BMW 5-Series E60 E61 Workshop Repair Service Manual 2007-2011 535i 535xi 535i GT 525i 528i 530i 550i PDF - MBMWE60E61OPES.zip

A full workshop, service and repair guide complete with electrical wiring schematics, covering every BMW 5'-series E60/E61 variant (petrol and diesel): 520i, 523i, 525i, 528i, 530i, 535i, 540i, 545i, 550i, M5, 520d, 525d FE, 530d and 535d — offering the technical detail needed to maintain, troubleshoot and overhaul your vehicle to the standard of a qualified technician.

The BMW E60/E61 All Models MY03-MY11 workshop service & repair manual contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 10,621 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Language: English

NA53 525i 2004-2005 (2003/09/01 to 2005/02/28)

NE53 525i 2006-2007 (2005/03/01 to 2007/02/28)

NU53 528i 2008-2010 (2007/03/01 to 2009/1 2/31 )

NA73 530i 2004-2005 (2003/01/01 to 2005/08/27)

NE73 530i 2006-2007 (2005/03/01 to 2007/02/28)

NW13 535i 2008-2010 (2007/03/01 to 2009/12/31)

NB33 545i 2004-2005 (2003/09/01 to 2005/08/31)

NB53 550i 2006-2007 (2005/09/01 to 2007/02/28)

NW53 550i 2008-2010 (2007/03/01 to 2009/12/31)

NF33 525xi 2006-2007 (2005/04/01 to 2007/02/28)

NV13 528xi 2008-2010 (2007/03/01 to 2009/12/31)

NF73 530xi 2006-2007 (2005/04/01 to 2007/02/28)

NV93 535xi 2008-2010 (2007/03/01 to 2009/12/31)

NN73 530xi Sport Wagon 2006-2007 (2005/04/01 to 2007/02/28)

PT73 535xi Sport Wagon 2008-2010

PT73 M5

MAIN SECTIONS

0 GENERAL DATA AND MAINTENANCE

1 ENGINE

2 TRANSMISSION

3 SUSPENSION, STEERING AND BRAKES

4 BODY

5 BODY EQUIPMENT

6 ELECTRICAL SYSTEM

7 EQUIPMENT AND ACCESSORIES

ELECTRICAL COMPONENT LOCATIONS

ELECTRICAL WIRING DIAGRAMS

ON-BOARD DIAGNOSTICS

TABLE OF CONTENTS (expanded view)

RAPAIR & MAINTENANCE

00 - MAINTENANCE & GENERAL NOTES

0000006 Vehicle test

0000009 Pre-delivery check

0000105 Standard scope of service

0000555 Interrogating fault memories in Diagnosis System

0000602 Service - air filter element

0000610 Service - engine oil

0000612 Service - front brakes

0000614 Service - rear brakes

0000616 Service - microfilter

0000618 Service - brake fluid

0000622 Service - spark plugs

0000624 Service - vehicle check

0000... Battery Checking display. If necessary, recharging battery

0000... Brake lines and connections visual inspection for leaks, damage, attachment and correct position

0000... Check horn, headlight flashers and hazard warning flashers

0000... Checking coolant level and concentration, correcting if necessary

0000... Checking instrument _ inscription lighting, interior _ luggage compartment _ glove box lights and blower

0000... Checking lighting system

0000... Checking of road safety (test drive)

0000... Check windscreen wash _ wipe system

0000... Diagnostic brief test

0000... Information _ warning labels

0000... Microencapsulated screws

0000... Resetting CBS display according to factory specification

0000... Seat belts Check condition of seat belt strap, check function of automatic reel, seat belt locking reel, seat belt buckle, seat belt clip and, if necessary, seat belt clasp

0000... Steering components Check for play, tightness, damage and wear

0000... Steering fluid fuel tank Check oil level

0000... Tyres checking and if necessary correcting inflation pressure, checking condition, tread depth and pattern

0000... Underbody incl. all visible components Check for damage, correct position, tightness, corrosion

0000... Vehicle care measures for inventory vehicles (new and used vehicles) as well as vehicles to be taken off the road that are in the hands of customers

0000... When driving on a race track

0000... Windscreen washer system checking fluid level, topping up if necessary

0000... Work instruction for removing the protective film

0001... Symbols used and information in repair instructions

0002000 Raising vehicle with trolley jack

0002001 Raising the vehicle using a vehicle lift

0011259 Oil change in rear differential incl. used oil disposal

0011500 Checking _ topping up oil level in automatic transmission (GA6HP26Z _ 6HP32Z)

0011... Checking _ topping up oil level in rear differential

0011... Information for handling the documents repair instructions, technical data, AZD

