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BMW 5 Series 535xi 2007-2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 535xi Generation Generation Name: E60/E61 Codes Chassis Code: E60 (Sedan), E61 (Touring/Wagon) 👋 Introduction Market Position Segment: Executive Mid-size Luxury Sedan/Wagon Competitive Analysis Competitors: Audi A6, Mercedes-Benz E-Class, Lexus GS, Infiniti M Key Features Powertrain Focus: Emphasis on the N54 twin-turbocharged engine and xDrive AWD system Target Audience: BMW enthusiasts, DIY mechanics, professional technicians 📋 Manual Details Coverage Areas Applicable Years: 2007, 2008, 2009, 2010 Vehicle Body Styles: Sedan (E60), Touring/Wagon (E61) Page Count Total Pages: 1660 Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Download Method: Instant Download 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (including N54 twin-turbocharged inline-6) Engine Management: Yes (including DME, fuel injection, ignition) Transmission Manual: Yes (e.g., GS6-37BZ for manual variants) Transmission Automatic: Yes (e.g., GA6HP19Z, GA6HP26Z for automatic variants) Drivetrain AWD: Yes (xDrive all-wheel drive system) Suspension: Yes (front and rear, including adaptive suspension if applicable) Steering: Yes (hydraulic power steering) Brakes: Yes (including ABS, DSC, brake pad replacement) Electrical System: Yes (wiring diagrams, component testing) Body Exterior: Yes (panels, doors, bumpers, glass) Body Interior: Yes (trim, seats, dashboard) HVAC: Yes (heating, ventilation, air conditioning) Infotainment Nav: Yes (iDrive system, audio, navigation) Procedures Included Routine Maintenance: Yes (oil change, filter replacement, fluid checks) Troubleshooting: Yes (diagnostic procedures, common faults) Component Removal Installation: Yes (step-by-step guides for all major components) Disassembly Assembly: Yes (detailed breakdown of components) Adjustments: Yes (alignment, idle speed, etc.) Technical Depth Depth: Comprehensive (bumper to bumper, includes detailed diagrams and specifications) Diagnostic Support: Yes (includes diagnostic information, troubleshooting charts) Pictorial Representation: Yes (step-by-step procedures with pictorial diagrams, drawings, photos) Special Tools: Yes (references and illustrations for required special service tools) Torque Specifications: Yes (includes critical torque values for assembly and installation) Wear Limits: Yes (includes specified wear limits for various components) 📊 Manual Specifications File Format Compatibility: Windows, Mac, Linux OS Print Quality Printable: Yes PDF Quality: High Resolution, All Pages Intact Binding Type Binding Type: Digital (PDF download) Paper Type Paper Type: N/A (Digital File) Software Requirement Required Software: Adobe Reader ⚙️ Engine Specifications Primary Engine Engine Code: N54B30 (for 535xi) Engine Type: 3.0L Twin-Turbocharged Inline-6 Performance Horsepower Hp: Approx. 300 hp @ 5800 rpm Torque Lb Ft: Approx. 300 lb-ft @ 1400 rpm Fuel System Fuel Delivery: Direct Injection (High-Pressure) Engine Features Valvetrain: Double VANOS, Valvetronic, Double Overhead Camshafts (DOHC), 24 valves Turbocharging System: Sequential Twin-Turbochargers 🔧 Transmission Standard Transmission Type Std: 6-Speed Manual (e.g., GS6-37BZ) Optional Transmission Type Opt: 6-Speed Automatic (e.g., GA6HP19Z, GA6HP26Z) Features Drivetrain: xDrive All-Wheel Drive 📐 Dimensions Exterior Wheelbase In: 116.4 inches Length In: 193.1 inches (Sedan) Width In: 72.7 inches Height In: 57.7 inches (Sedan), 58.3 inches (Touring) Weights Curb Weight Lbs: Approx. 