🏷️ Basic Information Identification Make: BMW Model: 5 Series Product Name: BMW 520i, 525i, 525d, 535d Workshop Manual Codes Engine Codes Covered: N43B20 (520i), N52B25 (525i), M57D25 (525d), M57D30 (535d - likely 3.0L variants) Chassis Codes Covered: E60 (Sedan), E61 (Touring) 👋 Introduction Market Position Market Segment: Executive/Luxury Mid-size Sedan and Wagon Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type/XF Key Features Design Philosophy: BMW's 'Ultimate Driving Machine' ethos, rear-wheel drive bias, sophisticated styling, premium interior materials. Technological Advancements: Introduction of iDrive infotainment system (early iterations), advanced chassis control systems, efficient yet powerful engine technologies. Target Audience: Professionals, executives, and discerning drivers seeking a blend of performance, luxury, and technology. 📋 Manual Details Coverage Areas Manual Type: Workshop Service / Repair Manual Language: English Format: PDF Page Count Page Count: Estimated 1500+ pages (typical for a complete workshop manual) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block, pistons, connecting rods, crankshaft, timing system, lubrication system, cooling system, intake and exhaust systems, fuel injection (gasoline and diesel), emissions control. Transmission Manual: Manual transmission (Getrag GS6-37BZ or similar) overhaul, clutch system, gear shift mechanism, driveline components (propeller shaft, driveshafts). Transmission Automatic: Automatic transmission (ZF 6HP19/21 for 520i/525i, ZF 6HP26 for 530i/535i, ZF 6HP26/28 for 525d/535d) overhaul, control systems, torque converter, fluid maintenance. Brakes: Brake system hydraulic circuits, ABS, DSC, brake calipers, discs, pads, parking brake, brake fluid specifications and bleeding procedures. Suspension Steering: Front and rear suspension systems (McPherson struts, multi-link), shock absorbers, springs, control arms, wheel bearings, power steering system (hydraulic or electric), steering rack, alignment specifications. Electrical System: Battery, alternator, starter motor, wiring diagrams for all circuits, fuse box locations and functions, lighting systems, ignition system, sensors and actuators, body control modules (BCM), comfort electronics. Bodywork: Body panel removal and installation, door mechanisms, hood, trunk, bumpers, glass, interior trim, seals, corrosion protection. HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, blower motor, climate control unit, diagnostic procedures. Safety Systems: Airbag system (SRS), seat belt pre-tensioners, diagnostic and reset procedures for safety systems. Procedures Included Maintenance: Scheduled maintenance procedures, oil changes, filter replacements, spark plug replacement, brake pad replacement, fluid level checks and top-offs, belt inspections and replacement. Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides, common fault codes and their interpretation, electrical system diagnostics. Repair: Detailed step-by-step repair instructions for all major systems, including component removal, overhaul, and reinstallation with torque specifications. Diagnostics: Procedures for using diagnostic tools (e.g., ISTA/D), interpreting sensor data, and performing system tests. Technical Depth Depth: Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and component specifications. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes (typical for professionally produced PDF manuals) Printable: Yes Print Quality Graphics Quality: High-resolution images, diagrams, and schematics (typical of factory-level documentation) Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine 520I Engine: BMW N43B20 2.0L Inline-4 Valvetronic/Double VANOS Petrol 525I Engine: BMW N52B25 2.5L Inline-6 Valvetronic/Double VANOS Petrol 525D Engine: BMW M57D25 2.5L Inline-6 Turbocharged Diesel (Common Rail) 535D Engine: BMW M57D30 3.0L Inline-6 Twin-Turbocharged Diesel (Common Rail - depending on exact model year/variant) Performance 520I Power: Approx. 170-177 hp @ 6400 rpm 520I Torque: Approx. 210-215 Nm @ 4250 rpm 525I Power: Approx. 218 hp @ 6500 rpm 525I Torque: Approx. 250 Nm @ 2750 rpm 525D Power: Approx. 177-190 hp @ 4000 rpm 525D Torque: Approx. 400-420 Nm @ 2000-2750 rpm 535D Power: Approx. 272-286 hp @ 4400 rpm 535D Torque: Approx. 560-580 Nm @ 1750-2250 rpm Fuel System 520I Fuel System: Electronic Port Fuel Injection (MPI) 525I Fuel System: Electronic Port Fuel Injection (MPI) 525D Fuel System: Common Rail Direct Injection (CRDI) with Turbocharging 535D Fuel System: Common Rail Direct Injection (CRDI) with Twin Turbocharging Diesel Particulate Filter: Likely equipped with DPF on later models/variants (check specific model year) 🔧 Transmission Standard 520I: 6-Speed Manual (Getrag GS6-37BZ or similar) 525I: 6-Speed Manual (Getrag GS6-37BZ or similar) 525D: 6-Speed Manual (Getrag GS6-45DZ or similar) 535D: 6-Speed Steptronic Automatic (ZF 6HP26/28 - standard for this model) Optional 520I: 6-Speed Steptronic Automatic (ZF 6HP19/21) 525I: 6-Speed Steptronic Automatic (ZF 6HP19/21) 525D: 6-Speed Steptronic Automatic (ZF 6HP26) Features Steptronic: Manual gear selection via selector lever or steering wheel paddles. 📐 Dimensions Exterior Length: Approx. 4841 mm (E60 Sedan) Width: Approx. 1846 mm Height: Approx. 1468 mm (E60 Sedan) Wheelbase: Approx. 2888 mm Weights Curb Weight 520I Manual: Approx. 1500 kg Curb Weight 535D Auto: Approx. 1780 kg Cargo Trunk Volume: Approx. 520 liters (E60 Sedan) 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (for E60/E61 generation) Active Features Dynamic Stability Control: Standard (DSC, Dynamic Stability Control), includes DTC (Dynamic Traction Control) Anti Lock Brakes: Standard (ABS, Anti-lock Braking System) Brake Assist: Standard (BA, Brake...