General Electrical System - Repair BMW M5 E60/E61

12 00...Notes/information on start assistance (jump starting)

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting engine with starting cable.

1. Ensure that jump lead wires are to appropriate cross-section size.
2. Only use fuse-protected jump leads.
3. Check whether the current supplying battery has 12 volts.
4. If engine is started from battery of another vehicle, ensure that there is no contact between the bodies of both vehicles.

If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling speed.

Carrying out

Always conform with the procedures to avoid injury to persons or damage to parts.

1. On automatic transmission, select "P" setting, apply handbrake.
2. Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect positive terminals of both batteries with one jump lead (red).
5. Use positive connection point in engine compartment for vehicles with one battery in trunk.
6. Then attach second jump lead (black) to negative terminal of donor battery and to engine ground or body ground on vehicle to be started.

Danger of explosion!

After engine of vehicle to be started has started up, first disconnect the jump lead on the negative terminal/ground connection. Then remove jump lead from positive terminals.

61 00. Version with AFS: setting steering angle (after reconnecting vehicle battery)

Note. Version with AFS

After RECONNECTING the vehicle battery, carry out the following procedure for setting the steering angle

1. Start engine.
2. Turn steering wheel left to full lock.
3. Turn steering wheel right to full lock.
4. Turn steering wheel to central position.
5. Turn off engine.
6. Turn on ignition (terminal 15), AFS telltale and Check Control message go out.

Note. Entry in the fault memory remains unaffected by this procedure, therefore if necessary

1. Connect diagnosis system.
2. Clear fault memory.

61 00... Battery

Note. Important notes and instructions for handling batteries can be found in

1. «DISCONNECTING BATTERY»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__12-00-notes-for-disconnecting-and) .
2. «BATTERY CHARGING»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-00-battery-charging) .
3. «WELDING WORK»(ref-201411-S19875819662006032100000)
4. «EXTERNAL JUMP-STARTING AID»(ref-201411-S35426663612006032100000) .

Battery Care And Maintenance

In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water up to the top marking.

The increasing number of electronic control units in the car reduces the self-discharging time of the battery (even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment specification.

Battery Test

The battery acid density can be used to measure the charge state. However this test produces uncertainty caused by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical version the acid density is 1.23 kg/l).

Another interference factor is the acid lamination immediately after filling with distilled water.

Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density test results.

61 00... Battery charging

If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle electrical system and removed. This prevents damage to paintwork and upholstery.

Ideally, battery charging is performed with BMW-approved charging computers.

If necessary, open existing plugs on the individual cells.

61 20 900 Disconnecting and connecting battery negative lead

Follow INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-101-removing-and-installingreplacing)

Version with intelligent battery sensor (IBS)

Loosen nut (1).

Tightening torque: 5 Nm

Detach battery negative lead (3) with IBS (2) in upward direction, lay to one side and secure.

Scheme 1

Version without intelligent battery sensor (IBS)

Disconnect battery negative lead (1).

Tightening torque: 5 Nm

Scheme 2

Necessary preliminary tasks

1. Remove battery cover or open right luggage compartment trim panel «51 47 220 REMOVING AND INSTALLING/REPLACING TRUNK TRIM PANEL ON RIGHT SIDE PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing) .

Disconnect battery negative lead (1).

Tightening torque: 5 Nm

Scheme 3

61 00... Notes on handling optical fibers

1. The minimum permitted bending radius is 25 mm
2. Do not subject optical fibers to compressive and tensile load
3. Protect optical fibers against the effects of heat greater than 85°C (e.g. during welding work, drying work with infrared heater or hot air blower)
4. Optical fibers are permitted to show only one junction point (bridge), replace optical fibers if necessary

Note. The optical fibers are colored differently as follows

1. Green =MOST ( M edia O riented S ystems T ransport) optical fibers
2. Yellow= ISIS ( I ntelligent S afety and I ntegration S ystem) optical fibers
3. Orange=repair optical fibers

Follow instructions for TREATING CABLES AND FIBRE-OPTIC CABLES .

61 00... Notes on handling wiring harnesses and cables

The following applies in general

To avoid damage, observe the following instructions

1. Avoid compressive and tensile loads
2. Make sure cables are laid without kinks or abrasions
3. Ensure non-contacting routing at sharp-edged body parts; use edge protection if necessary
4. Secure additionally laid cables/leads with cable ties

The following additionally applies

Shielded cables

Joins in the shield can cause problems with regard to noise radiation and interference immunity. Consequently, distinctions have to be drawn between the following types

Coaxial cable

1. Shielded RTK031 coaxial lines may only be repaired with special crimping tools.

CVBS cables

1. CVBS cables may not be repaired.
2. CVBS cables must be replaced in their entirety.

HSD cables

1. HSD cables may not be repaired.
2. HSD cables must be replaced in their entirety.

Fibre-optic cables

Note. Fibre-optic cables are colored differently as follows: Green = MOST ( M edia O riented S ystems T ransport) optical fibres Yellow = ISIS ( I ntegrated S ervice I nformation S erver) fibre-optic cables Orange=repair fibre-optic cables

TREATING CABLES AND FIBRE-OPTIC CABLES

FlexRay

It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT CONNECTORS .

Note. FlexRay lines may only reveal one separation point (bride); renew complete line if necessary. The cable is a twisted cable. If possible, maintain twisted cable after repair.

Airbag lines

Repairing

Ribbon cables

REPAIRING RIBBON CABLES

61 00 Repairing Airbag Cables

Safety regulations: See safety regulations for HANDLING COMPONENTS OF AIRBAG SYSTEM and instructions for DISCONNECTING AND CONNECTING BATTERY .

In event of non-visible damage to wiring harness

Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with insulating tape, do not under any circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead. Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open. See INSTRUCTIONS for cutting off, insulating, crimping cables, installing and removing contacts.

In event of visible damage

Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables. Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit hoses) with insulating tape to prevent cables from twisting open. See INSTRUCTIONS for cutting off, insulating, crimping cables, installing and removing contacts.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts

1. «CUTTING OFF AND INSULATING CABLES»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-cutting-to-length-and) .
2. «REPAIRING A PLUG CONNECTION USING BUTT CONNECTORS»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-butt-connector-for-repairing) .
3. «INSTALLING AND REMOVING CONTACTS»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) .

61 00... Safety instructions for handling vehicle battery

Battery acid is highly corrosive

Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective clothing, gloves and goggles.

Do not tilt the battery, acid may emerge from the vent opening.

In event of contact with acid

If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then consult a doctor without delay.

If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots of water.

Seek medical attention immediately if battery acid is accidentally swallowed.

Explosion hazard

Strictly no flames, sparks, naked light or smoking!

A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging is carried out must therefore always be well ventilated.

Avoid the formation of sparks when handling cables, wiring and electrical devices.

Turn the ignition lock to the 0 position before disconnecting or connecting the battery.

Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).

61 12 002 Replacing positive battery cable (from battery to luggage compartment connector)

Necessary preliminary tasks

1. Remove «LEFT LUGGAGE COMPARTMENT WHEEL ARCH TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-151-removing-and-installing) .
2. Remove «RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-161-removing-and-installingreplacing) .
3. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) .
4. Remove protective cover from distribution box/battery positive terminal (luggage compartment)

Lever out clips (1).

Release plastic nuts (2).

Remove underlay for luggage compartment floor panel (3).

Scheme 4

Disconnect plug connection (1). Disconnect plug connection (3) of IBS cable.

Unlock cable lug mounting and fold back.

Unscrew nut (2). Tightening torque: 15 Nm

Remove positive battery cable. Unscrew nut (5). Tightening torque

1. M6: 5 Nm
2. M8: 15 Nm

Pull safety battery terminal (4) upwards and remove.

Scheme 5

Open cable lug mounting (1).

Release screw (2).

Tightening torque: 15 Nm

Unclip and remove positive battery cable (3).

When installing, ensure

1. Cable lug mounting (1) is correctly seated on positive battery cable (3).
2. Screw is properly connected.

Unclip positive battery cable (1) from cable guides (2) and remove.

Scheme 6

61 12 013 Replacing battery negative lead

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT TRIM PANEL ON RIGHT SIDE WALL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing)
2. Remove equipment holder in luggage compartment

Slacken nut (1) on negative battery terminal.

Tightening torque: 5 Nm

Pull off negative battery cable with intelligent battery sensor (IBS) in upward direction.

Disconnect plug connection (2).

Disconnect plug connection (3).

Release nut (4) and battery negative lead (5).

Tightening torque

1. M8: 15 Nm
2. M6: 5 Nm

Scheme 7

Replacement: Carry out PROGRAMMING/CODING .

61 12 065 Replacing wiring harness for front bumper

Necessary preliminary tasks: Remove FRONT BUMPER TRIM .

Note. Operation is shown by way of example on the E63 (build date up to 09/2007). There may be differences in detail in the case of other vehicle models.

Disconnect plug connections (1) on ultrasonic transducer. Unclip wiring harness (2) from bumper trim.

Scheme 8

Unlock plug (1) in direction of arrow from bumper trim.

During installation, ensure wiring harness (2) is correctly laid.

Scheme 9

61 12 067 Replacing wiring harness for rear bumper

Operation is described in: Replacing REAR BUMPER TRIM .

61 12 200 Replacing wiring harness in left or right front door

Necessary preliminary tasks

1. Close front side window completely.
2. Remove «FRONT DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-41-000-removing-and-installing) .

Unlock plug connections (1) and disconnect.

Release door wiring harness (2) at point (3).

Unclip door wiring harness (2) at points (4).

Scheme 10

Detach SOUNDPROOFING on front door in working area.

Unfasten plug connection (1) and disconnect.

Cut through cable ties (2).

Disconnect door wiring harness (3) at retainer (4).

Unclip door wiring harness (3) in area of front window guide.

Installation

Make sure door wiring harness (3) is correctly laid.

Scheme 11

Note. Front side panel shown removed for purposes of clarity.

Release screw (1), fold door wiring harness plug on A-pillar (2) downwards slightly and remove.

Unlock plug connection behind and disconnect.

Pull rubber grommet (3) in direction of arrow out of front door (4).

Feed out door wiring harness towards front to A-pillar and remove.

Scheme 12

61 12 200 Replacing wiring harness in left or right front door (long version)

Necessary preliminary tasks

1. Close front side window completely
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
3. Remove «FRONT DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-41-000-removing-and-installing)
4. Remove «SOUND INSULATION IN FRONT DOOR»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-48-060-removing-and-installingreplacing)

Release cable (1) from door wiring harness (2).

Disconnect plug connection (3).

Release door wiring harness (2) at point (4).

Installation

Make sure door wiring harness (2) is correctly laid.

Scheme 13

Note. Front side panel shown removed for purposes of clarity.

Release screw (1), fold door wiring harness plug on A-pillar (2) downwards slightly and remove.

Unlock plug connection behind and disconnect.

Pull rubber grommet (3) in direction of arrow out of front door (4).

Feed out door wiring harness towards front to A-pillar and remove.

Scheme 14

61 12 210 Replacing wiring harness in left or right rear door

Necessary preliminary tasks

1. Close rear side window completely.
2. Remove «REAR DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-42-000-removing-and-installing) .

Unfasten plug connection (1) and disconnect.

Release door wiring harness (2) at point (3).

Unclip door wiring harness (2) at points (4).

Scheme 15

Detach SOUNDPROOFING on rear door in working area.

Unfasten plug connection (1) and disconnect.

Disconnect door wiring harness (2) at retainer (3).

Unclip door wiring harness (2) at points (4).

Installation

Make sure door wiring harness (2) is correctly laid.

Scheme 16

Note. For clearer illustration, shown with front door removed.

Release screw (1), fold door wiring harness plug on B-pillar (2) downwards slightly and remove.

Unlock plug connection behind and disconnect.

Pull rubber grommet (3) in direction of arrow out of rear door (4).

Feed out door wiring harness towards front to B-pillar and remove.

Scheme 17

61 12 210 Replacing wiring harness in left or right rear door (long version)

Necessary preliminary tasks

1. Close rear side window completely
2. Disconnect «BATTERY NEGATIVE CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
3. Remove «REAR DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-42-000-removing-and-installing)
4. Remove «SOUND INSULATION IN REAR DOOR»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-48-070-removing-and-installingreplacing)

Disconnect plug connection (1).

Disconnect door wiring harness (2) at retainer (3).

Installation

Make sure door wiring harness (2) is correctly laid.

Scheme 18

Note. For clearer illustration, shown with front door removed.

Release screw (1), fold door wiring harness plug on B-pillar (2) downwards slightly and remove.

Unlock plug connection behind and disconnect.

Pull rubber grommet (3) in direction of arrow out of rear door (4).

Feed out door wiring harness towards front to B-pillar and remove.

Scheme 19

61 12 265 Replacing wiring harness on left or right front seat

Operation is described in: Replacing WIRING HARNESS ON LEFT OR RIGHT FRONT SEAT (COMFORT SEAT) .

61 12 270 Replacing wiring harness on left or right front seat (comfort seat)

Necessary preliminary tasks

1. Remove «FRONT HEAD RESTRAINT»(/bmw/m5/e60e61-2004-2010/remont/seats/#seats-repair-instructions__52-17-390-removing-and-installingreplacing)
2. Remove «OUTER COVER ON FRONT SEAT»(ref-201425-S31854983452005102600000) .
3. Remove «FRONT SEAT»(ref-201425-S32209141532005102600000)
4. Remove «INNER COVER ON FRONT SEAT»(ref-201425-S10626497342005102600000)
5. Remove «REAR PANEL ON FRONT SEAT BACKREST»(ref-201425-S03992794572005102600000)

Disconnect all plug connections (1) and release cable tie (2).

Remove wiring harness.

Scheme 20

Unhook seat fabric at retaining points (1). Lever out clip (2).

Fold back seat fabric. Unhook backrest fabric at retaining points (3).

Fold back backrest fabric.

Scheme 21

Disconnect all plug connections (1). Release cable tie (2).

Remove wiring harness.

During installation, make sure wiring harness is correctly laid.

Scheme 22

61 13... Butt connector for repairing a plug connection

Note. The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors. The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Department.

Special tools

Scheme 23

1. Special tool 61 9 040 (crimping pliers)

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Scheme 24

Remove following parts

Scheme 25

1. Pre-packaged end of cable with requisite wire cross-section
2. Crimp connector for selected wire cross-section
3. Shrink-fit hose

Open secondary lock on housing.

Mark damaged contact (4) with socket number of housing and press it out of housing using appropriate special tool contained in special tool set 61 0 300 ).

