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BMW 525xi Complete Workshop Service Repair Manual 2006 2007

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🏷️ Basic Information Identification Make: BMW Model: 525xi Model Code: E60/E61 Production Years: 2006-2007 👋 Introduction Market Position Segment: Executive Sedan/Wagon Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS Key Features Chassis: E60 (Sedan) / E61 (Touring/Wagon) Drivetrain Type: All-Wheel Drive (xDrive) Design Philosophy: Sporty luxury, driver-centric cockpit, advanced technology 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Language: English Format: Downloadable PDF Page Count Estimated Pages: 2000+ 📖 Manual Coverage Systems Covered Engine: BMW N52B30 3.0L Inline-6 Transmission: 6-speed manual (GS6-37BZ), 6-speed automatic (GA6HP19Z) Drivetrain: xDrive All-Wheel Drive System Suspension: Front: Independent Double Wishbone; Rear: Independent Multi-link Brakes: Front: Ventilated Discs; Rear: Ventilated Discs, ABS, DSC Steering: Hydraulic Power Steering Electrical: Comprehensive wiring diagrams, ECU functions, sensor diagnostics Body: Exterior panels, interior trim, doors, glass, bumpers, chassis HVAC: Climate control system, A/C, heating, ventilation Fuel System: Fuel pump, injectors, fuel pressure regulation Exhaust System: Catalytic converters, mufflers, exhaust manifold Cooling System: Radiator, water pump, thermostat, hoses Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, brake fluid flush Engine Repair: Overhaul, component replacement (pistons, valves, timing chain), gasket seals Transmission Repair: Clutch replacement, automatic transmission service and overhaul, torque converter Brake Service: Pad/rotor replacement, caliper overhaul, ABS component testing Electrical Diagnostics: Troubleshooting electrical faults, module programming, sensor calibration Suspension And Steering: Component replacement (shocks, struts, control arms, tie rods), alignment procedures Body And Interior: Panel replacement, trim removal, door mechanism repair, glass installation HVAC Service: Refrigerant charging, leak detection, component replacement (compressor, evaporator) Fuel System Diagnostics: Injector testing, fuel pump pressure checks, fuel filter replacement Cooling System Repair: Leak testing, component replacement (water pump, thermostat), coolant flush Technical Depth Diagnostic Procedures: Step-by-step troubleshooting guides for common and complex faults, OBD-II codes interpretation Repair Techniques: Detailed instructions for component removal, installation, and adjustment, including torque specifications Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, color-coded and detailed Specifications And Tolerances: Precise measurements, clearances, and tolerances for all mechanical components Special Tools: Identification and usage instructions for BMW-specific tools required for certain repairs 📊 Manual Specifications File Format Digital Format: PDF Searchability: Fully searchable text Print Quality Resolution: High resolution, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: N52B30 Engine Type: Naturally Aspirated Inline-6 Displacement: 2996 cc (3.0 Liters) Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 10.7:1 Performance Horsepower: 255 hp @ 6600 rpm Torque: 236 lb-ft @ 2750 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), DISA intake manifold Fuel Type: Premium Unleaded Gasoline (91 Octane Recommended) Engine Management ECU Type: Bosch DME (Digital Motor Electronics) Valvetrain System: Double Overhead Camshafts (DOHC), 24 Valves, VANOS, Valvetronic 🔧 Transmission Standard Type: 6-Speed Manual (GS6-37BZ) Optional Type: 6-Speed Steptronic Automatic (GA6HP19Z) Features Drivetrain Configuration: xDrive All-Wheel Drive Fluid Specifications Manual Transmission Fluid: BMW MTF LT-2 (or equivalent) Automatic Transmission Fluid: BMW ATF LT-3 (or equivalent) Differential Fluid Front And Rear Differentials: BMW Hypoid Gear Oil G2 (or equivalent) 📐 Dimensions Exterior Length E60: 191.1 in (4853 mm) Length E61: 193.1 in (4905 mm) Width: 72.4 in (1839 mm) Height: 57.9 in (1471 mm) Wheelbase: 116.4 in (2956 mm) Interior Passenger Volume: 98.0 cu ft (2775 L) Cargo Trunk Volume E60: 14.0 cu ft (396 L) Cargo Volume E61: 25.1 cu ft (711 L) / 56.4 cu ft (1600 L) with rear seats folded Weights Curb Weight Manual: 3858 lbs (1750 kg) Curb Weight Automatic: 3913 lbs (1775 kg) Gross Vehicle Weight Rating: 5027 lbs (2280 kg) Wheels And Tires Wheel Bolt Pattern: 5x120 Standard Wheel Size: 17 x 8.0 inches Standard Tire Size: 225/50R17 🛡️ Safety Features Ratings NHTSA Frontal Impact: 5-Star (Driver & Passenger) IIHS Side Impact: Good Active Features Traction Control: Dynamic Traction Control (DTC) Stability Control: Dynamic Stability Control (DSC) Braking System: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Airbags: Front, Side-Curtain, Knee Airbags Seatbelts: Pretensioners and force limiters 💡 Technology Features Infotainment Head Unit: iDrive infotainment system (CCC generation) Display Size: 6.5-inch or 8.8-inch central LCD screen Navigation: Optional Professional navigation system Audio: AM/FM stereo, CD player, optional SiriusXM satellite radio, Logic7 premium audio system. Driver Assistance Parking Sensors: Optional Park Distance Control (PDC) Adaptive Cruise Control: Optional Active Cruise Control (ACC) Headlights: Standard Xenon headlights with adaptive feature Connectivity Bluetooth: Optional Bluetooth hands-free interface Auxiliary Input: Standard AUX input for audio devices 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 - 15,000 miles or 12 months, depending on driving conditions (indicated by Condition Based Service - CBS). Brake Fluid Flush: Every 2 years Engine Air Filter: Inspect every 30,000 miles, replace as needed. Cabin Air Filter: Inspect every 15,000 miles, replace as needed. Spark Plugs: Typically around 60,000 - 100,000 miles, depending on type. Transmission Fluid Service: Recommended...
