Maintenance and General Information - Repair Instructions BMW X5 E53

00 .. ... Lifting vehicle with a lifting platform

Note. Before driving onto a lifting platform, make sure there is sufficient ground clearance between the lifting platform and the car. The lifting platform must comply with the relevant statutory accident prevention regulations and be serviced according to the manufacturer's instructions.

Lifting platform securing points (1) must be fitted to the vehicle.

If necessary, remove these securing points (1) from the equipment pack and clip into bores in front and rear spoiler area from below.

Make sure that the locating plate (2) of the lifting platform arm does not touch (and thereby damage) adjoining components.

Scheme 1

Note. Follow the lifting gear operating instructions. In particular, follow the safety instructions and observe the carrying capacity of the lifting gear.

00 ... ... Notes on Using Repair Instructions, Technical Data, Tightening Torques

These repair instructions are intended to help expertly carry out maintenance and repair work.

The Repair Instructions describes the removal, installation and replacement of subassemblies in the vehicle.

The Repair Instructions describe tasks which can be carried out on series-production BMW Group vehicles and vehicles which have not been subsequently converted.

Cross-references to "Technical Data" and "Tightening Torques" must be complied with.

If there are no cross-references to tightening torques in the repair instructions, the excerpts from the company standard BMW N 600 02.0 must be observed.

Cross-references to other flat rate units are intended as an aid and can refer to a complete work operation or merely to individual work steps contained therein.

Cross-references to other flat rate units must not be considered as an extension of the labor performance standard.

In general, the individual work steps of the Repair Instructions describe only the removal of subassemblies. All removed subassemblies are reinstalled in reverse sequence. If particular features need to be observed during installation, they are identified as notes on installation. In contrast, complicated removal and installation procedures are described separately.

00 ... ... Raising vehicle with trolley jack (vehicle equipped with jacking point)

Raising vehicle at front

If necessary, remove front spoiler/spoiler lip.

Slide trolley jack under vehicle at front middle until the rubber contact plate is situated below the jacking point.

Raise vehicle with trolley jack.

Scheme 2

Raising vehicle at rear

00 .. ... Symbols used and information in repair instructions

Example

The caution symbol is used in all repair instructions.

However, use of the warning word "Caution!" is not binding in every case.

The notes, instructions and precautionary measures mentioned above retain their validity.

Note. Particular information on improved procedures for operation, testing, adjustment and upkeep. Also indicates the end of a repair section.

Recycling

Observe country-specific waste-disposal regulations

General information

Refers to other instructions: E.g.

Replacement

Carry out programming/coding.

Note. Many electronic control units must be programmed/coded (e.g. when replaced).

Note. Connect BMW diagnosis system

Note. Electronic control units and other electronic components - if handled incorrectly - can be damaged or destroyed by electrostatic discharge.

00 00 ... Battery: check acid level, top up with distilled water if necessary. If necessary, recharge battery.

Observe safety instructions for handling vehicle battery.

Installation locations

The battery is located in either the engine or luggage compartment.

Check acid level, top up with distilled water if necessary.

If level drops below Max. marking, top up distilled water to Max. marking.

00 00 ... Battery: check display (magic eye); if necessary, recharge battery

For further information on how to proceed, refer to 61 00 ... BATTERY CHARGING , lead calcium batteries, all models.

00 00 ... Body and underbody: checking for corrosion and damage

Inspect chassis, underbody and wheel arches and check for corrosion and damage.

00 00 ... Body and underbody: checking for corrosion and damage - except cavities

Visually inspect the underbody, wheel arches and frame members for rust and damage.

00 00 ... Brake and clutch hydraulic system: checking fluid level, topping up if necessary

Check fluid level in expansion tank; if necessary, top up brake fluid to Max. marking (1) (refer to Service Information Operating Fluids ).

Note. It is absolutely essential to rectify any identified faults after consulting the customer and to issue a separate invoice.

Scheme 3

Check brake lines and connections

Visual inspection in visible area for

1. leaks
2. traces of fluid
3. damage
4. crushing/flattening
5. correct routing of brake lines

00 00 ... Changing brake fluid

Note. Refer to BLEEDING BRAKE SYSTEM . Carry out operation in accordance with description, but for each wheel purge brake circuit with approx. 250 ml brake fluid.

