BMW 5 Series G30 - Service Manual - Repair Manual

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BMW 5 SERIES (G30) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for vehicles BMW 5 Series G30.
 
CONTENTS:

REPAIR INSTRUCTIONS

00 Maintenance and general note
- 00 Maintenance
- 01 Safety information, note regarding the handling of the repair instructions
- 02 Raise vehicle and tow away
- 03 Tightening specifications
- 04 12 V vehicle electrical system
- 05 High-voltage electrical system
- 06 Vehicle-specific notes
- 07 Operating fluids
- 10 Heating/air conditioning system
- 11 General maintenance

11 Engine
- 00 Engine
- 12 Cylinder head with lid
- 13 Oil sump
- 14 Case Covers
- 15 Crankcase ventilation
- 21 Crankshaft and Bearings
- 22 Flywheel
- 23 Vibration damper
- 24 Connecting Rods and Bearings
- 25 Pistons with Rings and Pins
- 27 Counterbalance shafts
- 28 Drive belt with tensioning and deflecting element
- 31 Camshaft
- 33 Rocker arm with bearing
- 34 Valves with springs
- 36 Variable camshaft control
- 37 Variable valve gear
- 40 Oil supply
- 41 Oil pump with strainer and motor
- 42 Oil filters and lines
- 44 Oil cooler with supply and drain lines
- 51 Coolant pump with drive
- 53 Thermostat and engine-proof coolant lines
- 61 Intake manifold
- 65 Charger with control
- 66 Vacuum pump
- 74 Exhaust-gas recirculation valve
- 78 CO adjustment, oxygen sensor
- Engine

12 Engine electrical system
- 00 Engine electrical system
- 12 Ignition lead, spark plugs
- 13 Ignition coil
- 14 Electronic Shift Units or Control Units
- 35 Electrical machines
- 36 Control of hybrid / E-drive
- 41 Starter motor with mounting
- 42 Starter line
- 51 Engine wiring harness
- 61 Oil pressure, oil temperature, oil level display
- 63 Switches and relays
- 90 Control unit box
- Engine electrical system

13 Fuel preparation and control
- 00 Fuel preparation, check
- 31 Fuel pump with drive and line
- 51 Injection pump, control section, mixture control unit
- 53 Fuel Injector Nozzles and Lines
- 54 Throttle valve and operation
- 62 Senders for Control Unit
- 71 Intake silencer
- 72 Air filter
- 90 Carbon canister ventilation

16 Fuel supply
- 00 Fuel supply
- 11 Fuel tank with fuel filler pipe
- 12 Lines
- 13 Crankcase ventilation, emission monitoring
- 14 Delivery, preparation and content measurement, control units, electric fuel pump
- Fuel supply

17 Cooling
- 00 Cooling, check
- 10 Radiator, expansion tank, lines
- 11 Engine oil cooler and mounting parts
- 21 Oil cooler
- 22 Oil cooler lines
- 51 Charge air cooler with mounting
- 61 Auxiliary coolant pump for electric motor
- Cooling

18 Exhaust system
- 00 Exhaust system
- 12 Silencer
- 31 Exhaust pipe with suspension
- 32 Exhaust gas catalytic converter

22 Engine and transmission mounting
- 11 Engine mounting
- 32 Transmission mounting, automatic transmission

23 Manual gearbox
- 00 Manual gearbox
- Manual gearbox

24 Automatic transmission
- 00 Automatic transmission
- 11 Transmission Case, Oil Sump
- 13 Transmission Extension, Bearings, Sealing Ring
- 14 Mechanical attachments
- 30 Electro-hydraulic control parts and elements
- 31 Oil pump
- 34 Shift valves, parking lock
- 40 Torque converter

26 Propeller shaft
- 11 Single or multiple part propeller shaft
- 12 Centre console assembly

27 Transfer box
- 10 Transfer box

31 Front axle, front suspension
- 00 Front axle in general
- 10 Front Axle Suspension
- 11 Front axle support
- 12 Wishbones and struts including rubber mounts
- 21 Wheel Bearings and Steering Knuckle
- 31 Spring Struts
- 33 Spring with mounting
- 35 Anti-roll bar
- 60 Output shaft
- Front axle, front suspension