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BMW 525xi Complete Workshop Service Repair Manual 2006 2007
🏷️ Basic Information
Identification
Make:
BMW
Model:
525xi
Model Code:
E60/E61
Production Years:
2006-2007
👋 Introduction
Market Position
Segment:
Executive Sedan/Wagon
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS
Key Features
Chassis:
E60 (Sedan) / E61 (Touring/Wagon)
Drivetrain Type:
All-Wheel Drive (xDrive)
Design Philosophy:
Sporty luxury, driver-centric cockpit, advanced technology
📋 Manual Details
Coverage Areas
Manual Type:
Complete Workshop Service Repair Manual
Language:
English
Format:
Downloadable PDF
Page Count
Estimated Pages:
2000+
📖 Manual Coverage
Systems Covered
Engine:
BMW N52B30 3.0L Inline-6
Transmission:
6-speed manual (GS6-37BZ), 6-speed automatic (GA6HP19Z)
Drivetrain:
xDrive All-Wheel Drive System
Suspension:
Front: Independent Double Wishbone; Rear: Independent Multi-link
Brakes:
Front: Ventilated Discs; Rear: Ventilated Discs, ABS, DSC
Steering:
Hydraulic Power Steering
Electrical:
Comprehensive wiring diagrams, ECU functions, sensor diagnostics
Body:
Exterior panels, interior trim, doors, glass, bumpers, chassis
HVAC:
Climate control system, A/C, heating, ventilation
Fuel System:
Fuel pump, injectors, fuel pressure regulation
Exhaust System:
Catalytic converters, mufflers, exhaust manifold
Cooling System:
Radiator, water pump, thermostat, hoses
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, brake fluid flush
Engine Repair:
Overhaul, component replacement (pistons, valves, timing chain), gasket seals
Transmission Repair:
Clutch replacement, automatic transmission service and overhaul, torque converter
Brake Service:
Pad/rotor replacement, caliper overhaul, ABS component testing
Electrical Diagnostics:
Troubleshooting electrical faults, module programming, sensor calibration
Suspension And Steering:
Component replacement (shocks, struts, control arms, tie rods), alignment procedures
Body And Interior:
Panel replacement, trim removal, door mechanism repair, glass installation
HVAC Service:
Refrigerant charging, leak detection, component replacement (compressor, evaporator)
Fuel System Diagnostics:
Injector testing, fuel pump pressure checks, fuel filter replacement
Cooling System Repair:
Leak testing, component replacement (water pump, thermostat), coolant flush
Technical Depth
Diagnostic Procedures:
Step-by-step troubleshooting guides for common and complex faults, OBD-II codes interpretation
Repair Techniques:
Detailed instructions for component removal, installation, and adjustment, including torque specifications
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems, color-coded and detailed
Specifications And Tolerances:
Precise measurements, clearances, and tolerances for all mechanical components
Special Tools:
Identification and usage instructions for BMW-specific tools required for certain repairs
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Fully searchable text
Print Quality
Resolution:
High resolution, suitable for printing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
N52B30
Engine Type:
Naturally Aspirated Inline-6
Displacement:
2996 cc (3.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
10.7:1
Performance
Horsepower:
255 hp @ 6600 rpm
Torque:
236 lb-ft @ 2750 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), DISA intake manifold
Fuel Type:
Premium Unleaded Gasoline (91 Octane Recommended)
Engine Management
ECU Type:
Bosch DME (Digital Motor Electronics)
Valvetrain
System:
Double Overhead Camshafts (DOHC), 24 Valves, VANOS, Valvetronic
🔧 Transmission
Standard
Type:
6-Speed Manual (GS6-37BZ)
Optional
Type:
6-Speed Steptronic Automatic (GA6HP19Z)
Features
Drivetrain Configuration:
xDrive All-Wheel Drive
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 (or equivalent)
Automatic Transmission Fluid:
BMW ATF LT-3 (or equivalent)
Differential Fluid
Front And Rear Differentials:
BMW Hypoid Gear Oil G2 (or equivalent)
📐 Dimensions
Exterior
Length E60:
191.1 in (4853 mm)