1. Bleed brake system without ABS.
2. Bleed brake system with ABS.
3. Bleed brake system with ABS/ASC + T.
4. Bleed brake system with DSC.

00 00 ... Changing coolant

For further information on how to proceed, refer to COOLANT CHECKING COOLING SYSTEM .

1. Draining and topping up coolant
2. Bleeding cooling system and checking for water leaks

For filling quantity, refer to COOLING SYSTEM - TECHNICAL DATA - X5 (4.4L) .

00 00 ... Changing differential oil

Change oil with rear axle differential at normal operating temperature.

Final drive oil, refer to Operating Fluids .

For filling quantity, refer to 11 40 OIL SUPPLY E53/M62 Technical Data.

Unscrew drain plug (2), clean and reinstall.

Unscrew the filler screw plug (1).

Pour in differential oil until overflowing. Install filler screw plug (1).

Installation

Tightening Torque, refer to ENGINE - TECHNICAL DATA - X5 .

Scheme 4

00 00 ... Changing engine oil and oil filter

Carry out oil service at normal operating temperature.

First replace oil filter, then change oil.

Clean sealing surfaces.

Add engine oil in accordance with inspection sheet.

Run engine at idle until oil indicator lamp goes out.

Check oil filter housing and drain plug for leaks.

Switch off engine, check oil level, correct if necessary (car must be on a horizontal level surface).

Remove any oil traces.

Fill out oil documentation.

Note. Advise customers of any changes in engine oil (e.g. fuel, water or swarf in oil).

For subsequent procedure, refer to BMW ENGINE OIL SERVICE .

00 00 ... Changing front axle differential oil

Change oil with manual transmission at normal operating temperature.

Drain oil from front axle differential.

Undo filler plug (1).

Installation

Replace sealing ring.

Top up oil up to lower edge of filler plug.

Scheme 5

00 00 ... Changing oil in transfer box (NV125/LWX500)

Change oil with transfer box at normal operating temperature.

Failure to comply with this requirement will result in serious damage to the transfer box!

E53

Drain off oil.

Undo filler plug (1).

Installation

Replace sealing ring.

Tightening torque, see TORQUE SPECIFICATIONS .

Top up oil up to lower edge of filler plug.

Scheme 6

00 00 ... Checking coolant level In event of topping up: checking concentration

Check coolant level in expansion tank. Coolant level must be between Min. and Max. markings.

If necessary, top up coolant to max. fill level.

Check concentration with antifreeze tester (SWZ) in coolant expansion tank.

If necessary, drain differential quantity from radiator drain plug and to up with recommended coolant, refer to Operating Fluids .

Checking parking brake

There must be no braking effect when the 1st tooth is engaged. The differential of the wheel circumferential forces (left/right wheel) must deviate by max. 30 % from the higher value (measured on the roller dynamometer). Make a readjustment in event of larger deviations in wheel circumferential force.

It must be possible to brake with locked wheels with the handbrake.

The hand/parking brake must be readjusted if the actuating travel exceeds 10 teeth.

For subsequent procedure, refer to PARKING BRAKE .

Horn

Check function.

Note. In the case of twin-tone fanfares, make sure that both fanfares are working properly.

Headlight flasher

Activate headlight flashers, check high-beam headlights and blue indicator lamp in instrument cluster for correct operation.

Hazard warning system

Check function.

Note. After consultation with the customer, rectify faults.

Instrument lighting

Check function of instrument and indicator/warning lamps.

Indication field lighting

Check function of light switches; dimmer; controls; heater/air conditioning; rear window demister; radio; (depending on equipment) on-board computer; power windows; electric sunroof; fog lamp.

Heater

Check function of all blower stages, air distribution and air outlet.

Exterior lights

Check function.

Engine compartment/luggage compartment lights

Check function.

Interior lights

Check function.

00 00 ... Checking roadworthiness

Take car for a test drive and check parking brake and brake pedal.

For cars with rear disk brakes, apply parking brake as instructed.

For subsequent procedure, refer to PARKING BRAKE .

Check steering for zero play, ease of movement and directional stability.