See repair instructions

OPENING PLUG HOUSINGS AND REMOVING CONTACTS of different plug systems

Scheme 26

Adhere to following procedure

Scheme 27

1. Cut off wire with faulty contact at point which is easily accessible
2. Strip insulation from end of wire at wiring harness end
3. Cut preassembled wire end to length and strip insulation

Refer also to repair instruction

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Crimp butt connector on preassembled wire end.

See repair instructions

CRIMPING ON STOP PARTS

Scheme 28

Push shrink-fit hose (8) onto free wire end.

Scheme 29

Crimp unused wire end to butt connector.

Scheme 30

Pull shrink-on sleeve over butt connector.

Scheme 31

With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until glue emerges uniformly all round.

Insert contact in housing.

Close secondary lock on housing.

Scheme 32

61 13... Connector housing, LCC contact (load current contact)

Socket housing

Press lock (1) with suitable tool (2) in direction of arrow out of socket housing (3).

Scheme 33

Pull lock (1) out of socket housing (2).

Scheme 34

Insert special tool 61 0 317 (release tool) into socket housing (1) and pull out wiring with LCC contact (2) in direction of arrow.

Scheme 35

Pin housing

Unlock locking slide (1) of pin housing (2) with suitable tool (3) in direction of arrow.

Scheme 36

Insert special tool 61 1 200 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.

Scheme 37

61 13... Crimping Micro Power Quadlock contacts (MPQ)

To crimp MPQ contacts, use hand pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping set 61 4 320 .

Note. Hand pliers (1) open automatically until limit position when handles are pressed together.

Scheme 38

Open hand pliers (1).

Note. Place contact (2) with utmost care in designated nest (observe line crosssection) in crimping head (3). Make sure it is exactly positioned.

Place MPQ contact (2) in crimping head (3).

Close hand pliers (1) one notch.

Scheme 39

Note. Follow procedure for CUTTING AND STRIPPING INSULATION from cables.

Insert stripped cable (2).

Close hand pliers (1) fully.

Open hand pliers (1) and remove cable (2).

Note. CHECK CONTACT FOR CORRECT CRIMPING .

Scheme 40

61 13... Crimping Micro Quadlock System contacts (MQS)

To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping set 61 4 320 .

Note. Pliers (1) open automatically as far as they will go when handles are pressed together.

Scheme 41

Open pliers (1).

Fold up contact carrier (2).

Insert MQS contact (3) in contact carrier (2).

Fold back contact carrier (2).

Scheme 42

Note. Follow procedure for CUTTING AND STRIPPING INSULATION from cables.

Close pliers (1) one notch.

Insert stripped cable (2).

Close pliers (1) fully.

Scheme 43

Open pliers (1).

Open contact carrier (2) gently and carefully remove MQS contact.

Note. CHECK CONTACT FOR CORRECT CRIMPING .

Scheme 44

61 13... Crimping annular contacts

Crimping annular contacts

Special tool 61 4 320

61 13... Crimping optical fibres

To crimp optical fibres, use hand pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping set 61 4 320 .

Note. Hand pliers (1) open automatically until limit position when handles are pressed together.

Scheme 45

Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).

Scheme 46

Open hand pliers (2).

Place pin contact or jack (1) in crimping head and secure with locking lever (3).

Scheme 47

Note. Follow procedure for CUTTING AND STRIPPING INSULATION FROM OPTICAL FIBRES .

Insert stripped optical fibre(1) until limit position into pin contact or jack (2).

Close hand pliers (3) fully.

Open hand pliers (3) and locking lever (4).

Remove optical fibre (1).

Scheme 48

Correct (A)

End of optical fibre (1) must be flush with tip of pin contact (2).

Wrong (B)

End of optical fibre (1) is not flush with tip of pin contact (2).

Scheme 49

61 13... Crimping stop parts

Crimping contact sleeves for 4 mm 2 comb connectors and ignition cable contacts

Use special tool kit 12 1 080 to attach ignition cable contacts and crimp 4 mm 2 contact sleeves for comb connectors.

1. 12 1 081 (hand pliers)
2. 12 1 083 (nest)

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Scheme 50

Release special tool 12 1 081

Squeeze grips (1) lightly and push release lever (2) in direction of arrow.

Or

Compress handles until limit position, hand pliers unlock automatically.

Scheme 51

Place 4 mm 2 contact sleeve in nest with anti-twist safeguard (1) as far as possible.

Scheme 52

Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.

Scheme 53

Note. Follow procedure for CUTTING AND STRIPPING INSULATION from cables.

Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in contact.

Compress crimping tool to limit position.

Crimping tool unlocks automatically.

Take contact out of crimping tool.

Scheme 54

4. Checking crimping

Check insulation crimping (8) and wire crimp (9) against following illustrations to ensure crimps are correctly located.

Note. Illustration shows butt connectors and contact sleeves for comb connectors knocked on one side. The crimping procedure is identical here.

Scheme 55

Correct crimping

Visible conductor end (10).

Visible insulation end (11).

Scheme 56

Incorrect crimping

Conductor end (10) inserted too far.

Insulation end (11) in wire crimp.

If necessary, repeat crimping with a new contact.

Scheme 57

Incorrect crimping

Conductor end (10) not visible.

Insulation end (11) not visible.

If necessary, repeat crimping with a new contact.

Scheme 58

61 13... Cutting off, stripping insulation and cutting optical fibres to length

To cut off, strip insulation and cut optical fibres to length, use hand pliers 61 4 321 (1) in conjunction with crimping head 61 4 322 (2) 61 4 320 from crimping set.

Note. Hand pliers (1) open automatically until limit position when handles are pressed together.

Scheme 59

Cutting optical fibre

Open hand pliers (1).

Place optical fibre (2) in cutting device (3).

Close pliers (1) and remove optical fibre (2).

Scheme 60

Stripping insulation from optical fibre

Open hand pliers (1).

Open lever (2) in direction of arrow.

Scheme 61

Slide optical fibre (1) into stripping device (2) until flush at point (3).

Close hand pliers (4) fully.

Close clamping lever (5) in direction of arrow.

Open hand pliers (4) by one tooth notch.

Open clamping lever (5) against direction of arrow again and remove optical fibre (1).

Note. A stripping replacement blade set is available under number 61 4 327.

Scheme 62

Cutting optical fibre to length

Pull pin (1) in direction of arrow.

Fold up blade retaining link (2) in direction of arrow.

Scheme 63

Remove blade (1) and replace.

Installation note

Make sure blade (1) is correctly seated on locating points (2).

Scheme 64

Open hand pliers (3).

Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping fixture.

Close hand pliers (3) fully and keep closed.

Remove optical fibre (1).

Scheme 65

61 13... Cutting to length and stripping insulation from cables

Stripped length

61 13... Fuse holder

Remove appropriate fuse from fuse holder (1).

Note. Identify the position when removing fuses.

Pull sliding lock (2) out of fuse holder (1) completely.

Scheme 66

With special tool 61 1 136 or 61 1 137 (pressing-off tool), press back retaining hooks (3) of appropriate contact and pull out cable.

Scheme 67

61 13... In-line plugs, 2-pin, System JPT ELA

Press lock (1) in direction of arrow and slide connector forward.

Scheme 68

Press lock (1) downward and slide out to one side.

Scheme 69

Unlock contact with special tool 61 1 136 and pull out cable (1) and contact towards rear.

Scheme 70

61 13... In-line plugs, 24-pin, Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Socket housing

Press locks (1) on cap (2) upwards on both sides.

Detach cap from contact carrier (3).

Note. Detaching the cap releases the secondary locks of the socket contacts.

Scheme 71

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Scheme 72

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of contact carrier (3).

Scheme 73

Pin housing

Press locks (1) on cap (2) upwards on both sides.

Detach cap from housing carrier (3).

Note. Detaching the cap releases the secondary locks of the pin contacts in the contact carriers.

Scheme 74

Pull contact carrier (1) out of housing carrier (2).

The pin contacts are pulled out of a contact carrier as described under "Socket housing".

Scheme 75

61 13... In-line plugs, 30-pin, Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Socket housing

Raise lock (1) on housing (2).

Push contact carrier (3) from rear out of housing (2).

Note. Pushing out the contact carrier releases the secondary locks of the socket contacts.

Scheme 76

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Scheme 77

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of contact carrier (3).

Scheme 78

Pin housing

Contacts 1... 13 and 19... 27

Raise locking slide (1) on both sides (2) of housing and detach.

Note. Detaching the locking slide releases the secondary locks of the pin contacts.

Scheme 79

Contacts 14... 18 and 28... 30

Pull slide (1) outwards completely.

Raise lock (2) on housing.

Pull contact carrier (3) out of housing.

Note. Pulling out the contact carrier releases the secondary locks of the pin contacts.

Scheme 80

The pin contacts are pulled out of a contact carrier as described under "Socket housing".

61 13... In-line plugs, 6- to 50-pin, System Elo

Unlock lock.

Scheme 81

Unfasten cable strap.

Installation

Cable clip must be reinstalled.

Scheme 82

Detach catch (1) from plug housing (2).

Scheme 83

Press out contact carrier (3) with wiring harness (4) through opening (5).

Scheme 84

Hold down arrester hook (6) of defective contact and pull cable and contact up to secondary lock (8).

Scheme 85

Hold down arrester hook once again in secondary lock (8) and pull cable and contact completely out of contact carrier.

Scheme 86

61 13... Inline plugs, 6-, 8- pin, System MQS

Press lock (1) in direction of arrow and slide plug forward.

Scheme 87

Press locking hook (2) downward and slide lock (1) out.

Scheme 88

Press down arrester hook (1) with screwdriver and pull out cable with contact towards rear.

Scheme 89

61 13... Inline plugs, 8-, 12- pin, System D2.5

Move connector upper section (1) and the connector lower section (2) against each other in direction of arrow.

Scheme 90

With special tool 61 1 132 (press-out tool) press back arrester hook (3) of appropriate contact and pull out cable with contact.

Scheme 91

61 13... Installing comb connector for retrofitting/repairs

Note. The repair range IV for vehicle electrical system contained the required special tools and individual parts for retrofitting and repair work with the aid of fan connectors. The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts Department.

Special tools

Scheme 92

1. Special tool 61 9 040 (crimping pliers)

Choose contact sleeve (up to 4 mm 2 ) in accordance with wire cross-section.

Scheme 93

Alternatively

Choose contact sleeves (up to 2.5 mm 2 ) for comb connectors.

Scheme 94

Cut through wire loop in wiring harness at established point.

Strip insulation from both wire ends.

See repair instructions

CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES

Scheme 95

Crimp contact sleeves on both wire ends.

See repair instructions

CRIMPING ON STOP PARTS

Note. If using repair kit for contact sleeves, refer to repair instructions: BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .

Scheme 96

Crimp connecting cable for retrofitting likewise with contact sleeve.

Scheme 97

Cut required number of poles to length for comb connectors.

Scheme 98

Special tool 61 9 041 (hand pliers) in conjunction with 61 9 042 (matrix) are used for pushing contact sleeves onto comb connectors.

See repair instructions

SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .

Scheme 99

Unlock special tool 61 9 041

Squeeze grips (1) lightly and push release lever (2) in direction of arrow.

Or

Compress handles until limit position, hand pliers unlock automatically.

Scheme 100

Insert prepared comb connectors (3) in special tool 61 9 041/61 9 042.

Scheme 101

Attach wire with contact sleeve to comb connector.

Scheme 102

Press hand pliers together and slide on contact sleeve until limit position.

Scheme 103

Push on further contact sleeves for potential branching.

Scheme 104

Installation in wet area (engine compartment, wheel arch)

Apply sealing compound on both sides and press into contacts (1).

Fit heat-shrink tubing and heat up with hot air blower (2) (approx. 250 °C).

Note. Ensure that comb connector has sufficient contact surface on attachment point. Do not heat-shrink tubing on edges of comb connector too strongly, risk of cracking.

Scheme 105

Allow heat-shrink tubing to cool down until hand-warm. Then press sealing material again into contacts and onto edges of comb connector.

If necessary, carefully heat-shrink tubing again.

Installation in dry area (interior, luggage compartment)

Slide assembled comb connector into insulation housing until it locks into place.

Scheme 106

61 13... Main relay connector for DME

Open locking clamp (1) for the corresponding cable.

Scheme 107

With special tool 61 1 136 or 61 1 137 (pressing-off tool), press back retaining hooks (2) of appropriate contact and pull out cable with contact.

Scheme 108

61 13... Relay carrier

Place special tool 61 1 153 against relay carrier (1) and carefully pull in direction of arrow until the locking tabs (2) of the relay carrier are raised up.

Scheme 109

Pull relay carrier (2) in direction of arrow into the first catch (3).

Scheme 110

Press down arrester hook (4) of corresponding contact and pull out the cable with contact.

With special tool 61 1 136 or 61 1 137 (press out) press out dual spring contacts.

Scheme 111

61 13... Removing and installing/replacing OBD-II socket

Necessary preliminary tasks

1. Remove «FOOTWELL SIDE TRIM PANEL ON A-PILLAR, LEFT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-43-070-removing-and-installingreplacing)

Release screws (1).

Remove OBD-II socket (2) from dashboard carrier (3).

Scheme 112

Remove OBD-II socket cover (2) from OBD-II socket (1).

Unlock slide plate (3) with a suitable tool in direction of arrow.

Insert special tool 61 0 315 into OBD-II socket (1) in the direction of the arrow and press out the associated flat spring contact (4). Press remaining flat spring contacts out of OBD-II socket (1) with special tool 61 0 315 .

Scheme 113

Installation note

Pay attention to pin assignment of OBD-II socket (1).

Make sure flat spring contacts and slide plate (3) are correctly engaged and seated in OBD-II socket (1).

61 13... Removing and installing/replacing fibre-optic cable connector

Necessary preliminary tasks

1. Remove «TRIM ON C-PILLAR AT BOTTOM LEFT»(ref-566696-S02654123482013071500000) .

Insert a small screwdriver into openings (1).

Expand catches of cover (2) and remove cover (2) in direction of arrow.

Scheme 114

Note. Fibre-optic cables with locks at top can be removed directly. Before the fibre-optic cables with locks at the bottom are removed, the fibre-optic cable connector (4) must be removed from the holder (3).

Removing a fibre-optic cable

Lift lock (1) carefully and feed fibre-optic cable (2) out of connector (4).

Installation

Make sure fibre-optic cable (2) is correctly engaged in fibre-optic cable connector (4).

