🏷️ Basic Information

Make:

BMW

Model:

5 Series

Product Name:

BMW 520i, 525i, 525d, 535d Workshop Manual

Engine Codes Covered:

N43B20 (520i), N52B25 (525i), M57D25 (525d), M57D30 (535d - likely 3.0L variants)

Chassis Codes Covered:

E60 (Sedan), E61 (Touring)

👋 Introduction

Market Segment:

Executive/Luxury Mid-size Sedan and Wagon

Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type/XF

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

Manual Type:

Workshop Service / Repair Manual

Language:

English

Format:

PDF

Page Count:

Estimated 1500+ pages (typical for a complete workshop manual)

📖 Manual Coverage

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.

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.

Depth:

Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and component specifications.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Yes (typical for professionally produced PDF manuals)

Printable:

Yes

Graphics Quality:

High-resolution images, diagrams, and schematics (typical of factory-level documentation)

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

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)

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

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

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)

520I:

6-Speed Steptronic Automatic (ZF 6HP19/21)

525I:

6-Speed Steptronic Automatic (ZF 6HP19/21)

525D:

6-Speed Steptronic Automatic (ZF 6HP26)

Steptronic:

Manual gear selection via selector lever or steering wheel paddles.

📐 Dimensions

Length:

Approx. 4841 mm (E60 Sedan)

Width:

Approx. 1846 mm

Height:

Approx. 1468 mm (E60 Sedan)

Wheelbase:

Approx. 2888 mm

Curb Weight 520I Manual:

Approx. 1500 kg

Curb Weight 535D Auto:

Approx. 1780 kg

Trunk Volume:

Approx. 520 liters (E60 Sedan)

🛡️ Safety Features

Euro Ncap Rating:

5 Stars (for E60/E61 generation)

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 Assist)

Electronic Brake Force Distribution:

Standard (EBD)

Airbags:

Front airbags (driver/passenger), side airbags, head airbags (curtain), optional knee airbags.

Seat Belts:

Three-point inertia-reel seat belts with pretensioners and belt force limiters.

💡 Technology Features

Idrive System:

First generation iDrive system with central controller, offering navigation, entertainment, climate control, and vehicle settings. Early versions were criticized for complexity.

Audio Options:

Standard stereo, Hi-Fi system, Logic 7 premium audio system.

Adaptive Headlights:

Optional Xenon Adaptive Headlights that swivel with steering input.

Parking Assist:

Optional Park Distance Control (PDC) front and rear, and optional rearview camera.

Cruise Control:

Standard cruise control, optional Active Cruise Control (ACC) with Stop & Go function on later models.

Bluetooth:

Optional Bluetooth hands-free interface with music streaming capabilities.

Usb Aux:

Optional USB/Aux-in ports for audio devices.

🔧 Maintenance

Oil Change Interval:

Condition Based Service (CBS) system, typically around 15,000-25,000 km or 12-24 months, depending on driving conditions.

Spark Plug Replacement Interval:

Typically 60,000-100,000 km for petrol engines (depending on plug type).

Brake Fluid Change:

Every 2 years.

Engine Oil 520I:

BMW Longlife-01 (LL-01) or LL-04 specification, SAE 0W-30 or 5W-30.

Engine Oil 525I:

BMW Longlife-01 (LL-01) or LL-04 specification, SAE 0W-30 or 5W-30.

Engine Oil 525D/535D:

BMW Longlife-04 (LL-04) specification, SAE 5W-30.

Coolant:

BMW Blue Performance Coolant (G48), a 50/50 mix with distilled water.

Automatic Transmission Fluid:

ZF Lifeguardfluid 6 (for 6HP19/21/26) or ZF Lifeguardfluid 8 (for 6HP28). Refer to specific transmission codes for exact type.

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent.

Common Problems E60:

Water pump failures (N52 engines), oil leaks (valve cover gaskets, oil pan gaskets), VANOS solenoid issues, ABS/DSC sensor failures, diesel particulate filter (DPF) clogging (diesel models), swirl flap issues (M57 diesel engines), electrical gremlins (especially early iDrive systems).

Recommended Checks:

Regular inspection of cooling system hoses and connections, serpentine belt condition, and checking for oil/fluid leaks.

📚 Vehicle History

Bmw Philosophy:

Renowned for engineering excellence, sporty driving dynamics, and premium quality since its inception.

E60 Introduction:

The E60 generation of the BMW 5 Series was introduced in 2003, replacing the E39. It featured a controversial redesign by Chris Bangle, marking a significant shift in BMW's styling language.

Production Years:

2003-2010 (for E60/E61 generation)

Manufacturing Locations:

Mainly Dingolfing, Germany; also Austria, Egypt, Russia, China, India, Thailand, and South Africa (CKD assembly).

🏆 Awards & Recognition

Performance Reviews:

Consistently praised by automotive journalists for its engaging driving dynamics, comfortable ride, and refined powertrains, despite some criticism of the iDrive interface.

Safety Awards:

Achieved top safety ratings in crash tests from organizations like Euro NCAP, reflecting BMW's commitment to occupant safety.