel injection, emissions control, sensor diagnostics (MAF, O2, crank/cam position), throttle body control Transmission Manual: Clutch, gearbox components, shift mechanism, repair, overhaul, fluid specifications Transmission Automatic: Automatic transmission repair, valve body, torque converter, solenoids, electronic control unit, fluid type and capacity, torque specifications Drivetrain: Driveshafts, CV joints, differential, wheel bearings, rear axle assembly Suspension: Front and rear suspension components, control arms, bushings, shock absorbers, struts, coil springs, sway bars, steering knuckles, alignment specifications Steering: Power steering system, steering rack, steering column, tie rods, power steering fluid type and capacity Brakes: Brake system components (discs, pads, calipers, lines), ABS system, DSC (Dynamic Stability Control), brake fluid type, bleeding procedures, parking brake Electrical System: Battery, alternator, starter motor, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM) Comfort Systems: HVAC (Heating, Ventilation, Air Conditioning) system, climate control, blower motor, evaporator, condenser, refrigerant type, cabin air filter replacement Body And Chassis: Body panel removal/installation, door mechanisms, hood, trunk, bumpers, interior trim, sound deadening, chassis components Infotainment And Navigation: iDrive system, radio, CD changer, navigation system, speaker replacement, antenna system Safety Systems: Airbag system (SRS), seat belt pre-tensioners, safety module diagnostics Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant checks and flushes, brake fluid replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, wiring diagram interpretation for fault finding Repair And Rebuild: Detailed step-by-step instructions for component replacement, repair, and complete overhaul of major systems Diagnostics: OBD-II (On-Board Diagnostics) system, fault code reading and clearing, sensor data analysis, live data stream interpretation Adjustment And Calibration: Throttle body adaptation, idle speed control, steering angle sensor calibration, headlight aiming Installation And Replacement: Component installation, replacement procedures for wear items and faulty parts Technical Depth Depth Of Coverage: Comprehensive A-Z coverage, suitable for DIY enthusiasts and professional mechanics Visual Aids: Includes clear step-by-step instructions with accompanying photographs and diagrams Specifications: Detailed torque specifications, clearances, fluid capacities, and diagnostic parameters 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text for quick access to information Printability: Printable on a page-by-page or chapter-by-chapter basis Device Accessibility: Accessible on any device with Adobe Reader installed Print Quality Image Resolution: High-quality images and diagrams for clarity Text Clarity: Crisp, clear text for easy reading Binding Type Binding: Digital Download (No physical binding) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-6 and V8 Naturally Aspirated (N62 series) and V8 Naturally Aspirated (S85 for M5) Displacement Variants: 3.0L (N62B30), 3.5L (N62B35), 4.0L (N62B40), 4.4L (N62B44), 4.8L (N62B48), 5.0L (S85B50 for M5) Performance Horsepower Range: Approx. 255 hp (525i/528i) to 360 hp (545i/550i) and 500 hp (M5) Torque Range: Approx. 260 lb-ft (525i/528i) to 360 lb-ft (545i/550i) and 383 lb-ft (M5) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Engine Management Ignition System: Coil-on-plug ignition system Valve Actuation: Double Overhead Camshafts (DOHC), VANOS (Variable Valve Timing), VALVETRONIC (on later models) 🔧 Transmission Standard Transmission Type Std: 6-speed Manual Transmission (SMG on some models, especially M5) Optional Transmission Type Opt: 6-speed Steptronic Automatic Transmission Features Transmission Features: Adaptive shift programs, manual mode (Steptronic), paddle shifters (optional on some models) Fluid Specifications Automatic Transmission Fluid Type: BMW recommends specific ATF (e.g., LT-3, Shell M-1375.4) - refer to manual for exact spec by VIN Manual Transmission Fluid Type: BMW recommends specific gear oil (e.g., MTF LT-2) - refer to manual for exact spec 📐 Dimensions Exterior Wheelbase E60: 116.4 inches (2956 mm) Wheelbase E61: 116.4 inches (2956 mm) Length E60: 191.1 inches (4855 mm) Length E61: 192.2 inches (4882 mm) Width: 72.7 inches (1846 mm) Height E60: 57.4 inches (1458 mm) Height E61:...

