🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E60 (Sedan), E61 (Wagon/Touring)

Covered Models:

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

Model Years:

2003, 2004, 2005, 2006, 2007

👋 Introduction

Segment:

Executive Sedan/Wagon

Target Audience:

Luxury car buyers, performance enthusiasts

Competitors:

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

Platform Innovation:

Introduction of iDrive infotainment system, advanced chassis dynamics (Dynamic Drive, Adaptive Drive options)

Engine Options:

Wide range of inline-6 and V8 gasoline engines, including high-performance M5 variant

📋 Manual Details

Coverage Type:

Complete Factory Service Repair Workshop Manual

Download Format:

PDF

Accessibility:

Instant download, usable on multiple devices

Licensing:

Lifetime usage, no expiry or renewal fees

Compatibility:

Windows and macOS

Estimated Pages:

Hundreds of pages (specific count not provided but described as extensive)

Type:

Service Repair Workshop Manual

Language:

English (assumed based on product description)

File Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, rebuilding, cylinder head, pistons, crankshaft, camshaft, timing systems (chain/belt), lubrication, cooling

Engine Performance:

Fuel injection systems (direct and indirect), ignition systems, emissions control, engine management systems (DME), turbocharging/supercharging (where applicable)

Transmission Manual:

Manual gearbox repair, clutch system, shift mechanisms

Transmission Automatic:

Automatic transmission repair, valve body, torque converter, transmission control unit (TCU), fluid servicing

Drivetrain:

All-wheel drive (xDrive) system, differential (front, rear, center), drive shafts, axles, CV joints

Suspension:

Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, steering linkage

Steering:

Power steering system (hydraulic/electric), steering rack, steering column, wheel alignment specifications

Brakes:

Brake system overhaul, disc brakes, calipers, pads, rotors, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), EBD (Electronic Brakeforce Distribution), brake fluid specifications

Electrical System:

Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), charging system

Body And Chassis:

Body panel removal/installation, doors, hood, trunk, bumpers, chassis structure, rust repair, corrosion prevention

Interior:

Dashboard removal, seats, upholstery, trim panels, climate control system (HVAC), audio systems, airbags

Climate Control:

HVAC system components, refrigerant handling, blower motor, climate control modules, cabin air filter replacement

Infotainment And Electronics:

iDrive system, navigation, audio components, dashboard displays, sensors, control modules (ECU, TCU, ABS module, etc.)

Diagnostic Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, diagnostic tool usage (e.g., ISTA/D, DIS)

Scheduled Maintenance:

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

Repair Procedures:

Step-by-step instructions for all major repairs, component replacement, and system overhauls

Troubleshooting:

Systematic diagnosis of common and uncommon problems with detailed troubleshooting trees

Inspections:

Pre-purchase inspections, routine inspections, specific component checks

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Technical Data Specifications:

Torque specifications, clearances, fluid capacities, pressure readings, diagnostic values

Depth:

Professional-level repair and diagnostic information

Detail Level:

Detailed photos, exploded diagrams, step-by-step instructions

Rebuild Instructions:

Complete engine and transmission rebuild procedures

📊 Manual Specifications

Format:

PDF

Printability:

Printable pages (single or full manual)

Binding:

N/A (Digital download)

Paper:

N/A (Digital download)

⚙️ Engine Specifications

525I (2003-2005):

2.5L M54B25 Inline-6

525I (2006-2007):

3.0L N52B30 Inline-6

528I:

Discontinued in North America for E60 generation after 2000 model year, but models exist in other markets.

530I:

3.0L M54B30 Inline-6 (2003-2005), 3.0L N52B30 Inline-6 (2006-2007)

535I:

3.0L N54B30 Twin-Turbo Inline-6 (introduced 2007)

545I:

4.4L N62B44 V8

550I:

4.8L N62B48 V8

M5:

5.0L S85B50 V10

Horsepower Range:

Approx. 215 hp (525i M54) to 500 hp (M5 S85)

Torque Range:

Approx. 214 lb-ft (525i M54) to 383 lb-ft (M5 S85)

Injection Type:

Sequential Multi-Point Fuel Injection (MPI) for N/A, Direct Injection (DI) for N54, Naturally Aspirated for S85

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

🔧 Transmission

Transmission Standard Options:

6-speed manual (standard on some models), 6-speed Steptronic automatic

Transmission Optional Options:

6-speed SMG III (Sequential Manual Gearbox) for M5

Gearbox Features:

Adaptive shift logic, manual shifting via selector lever or paddle shifters (optional)

📐 Dimensions

Sedan Length:

Approx. 191.1 inches (4855 mm)

Wagon Length:

Approx. 193.1 inches (4906 mm)

Width:

Approx. 72.1 inches (1831 mm)

Height:

Approx. 57.7 inches (1466 mm) for sedan, 57.0 inches (1448 mm) for wagon

Wheelbase:

Approx. 116.4 inches (2956 mm)

Curb Weight Range:

Approx. 3,700 lbs to over 4,000 lbs (depending on engine and options)

🛡️ Safety Features

NHTSA Front Impact:

5-star rating (for applicable models/years)

IIHS Top Safety Pick:

Awarded Top Safety Pick for various model years within this range

Active Safety Systems:

ABS, DSC, Traction Control (ASC+T), Dynamic Drive (optional), Active Steering (optional), Run-Flat Tires

Passive Safety Features:

Front airbags, side airbags, curtain airbags, active head restraints, front and rear crumple zones

💡 Technology Features

Infotainment System:

iDrive (IDrive Controller, CCC - Car Communication Computer)

Navigation:

Optional professional navigation system with DVD maps

Audio:

Professional Hi-Fi audio system, optional Harman Kardon surround sound

Driver Assistance Features:

Optional: Adaptive Cruise Control (ACC), Head-Up Display (HUD), Parking Distance Control (PDC), Xenon Adaptive Headlights, Lane Departure Warning

Connectivity Options:

Bluetooth connectivity for phone, USB interface (later models/options), SiriusXM satellite radio

🔧 Maintenance

Oil Change Interval:

Variable, often indicated by Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually

Brake Fluid Flush:

Every 2 years

Coolant Flush:

Initial: 4 years, then every 2 years thereafter (BMW Blue or similar approved coolant)

Engine Oil:

SAE 5W-30 or 5W-40 Synthetic, meeting BMW LL-01 or LL-04 specifications (check specific engine)

Transmission Fluid Auto:

BMW ATF LT-5 (e.g., Esso/Mobil LT 71141) or equivalent spec for GM 5-speed/6-speed auto

Power Steering Fluid:

Pentosin CHF 11S or equivalent

Common Issues E60:

Water pump/thermostat failures (especially with N52/N54), VANOS solenoids/seals, oil leaks (valve cover gaskets, oil pan gaskets), CCV system issues (N52), ignition coil failures, eccentric shaft sensor failure (N62), power steering leaks, EGS (transmission control module) failures, iDrive system glitches, active steering pump failure.

📚 Vehicle History

Brand Focus:

Performance, luxury, engineering excellence

Generation:

E60/E61 generation, replacing the E39 5 Series

Design Language:

Introduction of Chris Bangle's controversial 'flame surfacing' design language

Production Period:

2003-2010 (E60/E61 generation); Manual covers 2003-2007 portion of this generation.

🏆 Awards & Recognition

Car And Driver 10 Best:

5 Series (E60) named to Car and Driver's 10 Best list multiple times during its production run.

Motor Trend Car Of The Year:

Competitors often featured, but E60 itself did not win this specific award during its main production years.

Jdp Power Initial Quality:

Typically received good to above-average ratings in J.D. Power studies for its class.