BMW X5 2004 E53 Workshop Manual

TABLE OF CONTENTS
Subject Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hood/Front Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Doors/Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Climate Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Cargo Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
EHC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Wheels & Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
STO36 X5

2
Introduction
The X5 marks BMW’s introduction into the luxury “Sports Activity Vehicle (SAV)” niche seg-
ment of the Sport Utility Vehicle market. While carrying the designation X5, the vehicle is not
based on the 5 Series but it is its own new car-like platform. The X5 is offered with two
engine variants:
• The 4.4 liter M62 TU engine equipped with the A5S 440 Z automatic transmission.
• The 3 liter M54 engine with either the GM 5 automatic or 5 speed manual transmission
The X5 incorporates the following
features:
• Four wheel independent sus-
pension (BMW tradition)
• Full time - all wheel drive
(planetary gear transfer case)
• All road vehicle (ON/OFF road
capabilities)
• High ground clearance
• Unitized body and Chassis
(car like ride and handling)
• Double pivot front suspension
• “Integral Link” rear suspen-
sion with air spring self level-
ing
• X5 specific traction control
system
Two different suspension options are offered (standard and sport) with different springs,
shock absorbers and stabilizers.
The X5 has 180 mm ground clearance, for both suspensions to allow off road travel.
However, the suspension travel is the same as the E39 which allows the X5 to retain a car
like feel when driven every day.
00530000

3
Body
The design of the X5 originated in California at BMW’s Design Works. The SAV look was
further developed and refined in Munich. Traditional BMW features such as the Kidney
grilles, quad headlights, reverse link rear side window trim and typical rear tail light treat-
ment allow the X5 to assume a BMW identity. Yet the unique side and hood treatments as
well as the large wheel house openings and high ground clearance set the X5 apart as its
own distinctive vehicle.
The design criteria for the X5 was to develop a vehicle with the superb handling and sporty
driving characteristics that are typically BMW, yet produce an all wheel drive vehicle that can
also be used off-road. This was achieved through the use of independent front suspension
and multi-link rear suspension components that are taken from the E38/E39 vehicle design
and expanded by the addition of front drive components.
The entire body shell/frame assembly of the
X5 is reinforced to ensure optimized body
rigidity.
In addition to the cross bracing on the front
suspension/engine carrier, an additional
panel is installed between the bulkhead and
transmission tunnel.
The floor pan of the X5 is reinforced with
additional ribbing and cross braces to
increase the lateral rigidity. A continuous seat
cross brace is connected to the floor pan
and side sill for reinforcement.
41530001
41530002
Cross
Brace
41530003
Reinforcement Panel

4
Specifications
00530011-1

5
Specifications
X5 3.0iX5 4.4i
Doors 5 5
Length 4666 mm 4666 mm
Width 1872 mm 1872 mm
Height 1717 mm 1717 mm
DImensions:
Vechicle Weigth withTransmission:
Automatic 2015 Kg 2085 Kg
Manual 1990 Kg Not Available
General
Fuel 92l 92l
Drag Coefficient 0.35 0.36
Payload 610 kg 555 kg
Roof Load 150 kg 150 kg
Gross Weight 2600 kg Not Available
Manual Trans.
Gross Weight 2625kg 2650kg
Auto Trans.
Cargo Volume 16.1/54.4 cu ft. 16.1/54,4 cu ft.
Towed Weight Braked 1600 kg Not Available
Manual
Towed Weight Braked 1700 kg 750 kg
Automatic
Turning Circle 39.7 ft. 39.7 ft.
X5 3.0iX5 4.4i
X5 3.0iX5 4.4i
Designation M54B30 M62 TU B44
Engine Management Syst. MS 43 ME 7.2
Horsepower (HP) 225@5900RPM 282@5400RPM
Torque 293@3500RPM 440@3600RPM
Bore 84mm 92mm
Stroke 89.6mm 82.7mm
Compression 10.2:1 10.0:1
X5 3.0iX5 4.4i
Engine:

6
Hood/Front Grille
The hood on the X5 is distinctive, with two IHKA air intake hood scopes in the center lead-
ing down to the traditional BMW twin grilles.
The grilles are integrated into the hood with
the secondary hood latch springing out from
the grille when the hood is opened.
The four round headlights complete the front
end with Xenon low beans as an option for
the X5. The fog lights as well as the headlight
washers are integrated into the bumper.
Hood Scoops
41530004
41530005
63530001

7
Doors/Mirrors
The doors on the X5 incorporate side bars which serve as side impact protection without
the use of the metal hooks found on the sedans. The mirrors are aero style that includes
cascade lighting at the bottom of the mirror for vehicle entry at night. The lights are
switched on when the vehicle is unlocked to light the ground around the door.
Running boards, integrated into the rocker panels, provide ease of entry on the left and right
sides.
41530010 63530004

8
The door handles are similar in design to the E46
and pull out and upward for opening. Removal of
the handles is also similar to the E46.
There are no serviceable components on the
lock/latch. The assembly must be replaced as a
unit.
The lock cylinder is removed by removing the
torx screw through the access hole in the door.
Once the screw is removed, the lock cylinder can
be pushed out of the handle assembly.
The handle is removed by loosening the hex nut
holding the handle to the latch mechanism.
The handle is then removed by pulling it out and
down to release it from the latch. The handle is
turned down to the left to release it from the door
latch assembly.
41530011
Hex Nut
41530007
41530008
Door Handle

9
Interior/Seats
The instrument cluster and dashboard layout is similar to other BMW models with all of the
controls in easy reach of the driver. The instrument cluster variations (high and base) are
taken from the E39 as are all driver information electronic systems.
The center console contains the radio or navigation system and the climate control panel
along with the central switch panel (SZM).
8453000164530003
High ClusterBase Cluster
6253001262530013
DSCPDC

10
Interior
Located above the windshield in the center is the overhead console that contains the uni-
versal remote switch panel, interior lighting/map panel, sunroof switch and grille for the tele-
phone hands-free microphone. The light panel contains a single bulb which is controlled by
the ZKE, as well as two map reading lamps. The switch provides a ground signal which the
GM recognizes as a request to either turn the interior lights on or off. If the switch is held >
3 seconds, the lights are switched off in the work shop mode as on other models.
Incorporated into the overhead con-
sole, behind the universal remote
switch, is a sunglass storage com-
partment
1
23
63530001
63530002
Sunroof SwitchMicrophone
Right Map LightLeft Map Light
Interior Light
Sunglass Holder
Universal Remote