BMW 535xi Sport Wagon 2007-2010 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 535xi Sport Wagon Model Generation: E61 (Second Generation) Model Years Covered: 2007, 2008, 2009, 2010 Codes Chassis Code: E61 Engine Code Identifier: N54B30 👋 Introduction Market Position Segment: Mid-size Luxury Sport Wagon/Touring Vehicle Target Audience: Discerning drivers seeking a blend of luxury, performance, practicality, and all-weather capability Competitive Analysis Key Competitors: Audi A6 Allroad, Mercedes-Benz E-Class Wagon (E350 4MATIC), Volvo V70/XC70, Audi A4 allroad quattro Key Features Driving Dynamics: Renowned BMW driving dynamics, xDrive all-wheel-drive, sport-tuned suspension (often standard or part of 'Sport' package) Engine Performance: Powerful and responsive twin-turbocharged inline-6 engine Practicality: Versatile cargo space of a wagon, comfortable interior, premium appointments Luxury: High-quality interior materials, advanced technology features for its era, premium brand prestige 📋 Manual Details Coverage Areas Primary Coverage: Mechanical and electrical systems, bodywork, diagnostics, maintenance, repair, troubleshooting, specifications Additional Coverage: Technical service bulletins (TSBs) relevant to the model years, wiring diagrams, component locations Page Count Estimated Page Count: Comprehensive, likely exceeding 2000 pages Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine: 3.0L Twin-Turbocharged Inline-6 (N54B30), including fuel injection, ignition, cooling, lubrication, engine management, emissions control, turbocharger system, intercooler Transmission: 6-speed Steptronic automatic transmission (GS6-37BZ), including shift control, torque converter, transmission fluid, mechatronics unit, basic diagnostic procedures Drivetrain: xDrive all-wheel-drive system, including transfer case, front and rear differentials, axle shafts, driveline components Suspension: Front and rear suspension systems (double-wishbone front, multi-link rear), adaptive drive, active steering, ride height control (if equipped), shock absorbers, springs, control arms, bushings Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), DTC (Dynamic Traction Control), electronic parking brake, brake pad/rotor replacement, brake fluid specifications Steering: Hydraulic power steering system, steering column, steering rack, power steering fluid Electrical: 12V battery system, alternator, starter motor, power distribution, lighting systems (headlights, taillights, interior), fuses, relays, wiring harnesses, diagnostic connectors (OBD-II) Body: Body panels, doors, hood, tailgate, bumpers, glass, seals, interior trim, chassis components, rust prevention HVAC: Automatic climate control, A/C system components, heater core, blower motor, refrigerant, diagnostic procedures Comfort Systems: Power seats, sunroof operation, keyless entry, central locking, interior lighting, comfort access system Infotainment: iDrive system (CCC or CIC depending on production date), radio, navigation, satellite radio, Bluetooth integration, speaker systems Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid service Repair: Engine component repair/replacement (e.g., turbos, injectors, ignition coils), transmission overhaul (basic), brake system repair, suspension component replacement, electrical component diagnostics and repair, body panel repair Diagnostics: Troubleshooting guides for common issues, diagnostic trouble codes (DTCs) interpretation, electrical circuit tracing, symptom-based diagnostics Troubleshooting: Step-by-step troubleshooting for engine performance, starting issues, electrical faults, HVAC problems, transmission shifting issues Technical Depth Depth Level: Comprehensive, covering basic to advanced repair and diagnostics suitable for professional technicians and experienced DIYers Diagnostic Tools: Reference to BMW-specific diagnostic tools (e.g., ISTA/D, INPA) and procedures, OBD-II scanner usage Wiring Diagrams: Detailed electrical wiring diagrams for all major systems, including pinouts and connector information 📊 Manual Specifications File Format File Format: PDF Print Quality Image Resolution: High resolution for clear viewing of diagrams and text Searchability: Likely text-searchable PDF for quick information retrieval Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, Twin-Turbocharged (N54B30) Displacement: 2979 cc (3.0 Liters) Bore X Stroke: 84.0 mm x 90.0 mm Compression Ratio: 10.2:1 Valve Train: Double Overhead Camshafts (DOHC), 4 valves per cylinder, Double VANOS (Variable Valve Timing) Performance Horsepower: 300 hp @ 5800 rpm Torque: 300 lb-ft @ 1400-5000 rpm Fuel System Fuel Delivery: Direct Injection (High-Pressure Fuel System), Twin Turbochargers Recommended Fuel: Premium Unleaded (91 octane or higher) 🔧 Transmission Standard Transmission Type: 6-Speed Steptronic Automatic Transmission Transmission Model: GS6-37BZ Optional Optional Transmission: None offered for 535xi in these model years Features Transmission Features: Manual shift mode (Steptronic), adaptive shift programs, torque converter lock-up 📐 Dimensions Exterior Length: 4801 mm (189.0 inches) Width: 1846 mm (72.7 inches) Height: 1460 mm (57.5 inches) Wheelbase: 2990 mm (117.7 inches) Front Track: 1515 mm (59.6 inches) Rear Track: 1534 mm (60.4 inches) Weights Curb Weight: Approx. 1850 kg (4079 lbs) Gross Vehicle Weight Rating: Approx. 2380 kg (5247 lbs) Cargo Cargo Volume: 560 liters (19.8 cubic feet) with rear seats up, expandable to 1700 liters (60.0 cubic feet) with rear seats folded 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: 5-Star (Driver and Passenger) IIHS Front Offset Crash Test Rating: Good IIHS Side Impact Crash Test Rating: Good Active Features Active Safety Systems: ABS, DSC (Dynamic Stability Control), DTC (Dynamic Traction Control), Electronic Brake-force Distribution (EBD), Brake Assist Tire Pressure Monitoring: Standard Passive Features...