00... BMW Condition Based Service (petrol _ gasoline vehicles)

00 Danger of poisoning if oil is ingested _ absorbed through the skin

00... Notes on SMG transmission service functions

00 Risk of injury if oil comes into contact with eyes and skin

00 Safety instructions for handling oil

0 operating fluid overview

1100300 Engine oil consumption measurement

1200... Notes for disconnecting and connecting battery

5.1.1 Axles

6100... Notes on handling optical fibres

6100... Notes on handling the high pressure cleaner

6100... Notes on handling wiring harnesses and cables

6112... Information on intelligent battery sensor (IBS)

6120... Notes on AGM battery

6400... Information on using cleaning agent _ paints (personal protection equipment)

6450... Instructions for handling R 134a refrigerant

6452... Notes on changing the air conditioning compressor, determining the amount of refrigerant oil (amount of refrigerant oil of new air conditioning compressor not known)t

7.1.1 Installation safety of the seat belts _ seat belt buckles

7.11 Odometer (if present)

7.12 Driving dynamics control (Electronic Stability Program, ESP) (if installed _ required)

7.1.2 Status of the seat belts _ seat belt buckles

7.1.3 Belt force limiter

7.1.4 Seat belt tensioner

7.1.5 Airbag

7.1.6 Supplementary restraint systems (SRS)

Abbreviations

Addition to special tools cabinet All model series

Arguments pertaining to engine oil consumption

Battery recharging intervals for booth vehicles, battery charging calendars and battery tags (12-V battery, high-voltage battery unit)

Brake fluid - Operating Fluids Specification

Brake fluid service 342200223 Bonnet gas strut check with active pedestrian impact mitigation302240(SA8TF)

Brake fluid service E60, E61, E63, E64 (check water outlets in units compartment)

Brake fluid service - extension of the first brake fluid interval to 36 months

CBS general - Reset is lost

Changed emissions test indicator BMW Condition Based Service

Changed service interval 530i 550i (E60sec)

Changes in maintenance intervals (air cleaner, diesel fuel filter)

Complete vehicle

Drawbar load sign omitted All with options 235 and 3AC

Emergency Services (BMW _ MINI) from issue September 2009

Engine oil service - countries with higher levels of dust Check the air filter element for contamination

Engine oil - varying colours _ smell after initial filling in the works

Extract from BMW Group Standard302240GS30224090003-2

FEB-FEB-NED-TESTMODULE-AKTUELL

Final drive oil - new oil quality from 07 _ 2011

Form for equipotential bonding screw connections

General and legal information on performing the periodic exhaust-gas (emissions) test in EU countries

Handling the acoustic camera

Harmonisation of oil change intervals BMW

Ignition key data tapping on CBS vehicles

IMIB_Next

List of contents

M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2

M12 and M12x1.5 - maximum tightening torques acc. to BMW GS 90003-2

M14 and M14x1.5 - maximum tightening torques acc. to BMW GS 90003-2

M16 and M16x1.5 - maximum tightening torques acc. to BMW GS 90003-2

M18 and M18x1.5 - maximum tightening torques acc. to BMW GS 90003-2

M4 and M5 - maximum tightening torques acc. to BMW GS 90003-2

M6 and M7 - maximum tightening torques acc. to BMW GS 90003-2

M8 and M8 x 1 - maximum tightening torques acc. to BMW GS 90003-2

Main group 00

Master document for exhaust emission inspection (AU) target data

Modifications to 342200235Condition Based Service342200235 maintenance system

New CBS item Pre-delivery check E60, E61, E63, E64, E65, E66, E67, E87, E90

New Maintenance Records service booklet and maintenance documentation All models

New repair methods 342200235Gluing _ Riveting342200235 on steel bodies

Notes on radio-operated system (vehicle access, radio-operated opening, radio-operated closing)

Parking brake function check - new procedure in the standard service scope _ rear brake service

Reduced spark plug change intervals

Service Booklets Servicing records _ stamp spaces E60 E61 E63 E64 E65 E66 E67

Service intervals for countries with low fuel grade (SA988 _ SA8KE, SA8KM, SA984, SA8KK, SA8KL, SA8KH, SA8KP)

