BMW 525xi Complete Workshop Service Repair Manual 2006 2007

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🏷️ Basic Information Identification Make: BMW Model: 525xi Model Code: E60/E61 Production Years: 2006-2007 👋 Introduction Market Position Segment: Executive Sedan/Wagon Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS Key Features...

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Description

🏷️ Basic Information

Identification

Make:

Model:

525xi

Model Code:

E60/E61

Production Years:

2006-2007

👋 Introduction

Market Position

Segment:

Executive Sedan/Wagon

Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS

Key Features

Chassis:

E60 (Sedan) / E61 (Touring/Wagon)

Drivetrain Type:

All-Wheel Drive (xDrive)

Design Philosophy:

Sporty luxury, driver-centric cockpit, advanced technology

📋 Manual Details

Coverage Areas

Manual Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable PDF

Page Count

Estimated Pages:

2000+

📖 Manual Coverage

Systems Covered

Engine:

BMW N52B30 3.0L Inline-6

Transmission:

6-speed manual (GS6-37BZ), 6-speed automatic (GA6HP19Z)

Drivetrain:

xDrive All-Wheel Drive System

Suspension:

Front: Independent Double Wishbone; Rear: Independent Multi-link

Brakes:

Front: Ventilated Discs; Rear: Ventilated Discs, ABS, DSC

Steering:

Hydraulic Power Steering

Electrical:

Comprehensive wiring diagrams, ECU functions, sensor diagnostics

Body:

Exterior panels, interior trim, doors, glass, bumpers, chassis

HVAC:

Climate control system, A/C, heating, ventilation

Fuel System:

Fuel pump, injectors, fuel pressure regulation

Exhaust System:

Catalytic converters, mufflers, exhaust manifold

Cooling System:

Radiator, water pump, thermostat, hoses

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, brake fluid flush

Engine Repair:

Overhaul, component replacement (pistons, valves, timing chain), gasket seals

Transmission Repair:

Clutch replacement, automatic transmission service and overhaul, torque converter

Brake Service:

Pad/rotor replacement, caliper overhaul, ABS component testing

Electrical Diagnostics:

Troubleshooting electrical faults, module programming, sensor calibration

Suspension And Steering:

Component replacement (shocks, struts, control arms, tie rods), alignment procedures

Body And Interior:

Panel replacement, trim removal, door mechanism repair, glass installation

HVAC Service:

Refrigerant charging, leak detection, component replacement (compressor, evaporator)

Fuel System Diagnostics:

Injector testing, fuel pump pressure checks, fuel filter replacement

Cooling System Repair:

Leak testing, component replacement (water pump, thermostat), coolant flush

Technical Depth

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and complex faults, OBD-II codes interpretation

Repair Techniques:

Detailed instructions for component removal, installation, and adjustment, including torque specifications

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, color-coded and detailed

Specifications And Tolerances:

Precise measurements, clearances, and tolerances for all mechanical components

Special Tools:

Identification and usage instructions for BMW-specific tools required for certain repairs

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text

Print Quality

Resolution:

High resolution, suitable for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

N52B30

Engine Type:

Naturally Aspirated Inline-6

Displacement:

2996 cc (3.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

10.7:1

Performance

Horsepower:

255 hp @ 6600 rpm

Torque:

236 lb-ft @ 2750 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), DISA intake manifold

Fuel Type:

Premium Unleaded Gasoline (91 Octane Recommended)

Engine Management

ECU Type:

Bosch DME (Digital Motor Electronics)

Valvetrain

System:

Double Overhead Camshafts (DOHC), 24 Valves, VANOS, Valvetronic

🔧 Transmission

Standard

Type:

6-Speed Manual (GS6-37BZ)

Optional

Type:

6-Speed Steptronic Automatic (GA6HP19Z)

Features

Drivetrain Configuration:

xDrive All-Wheel Drive

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-2 (or equivalent)

Automatic Transmission Fluid:

BMW ATF LT-3 (or equivalent)

Differential Fluid

Front And Rear Differentials:

BMW Hypoid Gear Oil G2 (or equivalent)

📐 Dimensions

Exterior

Length E60:

