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BMW 528i Complete Workshop Service Repair Manual 2008 2009 2010

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🏷️ Basic Information Identification Make: BMW Model: 528i Generation: E60/E61 (Facelift) Chassis Code: E60 (Sedan) / E61 (Wagon/Touring) Model Years Covered: 2008, 2009, 2010 👋 Introduction Market Position Vehicle Segment: Executive Sedan/Wagon Target Audience: Luxury car buyers seeking performance, comfort, and advanced technology Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS Key Features Chassis Platform: BMW E60/E61 platform Design Philosophy: Focus on driving dynamics ('The Ultimate Driving Machine') 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Language: English Format: Downloadable (typically PDF) Page Count Estimated Page Count: Over 2000 pages (typical for comprehensive BMW workshop manuals) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, diagnostics, cooling system, lubrication system, fuel injection, ignition system Engine Management: ECU operation, sensor diagnostics, emission control systems (including NOx sensors, DPF if applicable to specific market variants) Transmission Manual: Clutch, gearbox assembly, disassembly, adjustments, clutch hydraulic system Transmission Automatic: Automatic transmission assembly, disassembly, torque converter, mechatronics, control modules, fluid servicing Drivetrain: Driveshafts, differentials, axles, wheel bearings Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering knuckles, wheel alignment Steering: Power steering system (hydraulic or electric depending on specific build), steering rack, steering column, steering angle sensor Brakes: Brake system components (calipers, rotors, pads), hydraulic system, ABS, DSC (Dynamic Stability Control), brake booster, parking brake (mechanical or electronic) Electrical System: Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn Body And Chassis: Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass, sunroof, chassis structural components HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant servicing, blower motor, climate control module Infotainment And Comfort: Radio, navigation system (CCC/CIC), speakers, power seats, heated seats, climate control panel Procedures Included Preventative Maintenance: Oil changes, filter replacements (oil, air, cabin), spark plug replacement, fluid checks and flushes Routine Repairs: Brake pad/rotor replacement, battery replacement, tire rotation, wiper blade replacement Engine Diagnostics And Repair: Troubleshooting engine performance issues, cylinder head removal/installation, piston/ring replacement, valve adjustments Transmission Service And Repair: Automatic transmission fluid and filter change, manual transmission clutch replacement, diagnostic procedures for shifting issues Suspension And Steering Repair: Replacement of ball joints, tie rod ends, wheel bearings, shock absorbers, steering rack repair/replacement Brake System Overhaul: Brake bleeding, caliper rebuild/replacement, ABS sensor replacement, DSC module diagnostics Electrical Troubleshooting: Using wiring diagrams to diagnose electrical faults, testing sensors and actuators, component replacement HVAC System Repair: Refrigerant recharging, blower motor replacement, evaporator core replacement, heater core replacement Bodywork And Collision Repair: Panel replacement, door hinge adjustment, bumper repair, glass replacement Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagnostic Procedures: Detailed troubleshooting guides, fault code interpretation, diagnostic tool usage (e.g., ISTA/D, INPA) Torque Specifications: Included for all critical fasteners Wiring Diagrams: Detailed electrical schematics for all vehicle systems Special Tools: Identification and usage instructions for BMW-specific tools 📊 Manual Specifications File Format File Type: Likely PDF (printable, searchable) Print Quality Image Resolution: High resolution for clear diagrams and illustrations Binding Type Binding: N/A (Downloadable, typically PDF) Paper Type Paper Quality: N/A (Downloadable, typically PDF) ⚙️ Engine Specifications Primary Engine Engine Code Variant: N52B30 (3.0L Inline-6) 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 Valve Train: DOHC, 4 valves per cylinder, Double VANOS, Valvetronic Performance Horsepower: 230 hp @ 6500 rpm Torque: 200 lb-ft (271 Nm) @ 2750 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-Point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Emission Control: Closed-loop emission control system, catalytic converters, secondary air injection 🔧 Transmission Standard Transmission Type Std: 6-speed Manual (SMG optional in some markets/builds) Optional Transmission Type Opt: 6-speed Steptronic Automatic with Adaptive Transmission Control (ATC) Features Automatic Transmission Features: Sport mode, Manual mode (Sequential Gearshift), Paddle shifters (optional) Fluid Specifications Automatic Transmission Fluid: BMW ATF LT-5 or equivalent (consult manual for exact part number) Manual Transmission Fluid: BMW MTF LT-2 or equivalent (consult manual for exact part number) 📐 Dimensions Exterior Length: Approx. 191.1 inches (4853 mm) Width: Approx. 72.2 inches (1833 mm) Height: Approx. 58.1 inches (1476 mm) Wheelbase: Approx. 116.4 inches (2956 mm) Weights Curb Weight: Approx. 3700-3850 lbs (1678-1746 kg) depending on configuration 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (for 2008-2010 E60 model) IIHS Top Safety Pick: Yes (for applicable years) Active Features Traction Control: Dynamic Traction Control (DTC) Stability Control: Dynamic Stability Control (DSC) Braking Assist: Anti-lock Braking System (ABS), Brake Fade Compensation, Brake Drying Passive Features Airbags: Front airbags, front side-impact airbags, head protection system (front and rear side curtain airbags) Seatbelts: 3-point inertia-reel seatbelts with pretensioners and force limiters 💡 Technology Features Infotainment Infotainment System: iDrive (CCC or updated CIC system depending...
