Market Position:
The BMW E60, particularly the 5 Series sedan and wagon, represented BMW's executive car segment during its production run. Known for its blend of luxury, performance, and advanced technology, it competed with vehicles like the Mercedes-Benz E-Class and Audi A6.
Brand Perception:
BMW is perceived as a manufacturer of high-performance luxury vehicles, emphasizing driving pleasure, advanced engineering, and premium quality.
Competitive Analysis:
The E60 continued BMW's legacy of driver-focused vehicles. Its advanced iDrive infotainment system, sophisticated chassis dynamics, and a range of powerful inline-six and V8 engines positioned it as a premium offering in its class. This manual provides the essential information to maintain these complex systems.
Key Features:
The E60 generation introduced significant technological advancements for BMW, including the iDrive system, Active Steering, and advanced electronic driver aids. The availability of various engine options, from efficient six-cylinders to potent V8s and M performance variants, offered a diverse lineup.
Systems Covered:
General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection, Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle, and more.
Engine Mechanical:
Covers engine disassembly, assembly, component identification, torque specifications, timing procedures, and rebuild instructions for various engine variants (e.g., N52, N62, M57).
Transmission Mechanical:
Detailed procedures for manual and automatic transmission servicing, repair, clutch replacement, torque converter servicing, and differential/drive axle maintenance.
Brake System:
Includes comprehensive information on hydraulic brake systems, ABS components, electronic parking brake (EPB) service (if applicable), brake pad/rotor replacement, caliper overhaul, and bleeding procedures.
Electrical System:
Extensive coverage of the E60's complex electrical architecture, including detailed wiring diagrams, fuse box layouts, component testing, diagnostic procedures for modules (e.g., DME, EGS, ABS/DSC), and troubleshooting common electrical faults.
Suspension Steering:
Covers front and rear suspension components, steering rack service, power steering system, wheel alignment procedures, and replacement of control arms, ball joints, and shock absorbers.
Cooling Fuel Emission:
Details on cooling system components (radiator, water pump, thermostat), fuel injection systems, fuel pump and filter replacement, emission control systems, and related sensors and actuators.
HVAC Body Interior:
Instructions for servicing the climate control system (heater core, A/C compressor, refrigerant), body panel removal and installation, interior trim components, and safety restraint systems (airbags, seat belts).
Procedures Included:
Step-by-step instructions for complete disassembly and reassembly, diagnostics, repair, replacement, and routine maintenance.
Troubleshooting Guides:
Diagnostic flowcharts and tables to help identify and resolve common vehicle malfunctions, from engine performance issues to electrical gremlins.
Maintenance Schedules:
Recommended service intervals for routine maintenance tasks such as oil changes, filter replacements, fluid checks, brake inspections, and spark plug changes.
Technical Specifications:
Includes torque specifications for critical fasteners, fluid capacities, engine compression ratios, bore/stroke dimensions, and other essential technical data for accurate repairs.
Diagnostic Codes:
Guidance on interpreting OBD-II diagnostic trouble codes (DTCs) related to engine management, ABS, airbags, and other systems.
Technical Depth:
Detailed procedures suitable for both DIY enthusiasts and experienced mechanics, including hundreds of photos and illustrations for guidance.
File Format Details:
PDF, compatible with Adobe PDF Reader. Searchable text is highly probable for PDF manuals of this nature.
Compatibility:
Compatible with all versions of Windows and Mac operating systems. Accessible via web browser on any computer or mobile device.
Requirements:
Requires Adobe PDF Reader and Winzip (both free downloads) for full functionality.
Printability:
Printable (entire manual or specific pages), allowing users to take physical copies to the workshop.
Binding Type:
N/A (Digital PDF format, no physical binding).
Paper Type:
N/A (Digital PDF format, no physical paper).
Engine Variants:
The E60 platform was offered with a wide array of gasoline and diesel engines. Key gasoline engines include the N52 (naturally aspirated inline-6), N62 (naturally aspirated V8), and N54/N55 (twin-turbocharged inline-6 for later models and M variants). Diesel options typically included M57 (turbocharged inline-6).
Engine Codes Examples:
N52B30 (3.0L Inline-6), N62B48 (4.8L V8), S85B50 (5.0L V10 - M5).
Engine Performance:
Horsepower and torque varied significantly by engine. For example, the 530i (N52) typically produced around 255 hp, while the 550i (N62 V8) offered around 360 hp. The M5 variant (S85 V10) delivered a remarkable 500 hp.
