Basic Information Identification Make: BMW Model: 5 Series Sub Model: 525i Generation Chassis Code: E60 Codes Engine Code Identifier: M54B25 Introduction Market Position Vehicle Segment: Executive Sedan (Luxury Mid-size) Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type. Key Features Vehicle Highlights: Balanced ride and handling, premium interior, advanced technology for its era, inline-six engine refinement. Manual Purpose Target Audience: Professional mechanics and DIY enthusiasts seeking comprehensive repair and maintenance information. Manual Details Coverage Areas Covered Years: 2003, 2004, 2005, 2006, 2007 Page Count Total Pages: 1660 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Digital Format: PDF Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul, assembly, disassembly, testing, and adjustment procedures for the M54B25 engine. Engine Electrical: Ignition system, fuel injection system (DME - Digital Motor Electronics), sensor diagnostics, starting and charging systems. Transmission: Automatic and manual transmission service, repair, removal, installation, and fluid specifications. Drivetrain: Front axle, rear axle, driveshafts, differentials, and CV joints. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, and alignment procedures. Steering: Power steering system, steering rack, steering column, and associated components. Brakes: Front and rear brake systems, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pad and rotor replacement, caliper service, brake fluid bleeding. Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, and fuel pressure testing. Cooling System: Radiator, water pump, thermostat, coolant hoses, and fan assembly. Exhaust System: Exhaust manifolds, catalytic converters, mufflers, and pipes. Body And Chassis: Body panels, doors, windows, locks, hinges, and structural components. Electrical System: Lighting systems (headlights, taillights, interior lights), wiring diagrams, fuse box locations, battery service, starter, alternator. Climate Control: HVAC system (Heating, Ventilation, and Air Conditioning), climate control unit, compressor, refrigerant handling. Safety Systems: Airbag system (SRS), seat belt mechanisms, and associated sensors. Diagnostic Troubleshooting: Extensive troubleshooting guides, fault codes, symptom-based diagnostics, and testing procedures for all major systems. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, battery maintenance. Repair Procedures: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Adjustment Procedures: Adjustment of brakes, clutch, parking brake, engine idle, and other critical systems. Troubleshooting Guides: Systematic approaches to diagnosing and resolving common and uncommon vehicle issues. Torque Specifications: Precise tightening torques for all fasteners in engine, chassis, and bodywork. Diagnostic Charts: Flowcharts and diagnostic trees to aid in fault finding. Special Tool References: Identification and usage instructions for specialized BMW service tools required for specific repairs. Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic information. Pictorial Guidance Illustrations: Detailed illustrations, exploded diagrams, drawings, and photos guiding through service and repair procedures. Manual Specifications File Format Format Details: PDF (Portable Document Format), universally compatible. Print Quality Printability: Fully printable, allowing users to print specific sections or the entire manual. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Simulation: Simulates high-quality workshop manual paper for clarity and detail. Compatibility Operating Systems: Compatible with Windows, Mac, and Linux operating systems via Adobe Reader. Requirements Software Requirement: Adobe Reader (or compatible PDF viewer) required. Engine Specifications Primary Engine Engine Model: M54B25 Engine Type: Naturally Aspirated Inline 6-Cylinder Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 82 mm x 79.5 mm Compression Ratio: 10.2:1 Performance Horsepower: 184 hp @ 6000 rpm Torque: 175 lb-ft (237 Nm) @ 3500 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) via Bosch Motronic DME Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Other Valve Train: Double Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing) on intake and exhaust camshafts. Transmission Standard Standard Transmission: 6-Speed Manual Transmission Optional Optional Transmission: 6-Speed Steptronic Automatic Transmission Features Automatic Features: Manual shifting mode (Steptronic), adaptive shift control. Dimensions Exterior Length: Approx. 4841 mm (190.6 inches) Width: Approx. 1800 mm (70.9 inches) Height: Approx. 1468 mm (57.8 inches) Weights Curb Weight: Approx. 1550-1600 kg (3417-3527 lbs) depending on transmission. Safety Features Ratings IIHS Crash Test: Good (front and side impact) for models tested by IIHS in corresponding years (subject to specific testing protocols). Active Features Active Safety Systems: ABS, DSC (Dynamic Stability Control), Traction Control System (TCS), CBC (Cornering Brake Control). Passive Features Passive Safety Systems: Front airbags, side airbags, head protection system (HPS), active headrests, three-point seatbelts with pre-tensioners. Technology Features Infotainment Infotainment System: Optional iDrive system (CCC generation), professional navigation, CD player, optional Logic 7 audio system. Driver Assistance Driver Assistance Features: Park Distance Control (PDC), cruise control, optional adaptive headlights. Connectivity Connectivity Options: Bluetooth integration (optional, depending on model year and iDrive version), auxiliary input (later models). Maintenance Service Intervals Oil Change Interval: Variable service interval system (CBS) based on driving conditions, typically around 10,000-15,000 miles or 12-24 months. Major...