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BMW 525xi 528xi 530xi 535xi 2006-2010 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Codes Chassis Code: E60/E61 Engine Codes: N52B30 (525xi/530xi), N54B30 (535xi), N52B25 (525xi) 👋 Introduction Market Position Segment: Executive/Luxury Sedan and Wagon Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Cadillac CTS, Jaguar S-Type. Key Features Performance Focus: Emphasis on sporty driving dynamics, powerful inline-six engines, and the advanced xDrive all-wheel-drive system. Technology Integration: Introduction of the iDrive infotainment system, electronic parking brake, and advanced driver assistance features. 📋 Manual Details Coverage Areas Covered Models: BMW 525xi, 528xi, 530xi, 535xi Covered Years: 2006, 2007, 2008, 2009, 2010 Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul procedures for N52 and N54 inline-six engines (naturally aspirated and twin-turbocharged), including cooling, lubrication, fuel injection, ignition, emissions, and engine management systems. Transmission: Comprehensive coverage of automatic transmissions (e.g., ZF 6HP series) and manual transmissions, including removal, installation, internal component repair, torque converter service, and fluid specifications. Drivetrain: All-wheel drive (xDrive) system coverage, including transfer case, front and rear differentials, driveshafts, CV joints, and related components. Suspension: Front and rear suspension systems (MacPherson struts front, multi-link rear), including wheel alignment, shock absorbers, springs, control arms, bushings, and anti-roll bars. Brakes: Hydraulic brake system, including ABS, DSC (Dynamic Stability Control), brake booster, master cylinder, brake calipers, rotors, pads, brake lines, and bleeding procedures. Steering: Hydraulic power steering system, steering rack, tie rods, and related components. Electrical: Complete electrical system diagnostics, including wiring diagrams, fuse box locations, relays, battery, alternator, starter motor, lighting, power windows, seats, mirrors, and body control modules (BCM). Body: Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement, and convertible top mechanisms (if applicable). HVAC: Heating, ventilation, and air conditioning system, including refrigerant service, compressor, condenser, evaporator, blower motor, climate control modules, and cabin air filter replacement. Comfort Controls: Seat heating/ventilation, multi-zone climate control, power seats, and memory functions. Infotainment: iDrive system, navigation, audio system, and related components diagnostics and troubleshooting. Procedures Included Maintenance: Scheduled maintenance procedures (oil changes, filter replacements, spark plugs, brake fluid flushes, coolant changes, drive belt inspection/replacement). Troubleshooting: Extensive diagnostic flowcharts, symptom-based troubleshooting guides, and diagnostic trouble code (DTC) explanations. Repair: Step-by-step repair instructions for all major mechanical and electrical systems, including component removal, disassembly, reassembly, and reinstallation. Diagnostics: Detailed procedures for using BMW's diagnostic tools (e.g., ISTA/D) and understanding sensor data and system parameters. Specifications: Torque specifications for all fasteners, fluid capacities, and dimensional data. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes and filter replacements to complete engine and transmission overhauls, electrical system diagnosis, and bodywork repairs. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear diagrams and illustrations. Searchability: Fully text-searchable for quick access to specific information. Print Quality Printability: Printable for convenient workshop use. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 525Xi/530Xi (N52B30): 3.0L Naturally Aspirated Inline-6, 24 valves, Double VANOS, Valvetronic. Horsepower: 215-255 hp. Torque: 214-220 lb-ft. 535Xi (N54B30): 3.0L Twin-Turbocharged Inline-6, 24 valves, Double VANOS, High Precision Direct Injection. Horsepower: 300 hp. Torque: 300 lb-ft. 525Xi (N52B25): 2.5L Naturally Aspirated Inline-6, 24 valves, Double VANOS, Valvetronic. Horsepower: 215 hp. Torque: 185 lb-ft. Fuel System Fuel Delivery: Multi-point fuel injection (N52) / Direct injection with piezo injectors (N54). Fuel Type: Premium Unleaded Gasoline (91+ octane recommended). 🔧 Transmission Standard Transmission Type: 6-speed manual transmission (less common on xi models). Optional Transmission Type: 6-speed Steptronic automatic transmission (widely fitted). Features Automatic Features: Adaptive shift logic, manual mode (Steptronic), paddle shifters (optional). Drivetrain Type Drivetrain: xDrive All-Wheel Drive (standard on all listed models). 📐 Dimensions Exterior Wheelbase: 116.4 inches (2957 mm) Length: 193.1 inches (4904 mm) Width: 72.5 inches (1841 mm) Height: 57.7 inches (1466 mm) Weights Curb Weight: Approx. 3700-4000 lbs (1680-1815 kg), varying by model and equipment. Gross Vehicle Weight Rating: Approx. 4800-5000 lbs (2177-2268 kg). 🛡️ Safety Features Ratings NHTSA Front Impact: 5 Stars (2006 models) IIHS Side Impact: Good (2006 models) IIHS Roof Strength: Good (2006 models) Active Features Stability Control: Dynamic Stability Control (DSC), Dynamic Traction Control (DTC), All-Season Traction. Braking Systems: Anti-lock Braking System (ABS), Electronic Brake Force Distribution (EBD), Brake Assist. Passive Features Airbags: Front airbags (driver and passenger), front side-impact airbags, front and rear head protection system (air curtains). Seat Belts: Three-point inertia-reel seat belts with front seat pretensioners and force limiters. Child Seating: LATCH (Lower Anchors and Tethers for Children) system. 💡 Technology Features Infotainment System Name: iDrive (Professional or Business Navigation System) Features: Central color display, navigation, radio, CD player, Bluetooth connectivity (optional), voice control. Driver Assistance Adaptive Cruise Control: Optional Active Cruise Control (ACC) with Stop & Go function. Parking Aids: Park Distance Control (PDC)...