Scheme 115

Removing connector (2) from holder (3)

Release lock in bore (1) by pressing and remove fibre-optic cable connector (2) in direction of arrow from holder (3).

Scheme 116

61 13... Repairing ribbon cables

Place ribbon cables (1) in connector housing (2) and close cover (3).

Scheme 117

Place connector housing (1) in pliers (2) 61 1 190 .

Close pliers (2).

Scheme 118

61 13... Socket housing (radio plug), Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Removing MPQ contacts from radio plug

Press lock (1) in direction of arrow.

Detach secondary lock (2) from radio plug.

Scheme 119

Feed special tool 61 1 135 past side of contact.

Press special tool 61 1 135 in direction of arrow.

Pull wire (1) with socket contact out of radio plug (2).

Scheme 120

Removing MQS contacts from contact carrier

Press lock (1) in direction of arrow and pull housing (2) out of radio plug.

Scheme 121

Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (3).

Note. When the contact carrier is pulled out, the secondary locks of the socket contacts are raised.

Scheme 122

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Note. The illustration shows an 8-pin female connector housing where contact removal is identical.

Scheme 123

Depress retaining hook in secondary lock (1) once again. Remove wire with female contact (2) from contact carrier (3) completely.

Scheme 124

Removing MPQ contacts from contact carrier

Remove contact carrier (1) with MQS contacts from the radio plug.

Raise lock (2) on radio plug.

Remove contact carrier (3) from radio plug.

Scheme 125

Press lock (1) in direction of arrow.

Pull secondary lock (2) in the direction of the arrow and out of contact carrier (3) completely.

Scheme 126

Press special tool 61 1 135 against inside of contact in contact carrier (2).

Remove wire with female contact (1) from contact carrier (2).

Scheme 127

61 13... Socket housing 42-, 43-pin, Hybrid System MQS/MPQ

Manufactured by AMP: The following contact types without strand sealing can be fitted in the socket housings

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Open secondary locks (1) on socket housing.

Press back retaining hook of MQS contacts (2) with special tool 61 1 134 and pull out cable with contact.

Press back retaining hook of MPQ contacts (3) with screwdriver or similar tool and pull out cable with contact.

Scheme 128

Installation

Bend open retaining hook of contacts gently before inserting into plug housing.

To install contacts, observe cavity numbers on reverse side of socket housing.

Scheme 129

61 13... Socket housings, 2x21-, 2x27-pin, Hybrid Systems MQS/MPQ, Elo/Elo- Power

Manufactured by AMP: The following contact types without strand sealing can be fitted in the socket housings

1. MQS (Micro Quadlock System)
2. MPQ, width 2.8 mm (Micro Power Quadlock)
3. MPQ, width 5.2 mm (Micro Power Quadlock)

Manufactured by Siemens: The following contact types without strand sealing can be fitted in the socket housings

1. Elo (electronic contact)
2. Elo-Power 2.8 mm wide (electronic contact for heavy loads)
3. Elo-Power 5.2 mm wide (electronic contact for heavy loads)

Raise lock (1) on housing (2).

Push contact carrier (3) from rear out of housing.

Note. The second contact carrier is pushed out in the same way.

Pushing out the contact carrier releases the secondary locks of the socket contacts.

Scheme 130

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.

Pull wire with socket contact in direction of arrow as far as secondary lock (2).

Scheme 131

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of contact carrier (3).

Scheme 132

61 13... Socket of tab connector housings

Unlock hooks (1) with special tool 61 1 360 and push plug housing out of the socket.

Scheme 133

61 13 Special tools for wiring harness repairs

Special tools required

1. 12 1 080
2. «61 0 200»(ref-566631-S31386497692013071500000)
3. «61 0 210»(ref-566631-S41356729202013071500000)
4. «61 0 220»(ref-566631-S24473887782013071500000)
5. «61 0 230»(ref-566631-S12656856812013071500000)
6. «61 0 300»(ref-566631-S01230043252013071500000)
7. 61 0 400
8. «61 1 190»(ref-296168-S32812738572008082000000)
9. «61 4 320»(ref-566631-S28716717272013071500000)
10. 61 9 041
11. 61 9 044

Release and press-out tool

1. Special tool «61 0 300»(ref-566631-S01230043252013071500000)
2. Special tool 61 0 400 (MINI N12/N14)

Scheme 134

Cutting to length and stripping insulation from cables

Scheme 135

1. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-cutting-to-length-and)

Crimping stop parts (small contacts)

Scheme 136

1. Special tool «61 4 320»(ref-566631-S28716717272013071500000) Tool without crimping head «(STRIPPING INSULATION AND CUTTING FIBRE-OPTIC CABLES TO LENGTH)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-cutting-off-stripping-insulation) «(CRIMPING FIBRE-OPTIC CABLE CONTACTS)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-optical-fibres) «(CRIMPING MQS CONTACTS)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-quadlock-system) «(CRIMPING MPQ CONTACTS)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-micro-power-quadlock) Replacement blade (face-cutting fibre-optic cables) Replacement blade with tool (insulation stripping unit) (not shown) Universal crimping head (not shown)

Crimping stop parts (large contacts)

1. Special tool «61 0 200»(ref-566631-S31386497692013071500000) (crimping set)
2. Special tool «61 0 210»(ref-566631-S41356729202013071500000) (matrix set
3. Special tool «61 0 220»(ref-566631-S24473887782013071500000) (matrix set SLK 2.8)
4. Special tool «61 0 230»(ref-566631-S12656856812013071500000) (matrix set MAK 8/DFK4)

Scheme 137

Crimping antenna elbow plugs

1. Special tool 61 9 041 (pliers)
2. Special tool 61 9 044 (matrix)

1. Antenna elbow plug on radio receiver

Repair kit for ignition cables and for crimping fan connector receptacles 4 mm 2

1. Special tool 12 1 080

Handling

1. «CRIMPING STOP PARTS (CONTACTS)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-stop-parts)

Repairing ribbon cables

1. Special tool «61 1 190»(ref-296168-S32812738572008082000000)

Handling

1. «REPAIRING RIBBON CABLES»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-repairing-ribbon-cables)

61 13... Treating cables and fibre-optic cables

Note. Special tools referred to in the repair instructions below are contained in the following special tool kits

Subject of repair instructions

1. «SPECIAL TOOLS FOR WIRING HARNESS REPAIRS»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-special-tools-for-wiring)
2. «CUTTING CABLES TO LENGTH AND STRIP INSULATION»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-cutting-to-length-and)
3. Crimping stop parts (contacts). See «CRIMPING ANNULAR CONTACTS»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-annular-contacts) and «CRIMPING STOP PARTS»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-stop-parts)
4. «BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-butt-connector-for-repairing)
5. «FAN CONNECTOR FOR RETROFITTING/REPAIRS»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-installing-comb-connector-for)
6. Aerial elbow plug on radio receiver
7. «CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBRES»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-cutting-off-stripping-insulation)
8. «CRIMPING OPTICAL FIBRES»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-crimping-optical-fibres)
9. Insulation displacement connector for «REPAIRING RIBBON CABLES»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-13-repairing-ribbon-cables)

61 13.. Unlocking and disconnecting different plug connections

Note. Examples of unlocking and disconnecting different plug connections.

Press lock and open clamp in direction of arrow.

Disconnect plug connection.

Scheme 138

Press lock and open clamp in direction of arrow.

Disconnect plug connection.

Scheme 139

Open clip in direction of arrow and disconnect plug connection in direction of arrow.

Scheme 140

Press lock and disconnect plug connection in direction of arrow.

Scheme 141

Press lock and disconnect plug connection in direction of arrow.

Scheme 142

Press lock and disconnect plug connection in direction of arrow.

Scheme 143

Press lock and disconnect plug connection in direction of arrow.

Scheme 144

Press lock and disconnect plug connection in direction of arrow.

Scheme 145

Press lock and disconnect plug connection in direction of arrow.

Scheme 146

Press the lock and detach plug connection.

Scheme 147

Press the lock and detach plug connection.

Scheme 148

Press the lock on both sides and detach plug connection.

Scheme 149

Press the lock and detach plug connection.

Scheme 150

61 13 040 Replacing distribution box (passenger compartment)

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT TRIM ON SIDE PANEL ON RIGHT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing)
2. Disconnect «BATTERY NEGATIVE CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
3. Remove «TRIM FOR INSTRUMENT PANEL, BOTTOM LEFT»(ref-297306-S16986874072008082900000) (same as right side)
4. Remove «RIGHT GLOVEBOX WITH HOUSING»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-366-removing-and-installing)

Release screws (1) and remove distribution box (2).

Scheme 151

Disconnect all plug connections (1).

Unlock relay base (3) and disconnect.

Open cover (2) on positive battery cable and release nut underneath.

Tightening torque

1. M8: 15 Nm
2. M6: 5 Nm

Disconnect positive battery cable from distribution box.

Installation

Make sure positive battery cable is correctly seated on fuse box.

Scheme 152

Replacement

Remove fuses.

61 13 042 Replacing distribution box (luggage compartment)

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT TRIM ON SIDE PANEL ON RIGHT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing)
2. Disconnect «BATTERY NEGATIVE CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
3. Remove protective cover from distribution box/battery positive terminal (luggage compartment)

Open cover (1) and release nut underneath.

Tightening torque

1. M8: 15 Nm
2. M6: 5 Nm

Disconnect plug connection (2) in direction of arrow.

Scheme 153

Disconnect plug connection (1).

Release screws (2) and remove distribution box.

Scheme 154

Security replacement only

Remove rib (1).

Scheme 155

Remove rib (1).

Scheme 156

Replacement

Remove fuses and relays.

12 00... Notes for disconnecting and connecting battery

Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Before disconnecting battery

Switch off ignition.

Note. If the ignition is not turned off when the battery is disconnected, fault memories may be set in some control units.

General notes on disconnecting battery

1. Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
2. Cars with IBS on battery negative terminal: Do not under any circumstances pull/lever off pole shoes by force. Do not under any circumstances release socket-head cap screw of IBS.
3. Detach «TERMINAL OF BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) from car battery and second battery if fitted. Cover battery negative terminal(s) and secure.
4. When work is carried out on the electrical system, faults may be caused in the fault memories of some control units when the battery is connected.
5. When installing battery terminal, use tightening torque: 5 Nm

After connecting battery

Likewise, individual settings are lost and must be activated.

Example

1. Vehicles with automatic engine start-stop function (MSA): MSA function is active only after learning period (vehicle must not be woken for a period of approx. 6 hours) > if necessary, notify customer of the situation.
2. If necessary, activate «SUNROOF»(ref-297479-S10433237352008090200000)
3. If necessary, activate «POWER WINDOWS»(ref-297486-S29524437442008090200000)
4. If necessary, activate mirror with compass
5. Only E60, E61, E63, E64, E70, E71, E90, E91, E92, E93: mount «STEERING ANGLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-00-version-with-afs-setting)

Please refer to the Progman user documentation for further information on vehicle-specific activation.

Vehicles with a two-battery system

Starter and equipment batteries

A two-battery system has a starter battery circuit and an equipment battery circuit. A secondary control unit monitors both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from the secondary control unit via an isolating relay.

Two AGM batteries, whose design and properties are described in AGM BATTERIES , are used as a storage battery.

Receiving/giving starting assistance via jump start terminal

The engine can be jump-started with an external voltage supply via the jump start terminal on the right side of the engine compartment.

Note. The starter battery is isolated from the alternators when the engine hood/bonnet is open.

Giving starting assistance via the jump start terminal is thus limited by the capacity of the starter battery when the engine hood/bonnet is open.

Charging starter and equipment batteries via jump start terminal

The starter battery is charged as a matter of priority with a charger connected to the jump start terminal. The voltage at the starter battery is the decisive factor in determining whether the equipment battery is also included in the charging operation. The secondary control unit automatically detects a charging operation at a charging voltage at the starter battery of >= ace; 13.5 V. The isolating relay is closed and thus the equipment battery is connected in parallel. Both batteries are now charged.

Prerequisite

1. Terminal 61 inactive
2. Terminal 15 inactive

If terminal 15 becomes "active" during the charging operation, the isolating relay is opened immediately and again only the starter battery is charged.

Note. When the engine hood is open, the isolating relay is also opened in normal operation when the engine is running.

A special mode can be set by means of diagnosis for workshop/garage operation. The isolating relay is closed from terminal R in this operating mode. This mode is automatically reset once a distance of 5 km has been driven.

Trickle charging

Increased closed-circuit current consumption can be compensated with the aid of the battery trickle charger (special tool 61 2 410) via the jump start terminal.

Refer also to INSTRUCTIONS FOR CHARGING BATTERY

12 00... Instructions on starting aid

Do not start the engine with help of starting sprays.

Preparation

Conform with the following when starting engine with starting cable.

1. Ensure that jump lead wires are to appropriate cross-section size.
2. Only use fuse-protected jump leads.
3. Check whether the current supplying battery has 12 V voltage.
4. If engine is started from battery of another vehicle, ensure that there is no contact between the bodies of both vehicles.

If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling speed.

Carrying out

Always conform with the procedures to avoid injury to persons or damage to parts.

1. On automatic transmission, select "P" setting, apply handbrake.
2. Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake.
3. Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
4. First connect positive terminals of both batteries with one jump lead (red).
5. Use positive connection point in engine compartment for vehicles with one battery in trunk.
6. Then attach second jump lead (black) to negative terminal of donor battery and to engine ground or body ground on vehicle to be started.

Danger of explosion!

After engine of vehicle to be started has started up, first disconnect the jump lead on the negative terminal/ground connection. Then remove jump lead from positive terminals.

Note. Version with AFS

After reconnecting the vehicle battery, carry out the following procedure for setting the steering angle

1. Start engine.
2. Turn steering wheel left to full lock.
3. Turn steering wheel right to full lock.
4. Turn steering wheel to central position.
5. Turn off engine.
6. Turn on ignition (terminal 15), AFS telltale and Check Control message go out.

Note. Entry in the fault memory remains unaffected by this procedure, therefore if necessary

1. Connect diagnosis system.
2. Clear fault memory.

61 12... General information on intelligent battery sensor (IBS)

Note. Do not connect the charger to the 12 V charging socket. The 12 V charging socket is supplied with voltage by the rear power distribution box via relay. This relay drops out after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the voltage supply be registered by the vehicle.

1. Do not introduce any additional connections at the battery negative terminal.
2. Do not modify the grounding cable. The ground cable also serves heat dissipation.
3. Do not establish any connection between the IBS and the sensor screw.
4. Do not use force when disconnecting the pole shoe from the battery terminal: Do not pull on the ground cable. Do not place any tools under the IBS to lever off the pole shoe.
5. Do not use IBS connections as levers.
6. Use a torque wrench and set tightening torque in accordance with repair instructions.
7. Do not release or tighten down sensor screw (Torx screw).
8. Avoid contact between IBS and ground.

