🏷️ Basic Information

Make:

BMW

Model:

Sedan

Year:

2004

Chassis Code:

E60 (for 5 Series sedan)

Engine Codes Likely:

N52, N62 (depending on specific sedan model and engine)

👋 Introduction

Segment:

Executive/Luxury Sedan

Target Audience:

Owners seeking in-depth maintenance and repair knowledge, independent repair shops, enthusiasts.

Key Competitors 2004:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Cadillac CTS, Acura TL

Bmw Philosophy:

'The Ultimate Driving Machine' - emphasis on performance, handling, and advanced technology.

2004 Model Highlights:

Introduction of the E60 generation for the 5 Series, significant technological advancements, new engine options.

📋 Manual Details

Primary Regions:

North America, Europe (common for BMW manuals)

Language:

English

Manual Type:

Full Service Repair Manual

Estimated Page Count:

1500-2500+ (typical for comprehensive BMW service manuals)

Format:

Digital (PDF) likely, with potential for printed versions

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, timing system, cooling system, lubrication system, fuel system (injectors, pumps, lines)

Engine Management:

Engine Control Unit (ECU) diagnostics, sensor testing, ignition system, emission control systems (e.g., VANOS, Valvetronic)

Transmission:

Automatic transmission (e.g., GM 5L40-E, ZF 6HP series) and Manual transmission (e.g., Getrag GS6-37DZ), clutch system, torque converter, transmission control module (TCM)

Drivetrain:

Front-wheel drive (FWD) or Rear-wheel drive (RWD) specific components, differential, drive shafts, CV joints, axles

Suspension:

Front suspension (McPherson strut, multi-link), rear suspension (multi-link), springs, shock absorbers, control arms, bushings, anti-roll bars

Steering:

Power steering system (hydraulic or electric), steering rack, tie rods, steering column, steering angle sensor

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake calipers, rotors, pads, brake lines, master cylinder, brake booster

Electrical System:

12V battery, alternator, starter motor, fuse box locations, wiring diagrams, relays, power distribution

Body And Chassis:

Body panels, doors, hoods, trunk lid, bumpers, frame repair, corrosion protection

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, blower motor, A/C compressor, refrigerant, evaporator, heater core

Interior Trim:

Dashboard, door panels, seats, headliner, carpeting, console removal and installation

Lighting:

Headlights, taillights, interior lighting, fog lights, bulb replacement, wiring for lighting circuits

Infotainment And Electronics:

Radio/navigation system (iDrive), audio components, instrument cluster, communication systems

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement

Troubleshooting Diagnostics:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, wiring diagrams for fault tracing

Component Replacement:

Removal and installation of major and minor components (e.g., water pump, alternator, starter, fuel injectors, brake pads, sensors)

Rebuilding Overhauling:

Engine rebuild procedures, transmission overhaul, differential rebuild

Electrical Component Repair:

Repair of wiring harnesses, connector replacement, diagnosis of electrical faults

Bodywork And Paint:

Panel alignment, rust repair, minor body panel replacement, paint preparation (basic)

Software Updates:

Potential guidance on ECU software updates or module programming (may require specialized tools)

Wheel Alignment:

Specifications and procedures for wheel alignment

Tire Mounting And Balancing:

Specifications for tire mounting and balancing

Safety System Diagnostics:

ABS, DSC, airbag system troubleshooting (may require specialized diagnostic equipment)

Depth:

Comprehensive: Covers everything from basic maintenance to advanced diagnostics and component overhauls.

Diagnostic Focus:

Detailed diagnostic procedures, including symptom analysis and step-by-step troubleshooting guides.

Torque Specifications:

Extensive torque specifications for all fasteners and critical components.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems.

Special Tools:

Identification and usage of BMW-specific special tools required for certain procedures.

📊 Manual Specifications

Digital Format:

Searchable PDF, high-resolution images and diagrams.

Print Readability:

Clear and legible text, high-quality illustrations and diagrams suitable for printing.

Binding If Printed:

Likely professional perfect binding or spiral binding for ease of use on a workbench.

Paper Quality If Printed:

Durable, glossy paper for diagrams and photographs; standard matte paper for text.

⚙️ Engine Specifications

Common Engine Options 2004 Sedan:

3.0L Inline-6 (e.g., N52), 4.4L V8 (e.g., N62)

Inline 6 Horsepower Approx:

225-255 hp (depending on specific variant like 530i)

V8 Horsepower Approx:

325-360 hp (depending on specific variant like 545i)

Torque Figures Approx:

215-270 lb-ft (Inline-6), 315-360 lb-ft (V8)

Fuel Injection:

Electronic Fuel Injection (EFI) - typically multi-point or direct injection (DI) on newer models.

