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BMW 535i 2007 2008 2009 2010 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 535i Generation: E60/E61 Production Years Covered: 2007, 2008, 2009, 2010 Codes Chassis Code: E60 (Sedan), E61 (Wagon/Touring) 👋 Introduction Market Position Segment: Executive Mid-size Luxury Sedan/Wagon Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Infiniti M Key Features Engine Technology: Twin-turbocharged inline-six engine (N54), known for performance and responsiveness Driving Dynamics: BMW's signature 'Ultimate Driving Machine' characteristics, often equipped with Active Steering and Adaptive Drive options Interior Comfort: Premium materials, advanced comfort features, and driver-oriented cockpit Manual Usefulness Target Audience: Professional technicians and advanced DIY enthusiasts 📋 Manual Details Coverage Areas Primary Coverage: Workshop Repair and Service Secondary Coverage: Maintenance, Diagnostics, Troubleshooting Page Count Estimated Page Count: Over 2000 pages (typical for full workshop manuals) Manual Type Type: Factory-Authorized Workshop Repair Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (N54B30), Transmission (Automatic and Manual), Drivetrain (RWD, AWD xDrive) Chassis: Suspension (front and rear), Steering system, Brakes (hydraulic, ABS, DSC, Dynamic Drive) Electrical: Body Control Module (BCM), Lighting, Instrumentation, Comfort systems (HVAC, Seats), Infotainment, CAN Bus Communication Body: Exterior body panels, Interior trim, Body hardware, Safety systems (Airbags, Seatbelt pretensioners) Procedures Included Maintenance: Scheduled maintenance, Oil changes, Filter replacements, Fluid checks and top-offs Repair Engine: Engine assembly/disassembly, Component replacement (pistons, valves, seals), Turbocharger servicing, Fuel injector testing, Ignition system diagnostics Repair Transmission: Transmission fluid and filter changes, Torque converter replacement, Gearbox overhaul (manual and automatic) Repair Brakes: Brake pad and rotor replacement, Brake caliper servicing, ABS/DSC module diagnostics and replacement, Fluid bleeding Diagnostics: Fault code interpretation (DME, EGS, DSC, etc.), Live data analysis, Component testing, Troubleshooting guides Technical Depth Depth: Comprehensive: From basic fluid changes to complete engine rebuilds and complex electronic system diagnostics Diagnostic Tools: Details on using BMW's ISTA (Integrated Service Information) or INPA diagnostic software, wiring diagrams for troubleshooting 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, vector graphics for diagrams Print Quality Printable: Printable pages for workshop use Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: N54B30 Configuration: 3.0L (2979cc) Twin-Turbocharged Inline 6-cylinder Performance Horsepower: 300 hp @ 5800 rpm Torque: 300 lb-ft @ 1400 rpm Fuel System Injection Type: High-pressure direct fuel injection (piezo injectors) Fuel Type: Premium Unleaded Gasoline (91 AKI or higher) Cooling System Coolant Type: BMW Blue Antifreeze/Coolant (G48), 50/50 mix with distilled water Lubrication System Oil Type: BMW Longlife-01 (LL-01) approved 5W-30 synthetic oil Oil Capacity: 6.9 US quarts (6.5 liters) with filter change 🔧 Transmission Standard Type: 6-speed Manual Transmission (GS6-37BZ) Optional Type: 6-speed Automatic Transmission with Steptronic (GA6HP19Z) Features Automatic Transmission Features: Adaptive shift logic, Sport mode, Manual shifting via selector lever or paddle shifters (optional) Fluid Specs Automatic Transmission Fluid Type: BMW ATF 6 (Dexron VI compatible or equivalent) Fluid Capacity Automatic Transmission Fluid Capacity: Approx. 8-9 liters for complete fill (check specific service manual procedures for accurate capacity) 📐 Dimensions Exterior Sedan Length: 191.1 inches (4853 mm) Sedan Width: 72.4 inches (1839 mm) Sedan Height: 57.7 inches (1466 mm) Wheelbase: 116.4 inches (2956 mm) Cargo Sedan Trunk Volume: 14.0 cubic feet (396 liters) Weights Curb Weight Sedan: Approx. 