1. The IBS and wiring can be destroyed by mechanical strain upon battery replacement. Therefore avoid mechanical strain.
2. The size (capacity) of the battery required for the car is coded in the Car Access System (CAS).
3. Use the battery size (capacity) installed as standard upon battery replacement.
4. Recode the Car Access System (CAS) when installing a battery with a different capacity.
5. Register battery replacement via Service functions in diagnosis system.
6. Delete fault code entries in the Digital Engine Electronics (DME) associated with battery replacement.
7. Always proceed in accordance with the repair instructions.

Note. Battery draining possible in spite of the intelligent battery sensor IBS being fault-free. A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in conjunction with power management. For this reason, only replace the IBS when there is a corresponding fault entry in the DME or DDE.

Scheme 157

Introduction

In September 2002 so-called VRLA batteries, better known as AGM batteries , were introduced.

(VRLA stands for V alve R egulated L ead A cid, i.e. lead acid battery with pressure relief valve; AGM stands for A bsorbent G lass M at, i.e. absorbent glass fibre fleece)

AGM batteries are fitted in models with electrical loads/consumers which have a high energy demand.

With the option SA 146 (2nd battery), the AGM battery (70 Ah) is fitted as the 2nd battery.

The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful battery solutions.

Today, up to 100 servomotors, which have to be electrically powered, operate in a modern luxury-class motor vehicle. Added to these are safety, environmental and comfort and convenience elements which are increasingly becoming standard features, such as e.g. Anti-lock Brake System (ABS), Dynamic Stability Control (DSC), electric steering effort assistance (EPS), heated catalytic converter, electronic chassis and suspension control, air conditioning and navigation system. The power consumption is considerable even when the vehicle is parked.

The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits

1. Significantly longer service life
2. Increased starting reliability at low temperatures
3. Safe starting of engines with high starting current demands, e.g. high-performance diesel engines
4. 100 % freedom from maintenance
5. Low risk in event of an accident (reduced risk to the environment)

Service life of AGM battery

Scheme 158

Unlike the previously used lead calcium batteries, the sulfuric acid contained in batteries with fleece technology is not self-contained in the battery housing.

Instead, the sulfuric acid is 100 % bound up in glass fibre fleece mats (separators). Thus, no acid can escape if the battery housing is damaged. In addition, the AGM battery is sealed gas-tight. This is possible because the gases are converted back into water as a result of the separator permeability.

Brief description of components

An AGM battery can be recognized by its black housing and the lack of a so-called "Magic Eye".

Scheme 159

Construction

The AGM battery differs from the conventional lead calcium battery as follows

1. Larger plates: Larger plates provide for a 25 % higher power density.
2. Separators made of glass fibre fleece: These provide for up to 3 times higher cycle reliability. This in turn improves cold starting performance, current consumption and service life.
3. Gas-tight housing with pressure relief valve (see also "How it works" below): The cell plugs are welded and cannot be opened.
4. Acid bound up in the glass fibre fleece: The acid is not as previously self-contained in the housing, but 100 % bound up in the glass fibre fleece. This provides increased protection against acid leakage and thus represents a reduced risk to the environment.

How it works

The AGM battery differs from conventional batteries in its non-polluting and substance-retaining behavior during charging.

When vehicle batteries are charged, the two gases oxygen and hydrogen are released by electrolysis.

1. In a conventional wet lead calcium battery, the two gases hydrogen and oxygen are dissipated into the atmosphere.
2. In an AGM battery, the two gases are converted back into water: The oxygen which is created at the positive electrode during charging passes through the permeable glass fibre fleece to the negative electrode. At the negative electrode the oxygen reacts with the arriving hydrogen ions in the electrolyte to form water (oxygen cycle).

In this way, the gas and thus also the electrolyte are not lost.

Only in the event of an excessively heavy buildup of gas, i.e. excessively high pressure buildup (20 to 200 mbar), does the pressure relief valve discharge the gas. In this process, the pressure relief valve does not allow any oxygen in the air to enter. Because a valve regulates the pressure in the battery, the AGM battery is also known as a VRLA battery (Valve Regulated Lead Acid).

Notes and instructions for service personnel

It is necessary when handling an AGM battery to observe some particular points pertaining to battery changing and installation location.

Charging

Installation location

Housing

Battery care and maintenance

In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water up to the top marking.

The increasing number of electronic control units in the car reduces the self-discharging time of the battery (even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment specification.

Battery test

The battery acid density can be used to measure the charge state. However this test produces uncertainty caused by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical version the acid density is 1.23 kg/l).

Another interference factor is the acid lamination immediately after filling with distilled water.

Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density test results.

If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle electrical system and removed. This prevents damage to paintwork and upholstery.

Ideally, battery charging is performed with BMW-approved charging equipment.

If necessary, open existing plugs on the individual cells.

61 20... Battery replacement information

A vehicle battery is constructed for the installation location and the individual power requirements of the particular vehicle. These individual power requirements depend on the motorization and different types of optional equipment. The individually assigned vehicle battery is the ideal compromise between the power requirements of the vehicle electrical system and the weight and service life of the vehicle battery.

Vehicles with the automatic engine start-stop function or particular engine types and optional equipment are equipped with a special vehicle battery (AGM battery), since only this battery type can provide elevated power requirements over the extended service life. Installing a different vehicle battery can cause problems with vehicle electronics, can reduce functions or can cause leakage of battery acid.

In the event of an accident where the airbags are deployed in vehicles with a vehicle battery in the luggage compartment, the electrical connection between the vehicle battery and the trigger is automatically disconnected through pyrotechnics. This prevents possible short-circuiting.

Proper operation of all of these safety and convenience functions requires a battery that conforms with specifications and that is properly registered in vehicles with energy management systems (IBS, power module).

Vehicles with energy management systems (IBS, power module): Register battery replacement

The vehicle electrical system is informed about the vehicle battery characteristic data, such as type, size, age and current power capacity. Therefore, there will always be only one work scope provided that is permitted by the current status of information.

When installing a new vehicle battery, the battery must be registered and thus must also be registered with the vehicle electrical system.

Diagnosis system

Register battery replacement

1. Service functions
2. Body
3. Voltage supply
4. Register battery replacement

When retrofitting, a more powerful battery may be used. Standard batteries may always be replaced by AGM batteries with the same specifications.

When installing a battery of a different size or a different battery type, this change in vehicle data must be programmed into the vehicle data in accordance with specifications.

Programming system

1. Battery retrofitting

Battery acid is highly corrosive

Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective clothing, gloves and goggles.

Do not tilt the battery, acid may emerge from the vent opening.

In event of contact with acid

If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then consult a doctor without delay.

If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots of water.

Seek medical attention immediately if battery acid is accidentally swallowed.

Explosion hazard

Strictly no flames, sparks, naked light or smoking!

A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging is carried out must therefore always be well ventilated.

Avoid the formation of sparks when handling cables, wiring and electrical devices.

Turn the ignition lock to the 0 position before disconnecting or connecting the battery.

Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).

61 20 005 Testing battery with battery tester

Necessary preliminary tasks

Remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL .

Note. Use BMW-recommended battery tester to test the battery.

Procedure

Scheme 160

1. Turn off ignition and close doors
2. Connect battery tester directly to battery terminals
3. Select Battery test and confirm
4. Enter vehicle identification number
5. Enter battery data
6. Carry out battery test

61 20... Threshold values for battery inspection of all battery (telephone except for telephone battery)

Safety instructions for handling vehicle battery.

Test step 1 - before charging the battery

TEST STEP 1

Test step 2 - after charging the battery

TEST STEP 2

Note. If the battery has been tested from the positive terminal in the engine compartment, repeat the test for safety directly on the battery.

61 20 503 Vehicle battery - closed-circuit current monitoring

Necessary preliminary tasks

To access negative lead of battery, remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL .

Do not disconnect negative lead of battery.

Connect BMW diagnosis system.

Connect clip-on probe to negative lead of battery. The arrow on the current clamp must point towards the battery.

Measure closed-circuit current.

61 20... Battery open-circuit current test

Note. Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .

Scheme 161

The open-circuit current test is performed using the Diagnosis and Information System (DIS)

Follow INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-101-removing-and-installingreplacing)

Version with intelligent battery sensor (IBS)

Loosen nut (1).

Tightening torque: 5 Nm

Detach battery negative lead (3) with IBS (2) in upward direction, lay to one side and secure.

Version without intelligent battery sensor (IBS)

Disconnect battery negative lead (1).

Tightening torque: 5 Nm

Necessary preliminary tasks

1. Remove battery cover or open right luggage compartment trim panel «51 47 220 REMOVING AND INSTALLING/REPLACING TRUNK TRIM PANEL ON RIGHT SIDE PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing) .

Disconnect battery negative lead (1).

Tightening torque: 5 Nm

61 20 908 Performing battery "power reset" for programming/coding control units

The following steps must be carried out for a "power reset"

1. Switch off and disconnect battery charger
2. Switch off ignition
3. Cars with ignition key: Turn ignition key to 0 position
4. Cars with identification sensor: Remove identification sensor from slot
5. Cars with comfort access system: Make sure terminal is in 0 position
6. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
7. Reconnect battery negative terminal (to ensure bus activity)
8. Waiting time (5-10 seconds)
9. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
10. Waiting time (1 minute)
11. Connect battery negative terminal and tighten. Tightening torque: 5 Nm
12. Connect and switch on battery charger
13. Switch ignition on

61 21 010 Removing and installing battery

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT TRIM ON SIDE PANEL ON RIGHT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing) .
2. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) .

Disconnect plug connection (1) of IBS cable.

Release nut (3).

Tightening torque: 5 Nm

Detach safety battery terminal (2) towards top, lay to one side and secure.

Release nuts (4) and remove rollover protection (5).

Scheme 162

Release threaded pin (1) and remove holders (2).

Detach vent (4) in direction of arrow.

Fold both clips (3) open.

Pull battery (5) back from front fixture and remove towards top.

Installation

Make sure battery (5) is correctly seated in front fixture.

Scheme 163

61 21 010 Removing and installing (replacing) battery (M5)

To ensure the correct safety and convenience functions, install only the original battery (battery size and type) stored in the vehicle order. Observe BATTERY REPLACEMENT INFORMATION .

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing)

Disconnect BATTERY NEGATIVE LEAD (1).

Disconnect plug connection (2) of one-pin IBS cable (3).

Release nut (5) of safety battery terminal (4). Tightening torque: 5 Nm

Detach safety battery terminal (4) towards top, lay to one side and secure.

Scheme 164

Release nuts (1) and remove retaining bar (2).

Release threaded pin (1) and remove holders (2).

Detach vent (3) in direction of arrow.

Fold both clips (4) open.

Lift out battery (5).

Installation

Make sure battery (5) is correctly seated in associated mounts.

Scheme 165

Replacement

1. Read out fault memory, clear if necessary
2. On vehicles with IBS (intelligent battery sensor), «REGISTER BATTERY REPLACEMENT»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-20-battery-replacement-information)

General information on power supply

Note. Do not connect a trickle-charger to the cigarette lighter. Power is fed to the cigarette lighter from the rear power distributor via a relay. This relay is deactivated when terminal 15 is switched off. That means that a trickle-charger connected to the cigarette lighter is separated from the battery. Only recharge the battery using the external-start support point. Only then can the energy fed into the vehicle be registered.

Intelligent battery sensor

1. Do not attach any additional connections to the negative terminal of the battery.
2. Do not modify the earth cable in any way. The earth cable also serves to carry off heat.
3. Do not create a connection between the IBS (intelligent battery sensor) and the sensor screw.
4. Do not use force when disconnecting the terminal clamp from the battery terminal: Do not pull on the earth cable. Do not apply any tools under the IBS to lever off the terminal clamp.
5. Do not use the IBS connections as a lever.
6. Use a calibrated torque wrench with tightening torque set according to the Repair Instructions.
7. Do not loosen or tighten the sensor screw (Torx screw).
8. Prevent direct contact between the IBS and earth.

Change battery

When the battery is replaced, the IBS (intelligent battery sensor) and the wires could be damaged beyond repair by mechanical stressing.

Please note the following when replacing the battery

1. Always proceed in accordance with the repair instructions.
2. Avoid subjecting the integrated battery sensor to mechanical stress.

Note. When changing the battery, perform service function "Register battery renewal". When changing the battery, use the battery size (capacity) installed in production. The battery size needed for the vehicle is encoded in the Car Access System (CAS) and in the engine electronics (DME/DDE).

1. If a battery with a different capacity is fitted, the CAS must be recoded. Run "Battery" retrofit with Progman.
2. Erase any fault memory entry in the engine control unit relating to the battery replacement.

Micro-power module until 09/2005

Note. From 09/05, MPM function is integrated into the body-gateway module (KGM)

If consumers are cut off from the vehicle electrical system by the MPM, a fault will be registered in the fault memory. The following faults can be read off in the BMW diagnosis system

1. Fault at terminal 15
2. Cutoff with information about switch-off conditions. The information about the switch-off conditions is stored in the info memory used for storing additional information.
3. Undervoltage
4. Contact fault in relay contacts

Fault at terminal 15

1. If there is a different level at terminal 15, pin 14 and in the CAN message, the MPM will register a fault in the fault memory.
2. The MPM cyclically monitors the relay contacts every 100 milliseconds (ms) from terminal 15 ON. If the relay contacts do not remain closed, despite the switch-on conditions being satisfied, an entry will be made in the fault memory.

Alternator

Alternators manufactured by Bosch and by Valeo are installed on 5- and 6-Series vehicles.

1. Air-cooled alternator models are used.
2. The alternator model used depends on the engine installed and the vehicle's equipment specification.

Scheme 166

Scheme 167

Scheme 168

61 31 006 Removing and installing (replacing) fixture for steering column stalk (up to 09/2005)

Necessary preliminary tasks

1. Remove «TOP SECTION OF STEERING COLUMN CASING»(ref-201418-S28702315432005102600000) .
2. If necessary, remove deformation element for steering column trim.

Note. Follow instructions for HANDLING OPTICAL FIBRES .

Release screws (1).

Pull back fixture for steering column switch (2) in direction of arrow.

Disconnect plug connections behind and remove fixture for steering column stalk (2).

