BMW 535i Complete Workshop Service Repair Manual 2008 2009 2010
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🏷️ Basic Information Identification Make: BMW Model: 535i Model Generation: E60/E61 Model Years Covered: 2008, 2009, 2010 Codes Chassis Codes: E60 (Sedan), E61 (Wagon/Touring) 👋 Introduction Market Position Segment: Executive Sedan/Wagon Brand Positioning: Premium, performance-oriented luxury vehicle Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Cadillac CTS Key Features Powertrain Highlight: Twin-turbocharged inline-six engine (N54) offering strong performance and torque. Handling Focus: Renowned BMW driving dynamics, balanced chassis, available Adaptive Drive and Active Steering. Technology Integration: Advanced iDrive infotainment system, optional Head-Up Display, comprehensive driver assistance features. 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global (technical specifications generally applicable) Page Count Estimated Page Count: 1500+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (N54), Transmission (Automatic & Manual), Drivetrain (RWD/xDrive) Chassis: Suspension (Front & Rear), Steering, Brakes (Standard & Optional M Sport), Wheels & Tires Electrical: Engine Control Unit (ECU), Body Control Module (BCM), Lighting, HVAC Controls, Infotainment, Sensors, Wiring Diagrams Body And Interior: Body Panels, Doors, Glass, Seats, Upholstery, Trim, Climate Control System Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks & Replacements, Spark Plug Service, Brake Pad Replacement, Belt Service Repair: Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake Caliper Service, Electrical Component Diagnosis & Replacement, Body Panel Repair Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Fault Finding Procedures, System Testing Special Procedures: Turbocharger Replacement, Fuel Injector Service, Ignition Coil Replacement, Drivetrain Component Alignment, Software Updates/Programming (with appropriate tools) Technical Depth Depth: Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval Print Quality: High-resolution, suitable for printing individual pages or sections Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: N54B30 Engine Type: 3.0L Twin-Turbocharged Inline-6 (Inline-30) Bore X Stroke: 84.0 mm x 89.6 mm Compression Ratio: 10.2:1 Performance Horsepower: 300 hp @ 5800 rpm Torque: 300 lb-ft @ 1400-5000 rpm Fuel System Fuel Delivery: Direct Injection (High-Pressure Fuel System) Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Cooling System Coolant Type: BMW Blue Antifreeze/Coolant (G48 formulation or equivalent) Lubrication Oil Type: SAE 0W-30 Synthetic (BMW Longlife-01 or LL-01FE approved) Oil Capacity With Filter: Approx. 6.9 US quarts (6.5 liters) 🔧 Transmission Standard Type 2008-2009: ZF 6HP19TU 6-Speed Automatic Type 2010: ZF 8HP70 8-Speed Automatic (introduced in later production) Optional Manual Transmission: Getrag GS6-37BZ 6-Speed Manual (less common) Features Automatic Features: Steptronic (manual shifting mode), Adaptive Transmission Control (ATC) Fluid Specifications Automatic Transmission Fluid: ZF Lifeguardfluid 6 (for 6HP19TU), ZF Lifeguardfluid 8 (for 8HP70) or approved equivalents. 📐 Dimensions Exterior Length: E60 Sedan: ~191.8 inches Width: E60 Sedan: ~72.4 inches Height: E60 Sedan: ~58.0 inches Wheelbase: E60 Sedan: ~116.4 inches Cargo Trunk Volume: E60 Sedan: ~14.0 cubic feet Weights Curb Weight: Approx. 3700-3900 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (for applicable model years/testing) IIHS Side Impact: Good (for applicable model years/testing) Active Features Braking System: Four-wheel disc brakes with ABS, Electronic Brake-force Distribution (EBD), Brake Assist Stability Control: Dynamic Stability Control (DSC), Traction Control System (TCS) Optional Safety Features: Adaptive Headlights, Lane Departure Warning, Active Cruise Control Passive Features Airbags: Front airbags, side-impact airbags, front and rear head protection airbags (curtain airbags) 💡 Technology Features Infotainment System Name: iDrive (CCC or CIC depending on model year and options) Display: Central LCD display (various sizes, e.g., 7-inch or 8.8-inch) Navigation: Optional Professional Navigation System Driver Assistance Standard Features: Cruise Control, Parking Sensors (Front & Rear) Optional Features: Adaptive Cruise Control (ACC), Head-Up Display (HUD), Lane Departure Warning (LDW), Active Steering Connectivity Audio Options: CD player, optional SiriusXM Satellite Radio, USB/Auxiliary inputs (depending on option packages) Comfort Features Climate Control: Automatic climate control (dual-zone or multi-zone) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000-15,000 miles or annually, based on BMW's condition-based service (CBS) system or fixed intervals. Brake Fluid Flush: Every 2 years, regardless of mileage. Spark Plug Replacement: Generally around 60,000 miles for the N54 engine, consult manual for exact interval. Fluid Specifications Power Steering Fluid: BMW ATF Dexron III or equivalent (confirm specific BMW part number or specification) Brake Fluid Specification: DOT 4 Low Viscosity (LV) Brake Fluid (BMW Super-DOT 4 recommended) Known Issues N54 Engine Common Problems: High-pressure fuel pump (HPFP) failure, turbocharger wastegate rattle, ignition coil failure, PCV valve issues, carbon build-up on intake valves. Common Electrical Issues: Water pump failure (electric), thermostat failure, sensor failures (e.g., camshaft position sensor), iDrive system glitches. 📚 Vehicle History Brand Heritage Manufacturer: Bayerische Motoren Werke AG (BMW), a German luxury and performance automobile manufacturer. Model Evolution E60 Generation: The E60 generation of the 5...
Water pump failure (electric), thermostat failure, sensor failures (e.g., camshaft position sensor), iDrive system glitches.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW), a German luxury and performance automobile manufacturer.
Model Evolution
E60 Generation:
The E60 generation of the 5 Series was introduced in 2003, replacing the E39. The 535i model, powered by the N54 twin-turbo engine, debuted in 2008, marking a significant performance upgrade for the 5 Series line.
Production
Production Location:
Dingolfing, Germany
🏆 Awards & Recognition
Recognitions
Ward S 10 Best Engines:
The N54 engine received multiple 'Ward's 10 Best Engines' awards for its performance and technology.
Ratings
Consumer Reports Reliability:
Varied by year, often rated average to above average, with some specific model year concerns noted regarding the N54's early complexity.