32 Steering and Wheel Alignment
- 00 Steering, measurement
- 11 Mechanical steering gear
- 13 Steering gear with power steering unit
- 21 Steering column stalk, track rod, steering damper
- 31 Steering column
- 33 Steering Wheel
- 34 Airbag and airbag steering wheel
- Steering and Wheel Alignment

33 Rear axle, rear-wheel drive, guide
- 00 Rear axle, rear-wheel drive, guide
- 10 Rear axle final drive
- 11 Transmission housing with lid
- 17 Rear axle differential mountings
- 21 Output Shaft
- 31 Rear axle support
- 32 Trailing arms and struts
- 33 Rear Axle Suspension
- 34 Active rear axle kinematics
- 41 Wheel Bearings
- 52 Shock Absorbers
- 53 Springs with suspension
- 55 Anti-roll bar
- Rear axle, rear-wheel drive, guide

34 Brakes
- 00 Braking, check, ventilation
- 11 Front Wheel Brakes
- 21 Rear Wheel Brakes:
- 31 Foot and tandem brake master cylinder
- 32 Brake Lines
- 33 Brake servo
- 35 Electrical components / wear indicator
- 41 Parking brake
- 51 Mechanical hydraulic components
- 52 Electronic components
- Brakes

35 Pedals
- 11 Pedal Assembly Console
- 40 Accelerator pedal activation

36 Wheels with tyres
- 10 Wheels
- 11 Disc wheels (rims)
- 12 Tyres
- Wheels with tyres

37 Integrated Suspension Systems
- 00 Integrated suspension system in general
- 11 Control and suspension elements, front
- 12 Control and suspension elements, rear
- 14 Electric components

41 Body
- 00 Body
- 11 Support
- 12 Floor panels
- 14 Wheel arches
- 21 Side frames and pillars
- 22 Roof frame
- 31 Roof
- 32 Front and rear window frame
- 33 Front trim panel
- 34 Rear trim panel
- 35 Side Panels
- 51 Front doors
- 52 Rear doors
- 61 Engine compartment lid
- 62 Tailgate
- 63 Other flaps
- Body

51 Body equipment
- 00 General body equipment
- 11 Front Bumper
- 12 Rear bumper
- 13 Trim Parts, Covers, Handle Strip
- 14 Badges, labels, adhesive strips
- 16 Mirrors, Finishers, Ashtrays, Consoles
- 21 Door locks, handles, fittings, front
- 22 Door locks, handles, fittings, rear
- 23 Bonnet catch, locks
- 24 Tailgate catch, locks
- 31 Front and rear window
- 32 Power windows, manual operation, front
- 33 Power windows, electrical operation, front
- 34 Power windows, manual operation, rear
- 35 Power windows, electrical operation, rear
- 41 Front door trim panel with armrests
- 42 Rear door trim panel with armrests
- 43 Side Trim Panel with Armrests
- 44 Headlining
- 45 Trim, instrument trim panel
- 46 Trim panel, rear window storage shelf, roller sunblind
- 47 Floor/luggage compartment/engine compartment, trim panel
- 48 Front lid insulation lining
- 49 Tailgate trim panel
- 64 Front panel, front end
- 71 Gaskets and loose body components
- 72 Mucket for doors
- 75 Underbody panelling
- 76 Seals
- Body equipment

52 Seats and motorcycle seat
- 14 Front seat, normal, electric
- 16 Front seat, sports, electric
- 17 Front seat, comfort
- 24 Rear seat, normal
- 26 Rear seat, through-loading facility
- Seats and motorcycle seat

54 Slide/tilt sunroof and soft top
- 10 Slide/tilt sunroof/panorama glass roof
- 12 Slide/tilt sunroof
- 13 Panorama glass roof
- 34 Power Convertible Top
- Slide/tilt sunroof and soft top