3700-3800 lbs (1680-1725 kg) depending on options 🛡️ Safety Features Ratings NHTSA Front Crash Test: 5-Star Rating IIHS Top Safety Pick: Yes (for applicable years) Active Features Traction Control: Dynamic Stability Control (DSC), includes DTC (Dynamic Traction Control) Brake Assist: Anti-lock Braking System (ABS), Cornering Brake Control (CBC) Optional Driver Assist: Adaptive Cruise Control (ACC), Head-Up Display (HUD) Passive Features Airbags: Front airbags, Side airbags, Head protection airbags (curtain airbags) Seat Belts: Pretensioners, Force limiters 💡 Technology Features Infotainment System Name: iDrive (CCC or CIC depending on production date/options) Display: Central Information Display (CID) screen Navigation: Optional professional navigation system Driver Assistance Parking: Park Distance Control (PDC), optional rearview camera Lighting: Xenon Adaptive Headlights, optional High-beam Assistant Connectivity Bluetooth: Optional Bluetooth phone integration Usb Aux: Optional USB/audio interface 🔧 Maintenance Service Intervals Oil Service: Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually Brake Fluid Flush: Every 2 years (regardless of mileage) Engine Air Filter: Inspect at 30,000 miles, replace as needed or based on CBS Cabin Air Filter: Inspect at 30,000 miles, replace as needed or based on CBS Fluid Specifications Power Steering Fluid: Pentosin CHF 11S or BMW equivalent (check manual for exact spec) Brake Fluid: DOT 4 Low Viscosity (LV) Known Issues Engine N54: High-pressure fuel pump (HPFP) failures, Injector issues (misfires), Ignition coil failures, Turbocharger wastegate rattle, PCV valve issues Electrical: Water pump and thermostat failures (electric), PDC sensor failures, CIC/iDrive system glitches Suspension: Front control arm bushings wear, Rear suspension bushings, Active Steering pump issues Comfort Features: HVAC blower motor resistor failure, Seat heater elements 📚 Vehicle History Brand Heritage Bmw Philosophy: Focus on driving dynamics,...
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BMW 535i 2007 2008 2009 2010 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
535i
Generation:
E60/E61
Production Years Covered:
2007, 2008, 2009, 2010
Codes
Chassis Code:
E60 (Sedan), E61 (Wagon/Touring)
👋 Introduction
Market Position
Segment:
Executive Mid-size Luxury Sedan/Wagon
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Infiniti M
Key Features
Engine Technology:
Twin-turbocharged inline-six engine (N54), known for performance and responsiveness
Driving Dynamics:
BMW's signature 'Ultimate Driving Machine' characteristics, often equipped with Active Steering and Adaptive Drive options
Interior Comfort:
Premium materials, advanced comfort features, and driver-oriented cockpit
Manual Usefulness
Target Audience:
Professional technicians and advanced DIY enthusiasts
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Repair and Service
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting
Page Count
Estimated Page Count:
Over 2000 pages (typical for full workshop manuals)
Manual Type
Type:
Factory-Authorized Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (N54B30), Transmission (Automatic and Manual), Drivetrain (RWD, AWD xDrive)
Chassis:
Suspension (front and rear), Steering system, Brakes (hydraulic, ABS, DSC, Dynamic Drive)
Electrical:
Body Control Module (BCM), Lighting, Instrumentation, Comfort systems (HVAC, Seats), Infotainment, CAN Bus Communication
Body:
Exterior body panels, Interior trim, Body hardware, Safety systems (Airbags, Seatbelt pretensioners)
Procedures Included
Maintenance:
Scheduled maintenance, Oil changes, Filter replacements, Fluid checks and top-offs
Repair Engine:
Engine assembly/disassembly, Component replacement (pistons, valves, seals), Turbocharger servicing, Fuel injector testing, Ignition system diagnostics
Repair Transmission:
Transmission fluid and filter changes, Torque converter replacement, Gearbox overhaul (manual and automatic)
Repair Brakes:
Brake pad and rotor replacement, Brake caliper servicing, ABS/DSC module diagnostics and replacement, Fluid bleeding
Diagnostics:
Fault code interpretation (DME, EGS, DSC, etc.), Live data analysis, Component testing, Troubleshooting guides
Technical Depth
Depth:
Comprehensive: From basic fluid changes to complete engine rebuilds and complex electronic system diagnostics
Diagnostic Tools:
Details on using BMW's ISTA (Integrated Service Information) or INPA diagnostic software, wiring diagrams for troubleshooting
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text, vector graphics for diagrams
Print Quality
Printable:
Printable pages for workshop use
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
N54B30
Configuration:
3.0L (2979cc) Twin-Turbocharged Inline 6-cylinder
Performance
Horsepower:
300 hp @ 5800 rpm
Torque:
300 lb-ft @ 1400 rpm
Fuel System
Injection Type:
High-pressure direct fuel injection (piezo injectors)
Fuel Type:
Premium Unleaded Gasoline (91 AKI or higher)
Cooling System
Coolant Type:
BMW Blue Antifreeze/Coolant (G48), 50/50 mix with distilled water
Lubrication System
Oil Type:
BMW Longlife-01 (LL-01) approved 5W-30 synthetic oil
Oil Capacity:
6.9 US quarts (6.5 liters) with filter change
🔧 Transmission
Standard
Type:
6-speed Manual Transmission (GS6-37BZ)
Optional
Type:
6-speed Automatic Transmission with Steptronic (GA6HP19Z)
Features
Automatic Transmission Features:
Adaptive shift logic, Sport mode, Manual shifting via selector lever or paddle shifters (optional)
Fluid Specs
Automatic Transmission Fluid Type:
BMW ATF 6 (Dexron VI compatible or equivalent)
Fluid Capacity
Automatic Transmission Fluid Capacity:
Approx. 8-9 liters for complete fill (check specific service manual procedures for accurate capacity)
📐 Dimensions
Exterior
Sedan Length:
191.1 inches (4853 mm)
Sedan Width:
72.4 inches (1839 mm)
Sedan Height:
57.7 inches (1466 mm)
Wheelbase:
116.4 inches (2956 mm)
Cargo
Sedan Trunk Volume:
14.0 cubic feet (396 liters)
Weights
Curb Weight Sedan:
Approx. 3700-3800 lbs (1680-1725 kg) depending on options
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
5-Star Rating
IIHS Top Safety Pick:
Yes (for applicable years)
Active Features
Traction Control:
Dynamic Stability Control (DSC), includes DTC (Dynamic Traction Control)
Brake Assist:
Anti-lock Braking System (ABS), Cornering Brake Control (CBC)
Optional Driver Assist:
Adaptive Cruise Control (ACC), Head-Up Display (HUD)
Passive Features
Airbags:
Front airbags, Side airbags, Head protection airbags (curtain airbags)
Seat Belts:
Pretensioners, Force limiters
💡 Technology Features
Infotainment
System Name:
iDrive (CCC or CIC depending on production date/options)
Display:
Central Information Display (CID) screen
Navigation:
Optional professional navigation system
Driver Assistance
Parking:
Park Distance Control (PDC), optional rearview camera
Lighting:
Xenon Adaptive Headlights, optional High-beam Assistant
Connectivity
Bluetooth:
Optional Bluetooth phone integration
Usb Aux:
Optional USB/audio interface
🔧 Maintenance
Service Intervals
Oil Service:
Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually
Brake Fluid Flush:
Every 2 years (regardless of mileage)
Engine Air Filter:
Inspect at 30,000 miles, replace as needed or based on CBS
Cabin Air Filter:
Inspect at 30,000 miles, replace as needed or based on CBS
Fluid Specifications
Power Steering Fluid:
Pentosin CHF 11S or BMW equivalent (check manual for exact spec)
Brake Fluid:
DOT 4 Low Viscosity (LV)
Known Issues
Engine N54:
High-pressure fuel pump (HPFP) failures, Injector issues (misfires), Ignition coil failures, Turbocharger wastegate rattle, PCV valve issues
Electrical:
Water pump and thermostat failures (electric), PDC sensor failures, CIC/iDrive system glitches
Suspension:
Front control arm bushings wear, Rear suspension bushings, Active Steering pump issues
Comfort Features:
HVAC blower motor resistor failure, Seat heater elements
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Focus on driving dynamics, engineering excellence, and luxury
Model Evolution
E60 Introduction:
Introduced in 2003 (as a 2004 model), replacing the E39 5 Series. Featured controversial Chris Bangle design.
E60 Facelift:
Mid-cycle refresh (LCI) occurred around 2007-2008, introducing updated styling and technology.
Production
Manufacturing Locations:
Mainly Dingolfing, Germany; also other BMW plants globally.
🏆 Awards & Recognition
Recognitions
Ward Auto 10 Best Engines:
N54 engine was a multiple recipient of this award
Ratings
Car And Driver 10Best:
5 Series models often featured on Car and Driver's 10Best list during this era.
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