Scheme 169

Replacement

1. Remove «TRAVEL DIRECTION DIMMER SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-016-removing-and-installingreplacing) .
2. Remove «WINDSHIELD WIPER SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-040-removing-and-installingreplacing) .
3. If necessary, remove «CRUISE CONTROL SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-018-removing-and-installingreplacing) .
4. Remove «VOLUTE SPRING CASSETTE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-011-removing-and-installingreplacing)

Replacement

1. Carry out «PROGRAMMING/CODING»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-00-program-encode-the) with BMW scan tool.
2. Vehicles without active front steering: Carry out «STEERING ANGLE SENSOR ADJUSTMENT»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-996-carrying-out-steering)
3. Vehicles with active front steering: Carry out «ACTIVE FRONT STEERING START-UP/ADJUSTMENT»(ref-201418-S02824793292006032400000) .

61 31 006 Removing and installing/replacing fixture for steering column stalk (from 09/2005)

Necessary preliminary tasks

1. Remove «STEERING WHEEL»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-010-removing-and-installingreplacing) .
2. Remove «FRONT SECTION OF STEERING COLUMN TRIM»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-010-removing-and-installingreplacing)
3. Remove «LOWER SECTION OF STEERING COLUMN TRIM»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-020-removing-and-installing)
4. Remove «TOP SECTION OF STEERING COLUMN CASING»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-004-removing-and-installing)
5. If necessary, remove deformation element for steering column trim.

Disconnect plug connections from rear on fixture for steering column stalk (2).

Release screws (1).

Remove fixture for steering column switch (2) in direction of arrow.

Installation

Carry out STEERING ANGLE SENSOR ADJUSTMENT .

On vehicles with active front steering, steering angle sensor adjustment is performed by means of INITIAL OPERATION / adjustment of active front steering.

Scheme 170

Replacement

1. Remove «TRAVEL DIRECTION DIMMER SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-016-removing-and-installingreplacing)
2. Remove «WINDSHIELD WIPER SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-040-removing-and-installingreplacing)
3. If necessary, remove «CRUISE CONTROL SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-018-removing-and-installingreplacing)
4. Remove «VOLUTE SPRING CASSETTE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-011-removing-and-installingreplacing)
5. Carry out «VEHICLE PROGRAMMING/CODING»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-00-program-encode-the)
6. Carry out «STEERING ANGLE SENSOR ADJUSTMENT»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-996-carrying-out-steering) On vehicles with active front steering, steering angle sensor adjustment is performed by means of «INITIAL OPERATION»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__32-10-005-adjustment-for-active) / adjustment of active front steering

32 10 005 Adjustment for active front steering

Note. Adjustment of the active front steering must be carried out: after adjustment work on the front axle/steering after all mechanical work on the steering system after the battery has been disconnected or electrical plug connections on the steering column switch cluster have been disconnected after replacement/programming or coding of the following components: Steering column switch cluster DSC control unit Active front steering control unit ARS control unit

Connect vehicle to BMW diagnosis system.

Select and carry out initial operation/adjustment for active front steering under Service functions.

61 31 011 Removing and installing/replacing volute spring cassette (up to 09/2005)

Necessary preliminary tasks

1. Remove «FIXTURE FOR STEERING COLUMN STALK»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-006-removing-and-installing) .

Unlock catches (1) and remove volute spring cassette (2) in direction of arrow from fixture for steering column switch (3).

Scheme 171

Installation

Seat volute spring cassette exactly on plug connections (1), guide (2) and mounts (3).

Scheme 172

61 31 011 Removing and installing/replacing volute spring cassette (from 09/2005)

Necessary preliminary tasks

BATTERY NEGATIVE LEAD

1. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000) .
2. Remove «STEERING WHEEL»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-010-removing-and-installingreplacing)
3. Remove «FRONT STEERING COLUMN SHROUD»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-010-removing-and-installingreplacing)
4. Remove «LOWER SECTION OF STEERING COLUMN TRIM»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-020-removing-and-installing)
5. Remove «CRUISE CONTROL SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-018-removing-and-installingreplacing)
6. Remove «WINDSHIELD WIPER SWITCH»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-040-removing-and-installingreplacing)

Release screws (1).

Scheme 173

Unlock catches (1) and remove volute spring cassette (2) in direction of arrow from fixture for steering column switch (3).

Scheme 174

Installation

For purposes of clarity, fixture for steering column stalk (2) is shown removed.

Marking (3) must line up with marking (4).

Scheme 175

Installation

Drive pin (1) of volute spring (2) must line up correctly with opening (3) in inner ring of stalk.

Scheme 176

61 31 016 Removing and installing/replacing the travel direction dimmer switch

Necessary preliminary tasks

1. Disconnect «BATTERY EARTH LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000) .
3. Remove «STEERING WHEEL»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-010-removing-and-installingreplacing)
4. Remove «FRONT STEERING COLUMN SHROUD»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-010-removing-and-installingreplacing)

Release screws (1) and remove the travel direction dimmer switch (2) to the rear.

Scheme 177

61 31 018 Removing and installing/replacing cruise control switch

Necessary preliminary tasks

1. Disconnect «BATTERY EARTH LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000) .
3. Remove «STEERING WHEEL»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-010-removing-and-installingreplacing)
4. Remove «FRONT STEERING COLUMN SHROUD»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-010-removing-and-installingreplacing)

Release screws (1) and remove cruise control switch (2) towards rear.

Scheme 178

61 31 020 Removing and installing/replacing ignition starter switch

Necessary preliminary tasks

1. Move ignition lock to key position 0 (stop)
2. Remove «LOWER SECTION OF STEERING COLUMN TRIM»(ref-201418-S23099093512005102600000)

Insert a M2.5 screw in bore (2).

Installation

Remove screw in bore (2).

Scheme 179

Release screws (1). Tightening torque: 0.4 Nm

Installation

Secure screws (1) with sealing paint.

Replace the ribbon cable if damaged.

The ribbon cable leads to the CONTROL UNIT FOR THE CAR ACCESS SYSTEM .

Remove ignition starter switch (2).

Scheme 180

61 31 023 Removing and installing/replacing Start/Stop switch

Attach special tool 00 9 341 as illustrated.

Unclip Start/Stop switch with associated ribbon cable in direction of arrow.

Remove Start/Stop switch.

Scheme 181

61 31 035 Removing and installing/replacing switch for steering column adjustment

Necessary preliminary tasks

1. Remove «TOP SECTION OF STEERING COLUMN CASING»(ref-201418-S28702315432005102600000) .

Disconnect associated plug connections of steering column adjustment switch (1).

Unclip steering column adjustment switch (1) in direction of arrow.

Remove steering column adjustment switch (1) towards front from fixture for steering column stalk (2).

Scheme 182

61 31 037 Removing and installing/replacing lighting control unit

Attach special tool 64 1 020 at openings (1) and lever out catches (2).

Pull back lighting control unit (3).

Unlock and disconnect associated plug connection, remove lighting control unit (3).

Scheme 183

Installation

Make sure clips (1) are correctly seated on trim of lighting control unit (2).

Scheme 184

61 31 038 Removing and installing (replacing) switch for passenger airbag deactivation

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Open glovebox lid

Unclip switch receptacle for passenger airbag deactivation (1) in rear area by pressing in direction of arrow out of glovebox housing (2).

Feed switch receptacle for passenger airbag deactivation (1) in front area in direction of arrow out of glovebox housing (2).

Installation

Make sure switch receptacle for passenger airbag deactivation (1) is correctly engaged on glovebox housing (2).

Scheme 185

Disconnect plug connection (1).

Unlock catches (2) and feed switch for passenger airbag deactivation (4) in direction of arrow out of switch receptacle for passenger airbag deactivation (5).

Installation

Guides (3) and retaining lugs (6) must not be damaged or missing.

Make sure switch for passenger airbag deactivation (4) is correctly seated in switch receptacle for passenger airbag deactivation (5).

Scheme 186

Replacement

Remove LOCK CYLINDER FOR PASSENGER AIRBAG DEACTIVATION .

61 31 040 Removing and installing/replacing switch for windshield wipers

Necessary preliminary tasks

1. Disconnect «BATTERY EARTH LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Remove «FRONT SECTION OF STEERING COLUMN TRIM»(ref-201418-S30419295992005102600000) .
3. Remove «STEERING WHEEL»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-33-010-removing-and-installingreplacing)
4. Remove «FRONT STEERING COLUMN SHROUD»(/bmw/m5/e60e61-2004-2010/remont/manual-power-steering/#steering-and-wheel-alignment-repair__32-31-010-removing-and-installingreplacing)

Release screws (1) and remove windshield wiper switch (2) towards rear.

Scheme 187

61 31 044 Removing and installing/replacing center console switch cluster on left (from 03/2007)

Operation is described in

Removing and installing/replacing CENTRE CONSOLE SWITCH CLUSTER ON LEFT AND RIGHT (FROM 03/2007)

61 31 046 Removing and installing/replacing center console switch cluster on right (from 03/2007)

Operation is described in

Removing and installing/replacing CENTRE CONSOLE SWITCH CLUSTER ON LEFT AND RIGHT (FROM 03/2007)

61 31 052 Removing and installing/replacing center console switch cluster (up to 03/2007)

Necessary preliminary tasks

1. Remove «MIDDLE TRIM FOR INSTRUMENT PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-310-removing-and-installing) .

Unclip switch cluster in center console (1) all round and remove from middle trim for instrument panel (2).

Scheme 188

Replacement

Carry out PROGRAMMING/CODING .

61 31 052 Removing and installing/replacing center console switch cluster on left and right (from 03/2007)

Necessary preliminary tasks

1. Remove «MIDDLE TRIM FOR INSTRUMENT PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-310-removing-and-installing)

Unclip center console switch cluster on left and right (1) all round and remove from middle trim for instrument panel (2).

Scheme 189

Replacement

Carry out PROGRAMMING/CODING .

61 31 055 Removing and installing/replacing switch for SMG transmission (M5)

See REMOVING AND INSTALLING/REPLACING SWITCH FOR SMG TRANSMISSION (M5) .

61 31 062 Removing and installing/replacing button for steering wheel heating

This operation is described in

REMOVING AND INSTALLING/REPLACING SWITCH FOR STEERING COLUMN ADJUSTMENT .

61 31 069 Removing and installing/replacing indicator for front passenger airbag deactivation

Necessary preliminary tasks

1. Remove «FRONT ROOFLINER TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-44-removing-and-installing-front) .

Press locks (1) and unclip indicator for front passenger airbag deactivation (2) in direction of arrow from front roofliner trim (3).

Scheme 190

61 31 079 Removing and installing/replacing switch for hazard warning flashers/central locking

Lever out switch for hazard warning system/central locking (1) with special tool 64 1 020 and pull back.

Disconnect associated plug connection and remove switch for hazard warning system/central locking (1).

Scheme 191

61 31 083 Removing and installing/replacing switch for unlocking rear lid

Note. To unclip switch for unlocking rear lid (4), partially detach mucket (1).

Grip from outside behind footwell side trim panel on A-pillar on left (2).

Press retaining lugs (3) together and feed switch for unlocking rear lid (4) out of footwell side trim panel on A-pillar on left (2).

Disconnect associated plug connection and remove switch for unlocking rear lid (4).

Scheme 192

61 31 091 Removing and installing/replacing switch for left or right seat heating (rear)

Necessary preliminary tasks

1. Remove «REAR INSERT (IN STORAGE COMPARTMENT)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-rear) .

Note. Removal of switch for left seat heating (2) is depicted. Switch for right seat heating (4) is removed in the same way as switch for left seating (2). Press locks (1) together, feed switch for seat heating (2) out of rear insert (3) and remove.

Scheme 193

61 31 091 Removing and installing/replacing switch for left or right seat heating (rear, long version)

Necessary preliminary tasks

1. Remove «REAR INSERT (IN STORAGE COMPARTMENT)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-rear)

Press locks (1) together and press switches for seat heating (2) out of trim (3).

Scheme 194

61 31 103 Removing and installing/replacing left or right shift paddle for SMG transmission

Necessary preliminary tasks

1. Remove decorative trim for multifunction steering wheel switch. See «UP TO 09/2005»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-220-removing-and-installingreplacing) or «FROM 09/2005»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-220-removing-and-installingreplacing) .

Disconnect plug connection (1).

Release screws (2).

Remove shift paddle for SMG transmission (3) from steering wheel (4).

Installation

Scheme 195

1. Make sure wiring harness is routed exactly
2. Make sure shift paddle for SMG transmission (3) is correctly seated on steering wheel (4)

61 31 108 Removing and installing/replacing power switch (M5)

See REMOVING AND INSTALLING/REPLACING POWER SWITCH (M5) .

61 31 112 Removing and installing/replacing left or right shift paddle for automatic transmission

Operation is described in

Removing and installing/replacing left or right SHIFT PADDLE FOR SMG TRANSMISSION

61 31 104 Removing and installing/replacing shifters for SMG transmission (both)

Necessary preliminary tasks

1. Remove «STEERING WHEEL RETAINING PLATE (SPORTS STEERING WHEEL)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-220-removing-and-installingreplacing) .

Note. Illustrations show sports steering wheel (4) removed.

Disconnect plug connections (1).

Loosen screws (2).

Remove both shifters for SMG transmission (3) in direction of arrow from sports steering wheel (4).

Installation

Make sure electrical leads are correctly routed.

Scheme 196

61 31 109 Removing and installing/replacing Dynamic Stability Control switch (M5)

See REMOVING AND INSTALLING/REPLACING DYNAMIC STABILITY CONTROL SWITCH (M5) .

61 31 115 Replacing rocker switch for side window operation (front)

Necessary preliminary tasks

1. Remove «FRONT DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-41-000-removing-and-installing) .

Unscrew nut (1).

Unlock catches (2) and remove rocker switch for side window operation (3) downwards out of front door trim panel (4).

Scheme 197

Installation

Retaining hook (1) and plastic pin (2) must not be damaged.

Make sure rocker switch for side window operation (3) is installed in correct position.

Scheme 198

61 31 116 Replacing rocker switch for side window operation (rear)

Necessary preliminary tasks

1. Remove «REAR DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-42-000-removing-and-installing) .

Unscrew nut (1).

Unlock catches (2) and remove rocker switch for side window operation (3) downwards out of rear door trim panel (4).

Scheme 199

Installation

Retaining hook (1) and plastic pin (2) must not be damaged.

Make sure rocker switch for side window operation (3) is installed in correct position.