61 General vehicle electrical system
- 00 General vehicle electrical system, check
- 11 Wiring harness
- 12 Auxiliary cable
- 13 Plug connection, terminal
- 14 Power distribution box , current terminals
- 20 Battery
- 21 Battery with holder
- 25 High-voltage accumulator system
- 27 High-voltage battery unit individual component
- 31 Switch, sensor
- 33 Horn
- 34 Cigarette lighter, 12 V connections
- 35 Control Units, Modules
- 42 Voltage transformer
- 44 Convenience charging electronics (KLE)
- 61 Windscreen wipers
- 67 Headlight cleaning system
- 71 Windscreen washer system

62 Instruments
- 11 Instrument cluster
- 30 Head-Up Display
- Instruments

63 Lights
- 10 Headlight adjustment
- 11 Front lights
- 12 Headlight
- 14 Position lamps, rear reflectors
- 17 Front Fog Lamps, Additional Lamps
- 21 Rear light cluster
- 25 Brake lights
- 26 Number plate light
- 31 Interior lighting
- 99 Working time without specification/lights
- Lights

64 Heating and air conditioning
- 00 Note, overview components climate control
- 11 Heater and controls
- 12 Auxiliary heating with control element
- 22 Air vents and other outlets
- 31 Microfilter
- 50 Air conditioning, check
- 51 Heating and air-conditioning unit (evaporator), shift elements
- 52 Compressor
- 53 Condenser and dryer with lines
- Heating and air conditioning

65 Audio, navigation, information systems
- 12 Radio, audio amplifier, headunit
- 13 Speaker and cover
- 20 Aerial, interference suppression filter
- 24 Rear window aerial, TV amplifier, wave trap
- 50 Video and TV sets, central information display (CID)
- 75 Alarm system
- 76 Pedestrian protection
- 77 Airbag control units, airbag sensors
- 81 On-board computer
- Audio, navigation, information systems

66 Distance system, Cruise control, remote operation
- 12 Radio-controlled locking system
- 20 Park Distance Control (PDC)
- 31 Adaptive active cruise control (ACC)
- 32 Lane Change Warning
- 33 Parking Assist System
- 51 Front camera, camera lane departure warning (camera-based driver support systems)
- 53 Reversing camera (RFK), side view camera, top view camera
- 54 Night Vision
- Distance system, Cruise control, remote operation

67 Electric motor
- 00 Electric motor
- 11 Central locking unit / release drives
- 13 Mirror adjustment motor
- 31 Drive, seat adjustment
- 32 Fan (seat)
- 61 Slide/tilt sunroof / soft top drive
- 62 Electric motor for power window regulator
- Electric motor

71 Parts and accessories for engine and chassis
- 60 Various accessories

72 Body parts and accessories
- 00 General
- 11 Seat belts
- 12 Gas generators, airbag modules (with steering wheel airbag 3234)
- Body parts and accessories

84 Communication systems
- 10 Combox, TCB, USB hub, telephone
- 31 Hands-free system (microphone, speaker)
- Communication systems
- Vehicle preservation

99 Paint
- 00 General Paint
- Paint

SERVICE INFORMATION

00 Maintenance and general note
- 00 Maintenance
- 01 Safety information, note regarding the handling of the repair instructions
- 04 12 V vehicle electrical system
- 05 High-voltage electrical system
- 06 Vehicle-specific notes
- 07 Operating fluids
- 08 Exhaust-gas test, roadworthiness test
- 11 General maintenance
- Engine
- Fuel supply
- Front axle, front suspension

32 Steering and Wheel Alignment
- 11 Mechanical steering gear
- 13 Steering gear with power steering unit
- Steering and Wheel Alignment

33 Rear axle, rear-wheel drive, guide
- 10 Rear axle final drive
- Rear axle, rear-wheel drive, guide
- Brakes
- Wheels with tyres