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Typ: Car

Anbieter:

Art.-Nr: 427487

Sammlungen: ALL BMW

Verfügbarkeit: Auf Lager

Stichworte: 2007 2008 2009 2010 535xi Sport Wagon BMW Car Cars Misc

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

535xi Sport Wagon

Model Generation:

E61 (Second Generation)

Model Years Covered:

2007, 2008, 2009, 2010

Codes

Chassis Code:

Engine Code Identifier:

N54B30

👋 Introduction

Market Position

Segment:

Mid-size Luxury Sport Wagon/Touring Vehicle

Target Audience:

Discerning drivers seeking a blend of luxury, performance, practicality, and all-weather capability

Competitive Analysis

Key Competitors:

Audi A6 Allroad, Mercedes-Benz E-Class Wagon (E350 4MATIC), Volvo V70/XC70, Audi A4 allroad quattro

Key Features

Driving Dynamics:

Renowned BMW driving dynamics, xDrive all-wheel-drive, sport-tuned suspension (often standard or part of 'Sport' package)

Engine Performance:

Powerful and responsive twin-turbocharged inline-6 engine

Practicality:

Versatile cargo space of a wagon, comfortable interior, premium appointments

Luxury:

High-quality interior materials, advanced technology features for its era, premium brand prestige

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical and electrical systems, bodywork, diagnostics, maintenance, repair, troubleshooting, specifications

Additional Coverage:

Technical service bulletins (TSBs) relevant to the model years, wiring diagrams, component locations

Page Count

Estimated Page Count:

Comprehensive, likely exceeding 2000 pages

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine:

3.0L Twin-Turbocharged Inline-6 (N54B30), including fuel injection, ignition, cooling, lubrication, engine management, emissions control, turbocharger system, intercooler

Transmission:

6-speed Steptronic automatic transmission (GS6-37BZ), including shift control, torque converter, transmission fluid, mechatronics unit, basic diagnostic procedures

Drivetrain:

xDrive all-wheel-drive system, including transfer case, front and rear differentials, axle shafts, driveline components

