BMW 528xi 2007 2008 2009 2010 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 528xi Model Generation: E60/E61 Model Years Covered: 2007, 2008, 2009, 2010 Codes Chassis Code: E60 (Sedan) / E61 (Touring/Wagon) 👋 Introduction Market Position Vehicle Class: Executive Sedan/Wagon (mid-size luxury) Target Audience: Luxury car buyers seeking performance, comfort, and advanced technology. Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Infiniti M. Key Features Drivetrain Advantage: xDrive all-wheel-drive system provides enhanced traction and stability, especially in adverse weather. Engine Performance: Smooth, powerful, and efficient inline-6 engine. Driving Dynamics: Renowned BMW 'Ultimate Driving Machine' feel, with balanced chassis and responsive handling. Luxury Appointments: High-quality interior materials, sophisticated design, and advanced comfort features. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Language: English Format: PDF Coverage Scope: Comprehensive mechanical and electrical repair, maintenance, and diagnostics. Page Count Estimated Page Count: 1500+ pages (estimated for a comprehensive workshop manual of this era and scope) 📖 Manual Coverage Systems Covered Engine: N52B30 (3.0L Naturally Aspirated Inline-6) Engine Management: DME (Digital Motor Electronics) control, VANOS, Valvetronic, ignition, fuel injection. Transmission: ZF 6HP19 (Automatic Transmission) Drivetrain: xDrive All-Wheel Drive system (transfer case, front/rear differentials, drive shafts). Suspension: Front: MacPherson struts, multi-link. Rear: Multi-link independent suspension. Adaptive Drive (optional). Brakes: Front: Ventilated discs, fixed calipers. Rear: Ventilated discs, floating calipers. ABS, DSC (Dynamic Stability Control), brake assist. Steering: Hydraulic power steering, Servotronic speed-sensitive assist. Electrical System: 12V system, battery, alternator, starter, power distribution, fuses, relays. Body And Chassis: Body structure, doors, hood, trunk, interior trim, exterior trim, chassis components. Climate Control: Manual/Automatic HVAC, A/C system, heater core, blower motor, sensors. Infotainment And Comfort: iDrive system (CCC/CIC), audio system, navigation, comfort access, power seats, windows, mirrors. Lighting: Headlights (halogen, Xenon), taillights, interior lighting, fog lights. Safety Systems: Airbags (SRS), seat belts, pre-tensioners, crumple zones, pedestrian safety. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush. Engine Diagnostics And Repair: Compression testing, leak-down tests, component testing, internal engine repair (e.g., head gasket, timing chain). Transmission Service: Fluid and filter changes, torque converter replacement, valve body service, mechatronics unit repair. Drivetrain Maintenance: Transfer case fluid change, differential fluid change, driveshaft inspection/repair. Suspension And Steering Repair: Component replacement (shocks, struts, control arms, tie rods), alignment specifications. Brake System Service: Pad and rotor replacement, caliper service, bleeding procedure, ABS/DSC component diagnostics. Electrical Troubleshooting: Wiring diagrams, component testing, diagnostic connector (OBD-II) information, module diagnostics. Body And Interior Repair: Panel alignment, door mechanism repair, interior trim removal/installation, glass replacement. HVAC System Service: Refrigerant recharge, component replacement (compressor, evaporator, heater core), diagnosis of climate control faults. Infotainment System Diagnostics: Troubleshooting iDrive system errors, component replacement (head unit, display, modules). Safety System Repair: Airbag module replacement, seat belt replacement, sensor calibration. Diagnostic Trouble Codes DTCs: Listing and interpretation of common OBD-II and BMW-specific DTCs. Technical Depth Diagnostic Capability: Advanced diagnostics for engine, transmission, chassis control modules (ABS, DSC, Airbag), and body electronics. Repair Complexity: Covers everything from basic fluid changes to complex engine and transmission overhauls, including specialized component replacement. Wiring Diagrams: Detailed electrical schematics for all systems, essential for troubleshooting. Torque Specifications: Precise torque values for all fasteners, critical for proper assembly. Special Tools: Identification and usage instructions for BMW-specific tools required for certain procedures. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchable Text: Yes (typically, depending on OCR quality of original scans) Printable: Yes Digital Features: Hyperlinked table of contents and index for easy navigation. Print Quality Image Resolution: High resolution, suitable for viewing diagrams and illustrations clearly. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: N52B30 Engine Type: Naturally Aspirated, Inline-6 Cylinder Displacement: 2996 cc (3.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 10.7:1 Performance Horsepower: 230 hp @ 6500 rpm Torque: 200 lb-ft @ 2750-4250 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Bosch Motronic Fuel Type: Premium Unleaded Gasoline (91 AKI or higher recommended) Engine Features Valve Actuation: Valvetronic (electronically controlled valve lift) and Double VANOS (variable camshaft timing). Engine Materials: Aluminum alloy crankcase and cylinder head. 🔧 Transmission Standard Transmission Type: 6-speed Steptronic Automatic Transmission Transmission Code: ZF 6HP19 Optional Manual Transmission: Not available for the 528xi model in these years (xDrive typically paired with automatic). Features Gear Ratios: 1st: 4.17, 2nd: 2.34, 3rd: 1.52, 4th: 1.14, 5th: 0.87, 6th: 0.71, Reverse: 3.40 Transmission Fluid Type: BMW ATF 6 (Dexron VI equivalent) Transmission Fluid Capacity: Approximately 8.0 - 9.0 liters for a complete fill (including torque converter, varies). 📐 Dimensions Exterior Wheelbase: 113.7 inches (2880 mm) Length: 191.1 inches (4854 mm) Width: 72.4 inches (1839 mm) Height: 57.6 inches (1463 mm) Front Track: 60.9 inches (1546 mm) Rear Track: 61.2 inches (1554 mm) Interior Front Headroom: 38.4 inches (975 mm)...