Service Sheets - Condition-based Service _ Pre-delivery Check (ISTA, ISPA, Commercial Service Data)

Service - vehicle check - revised maintenance scope

Standard work scope - expansion of work scope (with slide _ tilt sunroof and panorama glass roof)

Supplement for target exhaust emissions inspection data of BMW and MINI vehicles from 04 _ 2009. Modified test specifications for petrol lean-mixture engines N43 and N53. Test procedure for hybrid vehicles

Test instructions for the exhaust-gas (emissions) test on BMW vehicles with petrol engines

Test instructions for the exhaust gas test (AU) on BMW vehicles with diesel engines from European emission classification EURO 6

Test instructions for the exhaust gas test (AU) on BMW vehicles with petrol engines from European emission classification EURO 6

Towing

Visible corrosion on vehicle add-on parts

Workshop Equipment - Planning Documentation

Workshop equipment sales

11 - ENGINE

00 Danger of poisoning if oil is ingested _ absorbed through the skin

00 Risk of injury if oil comes into contact with eyes and skin

00 Safety instructions for handling oil

1100050 Removing and installing engine (N62 _ N62TU )

1100300 Engine oil consumption measurement

1100670 Securing engine in installation position (N62, N62TU)

1100... Engine oil consumption measurement

1100... Engine oil service (N62 _ N62TU)

1100... Overview of consumables (Electronic Parts Catalogue)

