2003-2010 BMW 5 Series E60 Service and Repair Manual

This 2003–2010 BMW 5 Series (E60/E61) Service and Repair Manual Covers

Engine & Drivetrain

• Four-, six-, eight-, and ten-cylinder petrol engine servicing
• Four- and six-cylinder diesel engine servicing
• BMW engine management system diagnostics
• Fuel injection and ignition system repairs
• Turbocharger servicing (diesel and turbocharged petrol models)
• Double VANOS diagnostics
• Valvetronic system servicing (where equipped)
• Engine cooling and lubrication system servicing
• Exhaust and emissions control system repairs
• 6-speed manual transmission servicing
• 6-speed automatic transmission diagnostics and repair
• SMG transmission servicing (M5 models)
• Rear-wheel drive and xDrive drivetrain servicing
• Differential, driveshaft, and axle repairs

Chassis & Suspension

• Front and rear suspension diagnostics
• Dynamic Drive diagnostics (where equipped)
• Electronic Damper Control (EDC) servicing (where equipped)
• Active Steering diagnostics (where equipped)
• Wheel alignment specifications
• Suspension component inspection and replacement
• Wheel bearing servicing

Braking Systems

• Anti-lock Braking System (ABS)
• Dynamic Stability Control (DSC)
• Dynamic Traction Control (DTC)
• Cornering Brake Control (CBC)
• Electronic Brakeforce Distribution (EBD)
• Brake Assist diagnostics
• Electronic parking brake servicing (where equipped)

Electrical & Wiring

• Complete factory wiring diagrams
• CAN Bus, LIN Bus, and MOST Bus diagnostics
• Intelligent Battery Sensor (IBS) diagnostics
• Charging and starting system diagnostics
• Car Access System (CAS) diagnostics
• Light Module (LM) diagnostics
• Power distribution, fuse, and relay assignments
• iDrive and CCC/CIC infotainment diagnostics
• Instrument cluster diagnostics
• Adaptive Xenon headlamp diagnostics (where equipped)

Driver Assistance Systems

• Active Cruise Control (where equipped)
• Park Distance Control (PDC)
• Head-Up Display (where equipped)
• Lane Departure Warning (where equipped)
• Night Vision diagnostics (where equipped)
• Rain and light sensor diagnostics

Air Conditioning & HVAC

• Automatic climate control diagnostics
• HVAC control module servicing
• Refrigerant recovery and recharge procedures
• Heating and ventilation system repairs

Body & Interior

• Comfort Access diagnostics (where equipped)
• Central locking and window control diagnostics
• Power seat adjustment and memory functions
• Steering column adjustment diagnostics
• Interior trim removal and installation
• Exterior body repair procedures
• Airbag (SRS) system diagnostics

Diagnostics & Troubleshooting

• BMW ISTA/D and DIS diagnostic procedures
• Fault code (DTC) diagnostics
• Control module coding and programming
• Component activation and testing
• Electrical troubleshooting procedures
• Condition-Based Service (CBS) reset procedures

Common Error Codes Covered

This manual provides diagnostic and repair procedures for common BMW manufacturer-specific fault codes, including:

Engine Codes

• 2A82 – VANOS Intake Variable Camshaft Timing Fault
• 2A87 – VANOS Exhaust Variable Camshaft Timing Fault
• 30FF – Turbocharger Boost Pressure Too Low
• 2AAF – Fuel Pump Plausibility Fault
• 2E81 – Electric Coolant Pump Speed Deviation

Transmission Codes

• 4F85 – Gear Ratio Monitoring Fault
• 4F8A – Transmission Shift Monitoring Fault
• 507D – Transmission Control System Fault

ABS & Chassis Codes

• 5DF0 – Hydraulic Unit Pump Motor Fault
• 5E40 – Steering Angle Sensor Calibration Required
• 5DB3 – Wheel Speed Sensor Fault

Network Communication Codes

• A0B4 – Car Access System (CAS) Communication Fault
• A559 – Power Management Fault
• 9C54 – LIN Bus Communication Fault

Body Control Codes

• A6CF – Power Window Anti-Trap Fault
• A670 – Steering Column Adjustment Fault
• A8C4 – Comfort Access System Fault

The manual also includes hundreds of additional BMW-specific fault codes, wiring diagrams, diagnostic flowcharts, control module programming procedures, and factory repair specifications.

Who Is This Manual For?

• BMW dealership technicians
• Independent European vehicle repair workshops
• BMW performance specialists
• Automotive technicians
• Fleet maintenance professionals
• Experienced DIY mechanics

If you are servicing, maintaining, diagnosing, or repairing a 2003–2010 BMW 5 Series (E60/E61), this factory workshop manual provides the complete procedures and technical information required to perform repairs to BMW factory standards.

This manual applies to the 2003 BMW 5 Series, 2004 BMW 5 Series, 2005 BMW 5 Series, 2006 BMW 5 Series, 2007 BMW 5 Series, 2008 BMW 5 Series, 2009 BMW 5 Series and 2010 BMW 5 Series.