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Tipo: Car

Proveedor:

SKU: 427481

Colecciones: ALL BMW

Disponibilidad: En stock

Etiquetas: 2007 2008 2009 2010 528xi BMW Car Cars Misc

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Model:

528xi

Model Generation:

E60/E61

Model Years Covered:

2007, 2008, 2009, 2010

Codes

Chassis Code:

E60 (Sedan) / E61 (Touring/Wagon)

👋 Introduction

Market Position

Vehicle Class:

Executive Sedan/Wagon (mid-size luxury)

Target Audience:

Luxury car buyers seeking performance, comfort, and advanced technology.

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Infiniti M.

Key Features

Drivetrain Advantage:

xDrive all-wheel-drive system provides enhanced traction and stability, especially in adverse weather.

Engine Performance:

Smooth, powerful, and efficient inline-6 engine.

Driving Dynamics:

Renowned BMW 'Ultimate Driving Machine' feel, with balanced chassis and responsive handling.

Luxury Appointments:

High-quality interior materials, sophisticated design, and advanced comfort features.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English

Format:

Coverage Scope:

Comprehensive mechanical and electrical repair, maintenance, and diagnostics.

Page Count

Estimated Page Count:

1500+ pages (estimated for a comprehensive workshop manual of this era and scope)

📖 Manual Coverage

Systems Covered

Engine:

N52B30 (3.0L Naturally Aspirated Inline-6)

Engine Management:

DME (Digital Motor Electronics) control, VANOS, Valvetronic, ignition, fuel injection.

Transmission:

ZF 6HP19 (Automatic Transmission)

Drivetrain:

xDrive All-Wheel Drive system (transfer case, front/rear differentials, drive shafts).

Suspension:

Front: MacPherson struts, multi-link. Rear: Multi-link independent suspension. Adaptive Drive (optional).

Brakes:

Front: Ventilated discs, fixed calipers. Rear: Ventilated discs, floating calipers. ABS, DSC (Dynamic Stability Control), brake assist.

Steering:

Hydraulic power steering, Servotronic speed-sensitive assist.

Electrical System:

12V system, battery, alternator, starter, power distribution, fuses, relays.

Body And Chassis:

Body structure, doors, hood, trunk, interior trim, exterior trim, chassis components.

Climate Control:

Manual/Automatic HVAC, A/C system, heater core, blower motor, sensors.

Infotainment And Comfort:

iDrive system (CCC/CIC), audio system, navigation, comfort access, power seats, windows, mirrors.

Lighting:

Headlights (halogen, Xenon), taillights, interior lighting, fog lights.

Safety Systems:

Airbags (SRS), seat belts, pre-tensioners, crumple zones, pedestrian safety.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush.

Engine Diagnostics And Repair:

Compression testing, leak-down tests, component testing, internal engine repair (e.g., head gasket, timing chain).

Transmission Service:

Fluid and filter changes, torque converter replacement, valve body service, mechatronics unit repair.

Drivetrain Maintenance:

Transfer case fluid change, differential fluid change, driveshaft inspection/repair.

Suspension And Steering Repair:

Component replacement (shocks, struts, control arms, tie rods), alignment specifications.

Brake System Service:

Pad and rotor replacement, caliper service, bleeding procedure, ABS/DSC component diagnostics.

Electrical Troubleshooting:

Wiring diagrams, component testing, diagnostic connector (OBD-II) information, module diagnostics.

Body And Interior Repair:

Panel alignment, door mechanism repair, interior trim removal/installation, glass replacement.

