Positioning:
The 2007 BMW 525i (E60) represented BMW's mid-size executive sedan, known for its blend of luxury, performance, and advanced technology. This manual targets owners and independent repair shops seeking professional-level diagnostic and repair information.
Competitors:
Competed against vehicles like the Mercedes-Benz E-Class, Audi A6, Lexus GS, and Cadillac CTS. The 525i emphasized driving dynamics and technological integration.
Model Highlights:
Iconic BMW handling, sophisticated interior, powerful inline-six engine, advanced iDrive infotainment system, and a focus on driver engagement.
Engine Mechanical:
Engine assembly, cylinder head, valvetrain, pistons, crankshaft, lubrication system, cooling system.
Engine Electrical:
Ignition system, fuel injection, engine management (DME), emissions control, sensors, actuators.
Transmission:
Manual and Automatic transmission disassembly, assembly, diagnosis, repair, fluid specifications.
Drivetrain:
Driveshafts, differential, axles, wheel bearings.
Suspension:
Front and rear suspension components, struts, shocks, control arms, anti-roll bars, bushings.
Brakes:
Brake system components, ABS, DSC, brake fluid, pads, rotors, calipers, hydraulic lines.
Steering:
Power steering system, steering rack, tie rods, steering column.
Electrical System:
Battery, charging system, starter, lighting, power windows, locks, mirrors, wipers, horns.
Body And Chassis:
Body panels, doors, hood, trunk, bumpers, chassis components, corrosion protection.
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair, refrigerant handling.
Interior Trim:
Dashboard, seats, carpets, headliner, interior panels, airbag system safety precautions.
Diagnostics:
OBD-II diagnostics, fault code interpretation, troubleshooting procedures.
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and top-offs, belt inspection and replacement, spark plug replacement.
Repair Procedures:
Component removal and installation, rebuild procedures for major sub-assemblies.
Troubleshooting:
System-specific troubleshooting guides based on symptoms and fault codes.
Diagnostic Procedures:
Step-by-step diagnostic routines for electrical and mechanical systems.
Alignment And Adjustment:
Wheel alignment specifications, steering system adjustments.
Safety Precautions:
Proper procedures for working with high-voltage systems, airbags, and hazardous materials.
Depth:
Full mechanical and electrical repair and diagnosis, including component-level troubleshooting and rebuilding.
System:
iDrive infotainment system with integrated navigation, radio, CD player, and climate control.
Display:
Central dashboard display controlled via the iDrive rotary controller and buttons.
Features:
Optional: Adaptive Cruise Control (ACC), Head-Up Display (HUD), Parking Distance Control (PDC), Xenon Adaptive Headlights.
Options:
Bluetooth connectivity for phone calls (optional), USB interface for audio playback (later production or optional).
Oil Change Interval:
Variable, based on 'Condition Based Service' (CBS) system, typically around 10,000-15,000 miles or 12-24 months.
Spark Plug Replacement:
Approximately 60,000 miles.
Brake Fluid Flush:
Every 2 years regardless of mileage.
Coolant Flush:
Initial at 100,000 miles, then every 30,000-50,000 miles thereafter (BMW Blue coolant recommended).
Engine Oil Spec:
BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) compliant synthetic oil, typically 0W-30 or 5W-30.
Engine Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change.
Coolant Type:
BMW Blue Antifreeze/Coolant
Power Steering Fluid:
BMW ATF Dexron III/VI or Pentosin CHF 11S (check specific VIN for exact type).
Common Problems:
Oil pan gasket leaks, valve cover gasket leaks, CCV system failure (leading to rough idle and oil consumption), VANOS solenoid issues, water pump failures (often electric on later models), coolant expansion tank leaks, ignition coil failures.
E60 Specific Issues:
Early E60 models had some electronic gremlins with the iDrive system and various control modules. Some models experienced front suspension component wear (e.g., bushings, ball joints) due to weight and chassis design.
Brand Focus:
BMW has a long-standing reputation for producing performance-oriented luxury vehicles with a focus on driving dynamics ('The Ultimate Driving Machine').
E60 Introduction:
The E60 generation of the 5 Series was introduced for the 2004 model year, succeeding the E39. It featured a significant redesign with a more modern and aerodynamic profile, and the introduction of the iDrive system.
E60 Mid-Cycle Refresh:
A significant facelift occurred for the 2008 model year, but the 2007 model year represents the pre-facelift E60 with its distinctive styling cues.
Production Period:
2004-2010 (E60/E61 generation)
Manufacturing Locations:
Primary manufacturing was at BMW's Dingolfing plant in Germany.