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Vendor:

Sku: 458758

Collections: ALL BMW

Availability: In stock

Tags: 2003 2004 2005 2006 2007 5 Series 525 528 530 535 545 550 BMW Car Cars E60 E61 M5

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

E60 (Sedan), E61 (Touring/Wagon)

Engine Codes Covered:

N62B35, N62B40, N62B44, N62B48, S85B50

Codes

Model Designations:

525i, 528i, 530i, 535i, 545i, 550i, M5

👋 Introduction

Market Position

Segment:

Executive Luxury Sedan/Wagon

Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type

Key Features

Platform Highlights:

Advanced chassis dynamics, rear-wheel drive bias (optional xDrive all-wheel drive), sophisticated electronics, luxurious interior appointments

Technological Advancements:

Introduction of iDrive infotainment system, advanced driver assistance systems (optional), head-up display (optional)

Target Audience

Primary Audience:

Owners seeking to perform their own maintenance and repairs to save costs and gain a deeper understanding of their vehicle's mechanics.

📋 Manual Details

Coverage Areas

Manual Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable (PDF)

Delivery:

Instant Email Delivery

Compatibility:

All PC & MAC Computers, Tablets, Smartphones

Required Software:

Adobe Reader (Free)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine removal/installation, cylinder head, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel system, intake manifold, exhaust manifold

Engine Management:

Engine control unit (ECU) diagnostics, ignition system, fuel injection, emissions control, sensor diagnostics (MAF, O2, crank/cam position), throttle body control

Transmission Manual:

Clutch, gearbox components, shift mechanism, repair, overhaul, fluid specifications

Transmission Automatic:

Automatic transmission repair, valve body, torque converter, solenoids, electronic control unit, fluid type and capacity, torque specifications

Drivetrain:

Driveshafts, CV joints, differential, wheel bearings, rear axle assembly

Suspension:

Front and rear suspension components, control arms, bushings, shock absorbers, struts, coil springs, sway bars, steering knuckles, alignment specifications

Steering:

Power steering system, steering rack, steering column, tie rods, power steering fluid type and capacity

Brakes:

Brake system components (discs, pads, calipers, lines), ABS system, DSC (Dynamic Stability Control), brake fluid type, bleeding procedures, parking brake

Electrical System:

Battery, alternator, starter motor, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM)

Comfort Systems:

HVAC (Heating, Ventilation, Air Conditioning) system, climate control, blower motor, evaporator, condenser, refrigerant type, cabin air filter replacement

Body And Chassis:

Body panel removal/installation, door mechanisms, hood, trunk, bumpers, interior trim, sound deadening, chassis components

Infotainment And Navigation:

iDrive system, radio, CD changer, navigation system, speaker replacement, antenna system

Safety Systems:

Airbag system (SRS), seat belt pre-tensioners, safety module diagnostics

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant checks and flushes, brake fluid replacement

Troubleshooting:

Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, wiring diagram interpretation for fault finding

Repair And Rebuild:

Detailed step-by-step instructions for component replacement, repair, and complete overhaul of major systems

Diagnostics:

OBD-II (On-Board Diagnostics) system, fault code reading and clearing, sensor data analysis, live data stream interpretation

Adjustment And Calibration:

Throttle body adaptation, idle speed control, steering angle sensor calibration, headlight aiming

Installation And Replacement:

Component installation, replacement procedures for wear items and faulty parts

Technical Depth

Depth Of Coverage:

Comprehensive A-Z coverage, suitable for DIY enthusiasts and professional mechanics

Visual Aids:

Includes clear step-by-step instructions with accompanying photographs and diagrams

Specifications:

Detailed torque specifications, clearances, fluid capacities, and diagnostic parameters

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick access to information

Printability:

Printable on a page-by-page or chapter-by-chapter basis

Device Accessibility:

Accessible on any device with Adobe Reader installed

Print Quality

Image Resolution:

High-quality images and diagrams for clarity

Text Clarity:

Crisp, clear text for easy reading

Binding Type

Binding:

Digital Download (No physical binding)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-6 and V8 Naturally Aspirated (N62 series) and V8 Naturally Aspirated (S85 for M5)

Displacement Variants:

3.0L (N62B30), 3.5L (N62B35), 4.0L (N62B40), 4.4L (N62B44), 4.8L (N62B48), 5.0L (S85B50 for M5)

Performance

Horsepower Range:

Approx. 255 hp (525i/528i) to 360 hp (545i/550i) and 500 hp (M5)

Torque Range:

Approx. 260 lb-ft (525i/528i) to 360 lb-ft (545i/550i) and 383 lb-ft (M5)

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Engine Management

Ignition System:

Coil-on-plug ignition system

Valve Actuation:

Double Overhead Camshafts (DOHC), VANOS (Variable Valve Timing), VALVETRONIC (on later models)

🔧 Transmission

Standard

Transmission Type Std:

6-speed Manual Transmission (SMG on some models, especially M5)

Optional

Transmission Type Opt:

6-speed Steptronic Automatic Transmission

Features

Transmission Features:

Adaptive shift programs, manual mode (Steptronic), paddle shifters (optional on some models)

Fluid Specifications

Automatic Transmission Fluid Type:

BMW recommends specific ATF (e.g., LT-3, Shell M-1375.4) - refer to manual for exact spec by VIN

Manual Transmission Fluid Type:

BMW recommends specific gear oil (e.g., MTF LT-2) - refer to manual for exact spec

📐 Dimensions

Exterior

Wheelbase E60:

116.4 inches (2956 mm)

Wheelbase E61:

116.4 inches (2956 mm)

Length E60:

191.1 inches (4855 mm)

Length E61:

192.2 inches (4882 mm)

Width:

72.7 inches (1846 mm)

Height E60:

57.4 inches (1458 mm)

Height E61:

58.1 inches (1476 mm)

Weights

Curb Weight Range:

Approx. 3700 - 4200 lbs (1680 - 1905 kg)

Gvw Range:

Approx. 4800 - 5300 lbs (2180 - 2400 kg)

🛡️ Safety Features

Ratings

NHTSA Ratings:

Generally good ratings for its era, often 4 or 5 stars in frontal and side impacts (specific ratings vary by year and test).

Active Features

Active Safety Systems:

Dynamic Stability Control (DSC), Anti-lock Braking System (ABS), Dynamic Traction Control (DTC), optional Active Steering, Adaptive Cruise Control (ACC), Park Distance Control (PDC).

Passive Features

Passive Safety Features:

Frontal airbags, side airbags, curtain airbags, active head restraints, reinforced safety cell construction.

💡 Technology Features

Infotainment

Infotainment System:

BMW iDrive system (first generation), offering control over navigation, audio, climate, and vehicle settings.

Audio Options:

Standard HiFi audio, optional Logic 7 premium sound system.

Driver Assistance

Driver Assistance Features:

Park Distance Control (PDC), Adaptive Cruise Control (ACC), Xenon Adaptive Headlights, Head-Up Display (HUD) (optional).

Connectivity

Connectivity Options:

Bluetooth hands-free connectivity (optional), USB interface for audio playback (optional on later models).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 - 15,000 miles (16,000 - 24,000 km) or 12-24 months, depending on driving conditions and oil quality. Service Indicator System (CBS) will prompt.

Spark Plug Replacement:

Around 60,000 - 100,000 miles (96,000 - 160,000 km), depending on engine and spark plug type (e.g., iridium). Specific interval varies by engine variant.

Coolant Flush:

BMW recommends coolant replacement at approximately 60,000 miles (96,000 km) or 4 years.

Brake Fluid Flush:

Every 2 years, regardless of mileage, due to hygroscopic nature of brake fluid.

Fluid Specifications

Engine Oil Type:

BMW Longlife-01 (LL-01) or BMW Longlife-04 (LL-04) approved synthetic oil, typically 0W-30 or 5W-30 viscosity. Refer to owner's manual for specific viscosity for ambient temperature.

Engine Oil Capacity Approx:

6.5 - 8.5 quarts (6.2 - 8.0 liters), depending on engine variant.

Power Steering Fluid:

Pentosin CHF 11S or equivalent approved hydraulic fluid. Never use ATF.

Known Issues

Common Problems:

Valve cover gasket leaks, oil pan gasket leaks, CCV (Crankcase Ventilation) system failure leading to oil consumption, coolant expansion tank failure, alternator pulley failure, fuel pump issues, ignition coil failures, VANOS system solenoids, E60 M5 specific issues (e.g., rod bearings, clutch wear on SMG).

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW's long-standing reputation for building sporty, driver-focused luxury vehicles with advanced engineering.

Model Evolution

E60 Introduction:

The E60 generation of the 5 Series replaced the E39 and introduced significant styling and technological advancements, including the controversial iDrive system.

E61 Introduction:

The E61 Touring (wagon) variant was introduced in 2004, offering increased practicality while retaining the E60's driving dynamics.

M5 Variant:

The E60 M5, introduced in 2005, featured the high-revving S85 V10 engine, a bespoke chassis, and aggressive styling, making it a halo performance model.

Production

Production Years:

2003-2010 (model years 2004-2010 in North America)

Assembly Locations:

Germany (Dingolfing Plant), Austria, South Africa, and other locations depending on market.

🏆 Awards & Recognition

Recognitions

Ward Auto Ten Best:

The 4.8L V8 engine in the 545i was a recipient of the prestigious Ward's 10 Best Engines award for its smooth power delivery and technology.

Automotive Journalism Reviews:

Consistently praised by automotive journalists for its engaging driving dynamics, refined interior, and technological innovation for its time.