3900-4100 lbs (depending on body style and options) Gross Vehicle Weight Rating Gvwr Lbs: Refer to specific vehicle placard (typically around 5000-5200 lbs) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star (2008 model) NHTSA Front Impact Passenger: 5-Star (2008 model) IIHS Top Safety Pick: Yes (various years) Active Features Traction Control: Dynamic Traction Control (DTC), Dynamic Stability Control (DSC) Braking Assistance: Anti-lock Braking System (ABS), Brake Assist Passive Features Airbags: Front airbags, front side-impact airbags, head protection system (front and rear) Seatbelts: Active front head restraints, pretensioners 💡 Technology Features Infotainment Infotainment System: iDrive (CCC or CIC depending on production date) Navigation System: Optional Professional Navigation System Driver Assistance Cruise Control: Standard cruise control, optional Active Cruise Control (ACC) Parking Assistance: Optional front and rear Park Distance Control (PDC), optional rearview camera Connectivity Bluetooth: Optional Bluetooth connectivity for hands-free calling and audio streaming Convenience Keyless Entry: Standard keyless entry, optional Comfort Access keyless entry and start 🔧 Maintenance Service Intervals Oil Change Interval: Variable; typically every 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system. Refer to manual for precise CBS interpretation. Brake Fluid Change Interval: Every 2 years (BMW recommended) Spark Plug Replacement: Refer to manual; typically around 60,000-100,000 miles for N54 ignition coils and plugs Fluid Specifications Engine Oil Type: BMW Longlife-01 (LL-01) or BMW Longlife-01 FE (LL-01 FE) synthetic oil, SAE 0W-30 or 5W-30. Check manual for exact specification and viscosity. Coolant Type: BMW Blue Antifreeze/Coolant (G48 or similar G48 specification) Transmission Fluid Type Auto: BMW ATF LT-5 or equivalent specification (e.g., Dexron VI for some variants). Refer to specific transmission type in manual. Transmission Fluid Type Manual: BMW MTF LT-3 or equivalent Differential Fluid Type: BMW Hypoid Gear Oil SAF-XJ or SAF-XO (for xDrive) or SAF-AXLE OIL. Refer to manual for specific front/rear diffs. Known Issues Common Engine Problems: HPFP (High-Pressure Fuel Pump) failures, injector issues, ignition coil failures, turbocharger issues (wastegate rattle, oil leaks), vacuum leaks affecting boost Common Electrical Problems: CCC/CIC iDrive unit malfunctions, water damage to electronics (e.g., blower motor resistor,...
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BMW 5 Series 535xi 2007-2010 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Variant:
535xi
Generation
Generation Name:
E60/E61
Codes
Chassis Code:
E60 (Sedan), E61 (Touring/Wagon)
👋 Introduction
Market Position
Segment:
Executive Mid-size Luxury Sedan/Wagon
Competitive Analysis
Competitors:
Audi A6, Mercedes-Benz E-Class, Lexus GS, Infiniti M
Key Features
Powertrain Focus:
Emphasis on the N54 twin-turbocharged engine and xDrive AWD system
Target Audience:
BMW enthusiasts, DIY mechanics, professional technicians
📋 Manual Details
Coverage Areas
Applicable Years:
2007, 2008, 2009, 2010
Vehicle Body Styles:
Sedan (E60), Touring/Wagon (E61)
Page Count
Total Pages:
1660
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Download Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes (including N54 twin-turbocharged inline-6)
Engine Management:
Yes (including DME, fuel injection, ignition)
Transmission Manual:
Yes (e.g., GS6-37BZ for manual variants)
Transmission Automatic:
Yes (e.g., GA6HP19Z, GA6HP26Z for automatic variants)
Drivetrain AWD:
Yes (xDrive all-wheel drive system)
Suspension:
Yes (front and rear, including adaptive suspension if applicable)
Steering:
Yes (hydraulic power steering)
Brakes:
Yes (including ABS, DSC, brake pad replacement)
Electrical System:
Yes (wiring diagrams, component testing)
Body Exterior:
Yes (panels, doors, bumpers, glass)
Body Interior:
Yes (trim, seats, dashboard)
HVAC:
Yes (heating, ventilation, air conditioning)
Infotainment Nav:
Yes (iDrive system, audio, navigation)
Procedures Included
Routine Maintenance:
Yes (oil change, filter replacement, fluid checks)
Troubleshooting:
Yes (diagnostic procedures, common faults)
Component Removal Installation:
Yes (step-by-step guides for all major components)
Disassembly Assembly:
Yes (detailed breakdown of components)
Adjustments:
Yes (alignment, idle speed, etc.)
