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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...
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BMW 535i Complete Workshop Service Repair Manual 2008 2009 2010
🏷️ 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 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.
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