BMW 525i, 525xi, 528i, 528xi, 530i, 530xi, 535i, 535xi, 545i, 550i (E60, E61, 5 Series) Repair Manual 2004-2010

• BMW 525i, 525xi
• BMW 528i, 528xi
• BMW 530i, 530xi
• BMW 535i, 535xi
• BMW 545i
• BMW 550i

• 525i, 530i: M54 engine (2004-2005) | N52 engine (2006-2007)
• 528i: N52K engine (2008-2010)
• 535i: N54 twin turbo engine (2008-2010)
• 545i: N62 V8 engine (2004-2005)
• 550i: N62 TU V8 engine (2006-2010)

• Getrag GS6-17BG
• ZF GS6-37BZ | ZF GS6-53DZ
• Sequential Manual Gearbox (SMG)
• ZF GS6S37BZ, ZF GS6S53BZ (Remove, Install)

• ZF GA6HP19Z | GA6HP19Z TU
• ZF GA6HP26Z | GA6HP26Z TU

FUEL PUMP AND FUEL LEVEL SENDERS | ACCESSING FUEL PUMP AND FUEL LEVEL SENDERS

NOTE: Right side fuel pump/fuel level sender shown. Accessing left side fuel level sender is similar.

• Remove rear seat cushion. See 520 Seats.



• Peel back carpet to expose fuel sender service cover.



• Working at ride side fuel tank (see photo).



• Remove fasteners (A).



• Remove fuel pump access cover (B).



• Installation is reverse of removal.


FUEL PUMP AND FUEL LEVEL SENDER (RIGHT SIDE): REMOVING


• Drain fuel tank. See Fuel tank, draining in this repair group.



• Disconnect negative cable from battery.


CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given in 001 Warnings and Cautions.


• Remove left side fuel filter and level sender. See Fuel filter and fuel level sender (left side), removing in this repair group.



• Remove fuel pump access cover. See Accessing fuel pump and fuel level senders in this repair group.



• Slide electrical connector lock in direction of arrow, remove connector and fuel lines if equipped (see photo).

BRAKE SYSTEM | ELECTRONIC BRAKING AND STABILITY CONTROL

5 Series models are equipped with dynamic stability control (DSC). DSC is a computer controlled traction control system that uses the ABS system in conjunction with engine management controls to control wheel spin during acceleration and maintain vehicle stability while braking.

TROUBLESHOOTING

Brake performance is mainly affected by three factors:

1. Level and condition of brake fluid.



2. Ability of brake system to create and maintain pressure.



3. Condition of friction components.

Air in brake fluid makes the brake pedal feel spongy during braking or increases the brake pedal force required to stop. Fluid contaminated by moisture or dirt corrodes the system. Inspect the brake fluid inside the reservoir. If it is dirty or murky, or is more than two years old, replace fluid. See Brake system, bleeding in this repair group.

To check the function of the brake master cylinder, hold the brake pedal down hard with the engine running. If the pedal slowly falls to the floor, either the master cylinder is leaking internally or fluid is leaking externally.

Inspect the brake rotors for glazing, discoloration and scoring. Steering wheel vibration while braking at speed is often caused by warped rotors, but can also be caused by worn suspension components.

• General Data and Maintenance
• Fundamentals for the Do-It-Yourself Owner
• Maintenance Program
• Engine
• Engine Removal and Installation
• Cylinder Head Removal and Installation | Cylinder Head and Valvetrain
• Camshaft Timing Chain | Camshaft Timing Belt
• Lubrication System
• Ignition System - DME
• Battery, Starter, Alternator
• Fuel Injection - DME
• Fuel Tank and Fuel Pump
• Radiator and Cooling System
• Exhaust System
• Transmission
• Manual Transmission | Clutch
• Automatic Transmission
• Gearshift Linkage | Driveshaft
• Suspension,Steering and Brakes
• Front Suspension | Steering and Wheel Alignment
• Rear Suspension | Final Drive
• Brakes
• Body
• Fenders, Engine Hood | Doors | Trunklid, Tailgate
• Exterior Trim, Bumpers
• Interior Trim
• Central Locking
• Seats
• Electrical System | Fuses and Relays
• Wipers and Washers
• Switches and Electrical Accessories | Instruments| Radio
• Exterior Lighting
• Heating and Air Conditioning
• Equipment and Accessories
• Seat Belts | Airbag System (SRS)
• On-Board Diagnostics
• Wiring Diagrams