Scheme 200

61 31 117 Removing and installing/replacing power window switch (driver side) (long version or from 03/2007)

Necessary preliminary tasks

1. Remove «FRONT DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-41-000-removing-and-installing)
2. Remove «HANDLE RECESS IN FRONT DOOR»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-41-025-replacing-handle-recess)

Unlock catches (1) and remove switch for side window operation (2) downwards out of handle recess (3).

Installation

Catch (1) must not be damaged.

Make sure rocker switch for side window operation (2) is installed in correct position.

Scheme 201

61 31 118 Removing and installing/replacing power window switch (passenger side) (long version or from 03/2007)

Lever rocker switch (1) with special tool 00 9 317 upwards out of armrest.

Disconnect plug connection.

Scheme 202

Installation

Retaining hooks (1) of rocker switch (2) must not be damaged.

Make sure rocker switch (2) is correctly seated.

Scheme 203

61 31 133 Removing and installing/replacing AV connection socket

Necessary preliminary tasks

1. Remove «REAR INSERT (IN STORAGE COMPARTMENT)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-rear) .

Press locks (1) together, feed AV connection socket (2) out of rear insert (3) and remove.

Scheme 204

61 31 134 Removing and installing/replacing USB/audio interface connecting socket

Necessary preliminary tasks

1. Remove «TRIM FOR STORAGE TRAY»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-211-removing-and-installingreplacing)

Insert suitable screwdriver (1) through opening (2) in direction of arrow.

Note. Protect connecting socket wiring harness against being damaged by screwdriver (1).

Press against connecting socket (3) in lower area.

Remove connecting socket (3) in direction of arrow.

Scheme 205

Disconnect plug connection (1).

Installation

Scheme 206

1. Retaining lug (3) must not be damaged.
2. Make sure connecting socket (2) is correctly seated in storage compartment (4).

61 31 135 Removing and installing/replacing headphones connection socket

Necessary preliminary tasks

f

1. Remove «REAR INSERT (IN STORAGE COMPARTMENT)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-rear) .

Press locks (1) together, feed headphones connection socket (2) out of rear insert (3) and remove.

Scheme 207

61 31 135 Removing and installing/replacing headphones connection socket (long version)

Necessary preliminary tasks

1. Remove «REAR INSERT (IN STORAGE COMPARTMENT)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-rear)

Press locks (1) together and press headphones connection socket (2) out of trim (3).

Scheme 208

61 31 175 Removing and installing/replacing switch for slide/tilt sunroof

Necessary preliminary tasks

1. Remove «FRONT ROOFLINER TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-44-removing-and-installing-front) .

Press catches (1) and unclip switch for sunroof (2) in direction of arrow from front roofliner trim (3).

Scheme 209

Installation

1. Initialize «SLIDE/TILT SUNROOF»(ref-201426-S28202662402005102600000) .

61 31 176 Removing and installing/replacing emergency call button

Necessary preliminary tasks

1. Remove «FRONT ROOFLINER TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-44-removing-and-installing-front) .

Press catches (1) and unclip emergency call button (2) in direction of arrow from front roofliner trim (3).

Scheme 210

61 31 192 Replacing button for controller (until 09/2008)

Note. The number of buttons and shape of controller can vary depending on vehicle type.

Before 09/2008: Controller (1) has buttons on bottom only .

After 09/2008: Controller (2) has buttons top and bottom .

Button may be removed from controller (1) only!

Note. These repair instructions describe the removal of the button from controller (1)!

Scheme 211

Pull off button for controller (1) in direction of arrow.

Scheme 212

Installation

Fit button for controller (1) such that guides (2) are seated in mountings (3).

Press knob for controller (1) in middle until it engages.

Scheme 213

61 31 193 Removing and installing/replacing button unit (for on-board monitor)

Unclip button unit (1) with special tool 00 9 341 at retaining points (2) and lever out in direction of arrow.

Unlock and disconnect associated plug connection, remove button unit (1).

Scheme 214

61 31 195 Removing and installing (replacing) front controller (until 09/2008)

Note. The number of buttons and shape of controller can vary depending on vehicle type.

Before 09/2008: Controller (1) has buttons on bottom only .

After 09/2008: Controller (2) has buttons top and bottom .

Note. These repair instructions describe the removal and installation (replacement) of controller (1) !

Necessary preliminary tasks

1. Remove «STORAGE COMPARTMENT»(ref-297306-S14592971892008082900000) .

If necessary, disconnect plug connections.

Release screws (1).

Remove controller (2) in direction of arrow from storage compartment (3).

Scheme 215

Replacement

Carry out VEHICLE PROGRAMMING/CODING .

61 31 195 Removing and installing (replacing) front controller (from 09/2008)

Note. The number of buttons and shape of controller can vary depending on vehicle type.

Before 09/2008: Controller (1) has buttons on bottom only .

After 09/2008: Controller (2) has buttons top and bottom .

Note. These repair instructions describe the removal and installation (replacement) of controller (2) !

Necessary preliminary tasks

1. Remove «STORAGE COMPARTMENT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-200-removing-and-installing) .

Carefully raise catches (1) on controller holder (3) and remove controller (2) towards top.

Installation note

Make sure controller (2) is correctly engaged in controller holder (3).

Scheme 216

Replacement

Carry out VEHICLE PROGRAMMING/CODING .

61 31 199 Removing and installing/replacing switch combination for rear cabin seat adjustment

Necessary preliminary tasks

1. Remove «LOWER REAR PANEL FROM FRONT SEAT BACKREST ON RIGHT»(/bmw/m5/e60e61-2004-2010/remont/seats/#seats-repair-instructions__52-17-205-removing-and-installingreplacing)

Unlock retaining hooks (1) and press seat adjustment switch (2) out of rear panel (3).

Scheme 217

61 31 203 Replacing seat adjustment switch combination (fully electric front seat)

Necessary preliminary tasks

1. Remove «OUTER COVER ON FRONT SEAT»(ref-201425-S31854983452005102600000) .

Unfasten plug connection (1) and disconnect.

Loosen screws (2).

Unlock catch (3) in direction of arrow and remove seat adjustment switch combination (4) towards front.

Scheme 218

61 31 204 Replacing seat adjustment switch combination (semi-electric front seat)

Necessary preliminary tasks

1. Remove «OUTER COVER ON FRONT SEAT»(ref-201425-S31854983452005102600000) .

Lever out seat adjustment control button (1) with special tool 00 9 317 in direction of arrow.

Scheme 219

Unlock catches (1) in direction of arrow and remove seat adjustment switch combination (2) from cover (3).

Scheme 220

61 31 208 Removing and installing/replacing switch for front lumbar support

Necessary preliminary tasks

1. Remove «OUTER COVER ON FRONT SEAT»(ref-201425-S31854983452005102600000) .

Unlock catches (1) and remove switch for lumbar support (2) from cover (3).

Scheme 221

61 31 214 Removing and installing/replacing switch for Electronic Damper Control (M5)

See REMOVING AND INSTALLING/REPLACING SWITCH FOR ELECTRONIC DAMPER CONTROL (M5) .

61 31 220 Removing and installing/replacing multifunction steering wheel switch (up to 03/2007)

Necessary preliminary tasks

1. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000)

Note. Illustration shows steering wheel removed.

Release screws (1).

Remove retaining plate for steering wheel (2) from standard steering wheel (3).

Scheme 222

Note. Illustrations depict removal of the right multifunction steering wheel switch. The left multifunction steering wheel switch is removed in the same way.

Release screws (1).

Unclip right multifunction steering wheel switch (2) at point (3).

Disconnect associated plug connection and remove right multifunction steering wheel switch (2) with decorative strip.

Installation

Make sure guide pins (4) are correctly seated.

Make sure electrical leads (5) are correctly routed.

Scheme 223

Installation

Observe the following work steps to adjust the correct gap dimensions between decorative strips and airbag unit.

Scheme 224

1. Fit steering wheel retaining plate (1) with decorative strip (2) not yet screwed down on special tool «61 3 120»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-special-tools__61-3-120-feeler-gauge-for) .
2. Tighten screws (3).

Unlock catch (1) and remove right multifunction steering wheel switch (2) in direction of arrow from decorative strip (3).

Scheme 225

61 31 220 Removing and installing/replacing multifunction steering wheel switch (from 03/2007)

Necessary preliminary tasks

1. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000)

Release screws (1).

Disconnect plug connection (2).

Remove retaining plate (3) from steering wheel.

Installation

Make sure electrical leads are correctly routed.

Scheme 226

Note. Illustrations depict removal of the left multifunction steering wheel switch. The right multifunction steering wheel switch is removed in the same way.

Release screws (1).

Unclip multifunction steering wheel switch (2) at point (3).

Disconnect associated plug connections and remove multifunction steering wheel switch (2).

Installation

Make sure guide pins (4) are correctly seated.

Scheme 227

Installation

Observe the following work steps to adjust the correct gap dimensions between decorative strips and airbag unit.

Scheme 228

1. Fit airbag unit (1) on steering wheel retaining plate (2)
2. Align switches (3)
3. Tighten screws (4).

61 31 220 Removing and installing/replacing multifunction steering wheel switch (sports steering wheel, up to 09/2005)

Necessary preliminary tasks

1. Clamp off «BATTERY EARTH CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000) .

Note. Illustration shows steering wheel removed.

Release screws (1).

Lever out complete steering wheel retaining plate (4) with decorative trim (3) all round, do not tilt!

Release complete steering wheel retaining plate (4) with decorative trim (3) in direction of arrow from fixtures (2).

Disconnect associated plug connections and remove complete steering wheel retaining plate (4) with decorative trim (3).

Scheme 229

Installation

Make sure electrical leads are correctly routed.

Note. Illustrations depict removal of the left multifunction steering wheel switch. The right multifunction steering wheel switch is removed in the same way.

Release screws (1) and remove left multifunction steering wheel switch (2) from decorative trim (3).

Installation

Make sure there is a uniform gap between both multifunction steering wheel switches and decorative trim (3).

Scheme 230

61 31 220 Removing and installing/replacing multifunction steering wheel switches (sport steering wheel, from 09/2005)

Necessary preliminary tasks

1. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000)

Release screws (1).

Disconnect associated plug connections and remove switches (2) complete with decorative strip (3).

Installation

Make sure electrical leads are correctly routed.

Scheme 231

Release screws (2) and remove left multifunction steering wheel switches (3) from decorative strip (1).

Installation

Guide pins (4) must not be damaged and must be correctly inserted.

Make sure there is a uniform gap between both multifunction steering wheel switches (3) and decorative strip (1).

Scheme 232

61 31 231 Removing and installing/replacing steering wheel electronics control unit

Necessary preliminary tasks

1. Remove «AIRBAG UNIT»(ref-170471-S10869491912005011000000)

E60, E61: Version with standard steering wheel, illustrations show steering wheel removed

Release screws (1).

Remove steering wheel retaining plate (2) upwards out of multifunction steering wheel (3).

Scheme 233

E60, E61: Version with sports steering wheel; E63, E64, illustrations show steering wheel removed

Release screws (1).

Lever out complete steering wheel retaining plate (4) with decorative trim (3) all round, do not tilt!

Release complete steering wheel retaining plate (4) with decorative trim (3) in direction of arrow from fixtures (2).

Disconnect associated plug connections and remove complete steering wheel retaining plate (4) with decorative trim (3).

Scheme 234

Installation

Make sure electrical leads are correctly routed.

All

Pull steering wheel electronics control unit (1) in direction of arrow out of steering wheel (2).

Scheme 235

Unlock plug connections (1) and disconnect.

Remove steering wheel electronics control unit (2).

Installation

Guide pins (3) of steering wheel electronics control unit (2) must be exactly seated in associated mountings.

Make sure electrical leads (4) are correctly routed.

Scheme 236

61 31 233 Removing and installing/replacing Lane Departure Warning motor electrics (sport steering wheel)

Necessary preliminary tasks

1. Remove «DECORATIVE BAR FROM STEERING WHEEL»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-220-removing-and-installingreplacing)

Release screws (1) and remove retaining plate (2).

Tightening torque: 6 Nm

Scheme 237

Disconnect plug connection (1).

Release screw (2).

Release screws (3) and remove motor electrics (4) complete with electrical wires.

Installation

Replace screws (2 and 3).

1. Tightening torque: 3 Nm
2. Tightening torque: 4 Nm

Ensure correct cable routing.

Scheme 238

61 31 241 Removing and installing/replacing engine hood contact switch

Unfasten plug connection (1) and disconnect.

Pull engine hood contact switch (2) in direction of arrow and feed out of microfilter air duct (3).

Scheme 239

61 31 255 Replacing switch for outside mirror

This operation is described in

REPLACING ROCKER SWITCH FOR SIDE WINDOW OPERATION .

61 31 257 Removing and installing/replacing switch for left or right rear cabin monitor

Necessary preliminary tasks

1. Remove «UPPER REAR PANEL FROM FRONT SEAT BACKREST»(/bmw/m5/e60e61-2004-2010/remont/seats/#seats-repair-instructions__52-17-205-removing-and-installingreplacing) on left or right

Press locks (1) together and press switches for seat heating (2) out of trim (3).

Scheme 240

61 31 270 Replacing switch for reversing light

Note. The installation location of the reversing light switch can vary, depending on the transmission model.

Necessary preliminary tasks

1. If necessary, remove «REAR UNDERBODY PROTECTION»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-491-removing-and-installingreplacing)

Version A

Disconnect plug connection (1).

Release switch for reversing light (2).

Tightening torque: 16 Nm

Scheme 241

Version B

Disconnect plug connection (1).

Release switch for reversing light (2).

Tightening torque: 16 Nm

Scheme 242

61 31 287 Removing and installing/replacing driving dynamics switch

Necessary preliminary tasks

1. Remove «FINISHER FOR PRESELECTOR LEVER»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-210-removing-and-installingreplacing) .

Release screws (1).

If necessary, lever out actuation trim (4) with special tool 64 1 020 and remove.

Remove driving dynamics switch (2) in direction of arrow from finisher for preselector lever (3).

Scheme 243

61 31 299 Removing and installing/replacing clutch switch module

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Note. Clutch master cylinder (2) is removed for purposes of clarity.

Lever out clutch switch module (1) from clutch master cylinder (2) with screwdriver.

Unlock plug (4) and disconnect from housing (3).

Scheme 244

Installation

Clutch switch module is protected against incorrect installation.

Clutch switch module must snap audibly into place.

Scheme 245

61 31 310 Replacing brake light switch

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Unfasten plug connection (1) and disconnect.

Pull brake light switch (2) in direction of arrow out of brake light switch holder (3).

Installation

Scheme 246

1. Press brake pedal (4) to floor.
2. Slide brake light switch (2) as far as it will go into brake light switch holder (3).
3. Grip brake light switch holder (3), slowly return brake pedal (4) to starting position and pull back to stop .