191.1 in (4853 mm)

Length E61:

193.1 in (4905 mm)

Width:

72.4 in (1839 mm)

Height:

57.9 in (1471 mm)

Wheelbase:

116.4 in (2956 mm)

Interior

Passenger Volume:

98.0 cu ft (2775 L)

Cargo

Trunk Volume E60:

14.0 cu ft (396 L)

Cargo Volume E61:

25.1 cu ft (711 L) / 56.4 cu ft (1600 L) with rear seats folded

Weights

Curb Weight Manual:

3858 lbs (1750 kg)

Curb Weight Automatic:

3913 lbs (1775 kg)

Gross Vehicle Weight Rating:

5027 lbs (2280 kg)

Wheels And Tires

Wheel Bolt Pattern:

5x120

Standard Wheel Size:

17 x 8.0 inches

Standard Tire Size:

225/50R17

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

5-Star (Driver & Passenger)

IIHS Side Impact:

Active Features

Traction Control:

Dynamic Traction Control (DTC)

Stability Control:

Dynamic Stability Control (DSC)

Braking System:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)

Passive Features

Airbags:

Front, Side-Curtain, Knee Airbags

Seatbelts:

Pretensioners and force limiters

💡 Technology Features

Infotainment

Head Unit:

iDrive infotainment system (CCC generation)

Display Size:

6.5-inch or 8.8-inch central LCD screen

Navigation:

Optional Professional navigation system

Audio:

AM/FM stereo, CD player, optional SiriusXM satellite radio, Logic7 premium audio system.

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC)

Adaptive Cruise Control:

Optional Active Cruise Control (ACC)

Headlights:

Standard Xenon headlights with adaptive feature

Connectivity

Bluetooth:

Optional Bluetooth hands-free interface

Auxiliary Input:

Standard AUX input for audio devices

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000 - 15,000 miles or 12 months, depending on driving conditions (indicated by Condition Based Service - CBS).

Brake Fluid Flush:

Every 2 years

Engine Air Filter:

Inspect every 30,000 miles, replace as needed.

Cabin Air Filter:

Inspect every 15,000 miles, replace as needed.

Spark Plugs:

Typically around 60,000 - 100,000 miles, depending on type.

Transmission Fluid Service:

Recommended every 60,000-100,000 miles for automatic transmissions (lifetime fill often cited, but fluid degrades).

Fluid Specifications

Engine Oil:

SAE 5W-30 Synthetic, BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) approved.

Engine Oil Capacity:

6.5 US quarts (6.2 Liters)

Coolant:

BMW Blue Antifreeze/Coolant (G48) or equivalent, mixed 50/50 with distilled water.

Power Steering Fluid:

Pentosin CHF 11S or equivalent.

Known Issues

Valve Cover Gasket Leaks:

Common on N52 engines, leading to oil consumption and smell.

Oil Pan Gasket Leaks:

Another common source of oil leaks.

Crankcase Ventilation System:

Clogged PCV valve or hoses can cause rough running and leaks.

Water Pump And Thermostat:

Can fail prematurely, leading to overheating.

Transmission Bottles:

Oil leaks from the transmission cooler lines on automatic transmissions.

Window Regulators:

Can fail, preventing windows from operating.

Headlight Ballasts:

Xenon headlight system components can fail.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

Established in 1916, renowned for performance, luxury, and driving dynamics.

Model Evolution

E60 Generation:

Fourth generation of the BMW 5 Series, introduced in 2003. The E60/E61 represented a significant departure in design and technology from its E39 predecessor.

525Xi Positioning:

Mid-tier model in the 5 Series lineup, offering a balance of performance and luxury with the added benefit of all-wheel drive for enhanced traction in various conditions.

Production

Manufacturing Locations:

Main production facility: Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Car And Driver Best 10:

E60 generation models frequently appeared on Car and Driver's 10Best list during its production run for overall excellence.

Ward Auto Worlds 10 Best Engines:

The N52 engine received accolades for its smoothness and technology.

Ratings

Consumer Reports Reliability:

Mixed reliability ratings, with certain components known to require attention. This manual is crucial for addressing common wear items.