HVAC System Service:

Refrigerant recharge, component replacement (compressor, evaporator, heater core), diagnosis of climate control faults.

Infotainment System Diagnostics:

Troubleshooting iDrive system errors, component replacement (head unit, display, modules).

Safety System Repair:

Airbag module replacement, seat belt replacement, sensor calibration.

Diagnostic Trouble Codes DTCs:

Listing and interpretation of common OBD-II and BMW-specific DTCs.

Technical Depth

Diagnostic Capability:

Advanced diagnostics for engine, transmission, chassis control modules (ABS, DSC, Airbag), and body electronics.

Repair Complexity:

Covers everything from basic fluid changes to complex engine and transmission overhauls, including specialized component replacement.

Wiring Diagrams:

Detailed electrical schematics for all systems, essential for troubleshooting.

Torque Specifications:

Precise torque values for all fasteners, critical for proper assembly.

Special Tools:

Identification and usage instructions for BMW-specific tools required for certain procedures.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchable Text:

Yes (typically, depending on OCR quality of original scans)

Printable:

Digital Features:

Hyperlinked table of contents and index for easy navigation.

Print Quality

Image Resolution:

High resolution, suitable for viewing diagrams and illustrations clearly.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

N52B30

Engine Type:

Naturally Aspirated, Inline-6 Cylinder

Displacement:

2996 cc (3.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

10.7:1

Performance

Horsepower:

230 hp @ 6500 rpm

Torque:

200 lb-ft @ 2750-4250 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Bosch Motronic

Fuel Type:

Premium Unleaded Gasoline (91 AKI or higher recommended)

Engine Features

Valve Actuation:

Valvetronic (electronically controlled valve lift) and Double VANOS (variable camshaft timing).

Engine Materials:

Aluminum alloy crankcase and cylinder head.

🔧 Transmission

Standard

Transmission Type:

6-speed Steptronic Automatic Transmission

Transmission Code:

ZF 6HP19

Optional

Manual Transmission:

Not available for the 528xi model in these years (xDrive typically paired with automatic).

Features

Gear Ratios:

1st: 4.17, 2nd: 2.34, 3rd: 1.52, 4th: 1.14, 5th: 0.87, 6th: 0.71, Reverse: 3.40

Transmission Fluid Type:

BMW ATF 6 (Dexron VI equivalent)

Transmission Fluid Capacity:

Approximately 8.0 - 9.0 liters for a complete fill (including torque converter, varies).

📐 Dimensions

Exterior

Wheelbase:

113.7 inches (2880 mm)

Length:

191.1 inches (4854 mm)

Width:

72.4 inches (1839 mm)

Height:

57.6 inches (1463 mm)

Front Track:

60.9 inches (1546 mm)

Rear Track:

61.2 inches (1554 mm)

Interior

Front Headroom:

38.4 inches (975 mm)

Rear Headroom:

37.7 inches (958 mm)

Front Legroom:

41.5 inches (1054 mm)

Rear Legroom:

34.1 inches (866 mm)

Cargo

Cargo Volume Sedan:

14.0 cubic feet (400 liters)

Cargo Volume Touring:

17.7 cubic feet (500 liters) with rear seats up, expandable to 58.3 cubic feet (1650 liters) with seats folded.

Weights

Curb Weight Sedan:

Approx. 3,836 lbs (1740 kg)

Curb Weight Touring:

Approx. 4,100 lbs (1860 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4,960 lbs (2250 kg) for Sedan

Towing Capacity:

Typically not recommended or limited for North American models; check specific market regulations and owner's manual.

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

5 Stars (2007 model year, for Sedan)

NHTSA Side Crash Test:

5 Stars (2007 model year, for Sedan)

IIHS Front Small Overlap:

Not rated (vehicle pre-dates the IIHS small overlap test introduction)

Active Features

Yes, Anti-lock Braking System

Yes, Dynamic Stability Control (includes traction control)

Brake Assist:

All Wheel Drive:

Yes, xDrive intelligent all-wheel-drive system

Passive Features

Airbags:

Front airbags, front side-impact airbags, front and rear head protection system (curtain airbags).

Seatbelts:

3-point inertia-reel seat belts with pretensioners and force limiters.

Chassis Design:

High-strength steel safety cage, front and rear crumple zones.

💡 Technology Features

Infotainment

Infotainment System:

iDrive system (primarily CCC - Car Communication Computer, with later models potentially receiving the CIC - Car Information Computer upgrade).

Display Type:

Central dashboard display (color LCD).

Audio System:

Standard Hi-Fi audio, with optional Logic 7 (Harman Kardon) premium sound system.

Navigation:

Optional Professional Navigation system, typically DVD-based for this era.