Note. Removing brake light switch holder (2)

Press brake pedal.

Press catches (1) together and unclip brake light switch holder (2) from bearing block (3).

Scheme 247

61 31 330 Removing switch for glovebox light

Lever switch for glovebox light (1) with special tool 64 1 020 as pictured out of glovebox housing (2).

Unlock and disconnect associated plug connection, remove switch for glovebox light (1).

Scheme 248

61 31 334 Removing and installing/replacing grip trim for gear selector switch

Lever off side section (1) with special tool 00 9 322 from gear selector switch (2) and remove.

Installation

Position side section (1) on metal pins of gear selector switch (2) and uniformly press down firmly and without leaving a gap.

Scheme 249

Lever off front shell (1) with special tool 00 9 322 from gear selector switch (2) and remove.

Press P button (3) and remove front shell (1) starting from top.

Installation

Insert front shell (1) at bottom in retaining ring (4). Uniformly press front shell (1) upwards onto metal pins of gear selector switch (2) firmly and without leaving a gap.

Scheme 250

Lever off P button (1) with special tool 00 9 322 from gear selector switch (2) and uniformly remove.

Installation

After installing front shell, insert P button (1) into upper opening on gear selector switch and uniformly press in until it engages.

Scheme 251

61 31 342 Removing and installing/replacing gear selector switch

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Remove «TRIM FOR STORAGE COMPARTMENT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-211-removing-and-installingreplacing)

Disconnect plug connection (1).

Release screws (3) and lay emergence release mechanism to one side. Tightening torque: 1.6 Nm

Release screws (2). Tightening torque: 7.5 Nm

Remove gear selector switch (4) from center console (5).

Installation note

Align gear selector switch (4) centrally.

Scheme 252

Replacement

Modify spacer bolt.

Carry out VEHICLE PROGRAMMING/CODING .

61 31 382 Replacing level switch for coolant

Release screws (1).

Unlock plug connection for coolant level switch (4) and disconnect.

Pull coolant expansion tank (2) in direction of arrow out of grommet (3) underneath.

Installation

Make sure coolant expansion tank (2) is correctly seated in grommet (3).

If necessary, replace grommet (3).

Scheme 253

Reposition coolant expansion tank (2) as far as possible until coolant level switch (4) forms the highest point. This will prevent coolant from escaping on opening.

If necessary, catch escaping coolant and feed back in later.

Note. For purposes of clarity, illustration shows coolant expansion tank (2) removed.

Turn coolant level switch (1) in direction of arrow, pull upwards out of coolant expansion tank (2) and remove.

Scheme 254

61 31 492 Replacing level switch for windshield washer unit

E60 M5: Remove FRONT UNDERBODY PROTECTION

Note. For purposes of clarity, illustration shows front wheel removed.

Release screws.

Fold back wheel arch trim (1) in direction of arrow.

Scheme 255

Disconnect plug connection (1).

Turn level switch for windscreen washer unit (2) in direction of arrow and remove towards bottom from fluid reservoir for windscreen washer unit (3).

Scheme 256

61 31 996 Carrying out steering angle sensor adjustment

Note. Steering angle sensor adjustment must be carried out

1. Before adjustment work on the front axle/steering
2. After all mechanical work on the steering system
3. After replacement / coding / programming of the following components: Fixture for switches of steering column / switch cluster / steering angle sensor Dynamic Stability Control (DSC) control unit Control unit active anti-roll stabilization (ARS)

Connect vehicle to BMW diagnosis system or Software Service Station.

Select and carry out steering angle sensor adjustment under Service functions.

61 33 060 Removing and installing/replacing both fanfare horns

Release screws (1).

Detach cover (2) from front underride protection (3) and feed out in direction of arrow.

Remove cover (2).

Scheme 257

Unlock plug connections (1) and disconnect.

Release nuts (2) and remove fanfare horns (3).

Scheme 258

61 34... Removing and installing/replacing power socket in rear storage compartment

Necessary preliminary tasks

1. Remove «REAR INSERT (IN STORAGE COMPARTMENT)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-removing-and-installingreplacing-rear)

Carefully lever bulb holder (1) in direction of arrow off power socket (2).

Press power socket (2) out of trim (3).

Scheme 259

32 43 010 Removing and installing / replacing control unit for active front steering

After installation

1. Replacement only: Carry out «CODING»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-00-program-encode-the) using BMW scan tool.
2. Replacement/coding only: Carry out «ACTIVE FRONT STEERING START-UP/ADJUSTMENT»(ref-201418-S02824793292006032400000) .

Necessary preliminary tasks

1. Remove «RIGHT ENTRANCE STRIP»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-000-removing-and-installingreplacing) .
2. Remove «RIGHT FRONT SEAT»(ref-201425) .
3. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) .
4. If necessary, remove front right floor mat.
5. Remove «SIDE TRIM IN FRONT RIGHT FOOTWELL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-43-075-removing-and-installingreplacing) .
6. Fold back front right floor trim.
7. Remove kickplate in footwell in front of and next to control unit; if necessary, cut along specified lines with knife and secure later with adhesive tape.

Release screws (1).

Lay grounding cable to one side.

Installation

Secure grounding cable as illustrated to retaining plate.

Scheme 260

Raise active front steering control unit and turn over.

Unlock connector and remove.

Remove active front steering control unit.

Scheme 261

61 35... Notes on ESD protection (Electro Static Discharge)

Note. Electrical components which are particularly sensitive to electrostatic discharge (electronic control units, sensors, etc.) are marked with the ESD warning symbol.

E -Electro

S -Static

D -Discharge

Statically charged persons can discharge by touching electrical components.

Note. Humans can only detect a discharge starting from a level of approx. 3000 V.

The danger threshold for electrical components already starts from a level of approx. 100 V.

Scheme 262

Example: Mechatronic control unit.

Scheme 263

Touch electrical components by their housings only.

Scheme 264

1. When replacing electrical components, leave the replacement components in their original packaging until immediately before they are to be installed
2. If necessary, always return a removed component in its original packaging (always pack the component away immediately)
3. Read and comply with user information on using the associated ESD special tool 12 7 060 (anti-static mat)

Personal protective equipment

Electrically conducting clothing (high wool content, antistatic shoes required).

These can primarily be identified by the logo on the side.

Scheme 265

Scheme 266

Scheme 267

61 35 001 Removing and installing (replacing) trailer module

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-101-removing-and-installingreplacing) .
2. If necessary, remove storage tray for car jack
3. If necessary, remove spare wheel
4. Remove control unit cover
5. Remove «BATTERY»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-21-010-removing-and-installing)

Note. Depending on the equipment specification, the position of the trailer module (2) can vary.

Lift trailer module (2) out of equipment mounting (3).

Disconnect plug connection (1).

Scheme 268

61 35 015 Removing and installing (replacing) control unit for Car Access System

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Unfasten plug connection (2) and disconnect.

Replace ribbon cable (1) if

1. Plug connection for ribbon cable (1) is damaged
2. Control unit for Car Access System (3) is replaced

The ribbon cable leads to the IGNITION STARTER SWITCH .

Release screw (4) and remove control unit for Car Access System (3) in direction of arrow.

Scheme 269

Installation

Feed guide (1) of control unit for Car Access System (2) correctly into associated mounting.

Scheme 270

Replacement

Carry out PROGRAMMING/ENCODING .

Version with auxiliary heater

Initialize all AUXILIARY HEATER REMOTE CONTROLS .

61 35 030 Removing and installing (replacing) power module

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-101-removing-and-installingreplacing)
2. Remove spare wheel

Take off cover for control units (1).

Note. Make sure cover for control units (1) is correctly seated on locating pins (2).

Scheme 271

Unfasten plug connection (1) and disconnect.

Remove power module (2) in direction of arrow from mounting for control units (3).

Scheme 272

Replacement

Carry out PROGRAMMING/CODING .

61 35 076 Removing and installing/replacing control unit for backrest width adjustment

Necessary preliminary tasks

1. Remove switch combination for seat adjustment. See «SWITCH COMBINATION (FULLY ELECTRIC FRONT SEAT)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-203-replacing-seat-adjustment) or «SWITCH COMBINATION (SEMI-ELECTRIC FRONT SEAT)»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-31-204-replacing-seat-adjustment) .

Unclip cover (1) on front seat.

Scheme 273

Release screws (1) on thigh support.

Disconnect plug connection (2).

Remove thigh support (3) towards top.

Installation

Insert screws (1) with Loctite.

Scheme 274

Unclip trim (1) for thigh support carrier.

Scheme 275

Detach seat cover (1).

Tilt back seat cover (1) with padding towards middle of vehicle.

Scheme 276

Loosen retainers (1).

Tilt back thigh support (2) towards rear.

Remove all remnants of clips from seat cover and seat mechanism.

Installation

Bend new retainers closed with pliers 52 0 050 .

Scheme 277

Release screw (1) under tilted-up seat padding.

Unlock plug connections (2) and disconnect.

Remove control unit for backrest width adjustment (3) towards bottom.

Scheme 278

Replacement

Carry out PROGRAMMING/CODING .

61 35 080 Removing and installing (replacing) control unit for left or right seat adjustment (front seat)

Illustration of problem: (replacement only)

In the event of a faulty seat module, new variants with a 30 mm wider housing will be used as replacements as of 03/2005.

1. Seat module up to 03/2005 approx. 135 mm
2. Seat module from 03/2005 approx. 165 mm

This results (on the right seat only) in a collision with the central seat connector.

In vehicles up to 03/2005 it is therefore necessary to fit the right seat with a new seat pan (applicable from 03/2005).

The following SM variants are affected

1. SM H
2. SM BA/M
3. SM BA/M-HK

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) .
2. Remove «TRIMS FOR TOP RAIL»(ref-201425-S04861576462005102600000) .

Removal and installation

Note. To facilitate installation/removal of control unit, move seat upwards fully.

Unlock and disconnect all plug connections in area (1).

Unlock catches (2) towards rear, feed out control unit for seat adjustment (3) in direction of arrow and remove from seat rail (4).

Scheme 279

Installation

Make sure mounts (1) and retaining lugs (2) of control unit for seat adjustment (3) are correctly seated.

Scheme 280

Replacement

Remove trim for top rail on outside.

Unlock central seat connector (1) and disconnect.

Unlock and disconnect all plug connections from connector strips (2).

Scheme 281

Pull seat pan (1) forwards slightly and unclip from seat linkage.

Lift seat pan at rear left and right out of seat rail.

Scheme 282

Turn seat pan in seat mechanism and feed out towards front.

Unclip seat wiring harnesses from seat pan.

Remove seat pan.

Scheme 283

The new seat module is secured to the new seat pan in the area marked "R".

Wiring harness (1) must be re-laid accordingly.

Pay attention to new clip positioning (2).

Scheme 284

Carry out PROGRAMMING/CODING .

61 31 115 Replacing rocker switch for side window operation (front) (up to 03/2007)

Necessary preliminary tasks

1. Remove «FRONT DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-41-000-removing-and-installing) .

Slacken nut (1).

Unlock catches (2). Remove rocker switch for side window operation (3) downwards out of front door trim panel (4).

Scheme 285

Installation

Retaining hook (1) and plastic pin (2) must not be damaged.

Make sure rocker switch for side window operation (3) is installed in correct position.

Scheme 286

61 31 116 Replacing rocker switch for side window operation (rear) (up to 03/2007)

Necessary preliminary tasks

1. Remove «REAR DOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-42-000-removing-and-installing) .

Slacken nut (1).

Unlock catches (2). Remove rocker switch for side window operation (3) downwards out of rear door trim panel (4).

Scheme 287

Installation

Retaining hook (1) and plastic pins (2) must not be damaged.

Make sure rocker switch for side window operation (3) is installed in correct position.

Scheme 288

61 31 116 Replacing rocker switch for side window operation (rear, long version or from 03/2007)

Lever rocker switch (1) with special tool 00 9 317 upwards out of armrest.

Disconnect plug connection.

Scheme 289

Installation

Retaining hooks (1) of rocker switch (2) must not be damaged.

Make sure rocker switch (2) is correctly seated.

61 35 125 Removing and installing/replacing body module

Read out PROGRAMMING/CODING .

1. Print out and make a note of settings for car and key memory in CKM menu

Necessary preliminary tasks

1. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Remove «TRIM FOR INSTRUMENT PANEL, BOTTOM LEFT»(ref-297306-S16986874072008082900000) (same as right side)
3. Detach «AIRBAG CONTROL UNIT WITH GATEWAY MODULE»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#audio-navigation-anti-theft-and-restraints-repair__65-77-680-removing-and-installing) .

Note. Open glovebox.

Unclip pin (1) from retaining strap (2).

Scheme 290

Unclip pin (1) from shock absorber (2).

Scheme 291

Open rotary clips (1) and remove.

Remove cover (2) in direction of arrow.

Scheme 292

Release screws (1).

Pull fuse holder (2) back slightly.

Scheme 293

Unlock plug connections (1) and disconnect.

Unlock catches (3) in direction of arrow and remove body module (2) from equipment carrier (4).

Scheme 294

Replacement

Carry out PROGRAMMING/CODING .

Check printed-out or noted-down settings for car and key memory in CKM menu and reset if necessary.

61 35 127 Removing and installing/replacing body gateway module

Read out PROGRAMMING/CODING .

1. Print out and make a note of settings for car and key memory in CKM menu

Necessary preliminary tasks

1. Disconnect «NEGATIVE BATTERY CABLE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair)
2. Remove «TRIM FOR INSTRUMENT PANEL, BOTTOM LEFT»(ref-297306-S16986874072008082900000) (same as right side)

Note. Open glovebox.

Unclip pin (1) from retaining strap (2).

Scheme 295

Unclip pin (1) from shock absorber (2).

Scheme 296

Open rotary clips (1) and remove cover (2) in direction of arrow.

Scheme 297

Release screws (1).

Pull fuse holder (2) back slightly.

Scheme 298

Detach AIRBAG CONTROL UNIT WITH GATEWAY MODULE .

Unlock plug connections (1) and disconnect.

Unlock catches (3) in direction of arrow and remove body module (2) from equipment carrier (4).

Scheme 299

Replacement

Carry out PROGRAMMING/CODING .

1. Check printed-out or noted-down settings for car and key memory in CKM menu and reset if necessary

61 35 177 Removing and installing (replacing) rain/light sensor

Necessary preliminary tasks

Version with Autobeam

1. Remove «INTERIOR REAR-VIEW MIRROR»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-060-removing-and-installingreplacing)

Detach two-part mirror base cover (1) by pressing from below.