Suspension:

Front and rear suspension systems (double-wishbone front, multi-link rear), adaptive drive, active steering, ride height control (if equipped), shock absorbers, springs, control arms, bushings

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), DTC (Dynamic Traction Control), electronic parking brake, brake pad/rotor replacement, brake fluid specifications

Steering:

Hydraulic power steering system, steering column, steering rack, power steering fluid

Electrical:

12V battery system, alternator, starter motor, power distribution, lighting systems (headlights, taillights, interior), fuses, relays, wiring harnesses, diagnostic connectors (OBD-II)

Body:

Body panels, doors, hood, tailgate, bumpers, glass, seals, interior trim, chassis components, rust prevention

HVAC:

Automatic climate control, A/C system components, heater core, blower motor, refrigerant, diagnostic procedures

Comfort Systems:

Power seats, sunroof operation, keyless entry, central locking, interior lighting, comfort access system

Infotainment:

iDrive system (CCC or CIC depending on production date), radio, navigation, satellite radio, Bluetooth integration, speaker systems

Procedures Included

Maintenance:

Routine maintenance, oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid service

Repair:

Engine component repair/replacement (e.g., turbos, injectors, ignition coils), transmission overhaul (basic), brake system repair, suspension component replacement, electrical component diagnostics and repair, body panel repair

Diagnostics:

Troubleshooting guides for common issues, diagnostic trouble codes (DTCs) interpretation, electrical circuit tracing, symptom-based diagnostics

Troubleshooting:

Step-by-step troubleshooting for engine performance, starting issues, electrical faults, HVAC problems, transmission shifting issues

Technical Depth

Depth Level:

Comprehensive, covering basic to advanced repair and diagnostics suitable for professional technicians and experienced DIYers

Diagnostic Tools:

Reference to BMW-specific diagnostic tools (e.g., ISTA/D, INPA) and procedures, OBD-II scanner usage

Wiring Diagrams:

Detailed electrical wiring diagrams for all major systems, including pinouts and connector information

📊 Manual Specifications

File Format

File Format:

Print Quality

Image Resolution:

High resolution for clear viewing of diagrams and text

Searchability:

Likely text-searchable PDF for quick information retrieval

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-cylinder, Twin-Turbocharged (N54B30)

Displacement:

2979 cc (3.0 Liters)

Bore X Stroke:

84.0 mm x 90.0 mm

Compression Ratio:

10.2:1

Valve Train:

Double Overhead Camshafts (DOHC), 4 valves per cylinder, Double VANOS (Variable Valve Timing)

Performance

Horsepower:

300 hp @ 5800 rpm

Torque:

300 lb-ft @ 1400-5000 rpm

Fuel System

Fuel Delivery:

Direct Injection (High-Pressure Fuel System), Twin Turbochargers

Recommended Fuel:

Premium Unleaded (91 octane or higher)

🔧 Transmission

Standard

Transmission Type:

6-Speed Steptronic Automatic Transmission

Transmission Model:

GS6-37BZ

Optional

Optional Transmission:

None offered for 535xi in these model years

Features

Transmission Features:

Manual shift mode (Steptronic), adaptive shift programs, torque converter lock-up

📐 Dimensions

Exterior

Length:

4801 mm (189.0 inches)

Width:

1846 mm (72.7 inches)

Height:

1460 mm (57.5 inches)

Wheelbase:

2990 mm (117.7 inches)

Front Track:

1515 mm (59.6 inches)

Rear Track:

1534 mm (60.4 inches)

Weights

Curb Weight:

Approx. 1850 kg (4079 lbs)

Gross Vehicle Weight Rating:

Approx. 2380 kg (5247 lbs)

Cargo

Cargo Volume:

560 liters (19.8 cubic feet) with rear seats up, expandable to 1700 liters (60.0 cubic feet) with rear seats folded

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

5-Star (Driver and Passenger)