Check clutch for problem-free disengagement and non-spasmodic driving off at normal operating temperature.

Check function of all drive positions and driving programs in cars with automatic transmissions.

Visually inspect shock absorbers for leaks.

Check function of indicator/warning lamps and Check Control system.

Check relevant documentation for dates of technical inspection and emissions test. Advise customer of inspection dates.

00 00 ... Diagnostic brief test

Connect MoDiC or DIS Tester to diagnosis socket or OBD socket.

Switch on ignition.

Carry out vehicle identification.

Click on Brief test.

The brief test is carried out.

Note. For motor vehicle diagnostics, the brief test is essential for evaluating possible stored diagnostic trouble codes. In the brief test, the control units are physically identified in succession and their fault memories read out. If the fault memory has been read out, the faults appear in the "Fault pattern selection" mask in the "Fault memory contents" field.

00 00 ... Engine oil service

Carry out oil service at normal operating temperature.

First replace oil filter, then change oil.

Clean sealing surfaces.

Add engine oil.

Run engine at idle until oil level and oil pressure warning lamps go out.

Check oil filter housing and oil drain plug for leaks.

Switch off engine, check oil level, correct if necessary (car must be on a horizontal level surface).

Remove any oil traces.

Note. Advise customers of any changes in engine oil (e.g. fuel, water or swarf in oil).

Condition

Check exhaust system for rust and cracks.

Check screw connections on flanged joints and clamping sleeves for damage.

Note. Inform customer if exhaust system shows signs of heavy rust.

Routing

Check that exhaust system is correctly routed and free of obstructions on the underbody.

Mounting

Check rubber mounts and rubber rings for cracks and whether any are missing.

Leaks

Check exhaust system at flanged joints and clamping sleeves for black combustion residues.

Note. After consultation with the customer, rectify faults and issue a separate invoice.

00 00 ... Fault memory interrogation

Connect MoDiC or DIS Tester to diagnosis socket or OBD socket.

Read fault memory.

Note. For more information, refer to operating instructions for MoDiC or DIS Tester.

00 00 ... Front and rear brake linings: checking lining thickness with measuring gauge. If linings are replaced: cleaning brake shafts, checking brake disk thickness and surface, applying grease to wheel centering on alloy wheels. If rear linings are replaced: checking parking brake linings

Check brake lining thicknesses with measuring gauge at front and rear. Refer to DISC - X5 .

Note. Issue a separate invoice for replacing the brake linings.

Remove front and (if necessary) rear disk brake linings. Refer to DISC - X5 .

Note. Clean brake shafts. Replace brake linings if they drop below minimum thickness (refer to DISC - X5 ). Replace brake disks if they drop below minimum thickness (refer to DISC - X5 ) and in event of scoring, heat cracks, lateral runout or thickness difference. Apply a thin coat of grease to wheel centering on light alloy wheels, refer to Operating Fluids .

Additional tasks when changing rear linings

Remove rear brake disks. For subsequent procedure, refer to DISC - X5 .

Note. Check parking brake lining for porosity and wear. Check expansion lever for ease of movement.

00 00 ... Fuel lines, hoses and tank(s): visual inspection for routing, condition and leaks

Check fuel lines and hoses and fuel system connections for traces of fluid.

Check fuel tank(s) and hoses for damage such as cracks, flattening etc.

Check that fuel lines are routed correctly.

00 00 ... Heating/air conditioning: replacing microfilter/carbon canister (shorten replacement interval accordingly in event of larger buildup of dust)

Replace microfilter(s), refer to CABIN AIR FILTER .

Scheme 7

INFORMATION / WARNING LABELS SPECIFICATION

00 00 ... Intake muffler: replacing air cleaner element (shorten replacement interval accordingly in event of larger buildup of dust)

Replace air cleaner.

00 00 ... Locking systems: checking status and function, oiling or greasing if necessary

Lock car and check that locks and central locking (incl. tank cap) work properly. Depending on car's appointments, check convenience closing function of windows and slide/tilt sunroof.

Check function and ease of movement at

1. Door/luggage compartment/bonnet/hood locks
2. Door brakes
3. Door/bonnet/hood/fuel filler cap/luggage compartment hinges
4. Arrester hooks on engine bonnet/hood and apply oil or grease if necessary.