Length E61:
193.1 in (4905 mm)
Width:
72.4 in (1839 mm)
Height:
57.9 in (1471 mm)
Wheelbase:
116.4 in (2956 mm)
Interior
Passenger Volume:
98.0 cu ft (2775 L)
Cargo
Trunk Volume E60:
14.0 cu ft (396 L)
Cargo Volume E61:
25.1 cu ft (711 L) / 56.4 cu ft (1600 L) with rear seats folded
Weights
Curb Weight Manual:
3858 lbs (1750 kg)
Curb Weight Automatic:
3913 lbs (1775 kg)
Gross Vehicle Weight Rating:
5027 lbs (2280 kg)
Wheels And Tires
Wheel Bolt Pattern:
5x120
Standard Wheel Size:
17 x 8.0 inches
Standard Tire Size:
225/50R17
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
5-Star (Driver & Passenger)
IIHS Side Impact:
Good
Active Features
Traction Control:
Dynamic Traction Control (DTC)
Stability Control:
Dynamic Stability Control (DSC)
Braking System:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Passive Features
Airbags:
Front, Side-Curtain, Knee Airbags
Seatbelts:
Pretensioners and force limiters
💡 Technology Features
Infotainment
Head Unit:
iDrive infotainment system (CCC generation)
Display Size:
6.5-inch or 8.8-inch central LCD screen
Navigation:
Optional Professional navigation system
Audio:
AM/FM stereo, CD player, optional SiriusXM satellite radio, Logic7 premium audio system.
Driver Assistance
Parking Sensors:
Optional Park Distance Control (PDC)
Adaptive Cruise Control:
Optional Active Cruise Control (ACC)
Headlights:
Standard Xenon headlights with adaptive feature
Connectivity
Bluetooth:
Optional Bluetooth hands-free interface
Auxiliary Input:
Standard AUX input for audio devices
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 - 15,000 miles or 12 months, depending on driving conditions (indicated by Condition Based Service - CBS).
Brake Fluid Flush:
Every 2 years
Engine Air Filter:
Inspect every 30,000 miles, replace as needed.
Cabin Air Filter:
Inspect every 15,000 miles, replace as needed.
Spark Plugs:
Typically around 60,000 - 100,000 miles, depending on type.
Transmission Fluid Service:
Recommended every 60,000-100,000 miles for automatic transmissions (lifetime fill often cited, but fluid degrades).
Fluid Specifications
Engine Oil:
SAE 5W-30 Synthetic, BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) approved.
Engine Oil Capacity:
6.5 US quarts (6.2 Liters)
Coolant:
BMW Blue Antifreeze/Coolant (G48) or equivalent, mixed 50/50 with distilled water.
Power Steering Fluid:
Pentosin CHF 11S or equivalent.
Known Issues
Valve Cover Gasket Leaks:
Common on N52 engines, leading to oil consumption and smell.
Oil Pan Gasket Leaks:
Another common source of oil leaks.
Crankcase Ventilation System:
Clogged PCV valve or hoses can cause rough running and leaks.
Water Pump And Thermostat:
Can fail prematurely, leading to overheating.
Transmission Bottles:
Oil leaks from the transmission cooler lines on automatic transmissions.
Window Regulators:
Can fail, preventing windows from operating.
Headlight Ballasts:
Xenon headlight system components can fail.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Established in 1916, renowned for performance, luxury, and driving dynamics.
Model Evolution
E60 Generation:
Fourth generation of the BMW 5 Series, introduced in 2003. The E60/E61 represented a significant departure in design and technology from its E39 predecessor.
525Xi Positioning:
Mid-tier model in the 5 Series lineup, offering a balance of performance and luxury with the added benefit of all-wheel drive for enhanced traction in various conditions.
Production
Manufacturing Locations:
Main production facility: Dingolfing, Germany
🏆 Awards & Recognition
Recognitions
Car And Driver Best 10:
E60 generation models frequently appeared on Car and Driver's 10Best list during its production run for overall excellence.
Ward Auto Worlds 10 Best Engines:
The N52 engine received accolades for its smoothness and technology.
Ratings
Consumer Reports Reliability:
Mixed reliability ratings, with certain components known to require attention. This manual is crucial for addressing common wear items.
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