41 Body
- 00 Body
- Body

51 Body equipment
- 00 General body equipment
- 11 Front Bumper
- 13 Trim Parts, Covers, Handle Strip
- 16 Mirrors, Finishers, Ashtrays, Consoles
- 41 Front door trim panel with armrests
- 42 Rear door trim panel with armrests
- 43 Side Trim Panel with Armrests
- 45 Trim, instrument trim panel
- 46 Trim panel, rear window storage shelf, roller sunblind
- Seats and motorcycle seat

61 General vehicle electrical system
- 20 Battery
- General vehicle electrical system
- Heating and air conditioning

65 Audio, navigation, information systems
- 77 Airbag control units, airbag sensors
- Audio, navigation, information systems
- Parts and accessories for engine and chassis

72 Body parts and accessories
- 00 General
- 11 Seat belts
- 12 Gas generators, airbag modules (with steering wheel airbag 3234)
- 14 Child seat quick connect system
- 60 Various accessories
- Body parts and accessories

99 Paint
- 00 General Paint
- Paint

TIGHTENING TORQUES

00 Maintenance and general note
- 03 Tightening specifications
- Maintenance and general note

11 Engine
- 00 Engine
- 11 Engine block
- 12 Cylinder head with lid
- 13 Oil sump
- 14 Case Covers
- 21 Crankshaft and Bearings
- 22 Flywheel
- 23 Vibration damper
- 24 Connecting Rods and Bearings
- 25 Pistons with Rings and Pins
- 27 Counterbalance shafts
- 28 Drive belt with tensioning and deflecting element
- 30 Control
- 31 Camshaft
- 36 Variable camshaft control
- 37 Variable valve gear
- 41 Oil pump with strainer and motor
- 42 Oil filters and lines
- 51 Coolant pump with drive
- 52 Fan
- 53 Thermostat and engine-proof coolant lines
- 61 Intake manifold
- 62 Exhaust manifold
- 65 Charger with control
- 66 Vacuum pump
- 78 CO adjustment, oxygen sensor
- Engine

12 Engine electrical system
- 12 Ignition lead, spark plugs
- 14 Electronic Shift Units or Control Units
- 31 Alternator with Drive and Mounting Parts
- 36 Control of hybrid / E-drive
- 41 Starter motor with mounting
- 42 Starter line
- 51 Engine wiring harness
- 52 Plug connections, terminals, loose parts
- 61 Oil pressure, oil temperature, oil level display
- 90 Control unit box

13 Fuel preparation and control
- 31 Fuel pump with drive and line
- 32 Fuel filter
- 51 Injection pump, control section, mixture control unit
- 52 Injection pump drive
- 53 Fuel Injector Nozzles and Lines
- 54 Throttle valve and operation
- 62 Senders for Control Unit
- 71 Intake silencer
- Fuel preparation and control

16 Fuel supply
- 10 Fuel storage and delivery
- 11 Fuel tank with fuel filler pipe
- 13 Crankcase ventilation, emission monitoring
- 14 Delivery, preparation and content measurement, control units, electric fuel pump
- 19 Selective catalytic reduction technology

17 Cooling
- 00 Cooling, check
- 11 Engine oil cooler and mounting parts
- 22 Oil cooler lines
- Cooling

18 Exhaust system
- 00 Exhaust system
- 12 Silencer
- 20 Exhaust system mounting/intermediate pipe
- 32 Exhaust gas catalytic converter
- 40 Exhaust manifold with integrated catalytic converter
- Exhaust system

22 Engine and transmission mounting
- 11 Engine mounting
- 32 Transmission mounting, automatic transmission

23 Manual gearbox
- 00 Manual gearbox
- Manual gearbox

24 Automatic transmission
- 00 Automatic transmission
- 11 Transmission Case, Oil Sump
- 13 Transmission Extension, Bearings, Sealing Ring
- 22 Planetary drive
- 23 Release clutches
- 30 Electro-hydraulic control parts and elements
- 31 Oil pump
- 34 Shift valves, parking lock
- 35 Wiring harness, shift elements and sensors
- 40 Torque converter
- 52 Internal gearshift
- Automatic transmission