00 00 ... Output shafts: checking gaiters for leaks

Turn rear right and left wheels by hand.

In so doing, check inner and outer gaiters for damage such as holes, cracks or porosity.

Check gaiters for leaks (emerging grease).

Check that strap retainers are securely attached to gaiters and whether any straps are missing.

00 00 ... Parking brake: checking function, adjusting/repairing as prescribed

For subsequent procedure, refer to CHECKING PARKING BRAKE .

00 00 ... Parking brake: checking lining thickness

Remove rear brake disks. Refer to DISC - X5 .

Check brake linings for minimum thickness and traces of wear such as cracks.

Check expansion lever for ease of movement, apply grease if necessary.

00 00 ... Positioning of multitrailer hood for maintenance and repair work

For maintenance and repair work, raise the hood using a lifting platform. Twin-column lifting platforms, body lifting platforms and twin-stamp underfloor platforms are suitable. The seating plates and areas of the lifting platform must be adjustable according to the dimensions. (Scheme 8)

Scheme 8

The lifting platform must conform to the relevant legal provisions of the accident prevention regulations and be serviced as specified. Comply with the lifting platform operating instructions, in particular the safety instructions and the carrying capacity.

Make sure you adhere to the BMW-recommended work area of 5 x 7 m and to an escape route of 0.6 m between two lifting platforms.

Please comply with the following instructions before raising the hood

1. Raise only when it is unloaded
2. Ensure sufficient clearance between the seating plates/seating areas and the GFP edge of the hood
3. The hood must always be positioned in the middle of the lifting platform.

Scheme 9

00 00 ... Raising BMW multi-trailer

The lifting platform must comply with the relevant statutory accident prevention regulations and be serviced according to the manufacturer's instructions. It is essential to follow the lifting platform operating instructions, in particular the safety instructions and carrying capacity!

Make sure you adhere to the BMW-recommended work area of 5 x 7 m and to an escape route of 0.6 m between two lifting platforms.

Before raising the BMW multi-trailer, please observe the following points

1. Raise the trailer only when it is unloaded
2. Remove a supplied loading ramp from the loading ramp frame so that all chassis areas of the BMW multi-trailer are freely accessible
3. There must be sufficient clearance between the carrier arms/flat girder bridges and the GFK aprons or the front guard of the BMW multi-trailer
4. The BMW multi-trailer must always be positioned in the middle of the lifting platform.

The areas (2) on the longitudinal members (1) marked in the adjacent diagram are the best areas for attaching the additional supports.

Scheme 10

General notes on using twin-pillar lifting platforms

For the twin-pillar lifting platforms described, the BMW multitrailer is positioned in the direction of travel on the platform. For lifting platforms which do not create sufficient clearance between disk wheel and carrier arms, move the BMW multitrailer against the direction of travel onto the platform.

Becker & Sohne twin-strut underfloor platform

The BMW multi-trailer can only be raised if it is supported at right angles to the direction of travel. For raising, use the high additional supports (1) of Becker & Sohne.

Scheme 11

MAHA twin-pillar lifting platform

The BMW multi-trailer can only be raised if you use the support plate attachment sleeves for transporters (1). Position the axle of the BMW multi-trailer in the direction of travel in front of the pillars of the platform in order to obtain the specified lifting ranges and to establish sufficient clearance between disk wheel and carrier arms. The long carrier arms raise the front and the short carrier arms raise the rear of the BMW multi-trailer.

Scheme 12

Romaico-Lift twin-pillar lifting platform

The BMW multi-trailer can only be raised if you use the 146 mm high attachments (1). Position the axle of the BMW multi-trailer in the direction of travel in front of the pillars of the platform in order to obtain the specified lifting ranges and to establish sufficient clearance between disk wheel and carrier arms. The long carrier arms raise the front and the short carrier arms raise the rear of the BMW multi-trailer.

Scheme 13

Working pit

The BMW multi-trailer can be serviced or repaired in conjunction with a working pit if the following measures are taken into consideration. The BMW multi-trailer must be secured against slipping/tilting sideways. The drawbar jockey wheel must be firmly secured against rolling.