1100 Overview of tightening torques

1112005 Removing and installing _ sealing left cylinder head cover (N62 _ N62TU)

1112006 Removing and installing _ sealing right cylinder head cover (N62 _ N62TU)

1112105 Removing and installing left cylinder head (N62302240from3022409 _ 03 and N62TU)

1112106 Removing and installing right cylinder head (N62302240from3022409 _ 03 and N62TU)

1112503 Disassembling and assembling cylinder head (N62 _ N62TU)

1112527 Remachining a valve seat - cylinder head disassembled (N62)

1112595 Checking a valve guide for wear (N62)

1112719 Milling cylinder head sealing face (N62 _ N62TU)

1112729 Checking cylinder head for water leaks (N62 _ N62TU)

1112 Overview of Technical Data

1112 Overview of tightening torques

1113010 Removing and installing _ replacing oil sump top section (N62 _ N62TU)

1113020 Removing and installing _ replacing oil sump bottom section (N62 _ N62TU)

1114080 Removing and installing gear case cover, left top (N62 _ N62TU)

1114085 Removing and installing gear case cover, right top (N62 _ N62TU)

1114110 Removing and installing lower gear case cover (N62 _ N62TU)

1114141 Replacing radial shaft seal in timing case cover at bottom (N62 _ N62TU)

1114151 Replacing the crankshaft radial shaft seal (N62 _ N62TU)

1121500 Replacing crankshaft (N62 _ N62TU)

1121531 Replacing all main crankshaft bearing shells (N62 _ N62TU)

1122000 Removing and installing _ replacing flywheel (N62 _ N62TU )

1123010 Removing and installing _ replacing the vibration damper (N62 _ N62TU)

1123031 Removing and installing _ replacing vibration damper hub (N62 _ N62TU)

1124571 Replacing all conrod bearings (N62 _ N62TU)

1125530 Removing and installing _ replacing all pistons (N62TU)

1125671 Replacing piston rings on all pistons (N62)

1128010 Replacing drive belt for alternator (N62 _ N62TU)

1128050 Replacing A _ C compressor drive belt (N62)

1128050 Replacing A _ C compressor drive belt with belt tensioner (N62 _ N62TU)

1130 Overview of tightening torques

1131032 Removing and installing _ replacing left intake camshaft (N62302240from3022409 _ 03 and N62TU)

1131034 Removing and installing _ replacing right intake camshaft (N62302240from3022409 _ 03 and N62TU)

1131036 Removing and installing _ replacing left exhaust camshaft (N62 _ N62TU)

1131038 Removing and installing _ replacing right exhaust camshaft (N62 _ N62TU)

1131052 Replacing both timing chains (N62 _ N62TU)

1131070 Checking camshaft timing on left side (N62 _ N62TU)

1131071 Check the timing for the camshafts on the right (N62 _ N62TU)

1131573 Adjusting camshaft timing on left side (N62 _ N62TU)

1131574 Adjusting camshaft timing on right side (N62 _ N62TU)

1131 Overview of tightening torques

1133516 Removing and installing _ replacing rocker arms on left inlet side (N62 from 9 _ 03

1133517 Removing and installing _ replacing rocker arms on right inlet side (N62 from 9 _ 03 and N62TU)

1134552 Removing and installing _ replacing all valves (N62)

1134560 Replacing all valve stem seals (N62)

1134715 Replacing all valve springs (N62)

1134715 Replacing all valve springs (N62TU)

1136047 Removing and installing _ replacing inlet and exhaust adjustment units on left side (N62 _ N62TU)

1136048 Removing and installing _ replacing inlet and exhaust adjustment units on right side (N62 _ N62TU)

1136715 Removing and installing _ replacing both left solenoid valves (N62 _ N62TU)

1136720 Removing and installing _ replacing both right solenoid valves (N62 _ N62TU)

1137006 Removing and installing _ replacing left eccentric shaft (N62302240from30224010 _ 03 and N62TU)

1137008 Removing and installing _ replacing right eccentric shaft (N62302240from30224010 _ 03 and N62TU)

1137012 Remove and install _ replace left intermediate lever (N62302240as of 9 _ 03 and N62TU)

1137014 Remove and install _ replace right intermediate lever (N62302240as of 9 _ 03 and N62TU)

1137022 Removing and installing _ replacing servomotor for left eccentric shaft (N62 _ N62TU)

1137024 Removing and installing _ replacing servomotor for right eccentric shaft (N62 _ N62TU)

1137035 Removing and installing _ replacing left eccentric shaft sensor (N62 _ N62TU)

1137040 Removing and installing _ replacing right eccentric shaft sensor (N62 _ N62TU)

1140000 Checking engine oil pressure

1141000 Removing and installing _ replacing oil pump (N62)

1143000 Removing and installing _ sealing guide tube for oil dipstick (N62)

1151000 Removing and installing _ replacing water pump (N62 _ N62TU)

1153000 Removing and installing _ replacing coolant thermostat (N62)

1161050 Removing and installing intake plenum (N62)

1166000 Removing and installing _ replacing vacuum pump (N62 _ N62TU)

1172000 Removing and installing _ replacing air pump (N62)

1178530 Replacing left oxygen control sensor (N62 _ N62TU)

1178533 Replacing right oxygen control sensor (N62 _ N62TU)

1178540 Replacing left oxygen monitor sensor (N62 _ N62TU)

1178543 Replacing right oxygen monitor sensor (N62 _ N62TU)

11. . . . . Equipment recoding special tool number of the transverse member for fixing the engine in the installation location

11 operating fluid overview

1213511 Replacing the ignition coil (N62TU)

6.1.9 Engine performance

6453... Instructions for desiccant insert replacement

6453... Instructions for replacement of air conditioning capacitors and radiator _ coolers

8-cylinder spark-ignition engine N62TU E60, E61, E63, E64, E65, E66, E70

9.0 BMW Longlife-17 FE+

BMW Quality Longlife-04 All

Camshaft

Case Covers

Cleaning the cylinder head intake ports and the combustion chamber with the walnut blaster

Connecting Rods and Bearings

Crankshaft and Bearings

Cylinder Head with Cover, BMW, N62TU

Cylinder Head with Cover

Cylinder Head with Valve Seat Cover, BMW, N62TU, B40

Emissions-control, Lambda oxygen sensor

Engine Block, Cylinder Crankcase, BMW, N62TU, B40

Engine block

Engine identification

Engine in general, BMW, N62TU, B40

Flywheel

Form for equipotential bonding screw connections

Guide tube for oil dipstick

Intake manifold

Leak-testing the air-intake system

Main group 11

Misfiring Engines N40 N42 N45 N46 N52 N62 N62TU N73

Oil Filter and Lines

Oil Pan

Oil Pump with Strainer and Drive

Oil pump with strainer and motor

Oil supply

Pistons with Rings and Pins, BMW, N62TU, B40

Pistons with Rings and Pins

Release _ pressing-off tool

Removing acoustic cover (N62 _ N62TU)

Removing radiator cover

Standard screw connection

Starter and Mounting Parts

Starter cable

Starter line

Thermostat

Vacuum pump

Vacuum supply All models

Valves with Springs, BMW, N62TU, B40

Variable Camshaft Control

Variable valve gear

Vibration damper

V-ribbed belt with Tension and Deflection Element

Water Pump and Drive

Wires to starter