Driver Assistance

Adaptive Headlights:

Optional Xenon Adaptive Headlights that swivel with steering input.

Parking Assistance:

Optional Parking Distance Control (PDC) sensors (front and rear), and optional rearview camera.

Cruise Control:

Standard cruise control, with optional Active Cruise Control (ACC) which maintains speed and distance to the vehicle ahead.

Head Up Display:

Optional Head-Up Display (HUD) projecting key information onto the windshield.

Connectivity

Bluetooth:

Optional Bluetooth hands-free interface, often integrated with the iDrive system.

Usb Aux:

Early models may have an AUX input; USB integration became more common with later iDrive updates (CIC).

Comfort Features

Comfort Access:

Optional keyless entry and start system.

Heated Ventilated Seats:

Optional heated seats standard; ventilated seats were a rarer option.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable Oil Service (Condition Based Service - CBS), typically ranging from 10,000 to 15,000 miles (16,000-24,000 km) or 12-24 months, depending on driving conditions.

Engine Oil Filter Interval:

Recommended every oil change.

Air Filter Interval:

Typically every 30,000 miles (48,000 km) or as per CBS.

Cabin Air Filter Interval:

Typically every 15,000-20,000 miles (24,000-32,000 km) or as per CBS.

Spark Plug Interval:

Typically every 60,000 miles (96,000 km) for N52 engine (NGK SILZKFR6A11 recommended).

Brake Fluid Flush Interval:

Every 2 years, regardless of mileage.

Coolant Flush Interval:

BMW recommends long-life coolant, often 5 years or 100,000 miles (160,000 km) for initial change, then every 2 years.

Transmission Fluid Change:

Although often considered 'lifetime' by BMW, it is highly recommended to change every 60,000-100,000 miles (96,000-160,000 km) for longevity, especially given the complexity of the ZF transmission.

Fluid Specifications

Engine Oil Type:

SAE 0W-30 or 0W-40 synthetic, meeting BMW LL-01 specification.

Engine Oil Capacity:

6.9 US quarts (6.5 liters)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) mixed 50/50 with distilled water.

Power Steering Fluid:

Pentosin CHF 11S or equivalent (ensure correct specification).

Known Issues

Valve Cover Gasket Leaks:

Common on N52 engines due to aging plastic components and seals. Causes oil smell and potential oil consumption.

Oil Pan Gasket Leaks:

Another common leak point, often requiring removal of exhaust and subframe components for access.

Ccv System Failures:

Crankcase Ventilation system can become clogged or fail, leading to oil leaks, rough idle, and potential engine damage if unaddressed.

Water Pump And Thermostat:

Aluminum water pumps on N52 engines can fail, often accompanied by a whistling sound or coolant loss. Thermostat can also become stuck.

Eccentric Shaft Sensor:

Can fail on N52 engines, leading to SES light and misfires due to issues with the Valvetronic system.

Transmission Mechatronic Seal Leaks:

Can cause leaks at the transmission electrical connector, potentially leading to transmission faults.

Xdrive Transfer Case Issues:

Fluid changes are crucial; premature wear can occur if neglected. Clunking noises or binding can indicate issues.

Power Steering Pump Noise:

Can develop whining or groaning sounds, often due to low fluid or a failing pump.

Wiper Motor Failure:

A common failure point affecting both front and rear wipers (if equipped).

Window Regulator Failure:

Plastic components in the window regulator mechanism can break, causing windows to stop working or fall into the door.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW, Bayerische Motoren Werke AG, renowned for 'The Ultimate Driving Machine' philosophy, emphasizing performance, luxury, and engineering.

Model Evolution

E60 Generation:

The E60 generation (2003-2010) represented a significant styling and technological evolution from its predecessor (E39), featuring sharper lines and advanced electronics, including the introduction of iDrive.

528Xi Positioning:

The 528xi was positioned as a mid-tier model in the 5 Series range, offering a balance of performance and efficiency with the added benefit of all-wheel drive.

Production

Production Period:

The E60 generation was produced from 2003 to 2010. The 528xi model specifically utilized the N52 engine and xDrive system during the later years of this generation.

Manufacturing Locations:

Primary assembly in Dingolfing, Germany, with potential CKD (Completely Knocked Down) assembly in other global markets.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E60 5 Series generation was frequently recognized on Car and Driver's 10Best lists for its driving dynamics and overall excellence.

Wdc Award:

The E60 generation's design language also garnered praise, contributing to BMW's reputation for aesthetic appeal.

Ratings

Consumer Reports Reliability:

Consumer Reports ratings for this era of BMW often varied, with some areas being excellent and others requiring diligent maintenance due to complexity.

Certifications

Emissions Standards:

Meets ULEV II (Ultra Low Emission Vehicle II) standards in California and other adopting states.