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BMW 525xi 528xi 530xi 535xi 2006-2010 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Codes
Chassis Code:
E60/E61
Engine Codes:
N52B30 (525xi/530xi), N54B30 (535xi), N52B25 (525xi)
👋 Introduction
Market Position
Segment:
Executive/Luxury Sedan and Wagon
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Cadillac CTS, Jaguar S-Type.
Key Features
Performance Focus:
Emphasis on sporty driving dynamics, powerful inline-six engines, and the advanced xDrive all-wheel-drive system.
Technology Integration:
Introduction of the iDrive infotainment system, electronic parking brake, and advanced driver assistance features.
📋 Manual Details
Coverage Areas
Covered Models:
BMW 525xi, 528xi, 530xi, 535xi
Covered Years:
2006, 2007, 2008, 2009, 2010
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul procedures for N52 and N54 inline-six engines (naturally aspirated and twin-turbocharged), including cooling, lubrication, fuel injection, ignition, emissions, and engine management systems.
Transmission:
Comprehensive coverage of automatic transmissions (e.g., ZF 6HP series) and manual transmissions, including removal, installation, internal component repair, torque converter service, and fluid specifications.
Drivetrain:
All-wheel drive (xDrive) system coverage, including transfer case, front and rear differentials, driveshafts, CV joints, and related components.
Suspension:
Front and rear suspension systems (MacPherson struts front, multi-link rear), including wheel alignment, shock absorbers, springs, control arms, bushings, and anti-roll bars.
Brakes:
Hydraulic brake system, including ABS, DSC (Dynamic Stability Control), brake booster, master cylinder, brake calipers, rotors, pads, brake lines, and bleeding procedures.
Steering:
Hydraulic power steering system, steering rack, tie rods, and related components.
Electrical:
Complete electrical system diagnostics, including wiring diagrams, fuse box locations, relays, battery, alternator, starter motor, lighting, power windows, seats, mirrors, and body control modules (BCM).
Body:
Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement, and convertible top mechanisms (if applicable).
HVAC:
Heating, ventilation, and air conditioning system, including refrigerant service, compressor, condenser, evaporator, blower motor, climate control modules, and cabin air filter replacement.
Comfort Controls:
Seat heating/ventilation, multi-zone climate control, power seats, and memory functions.
Infotainment:
iDrive system, navigation, audio system, and related components diagnostics and troubleshooting.
Procedures Included
Maintenance:
Scheduled maintenance procedures (oil changes, filter replacements, spark plugs, brake fluid flushes, coolant changes, drive belt inspection/replacement).
Troubleshooting:
Extensive diagnostic flowcharts, symptom-based troubleshooting guides, and diagnostic trouble code (DTC) explanations.
Repair:
Step-by-step repair instructions for all major mechanical and electrical systems, including component removal, disassembly, reassembly, and reinstallation.
Diagnostics:
Detailed procedures for using BMW's diagnostic tools (e.g., ISTA/D) and understanding sensor data and system parameters.
Specifications:
Torque specifications for all fasteners, fluid capacities, and dimensional data.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid changes and filter replacements to complete engine and transmission overhauls, electrical system diagnosis, and bodywork repairs.
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear diagrams and illustrations.
Searchability:
Fully text-searchable for quick access to specific information.
Print Quality
Printability:
Printable for convenient workshop use.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
525Xi/530Xi (N52B30):
3.0L Naturally Aspirated Inline-6, 24 valves, Double VANOS, Valvetronic. Horsepower: 215-255 hp. Torque: 214-220 lb-ft.