Fuel System Type:
Most E60 models feature sophisticated multi-point fuel injection (MPI) or direct injection (DI) systems, managed by advanced Engine Control Units (ECUs).
Exterior Dimensions:
Specific dimensions vary by body style (Sedan/Touring). For the Sedan (E60): Length approx. 191.1 inches, Width approx. 72.5 inches, Height approx. 57.5 inches. Wheelbase approx. 116.4 inches.
Interior Dimensions:
The E60 offers a spacious and luxurious interior, characteristic of BMW's executive sedan class, with ample legroom and headroom for front and rear passengers.
Cargo Capacity:
Trunk capacity for the E60 sedan is approximately 15 cubic feet. The E61 Touring offers significantly more cargo space, particularly with the rear seats folded down.
Curb Weight:
Curb weight varies by engine and drivetrain, typically ranging from around 3,500 lbs for base models to over 4,000 lbs for V8 or xDrive variants.
Safety Ratings:
The E60 generally performed well in safety tests for its era. Specific ratings from NHTSA and IIHS vary by model year and test configuration but typically indicate good structural integrity.
Active Safety Features:
Standard safety features included ABS, traction control (DSC), stability control (DSC), and front/side airbags. Optional features could include adaptive headlights, lane departure warning, and active cruise control.
Passive Safety Features:
Multiple airbags (front, side, head protection), crumple zones, and a reinforced safety cell are standard passive safety features.
Infotainment System:
The E60 features the iDrive infotainment system, which controls navigation, audio, climate, and vehicle settings via a central controller and screen. Later models saw updates to the iDrive interface and increased functionality.
Idrive Versions:
The E60 saw the introduction and evolution of the iDrive system, starting with the original CCC (Car Communication Computer) and progressing to the updated CIC (Car Information Computer) in later model years.
Driver Assistance Features:
Available driver assistance systems include Park Distance Control (PDC), adaptive cruise control, lane departure warning, and automatic high beams. The manual details the operation and maintenance of these systems.
Connectivity Features:
Connectivity typically includes Bluetooth for hands-free calling and audio streaming, and USB interfaces for media playback on models equipped with the enhanced Bluetooth or USB adapter.
Service Intervals:
BMW's Condition Based Service (CBS) system monitors various fluid levels and component wear, providing timely service reminders. Typical intervals for oil changes are around 10,000-15,000 miles, with major services (spark plugs, brake fluid) every 30,000-60,000 miles, depending on engine and driving conditions.
Engine Oil Specification:
BMW recommends specific synthetic engine oils meeting BMW Longlife specifications, such as LL-01 or LL-04, with viscosities typically being 0W-30 or 5W-30 depending on climate. Referencing the manual for exact engine-specific recommendations is crucial.
Coolant Specification:
BMW Blue Coolant (G48) or equivalent antifreeze meeting BMW specifications.
Brake Fluid Specification:
DOT 4 High Performance brake fluid.
Transmission Fluid Spec Auto:
ZF Lifeguardfluid 6 (for 6HP transmissions) or equivalent.
Transmission Fluid Spec Manual:
BMW's specific manual transmission fluid (MTF) or approved equivalents, depending on gearbox type.
Common Issues:
Common E60 issues include cooling system leaks (water pump, thermostat), VANOS solenoid failures, ignition coil failures, active steering pump issues, and potential battery/alternator problems. Early models with the N62 V8 engine can be prone to oil consumption and valve stem seal wear.
E60 Specific Issues:
Water pump failures (plastic impeller), alternator pulley bearing failure, eccentric shaft sensor issues (N52), oil filter housing gasket leaks, and stepper motor failure in HVAC are commonly reported.
Brand Heritage:
BMW, founded in 1916, has a long-standing reputation for producing premium, performance-oriented vehicles, often referred to as the 'Ultimate Driving Machine'.
Model Evolution:
The E60 generation succeeded the E39 5 Series and was produced from 2003 to 2010. It marked a significant departure in styling and technology, introducing controversial design elements by Chris Bangle and the first iteration of the iDrive system.
Facelift:
The E60 received a mid-cycle facelift (LCI) around 2007, introducing updated styling cues, revised iDrive, and powertrain enhancements.
Production Location:
The E60 was primarily manufactured at BMW's Dingolfing plant in Germany. Other assembly locations existed in various countries for different markets.