26 Propeller shaft
- 11 Single or multiple part propeller shaft
- Propeller shaft

27 Transfer box
- 00 Transfer box
- 10 Transfer box
- Transfer box
- Twin-clutch gearbox (DKG)

31 Front axle, front suspension
- 00 Front axle in general
- 10 Front Axle Suspension
- 11 Front axle support
- 12 Wishbones and struts including rubber mounts
- 21 Wheel Bearings and Steering Knuckle
- 31 Spring Struts
- 35 Anti-roll bar
- 50 Front axle differential
- Front axle, front suspension

32 Steering and Wheel Alignment
- 00 Steering, measurement
- 13 Steering gear with power steering unit
- 21 Steering column stalk, track rod, steering damper
- 31 Steering column
- 33 Steering Wheel
- Steering and Wheel Alignment

33 Rear axle, rear-wheel drive, guide
- 00 Rear axle, rear-wheel drive, guide
- 11 Transmission housing with lid
- 17 Rear axle differential mountings
- 32 Trailing arms and struts
- 33 Rear Axle Suspension
- 34 Active rear axle kinematics
- 41 Wheel Bearings
- 52 Shock Absorbers
- 54 Spring strut, add-on parts
- 55 Anti-roll bar
- Rear axle, rear-wheel drive, guide

34 Brakes
- 00 Braking, check, ventilation
- 11 Front Wheel Brakes
- 21 Rear Wheel Brakes:
- 31 Foot and tandem brake master cylinder
- 32 Brake Lines
- 33 Brake servo
- 41 Parking brake
- 50 Slip control systems (ABS, ASC)
- 51 Mechanical hydraulic components
- 52 Electronic components
- Brakes

35 Pedals
- 11 Pedal Assembly Console
- 40 Accelerator pedal activation

36 Wheels with tyres
- 10 Wheels
- 20 Tyre monitoring systems
- Wheels with tyres

37 Integrated Suspension Systems
- 00 Integrated suspension system in general
- 12 Control and suspension elements, rear
- 14 Electric components

41 Body
- 00 Body
- 34 Rear trim panel
- 35 Side Panels
- 51 Front doors
- 52 Rear doors
- 61 Engine compartment lid
- 62 Tailgate
- Body

51 Body equipment
- 11 Front Bumper
- 12 Rear bumper
- 13 Trim Parts, Covers, Handle Strip
- 16 Mirrors, Finishers, Ashtrays, Consoles
- 21 Door locks, handles, fittings, front
- 22 Door locks, handles, fittings, rear
- 23 Bonnet catch, locks
- 24 Tailgate catch, locks
- 31 Front and rear window
- 32 Power windows, manual operation, front
- 34 Power windows, manual operation, rear
- 35 Power windows, electrical operation, rear
- 41 Front door trim panel with armrests
- 43 Side Trim Panel with Armrests
- 44 Headlining
- 45 Trim, instrument trim panel
- 46 Trim panel, rear window storage shelf, roller sunblind
- 47 Floor/luggage compartment/engine compartment, trim panel
- 61 Reinforcement, body
- 64 Front panel, front end
- 71 Gaskets and loose body components
- 74 Air duct
- 75 Underbody panelling
- Body equipment

52 Seats and motorcycle seat
- 10 Front seats
- 24 Rear seat, normal
- 26 Rear seat, through-loading facility

54 Slide/tilt sunroof and soft top
- 10 Slide/tilt sunroof/panorama glass roof
- 12 Slide/tilt sunroof
- Slide/tilt sunroof and soft top

61 General vehicle electrical system
- 14 Power distribution box , current terminals
- 20 Battery
- 21 Battery with holder
- 25 High-voltage accumulator system
- 27 High-voltage battery unit individual component
- 31 Switch, sensor
- 35 Control Units, Modules
- 42 Voltage transformer
- 44 Convenience charging electronics (KLE)
- 61 Windscreen wipers
- 71 Windscreen washer system
- General vehicle electrical system