Feed out two-part mirror base cover (1) and remove.

Note. Catches of two-part mirror base cover (1) must not be damaged.

Scheme 300

Disconnect plug connection (3).

Press locks (1) in direction of arrow and remove rain/light sensor (2) towards bottom.

Installation

Do not damage optical element covered by rain/light sensor (2).

If necessary, initialize RAIN/LIGHT SENSOR .

Scheme 301

Replacement

Carry out PROGRAMMING/CODING .

61 35 220 Removing and installing (replacing) control unit for left or right front door

Read out PROGRAMMING/CODING . Print out and make a note of settings for car and key memory in CKM menu

Necessary preliminary tasks

1. Remove «FRONT DOOR TRIM»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-41-000-removing-and-installing) .

Unlock plug connections (1) and disconnect.

If necessary, unclip electrical leads at points (2).

Release screws (3).

Remove control unit in front door (4).

Scheme 302

Replacement

Carry out PROGRAMMING/CODING .

Check printed-out or noted-down settings for car and key memory in CKM menu and reset if necessary.

61 35 285 Removing and installing (replacing) light module

Necessary preliminary tasks

1. Remove «TRIM PANEL FOR PEDAL ASSEMBLY»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-45-185-removing-and-installingreplacing) .

Unlock catch (1) and feed out/remove light module (2) in direction of arrow.

Scheme 303

Installation

Make sure light module (2) is correctly seated in mounting (3) and catch (1).

If necessary, unlock catch (1) and remove cover (2) from light module (3).

Installation: Make sure cover (2) is correctly seated on light module (3). Disconnect plug connection.

Scheme 304

Scheme 305

Replacement

Carry out PROGRAMMING/CODING .

61 35 502 Replacing trailer module(09/2001-09/2006)

Note. From 03/2009 trailer module AHM3+ will be replaced by trailer module AHM4R.

Plug connectors and associated pin assignments must be adapted if the old plug connector AHM3(+) is fitted.

1. Plug connector, new AHM4
2. Plug connector, old AHM3(+)

Scheme 306

Necessary preliminary tasks

1. Remove «TRAILER MODULE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-35-001-removing-and-installing)

Up to build date/version 03/2007 Series E60/61

Installation

Cut out device holder up to marking (1).

Make sure wiring harness is exactly routed.

Scheme 307

Note. Positions of plugs and associated pin assignments are set out in the diagnosis system.

The repair instruction represents the highest vehicle configuration. Pin assignments of plug connections may be absent if optional equipments are not fitted.

Special tools for disconnecting

Secondary lock

Special tool 61 0 324 (Release tool for secondary lock)

Primary lock

Special tool 61 0 316 (Release tool for flat spring contacts with double retaining tab "SPT 4.8" "JPT 2.8")

Special tool for crimping

Double flat spring contact

Crimping tool special tool 61 0 202 (crimping tool) with special tool 61 0 230 (matrix)

SPECIAL TOOL FOR CRIMPING REFERENCE CHART

Carry out VEHICLE PROGRAMMING/CODING .

61 35 502 Replacing trailer module (09/2006-03/2009)

Note. From 03/2009 trailer module AHM3+ will be replaced by trailer module AHM4R.

Plug connectors and associated pin assignments must be adapted if the old plug connector AHM3(+) is fitted.

1. Plug connector, new AHM4
2. Plug connector, old AHM3(+)

Necessary preliminary tasks

1. Remove «TRAILER MODULE»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-35-001-removing-and-installing)

From build date/version 03/2007 Series E60/61

Installation

Cut out device holder up to marking (1).

Cut out indentation in area (2).

Make sure AHM module is exactly seated and wiring harness is correctly routed.

Scheme 308

Note. Positions of plugs and associated pin assignments are set out in the diagnosis system.

The repair instruction represents the highest vehicle configuration. Pin assignments of plug connections may be absent if optional equipments are not fitted.

Special tools for disconnecting

Secondary lock

Special tool 61 0 324 (Release tool for secondary lock)

Primary lock

Special tool 61 0 316 (Release tool for flat spring contacts with double retaining tab "SPT 4.8" "JPT 2.8")

Special tool for crimping

Double flat spring contact

Crimping tool special tool 61 0 202 (crimping tool) with special tool 61 0 230 (matrix)

SPECIAL TOOL FOR CRIMPING REFERENCE CHART

Carry out VEHICLE PROGRAMMING/CODING .

61 35 679 Initializing rain/light (solar) sensor

Note. Initialization is necessary after: replacing windscreen replacing rain/light (solar) sensor replacing optical element on rain/light (solar) sensor installing a used rain/light (solar) sensor

Note. Connect BMW diagnosis system Initializing rain/light (solar) sensor

61 35 683 Replacing optics for solar rain/light sensor

Necessary preliminary tasks

Remove SOLAR RAIN/LIGHT SENSOR

Optics can only be replaced in the following equipment specifications

1. E60/E61 without head-up display
2. E60/E61 without lane departure warning

Carefully expand catches (1) of solar rain/light sensor (2).

Remove optical element (3).

Installation

Remove protective cover from replacement optical element.

Catches (1) of solar sensor (2) must not be damaged.

Observe laser markings (4) of fitting aid.

Scheme 309

When fitting a different type of windscreen, carry out CODING to determine the windscreen type for the light sensor.

Carry out INITIALIZATION to calibrate the rain sensor to the windscreen.

61 35 685 Replacing rain/light solar sensor

Expand two-part mirror base cover (1) by pressing from below and detach.

Feed out two-part mirror base cover (1) and remove.

If necessary, remove INTERIOR REARVIEW MIRROR .

Note. Catches of two-part mirror base cover (1) must not be damaged.

Scheme 310

Disconnect plug connection (1).

Unlock metal spring (3) in direction of arrow.

Pull off solar rain/light sensor (2) from windscreen.

Installation

Close plug connection (1) only after fitting solar rain/light sensor on windscreen!

Carefully clean the windscreen where it comes in contact with the solar rain/light sensor! Remove all silicone residues!

Pull off protective cover from new solar rain/light sensor. Do not touch the silicon-coated surface underneath!

Align solar rain/light sensor (2) and press firmly on windscreen. Pay attention to mechanical coding (5).

Press metal spring (3) centrally to ensure that retaining element (4) engages correctly in both hooks (6).

Scheme 311

Replacement

1. Carry out «CODING»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-00-program-encode-the) to determine the windscreen type for the light sensor.
2. Carry out «INITIALIZATION»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair__61-35-679-initializing-rainlight-solar) to calibrate the rain sensor to the windscreen.

61 35 795 Removing and installing (replacing) control unit for adaptive headlight

Necessary preliminary tasks

1. Remove «TRIM FOR INSTRUMENT PANEL, BOTTOM LEFT»(ref-297306-S16986874072008082900000) (same as right side)

Unlock catch (1) in direction of arrow.

Pull control unit for adaptive headlight (2) out of equipment carrier (3) slightly.

Unfasten plug connection (4) and disconnect.

Remove control unit for adaptive headlight (2).

Scheme 312

Replacement

Carry out PROGRAMMING/CODING .

61 35 900 Removing and installing/replacing ring antenna of electronic immobilizer

Necessary preliminary tasks

1. Remove «TOP SECTION OF STEERING COLUMN CASING»(ref-201418-S28702315432005102600000) .

Disconnect plug connection (1).

Position special tool 61 3 300 as illustrated with flattened side (A) to ring antenna of electronic immobilizer (2).

Lever out ring antenna of electronic immobilizer (2) in direction of arrow and remove.

Scheme 313

61 35 950 Removing and installing (replacing) control unit for comfort access system

Note. The comfort access system is a radio-based system and can be interfered with by radio waves from other systems (e.g. mobile phone).

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-101-removing-and-installingreplacing) .
2. Remove «LUGGAGE COMPARTMENT TRIM ON SIDE PANEL ON RIGHT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-220-removing-and-installingreplacing) .
3. Disconnect «BATTERY NEGATIVE LEAD»(/bmw/m5/e60e61-2004-2010/remont/horns/#general-electrical-system-repair) .
4. Remove «TRIM FOR INSTRUMENT PANEL, BOTTOM LEFT»(ref-297306-S16986874072008082900000) (same as right side)

Unclip pin (1) from shock absorber (2).

Scheme 314

Open rotary clips (1) and remove. Remove cover (2) in direction of arrow.

Scheme 315

Release screws (1). Pull fuse holder (2) back slightly.

Scheme 316

Disconnect plug connection (1). Unlock catch (2) in direction of arrow and remove control unit for comfort access system (3) from device carrier (4).

Scheme 317

Installation: Make sure control unit (3) is correctly seated in device carrier (4).

Replacement: Carry out PROGRAMMING/CODING .

61 35 953 Removing and installing/replacing interior antenna for comfort access system (front)

Necessary preliminary tasks

1. Remove «AUDIO SYSTEM CONTROLLER»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#audio-navigation-anti-theft-and-restraints-repair__65-12-200-removing-and-installing) .
2. Remove «STORAGE COMPARTMENT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-200-removing-and-installing) .

Unfasten screws (2). Remove middle function carrier (1) in direction of arrow.

Scheme 318

Remove middle air duct in direction of arrow.

Scheme 319

Detach felt (1) from interior antenna for comfort access system (2).

Scheme 320

Disconnect plug connection (1). Unclip interior antenna for comfort access system (2) from clip (3).

Scheme 321

61 35 954 Removing and installing/replacing interior antenna for comfort access system (rear)

Necessary preliminary tasks

1. Remove «STORAGE COMPARTMENT»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-16-200-removing-and-installing) .

Disconnect plug connection (1). Disconnect plug connection (2). Remove rear compartment air duct (3).

Scheme 322

Release screws (1). Remove interior antenna for comfort access system (2).

Scheme 323

61 35 965 Removing and installing/replacing rear parcel antenna for comfort access system

Necessary preliminary tasks

1. Remove both «TRIMS FOR ROOF PILLAR AT REAR (REAR)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-43-251-removing-and-installingreplacing)
2. Remove both «TRIMS FOR ROOF PILLAR AT REAR (FRONT)»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-43-255-removing-and-installingreplacing) .
3. Remove «BACKREST FOR REAR SEAT»(ref-201425-S16160072782005102600000)
4. Remove «PANEL FOR PARCEL SHELF»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-46-006-removing-and-installingreplacing)

Disconnect plug connection (1). Unfasten screws (2). Remove interior antenna for comfort access system (3).

Scheme 324

61 35 970 Removing and installing/replacing luggage compartment antenna for comfort access system

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-101-removing-and-installingreplacing)
2. Remove storage tray for car jack
3. Remove spare wheel
4. Remove control unit cover

Disconnect plug connection (1).

Pull luggage compartment antenna (2) for comfort access system from control unit receptacle (3).

Scheme 325

61 35 975 Removing and installing/replacing bumper antenna for comfort access system

Necessary preliminary tasks: Remove REAR BUMPER TRIM .

Disconnect plug connection (2). Press catches (1), feed out bumper antenna for comfort access system (3) in direction of arrow and remove.

Scheme 326

66 31 100 Removing and installing/replacing longitudinal dynamics module

See REMOVING AND INSTALLING/REPLACING LONGITUDINAL DYNAMICS MODULE .

71 60 100 Removing and installing/replacing control unit for trailer tow hitch unlocking

See REMOVING AND INSTALLING/REPLACING CONTROL UNIT FOR TRAILER TOW HITCH UNLOCKING .

61 00... Program / encode the control unit(s)

1. In order to avoid incorrect programming procedures and fault messages, it is essential when working with the ISTA/P programming system always to use the version.
2. Battery voltage must not drop below 13.0 V during programming. Connect battery charger prior to programming.

programming routine via ISTA/P

1. Connect the battery charger to the vehicle.
2. Connect the programming system with the vehicle.
3. Determine the action plan.
4. Accept action plan with the control units to be programmed/encoded and enabled, if necessary or work through.
5. Observe the reworking list!
6. If applicable, connect the workshop system to the vehicle depending on the rework list, run the brief test and delete the fault memory. NOTE: A switch to the workshop system may not necessarily be required with the integration of the service functions and the "Delete fault memory" function in ISTA/P. Check the rework list accordingly!
7. Compliance with the information about programming in workshop systems and the corresponding notes in the user documentation is required.

Place special tool 61 1 153 against relay carrier (1) and carefully pull in direction of arrow until the locking tabs (2) of the relay carrier are raised up.

Pull relay carrier (2) in direction of arrow into the first catch (3).

Press down arrester hook (4) of corresponding contact and pull out the cable with contact.

With special tool 61 1 136 or 61 1 137 (press out) press out dual spring contacts.

61 36 520 Removing and installing / replacing relief relay (EDC)

Necessary preliminary tasks

1. Remove «LUGGAGE COMPARTMENT FLOOR TRIM PANEL»(/bmw/m5/e60e61-2004-2010/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-47-101-removing-and-installingreplacing) .
2. Remove storage tray for car jack.
3. Remove spare wheel.
4. Remove control unit cover.

Detach relay (1).

Scheme 327

61 36 560 Removing and installing/replacing headlight washer relay

Necessary preliminary tasks

1. Open glovebox.

Unclip pin (1) from shock absorber (2).

Scheme 328

Open rotary clips (1) and remove cover (2) in direction of arrow.

Scheme 329

Detach relay (1).

Scheme 330

61 36 570 Removing and installing/replacing windshield wiper system relay

Necessary preliminary tasks

1. Remove «LOWER SECTION OF MICROFILTER HOUSING ON RIGHT»(/bmw/m5/e60e61-2004-2010/remont/cabin-air-filter/#cabin-air-filter) .

Release screws (1). Remove electronics box cover (2).

Scheme 331

Detach relay (1).

Scheme 332

Scheme 333

61 61... Adjusting left or right windscreen wiper

Correctly adjusting the contact angle of the wiper arms on the windscreen increases wiping quality. For adjustment, refer to the vehicle-specific repair instruction.

Scheme 334

A/B = Distance between windscreen wiper blade (2) and trim panel on cowl panel (1)

Note. Measurement is taken at the height of the locators (3) for the windscreen wiper arms

C= Contact angle between wiper blade center plane and windscreen

When adjusting with special tool 61 6 100 , set the scale value in accordance with the following table.

For RHD vehicles, change the preceding sign of the scale values.

1. LHD cars, scale range 0 to --10
2. RHD cars, scale range 0 to +10

61 61 010 Checking/adjusting contact angle of windshield wiper arms on windshield