IIHS Front Offset Crash Test Rating:

IIHS Side Impact Crash Test Rating:

Active Features

Active Safety Systems:

ABS, DSC (Dynamic Stability Control), DTC (Dynamic Traction Control), Electronic Brake-force Distribution (EBD), Brake Assist

Tire Pressure Monitoring:

Standard

Passive Features

Airbags:

Front dual-stage airbags, front side-impact airbags, head protection system (front and rear), knee airbags (driver's side)

Seat Belts:

3-point inertia-reel seat belts with pre-tensioners and force limiters for all seating positions

💡 Technology Features

Infotainment

Infotainment System:

iDrive system (Controller and display screen). Early models may have the 'Car Communication Computer' (CCC), later models typically have the 'Car Information Computer' (CIC) with improved graphics and functionality.

Audio Options:

Standard Hi-Fi audio, optional Logic 7 premium sound system, optional SiriusXM Satellite Radio.

Driver Assistance

Driver Assistance Features:

Parking sensors (front and rear), optional rearview camera, optional adaptive headlights, cruise control.

Connectivity

Connectivity Features:

Bluetooth connectivity for hands-free calling and audio streaming (depending on iDrive version and options), USB/Auxiliary input.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Condition-Based Service (CBS) system typically indicates service every 10,000-15,000 miles or annually, whichever comes first. Consult manual for exact CBS reset procedure.

Spark Plug Replacement:

Typically around 60,000 miles for the N54 engine. Consult manual for exact mileage and correct spark plug part number (e.g., NGK SILZKR7C11S or equivalent).

Cabin Air Filter Replacement:

Generally every 15,000-30,000 miles or annually, depending on driving conditions. Refer to manual for part number (e.g., Mann-Filter CUK 2529).

Fluid Specifications

Engine Oil:

SAE 5W-30, BMW Longlife-01 (LL-01) or BMW Longlife-04 (LL-04) approved synthetic oil. Consult manual for specific viscosity grade and approval for your region's fuel quality.

Transmission Fluid:

BMW ATF 6 (or equivalent approved fluid for ZF 6HPxx series transmissions). Consult manual for specific fluid type and quantity for the GS6-37BZ transmission.

Coolant:

BMW Blue Antifreeze/Coolant (G48 specification) or approved equivalent, mixed 50/50 with distilled water.

Brake Fluid:

DOT 4 (or DOT 4 LV for models with DSC).

Known Issues

Engine Common Issues:

High-pressure fuel pump (HPFP) failure, ignition coil failure, vacuum leaks (leading to rough idle/poor performance), turbocharger wastegate issues, carbon buildup on intake valves (direct injection characteristic).

Transmission Common Issues:

Mechatronics unit issues (less common on manual mode), valve body wear, occasional torque converter shudder. Regular fluid changes are critical.

Electrical Common Issues:

CCC/CIC unit malfunctions, water ingress in certain areas (e.g., footwells, tailgate), power seat module failures, sensor failures (e.g., ABS, oxygen sensors).

📚 Vehicle History

Brand Heritage

Brand Focus:

BMW is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, engineering precision, and driver engagement.

Model Evolution

E60 E61 Generation:

The E61 designation refers to the wagon variant of the fifth generation (E60) 5 Series. It succeeded the E39 wagon.

Key Technological Advancements:

Introduction of iDrive infotainment, advanced chassis control systems, direct injection and twin-turbocharging for the N54 engine.

Production

Production Location:

Primarily manufactured at BMW's Dingolfing plant in Germany.

🏆 Awards & Recognition

Recognitions

Ward'S Ten Best Engines:

The N54 engine family, including the 3.0L twin-turbo, was a multiple recipient of Ward's 10 Best Engines award during its production years for its power, efficiency, and refinement.

Ratings

Consumer Reports Reliability:

Reliability ratings varied for this generation. While generally good, specific issues like HPFP were noted. Consult the manual for detailed troubleshooting of potential problems.