Technical Depth
Depth:
Comprehensive (bumper to bumper, includes detailed diagrams and specifications)
Diagnostic Support:
Yes (includes diagnostic information, troubleshooting charts)
Pictorial Representation:
Yes (step-by-step procedures with pictorial diagrams, drawings, photos)
Special Tools:
Yes (references and illustrations for required special service tools)
Torque Specifications:
Yes (includes critical torque values for assembly and installation)
Wear Limits:
Yes (includes specified wear limits for various components)
📊 Manual Specifications
File Format
Compatibility:
Windows, Mac, Linux OS
Print Quality
Printable:
Yes
PDF Quality:
High Resolution, All Pages Intact
Binding Type
Binding Type:
Digital (PDF download)
Paper Type
Paper Type:
N/A (Digital File)
Software Requirement
Required Software:
Adobe Reader
⚙️ Engine Specifications
Primary Engine
Engine Code:
N54B30 (for 535xi)
Engine Type:
3.0L Twin-Turbocharged Inline-6
Performance
Horsepower Hp:
Approx. 300 hp @ 5800 rpm
Torque Lb Ft:
Approx. 300 lb-ft @ 1400 rpm
Fuel System
Fuel Delivery:
Direct Injection (High-Pressure)
Engine Features
Valvetrain:
Double VANOS, Valvetronic, Double Overhead Camshafts (DOHC), 24 valves
Turbocharging System:
Sequential Twin-Turbochargers
🔧 Transmission
Standard
Transmission Type Std:
6-Speed Manual (e.g., GS6-37BZ)
Optional
Transmission Type Opt:
6-Speed Automatic (e.g., GA6HP19Z, GA6HP26Z)
Features
Drivetrain:
xDrive All-Wheel Drive
📐 Dimensions
Exterior
Wheelbase In:
116.4 inches
Length In:
193.1 inches (Sedan)
Width In:
72.7 inches
Height In:
57.7 inches (Sedan), 58.3 inches (Touring)
Weights
Curb Weight Lbs:
Approx. 3900-4100 lbs (depending on body style and options)
Gross Vehicle Weight Rating Gvwr Lbs:
Refer to specific vehicle placard (typically around 5000-5200 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star (2008 model)
NHTSA Front Impact Passenger:
5-Star (2008 model)
IIHS Top Safety Pick:
Yes (various years)
Active Features
Traction Control:
Dynamic Traction Control (DTC), Dynamic Stability Control (DSC)
Braking Assistance:
Anti-lock Braking System (ABS), Brake Assist
Passive Features
Airbags:
Front airbags, front side-impact airbags, head protection system (front and rear)
Seatbelts:
Active front head restraints, pretensioners
💡 Technology Features
Infotainment
Infotainment System:
iDrive (CCC or CIC depending on production date)
Navigation System:
Optional Professional Navigation System
Driver Assistance
Cruise Control:
Standard cruise control, optional Active Cruise Control (ACC)
Parking Assistance:
Optional front and rear Park Distance Control (PDC), optional rearview camera
Connectivity
Bluetooth:
Optional Bluetooth connectivity for hands-free calling and audio streaming
Convenience
Keyless Entry:
Standard keyless entry, optional Comfort Access keyless entry and start
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable; typically every 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system. Refer to manual for precise CBS interpretation.
Brake Fluid Change Interval:
Every 2 years (BMW recommended)
Spark Plug Replacement:
Refer to manual; typically around 60,000-100,000 miles for N54 ignition coils and plugs
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or BMW Longlife-01 FE (LL-01 FE) synthetic oil, SAE 0W-30 or 5W-30. Check manual for exact specification and viscosity.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 or similar G48 specification)
Transmission Fluid Type Auto:
BMW ATF LT-5 or equivalent specification (e.g., Dexron VI for some variants). Refer to specific transmission type in manual.
Transmission Fluid Type Manual:
BMW MTF LT-3 or equivalent
Differential Fluid Type:
BMW Hypoid Gear Oil SAF-XJ or SAF-XO (for xDrive) or SAF-AXLE OIL. Refer to manual for specific front/rear diffs.
Known Issues
Common Engine Problems:
HPFP (High-Pressure Fuel Pump) failures, injector issues, ignition coil failures, turbocharger issues (wastegate rattle, oil leaks), vacuum leaks affecting boost
Common Electrical Problems:
CCC/CIC iDrive unit malfunctions, water damage to electronics (e.g., blower motor resistor, junction box), battery drain issues
Common Suspension Problems:
Worn control arm bushings, tie rod ends, strut mounts
📚 Vehicle History
Brand Heritage
Brand Focus:
Luxury, performance, engineering excellence
Model Evolution
E60 Introduction:
Introduced for the 2004 model year, replacing the E39
E60 Facelift:
Mid-cycle refresh in 2007, affecting styling and technology
535Xi Introduction:
Introduced with the 535i model, featuring the N54 engine and xDrive
Production
Production Years:
E60/E61: 2003-2010
Manufacturing Location:
Germany (Dingolfing Plant)
🏆 Awards & Recognition
Recognitions
Ward Auto Ten Best Engines:
N54 engine recognized multiple times by Ward's Auto
Ratings
Consumer Reports Reliability:
Varies by year; typically average to above average for the class, but some specific model years and powertrains may have lower ratings due to known issues.
Certifications
Epa Fuel Economy City Mpg:
Approx. 16-18 MPG (depending on transmission and year)
Epa Fuel Economy Highway Mpg:
Approx. 24-26 MPG (depending on transmission and year)
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