00 00 ... Replacing spark plugs

For further information on how to proceed, refer to 12 12 011 REPLACING ALL SPARK PLUGS (M60, M62) .

Special tools required

1. 61 1 110

Switch on ignition.

Connect resetter (special tool 61 1 110) to diagnosis connector in engine compartment.

Resetting oil service

Press yellow button (1) for oil service.

Green lamp (2) lights up.

Wait until yellow lamp (3) lights up and then goes out again.

Note. Check that oil service indicator has been reset.

Scheme 14

Reset service

Press red button (1) for inspection.

Green lamp (2) lights up.

Wait until red lamp (3) lights up and then goes out again.

Turn off ignition, wait 20 seconds and repeat procedure in order to adapt interval of annual inspection to inspection.

Note. Check that service interval indicator has been reset.

Scheme 15

Belt strap, retractor mechanism, belt interlock

Pull out strap and make sure it emerges without jerking.

Check belt strap for

1. folding
2. unraveling
3. pinches
4. cracks and tears
5. traces of melting

Retract belt strap; here the inertia reel mechanism must retract the strap automatically and without squeaking noises, the last section of the strap may have to be fed in.

Pull out belt strap in short tugs - locking reel must lock.

Belt buckle

The tongue on the belt strap must easily snap into place with an audible click.

When the "Press" button is pressed, the tongue must be ejected from the buckle under spring pressure.

Note. If the seat belt is damaged, you must replace the seat belt completely after consulting the customer; issue a separate invoice for this work.

Scheme 16

1. Steering wheel: Move steering wheel back and forth and check for zero clearance.
2. Tie rod joint: There must no clearance between tie rod arm (2) and tie rod joint (1).

Checking for leaks

The following illustrations shows the arrangement of the power steering components and lines.

Scheme 17

Check all visible connections, hoses, lines and steering gear for traces of fluid.

Checking for damage and wear

Check steering sleeves, flexible disk and axle and tie rod sleeves for damage (e.g. cracks, holes) for leaks or missing clamping bands on gaiters.

00 00 ... Steering fluid reservoir: checking fluid level, topping up if necessary

The steering fluid must be topped up if the level in the steering fluid reservoir is below the Max. marking.

00 00 ... Tires: checking inflation pressure, correcting if necessary (incl. spare wheel), checking external condition, tread depth, pattern. In event of nonuniform wear, carry out measurement and correction of wheel alignment

Check tire inflation pressure according to information plate on B-pillar. Inflation pressure in spare wheel must be 0.5 bar higher than the maximum specified value on the information plate.

Checking tire condition

1. Check tread depth of all tires with tire tread gauge or slide caliper.
2. Check tire tread and side walls for cuts and foreign objects such as nails or screws.
3. Check tire tread pattern for localized flattening and wear on one side; if necessary, carry out alignment after consulting customer and issue a separate invoice for this work. NOTE: For reasons of driving safety, only use tires of the same type and tread pattern on a single vehicle. Inform customer of any incorrect or worn tires.

00 00 ... Transmission (all gears): visually inspect for leaks.

Inspect visible area of transmission for traces of fluid, remove underbody protection if necessary.

00 00 ... Underfloor incl. all visible components: checking for damage, leaks, corrosion

Visual inspection in visible area for

1. Damage
2. Crushing (brake lines, electric cables, fuel lines)
3. Leaks (dripping oil, fuel or coolant)
4. Traces of fluid (remnants of oil, coolant, fuel)
5. Corrosion (exhaust system, body ...) NOTE: Advise customer of identified defects; if necessary, rectify defects after consulting customer.

00 00 ... Windshield wash/wipe system: checking wiper reservoir and spray nozzle adjustment

Check wiper blades for cracks and wiper area for streaks, replace if necessary.

The spray jet must emerge uniformly from the spray nozzle.

If necessary, replace spray nozzle and issue a separate invoice.

Checking spray nozzle adjustment of windshield washer system, adjusting if necessary, refer to 61 71 015 REMOVING AND INSTALLING/REPLACING A SPRAY NOZZLE .

Check spray nozzle adjustment of headlight washer system., adjust as necessary. See HEADLIGHT - CLEANING SYSTEM .