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BMW 528i Complete Workshop Service Repair Manual 2008 2009 2010
🏷️ Basic Information
Identification
Make:
BMW
Model:
528i
Generation:
E60/E61 (Facelift)
Chassis Code:
E60 (Sedan) / E61 (Wagon/Touring)
Model Years Covered:
2008, 2009, 2010
👋 Introduction
Market Position
Vehicle Segment:
Executive Sedan/Wagon
Target Audience:
Luxury car buyers seeking performance, comfort, and advanced technology
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS
Key Features
Chassis Platform:
BMW E60/E61 platform
Design Philosophy:
Focus on driving dynamics ('The Ultimate Driving Machine')
📋 Manual Details
Coverage Areas
Manual Type:
Complete Workshop Service Repair Manual
Language:
English
Format:
Downloadable (typically PDF)
Page Count
Estimated Page Count:
Over 2000 pages (typical for comprehensive BMW workshop manuals)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, diagnostics, cooling system, lubrication system, fuel injection, ignition system
Engine Management:
ECU operation, sensor diagnostics, emission control systems (including NOx sensors, DPF if applicable to specific market variants)
Transmission Manual:
Clutch, gearbox assembly, disassembly, adjustments, clutch hydraulic system
Transmission Automatic:
Automatic transmission assembly, disassembly, torque converter, mechatronics, control modules, fluid servicing
Drivetrain:
Driveshafts, differentials, axles, wheel bearings
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering knuckles, wheel alignment
Steering:
Power steering system (hydraulic or electric depending on specific build), steering rack, steering column, steering angle sensor
Brakes:
Brake system components (calipers, rotors, pads), hydraulic system, ABS, DSC (Dynamic Stability Control), brake booster, parking brake (mechanical or electronic)
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems (headlights, taillights, interior), horn
Body And Chassis:
Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass, sunroof, chassis structural components
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, refrigerant servicing, blower motor, climate control module
Infotainment And Comfort:
Radio, navigation system (CCC/CIC), speakers, power seats, heated seats, climate control panel
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, fluid checks and flushes
Routine Repairs:
Brake pad/rotor replacement, battery replacement, tire rotation, wiper blade replacement
Engine Diagnostics And Repair:
Troubleshooting engine performance issues, cylinder head removal/installation, piston/ring replacement, valve adjustments
Transmission Service And Repair:
Automatic transmission fluid and filter change, manual transmission clutch replacement, diagnostic procedures for shifting issues
Suspension And Steering Repair:
Replacement of ball joints, tie rod ends, wheel bearings, shock absorbers, steering rack repair/replacement
Brake System Overhaul:
Brake bleeding, caliper rebuild/replacement, ABS sensor replacement, DSC module diagnostics
Electrical Troubleshooting:
Using wiring diagrams to diagnose electrical faults, testing sensors and actuators, component replacement
HVAC System Repair:
Refrigerant recharging, blower motor replacement, evaporator core replacement, heater core replacement
Bodywork And Collision Repair:
Panel replacement, door hinge adjustment, bumper repair, glass replacement
Technical Depth
Depth Of Coverage:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Diagnostic Procedures:
Detailed troubleshooting guides, fault code interpretation, diagnostic tool usage (e.g., ISTA/D, INPA)
Torque Specifications:
Included for all critical fasteners
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems
Special Tools:
Identification and usage instructions for BMW-specific tools
📊 Manual Specifications
File Format
File Type:
Likely PDF (printable, searchable)
Print Quality
Image Resolution:
High resolution for clear diagrams and illustrations
Binding Type
Binding:
N/A (Downloadable, typically PDF)
Paper Type
Paper Quality:
N/A (Downloadable, typically PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Variant:
N52B30 (3.0L Inline-6)
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
Valve Train:
DOHC, 4 valves per cylinder, Double VANOS, Valvetronic
Performance
Horsepower:
230 hp @ 6500 rpm
Torque:
200 lb-ft (271 Nm) @ 2750 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Emission Control:
Closed-loop emission control system, catalytic converters, secondary air injection
🔧 Transmission
Standard
Transmission Type Std:
6-speed Manual (SMG optional in some markets/builds)
Optional
Transmission Type Opt:
6-speed Steptronic Automatic with Adaptive Transmission Control (ATC)
Features
Automatic Transmission Features:
Sport mode, Manual mode (Sequential Gearshift), Paddle shifters (optional)
Fluid Specifications
Automatic Transmission Fluid:
BMW ATF LT-5 or equivalent (consult manual for exact part number)
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent (consult manual for exact part number)
📐 Dimensions
Exterior
Length:
Approx. 191.1 inches (4853 mm)
Width:
Approx. 72.2 inches (1833 mm)
Height:
Approx. 58.1 inches (1476 mm)
Wheelbase:
Approx. 116.4 inches (2956 mm)
Weights
Curb Weight:
Approx. 3700-3850 lbs (1678-1746 kg) depending on configuration
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for 2008-2010 E60 model)
IIHS Top Safety Pick:
Yes (for applicable years)
Active Features
Traction Control:
Dynamic Traction Control (DTC)
Stability Control:
Dynamic Stability Control (DSC)
Braking Assist:
Anti-lock Braking System (ABS), Brake Fade Compensation, Brake Drying
Passive Features
Airbags:
Front airbags, front side-impact airbags, head protection system (front and rear side curtain airbags)
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters
💡 Technology Features
Infotainment
Infotainment System:
iDrive (CCC or updated CIC system depending on build date and options)
Navigation:
Optional Professional Navigation System
Driver Assistance
Parking Sensors:
Optional Park Distance Control (PDC) - front and rear
Cruise Control:
Standard cruise control; optional Active Cruise Control (ACC) with Stop & Go function
Headlights:
Halogen or Xenon Adaptive Headlights with LED angel eyes/daytime running lights
Connectivity
Bluetooth:
Optional Bluetooth connectivity for hands-free calling and audio streaming
Auxiliary Input:
Standard AUX input; optional USB adapter
🔧 Maintenance
Service Intervals
Oil Change Interval:
Condition Based Service (CBS) system, typically around 10,000-15,000 miles or as indicated by the vehicle's computer.
Air Filter Replacement:
Typically every 30,000-60,000 miles or as per CBS.
Cabin Filter Replacement:
Typically every 15,000-30,000 miles or annually.
Spark Plug Replacement:
Typically around 60,000 miles for the N52 engine.
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) or BMW Longlife-04 (LL-04) synthetic oil, typically 0W-30 or 5W-30 (consult manual for precise specification).
Engine Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change.
Coolant Specification:
BMW Blue Antifreeze (G48) or equivalent (50/50 mix with distilled water).
Brake Fluid Specification:
DOT 4 Low Viscosity (LV) or BMW DOT 4 equivalent.
Known Issues
Common Issues Engine N52:
Eccentric shaft sensor (Vanos solenoid related), oil leaks (valve cover gasket, oil filter housing gasket), PCV system issues, ignition coil failures.
Common Issues Transmission Auto:
Mechatronic unit failure, torque converter issues, valve body problems (often related to fluid degradation).
Common Issues Suspension:
Front control arm bushings, rear shock mounts, steering tie rod ends.
Common Issues Electrical:
Water pump failure (electric, with integrated thermostat), alternator issues, ABS/DSC sensor failures, iDrive system glitches.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Founding Year:
1916
Model Evolution
E60 Introduction:
The E60 5 Series replaced the E39 generation in 2003 (2004 model year in North America). The 528i designation was reintroduced for the 2008 model year, replacing the 525i.
Facelift E60 Lci:
The facelift (LCI - Life Cycle Impulse) for the E60 occurred for the 2008 model year, introducing updated styling (headlights, taillights, bumpers) and technology.
Production
Manufacturing Locations:
Mainly Dingolfing, Germany; also Spartanburg, USA and Regensburg, Germany for certain variants/export markets.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E60 generation 5 Series was a frequent recipient of Car and Driver's 10Best awards in its earlier years, often praised for its driving dynamics.
Ratings
Reliability Ratings:
Varies by source; generally considered above average for its class, but with specific common issues that require attention as detailed in the manual.
Certifications
Manufacturer Certification:
Factory authorized service information
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