535Xi (N54B30):
3.0L Twin-Turbocharged Inline-6, 24 valves, Double VANOS, High Precision Direct Injection. Horsepower: 300 hp. Torque: 300 lb-ft.
525Xi (N52B25):
2.5L Naturally Aspirated Inline-6, 24 valves, Double VANOS, Valvetronic. Horsepower: 215 hp. Torque: 185 lb-ft.
Fuel System
Fuel Delivery:
Multi-point fuel injection (N52) / Direct injection with piezo injectors (N54).
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended).
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission (less common on xi models).
Optional
Transmission Type:
6-speed Steptronic automatic transmission (widely fitted).
Features
Automatic Features:
Adaptive shift logic, manual mode (Steptronic), paddle shifters (optional).
Drivetrain Type
Drivetrain:
xDrive All-Wheel Drive (standard on all listed models).
📐 Dimensions
Exterior
Wheelbase:
116.4 inches (2957 mm)
Length:
193.1 inches (4904 mm)
Width:
72.5 inches (1841 mm)
Height:
57.7 inches (1466 mm)
Weights
Curb Weight:
Approx. 3700-4000 lbs (1680-1815 kg), varying by model and equipment.
Gross Vehicle Weight Rating:
Approx. 4800-5000 lbs (2177-2268 kg).
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5 Stars (2006 models)
IIHS Side Impact:
Good (2006 models)
IIHS Roof Strength:
Good (2006 models)
Active Features
Stability Control:
Dynamic Stability Control (DSC), Dynamic Traction Control (DTC), All-Season Traction.
Braking Systems:
Anti-lock Braking System (ABS), Electronic Brake Force Distribution (EBD), Brake Assist.
Passive Features
Airbags:
Front airbags (driver and passenger), front side-impact airbags, front and rear head protection system (air curtains).
Seat Belts:
Three-point inertia-reel seat belts with front seat pretensioners and force limiters.
Child Seating:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
System Name:
iDrive (Professional or Business Navigation System)
Features:
Central color display, navigation, radio, CD player, Bluetooth connectivity (optional), voice control.
Driver Assistance
Adaptive Cruise Control:
Optional Active Cruise Control (ACC) with Stop & Go function.
Parking Aids:
Park Distance Control (PDC) front and rear, optional rearview camera.
Connectivity
Bluetooth:
Optional Bluetooth hands-free phone integration.
Lighting
Headlights:
Standard Halogen headlights, optional Xenon Adaptive Headlights with automatic leveling and cleaning system.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions, monitored by the Condition Based Service (CBS) system.
Brake Fluid:
Every 2 years, regardless of mileage.
Coolant:
BMW recommends long-life coolant, often requiring replacement around 60,000-100,000 miles or 4-5 years.
Spark Plugs:
N52 engines: typically around 60,000 miles. N54 engines: typically around 45,000 miles, depending on driving style.
Fluid Specifications
Engine Oil:
SAE 0W-30 or 5W-30, BMW LL-01 approved synthetic oil.
Transmission Fluid Auto:
BMW ATF 6 (for ZF 6HP transmissions), specific ZF fluid (e.g., Lifeguard 6).
Coolant:
BMW Blue Antifreeze/Coolant (G48).
Brake Fluid:
DOT 4 (BMW recommends their own branded brake fluid, meeting the relevant BMW specifications).
Known Issues
Oil Leaks:
Common leaks from valve cover gasket, oil pan gasket, and oil filter housing seals.
Cooling System:
Water pump failures (often plastic impellers), thermostat issues, and radiator leaks.
N54 Twin Turbo:
High-pressure fuel pump (HPFP) failures, injector issues, and turbocharger wastegate rattle.
Electric Gremlins:
Battery issues (due to high electrical demand), alternator problems, and sensor failures, often related to water ingress or failing control modules.
Suspension Components:
Wear on control arm bushings, sway bar links, and ball joints, leading to steering looseness or knocking sounds.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's long-standing reputation for building performance-oriented luxury vehicles with a focus on driving pleasure ('The Ultimate Driving Machine').
Model Evolution
E60 Generation:
This generation of the 5 Series (E60 sedan, E61 wagon) represented a significant design and technological update from the previous E39 model, introducing a more aggressive styling and advanced electronic systems.
Production
Production Years:
The E60/E61 generation was produced from 2003 to 2010.
Manufacturing Locations:
Primarily manufactured in Dingolfing, Germany.
🏆 Awards & Recognition
Recognitions
Ward S 10 Best Engines:
The N54 3.0L twin-turbocharged inline-six engine received multiple 'Ward's 10 Best Engines' awards during its production run.
Consumer Reports:
Often rated highly for performance and handling, though reliability ratings varied across model years and specific components.
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