00 00 ... Windshield washer system and intensive cleaning system: checking fluid level, topping up if necessary

Top up reservoir for windshield washer system, if necessary rear window washer system and equipment-dependent intensive cleaning reservoir up to edge or up to marking.

Note. A ph-neutral window cleaning agent (antifreeze in winter) must always be added to the water.

00 00 249 BMW engine oil service (M60 / M62 / M73)

Change engine oil and oil filter.

Note. Do not damage main flow oil filter cover. Only open and tighten with socket wrench. Unfasten main flow oil filter cover. Engine oil now flows back into oil pan.

Installation

Tightening torque, refer to 11 42 2AZ in ENGINE - TIGHTENING TORQUES .

Scheme 18

Remove oil filter from oil filter cover.

Note direction of installation of oil filter insert.

Oil filter insert must locate in oil filter cover.

Scheme 19

Replace sealing ring and coat with oil.

Scheme 20

After draining oil from oil-filter housing, unscrew oil drain plug or draw out oil with a vacuum unit.

Replace sealing ring.

Tightening torque, refer to 11 13 1AZ ENGINE - TIGHTENING TORQUES

Scheme 21

Pour in engine oil.

Switch on engine and run at idle until oil indicator lamp goes out.

Stop engine and check oil level.

Note. Position car on a flat, horizontal surface.

00 11 259 Replenishing / changing rear differential oil

Failure to comply with this instruction will result in serious damage to the rear differential!

Replenishing rear differential oil

Undo oil filler plug (1).

Check rear differential oil level.

If necessary, pour in rear differential oil up to lower edge of opening for oil filler plug (1).

Scheme 22

Scheme 23

Changing rear differential oil

Note. The oil no longer has to be changed in rear differentials which do not have an oil drain plug (168K from 03/2003, 168L, 188L, 215L). Only change oil when rear differential is at normal operating temperature.

Recycling

Catch and dispose of emerging differential oil.

Observe country-specific waste-disposal regulations

Place oil collecting apparatus underneath.

Remove oil drain plug (1).

Drain and dispose of differential oil.

Undo oil filler plug (2).

Scheme 24

Installation

Scheme 25

1. Oil drain plug with sealing ring: Replace sealing ring (1). Tightening torque: 33 11 3AZ.
2. Oil drain plug with O-ring: Replace oil drain plug (2). Tightening torque: 33 11 9AZ.

Installation

Pour in rear differential oil up to lower edge of opening for oil filler plug (1).

Note. If necessary, refer to Technical Data for necessary fill quantities.

Scheme 26

Installation

Scheme 27

1. Oil filler plug with sealing ring: Replace sealing ring (1). Tightening torque: 33 11 3AZ.
2. Oil filler plug with O-ring: Replace oil filler plug (2). Tightening torque: 33 11 9AZ.

00 11 500 Checking/topping up fluid level in automatic transmission (A5S 440Z)

Failure to comply with this requirement will result in serious damage to the automatic transmission!

Scheme 28

1. Topping up transmission after a repair: Move selector lever to "P" position. Stand vehicle on a level surface and secure and rolling off. Open filler plug (1). Installation: Replace sealing ring. Top up transmission fluid until it emerges from filling orifice. Start engine. Replenish transmission fluid until it emerges from filling orifice. Insert filler plug (1). Tightening torque, 24 11 7AZ. Press brake pedal to floor and shift through all gears several times at idle speed. Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC to vehicle. Carry out fluid level check in accordance with instructions.
2. Checking fluid level: Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC to vehicle. Carry out fluid level check in accordance with instructions.

See also:
• 61 00 ... BATTERY CHARGING
• BLEEDING BRAKE SYSTEM
• COOLANT CHECKING COOLING SYSTEM
• COOLING SYSTEM - TECHNICAL DATA - X5 (4.4L)
• 11 40 OIL SUPPLY E53/M62
• TORQUE SPECIFICATIONS
• PARKING BRAKE
• CABIN AIR FILTER
• 12 12 011 REPLACING ALL SPARK PLUGS (M60, M62)
• HEADLIGHT - CLEANING SYSTEM
• ENGINE - TIGHTENING TORQUES
• BMW ENGINE OIL SERVICE
• CHECKING PARKING BRAKE