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Variable Valve Timing:

VANOS (Variable Valve Timing) is standard on most engines of this era.

Valvetronic Availability:

Valvetronic (electronically controlled valve lift) introduced on some engines, contributing to efficiency.

🔧 Transmission

Standard Transmission Type:

Likely 6-speed manual or 6-speed automatic transmission depending on model and market.

Optional Transmission Type:

SMG (Sequential Manual Gearbox) was an option on some performance models (e.g., M Sport).

Automatic Transmission Features:

Steptronic (manual shifting mode), adaptive shift programs.

Automatic Transmission Fluid:

Specific ATF (e.g., Dexron VI or proprietary BMW fluid like LT-3/LT-5) – critical for longevity.

Manual Transmission Fluid:

Specific manual transmission fluid (e.g., gear oil SAE 75W-90 GL-4/GL-5)

📐 Dimensions

Length Approx:

Approx. 191-193 inches (depending on specific sedan model, e.g., 5 Series E60)

Width Approx:

Approx. 71-73 inches

Height Approx:

Approx. 57-58 inches

Curb Weight Approx:

Approx. 3500-3900 lbs (depending on engine and features)

🛡️ Safety Features

NHTSA Crash Test Results:

Likely achieved high ratings (e.g., 4 or 5 stars) in frontal and side impact tests from NHTSA.

IIHS Crash Test Results:

Likely received 'Good' ratings in IIHS crash tests for frontal offset and side impact.

ABS:

Standard Anti-lock Braking System (ABS)

Dsc:

Standard Dynamic Stability Control (DSC) or similar electronic stability system.

Traction Control:

Standard Traction Control System (TCS).

Airbags:

Multiple airbags: Frontal, side-impact, and potentially curtain airbags.

Seatbelts:

Pretensioning seatbelts with force limiters.

Body Structure:

Reinforced safety cell, crumple zones.

💡 Technology Features

I Drive System:

Introduction of the iDrive infotainment controller and system, offering centralized control for navigation, audio, climate, and vehicle settings.

Navigation System:

Optional professional navigation system with CD-ROM maps.

Audio Systems:

Standard BMW Professional Radio, optional Harman Kardon surround sound system.

Parking Assist:

Optional Park Distance Control (PDC) - front and rear.

Cruise Control:

Standard cruise control, optional Active Cruise Control (ACC) with adaptive cruise functionality.

Bluetooth Integration:

Optional Bluetooth hands-free connectivity for mobile phones.

Headlights:

Standard halogen headlights, optional Xenon Adaptive Headlights for improved night vision.

🔧 Maintenance

Oil Change Interval:

Typically 10,000-15,000 miles or 12-24 months, depending on oil type and driving conditions (often indicated by the car's condition-based service system - CBS).

Air Filter Replacement:

Every 30,000-50,000 miles or as indicated by service indicators.

Cabin Air Filter Replacement:

Every 15,000-30,000 miles or annually.

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Spark Plug Replacement:

Varies by engine: typically 60,000 miles for standard plugs, up to 100,000 miles for iridium or platinum plugs.

Engine Oil Specification:

BMW Longlife-01 (LL-01) or BMW Longlife-04 (LL-04) approved synthetic oil, typically 5W-30 or 0W-30.

Coolant Specification:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based), mixed 50/50 with distilled water.

Power Steering Fluid:

BMW Power Steering Fluid (PSF) or Pentosin CHF 11S for hydraulic systems.

Common E60 Issues:

Oil leaks from valve cover gasket and oil pan gasket, PCV system issues, power steering hose leaks, water pump failures, swirl flap issues on diesel variants (if applicable), crankcase ventilation (CCV) system blockages.

E60 Electrical Issues:

Water ingress into headlight modules, battery discharge issues due to parasitic draw, iDrive system glitches, sensor failures (e.g., ABS wheel speed sensors).

📚 Vehicle History

Bmw Legacy:

Renowned for engineering excellence, performance, and luxury since its founding in 1916.

E60 Introduction:

The 2004 model year marks the introduction of the E60 generation for the BMW 5 Series sedan, replacing the E39. It featured a significant redesign and new technological integrations.

Manufacturing Locations:

Primary manufacturing plants in Germany (e.g., Dingolfing), with potential assembly in other global locations.