62 Instruments
- 11 Instrument cluster
- 30 Head-Up Display

63 Lights
- 11 Front lights
- 14 Position lamps, rear reflectors
- 17 Front Fog Lamps, Additional Lamps
- 21 Rear light cluster

64 Heating and air conditioning
- 00 Note, overview components climate control
- 11 Heater and controls
- 12 Auxiliary heating with control element
- 22 Air vents and other outlets
- 31 Microfilter
- 51 Heating and air-conditioning unit (evaporator), shift elements
- 52 Compressor
- 53 Condenser and dryer with lines
- Heating and air conditioning

65 Audio, navigation, information systems
- 12 Radio, audio amplifier, headunit
- 13 Speaker and cover
- 20 Aerial, interference suppression filter
- 50 Video and TV sets, central information display (CID)
- 75 Alarm system
- 77 Airbag control units, airbag sensors
- 82 Central display and operating unit

66 Distance system, Cruise control, remote operation
- 31 Adaptive active cruise control (ACC)
- 53 Reversing camera (RFK), side view camera, top view camera
- 54 Night Vision

67 Electric motor
- 11 Central locking unit / release drives
- 13 Mirror adjustment motor
- 31 Drive, seat adjustment
- 62 Electric motor for power window regulator

71 Parts and accessories for engine and chassis
- 60 Various accessories

72 Body parts and accessories
- 11 Seat belts
- 12 Gas generators, airbag modules (with steering wheel airbag 3234)
- Operating fluids, auxiliary materials

84 Communication systems
- 10 Combox, TCB, USB hub, telephone
- Paint

VEHICLE TECHNICAL DIAGNOSIS

00 Maintenance and general note
- 09 Abbreviations
- Engine
- Exhaust system
- Manual gearbox
- Steering and Wheel Alignment
- Rear axle, rear-wheel drive, guide
- Wheels with tyres
- Lights

FAULT ELIMINATION

Repair Manuals and Technical Data
- Maintenance and general note
- Engine
- Transfer box
- Front axle, front suspension
- Steering and Wheel Alignment
- Rear axle, rear-wheel drive, guide
- Brakes
- Body
- Body equipment
- Seats and motorcycle seat
- Slide/tilt sunroof and soft top
- Lights
- Heating and air conditioning

SI SPECIAL TOOLS

Repair Manuals and Technical Data
- Maintenance and general note
- Engine electrical system
- Clutch
- General vehicle electrical system

TECHNICAL DATA

11 Engine
- 40 Oil supply

23 Manual gearbox
- 00 Manual gearbox
- 23 Synchromesh

36 Wheels with tyres
- 10 Wheels

64 Heating and air conditioning
- 51 Heating and air-conditioning unit (evaporator), shift elements

REPAIR HINT

00 Maintenance and general note
- 00 Maintenance
- 01 Safety information, note regarding the handling of the repair instructions
- 08 Exhaust-gas test, roadworthiness test

11 Engine
- 00 Engine
- 11 Engine block
- Engine

12 Engine electrical system
- 31 Alternator with Drive and Mounting Parts

17 Cooling
- 00 Cooling, check

18 Exhaust system
- 00 Exhaust system
- 32 Exhaust gas catalytic converter

24 Automatic transmission
- 00 Automatic transmission

31 Front axle, front suspension
- 00 Front axle in general
- 20 Front wheel bearing

32 Steering and Wheel Alignment
- 31 Steering column
- Assessment of the rubber mounts on axle components

33 Rear axle, rear-wheel drive, guide
- 10 Rear axle final drive

34 Brakes
- 00 Braking, check, ventilation
- 41 Parking brake
- 50 Slip control systems (ABS, ASC)
- 52 Electronic components
- Brakes

36 Wheels with tyres
- 10 Wheels
- 11 Disc wheels (rims)
- 12 Tyres

AND MORE....