BMW 535xi Complete Workshop Service Repair Manual 2007 2008 2009 2010

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🏷️ Basic Information Identification Make: BMW Model: 535xi Model Generation: E60/E61 Model Years Covered: 2007, 2008, 2009, 2010 Chassis Codes: E60 (Sedan), E61 (Touring/Wagon) Powertrain Variant: xi (xDrive All-Wheel Drive)...

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标签: 2007 2008 2009 2010 535xi BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

535xi

Model Generation:

E60/E61

Model Years Covered:

2007, 2008, 2009, 2010

Chassis Codes:

E60 (Sedan), E61 (Touring/Wagon)

Powertrain Variant:

xi (xDrive All-Wheel Drive)

👋 Introduction

Market Position

Segment:

Executive Sedan/Wagon

Brand Image:

Luxury, performance, driving dynamics, technological innovation.

Competitive Analysis

Primary Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Cadillac CTS.

Key Features

Drivetrain:

Standard xDrive All-Wheel Drive for enhanced traction and stability.

Engine Technology:

Twin-turbocharged inline-six engine (N54) known for its power and responsiveness.

Infotainment:

Advanced iDrive system offering navigation, entertainment, and vehicle settings control.

Driving Dynamics:

Sport-tuned suspension, precise steering, and balanced chassis contribute to signature BMW driving feel.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain:

Yes (xDrive)

Suspension:

Brakes:

Steering:

Electrical System:

Body And Chassis:

Climate Control:

Infotainment System:

Diagnostic Troubleshooting:

Maintenance Schedules:

Wiring Diagrams:

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, rebuild procedures, torque specifications, component testing.

Engine Management:

Fuel injection, ignition system, emissions control, engine sensors and actuators, ECU diagnostics.

Transmission Automatic:

Fluid changes, transmission overhaul, torque converter, valve body diagnosis, electronic controls.

Transfer Case:

Service and repair procedures for the xDrive all-wheel-drive system, fluid specifications.

Suspension Front:

Struts, control arms, bushings, wheel bearings, alignment specifications.

Suspension Rear:

Multi-link suspension, shock absorbers, bushings, wheel alignment.

Steering System:

Power steering pump, steering rack, tie rods, steering column, alignment.

Brake System Front:

Disc brake pad replacement, caliper service, rotor replacement, ABS component location.

Brake System Rear:

Disc brake pad replacement, caliper service, rotor replacement, parking brake mechanism.

Body Exterior:

Panel removal and installation, door mechanisms, hood, trunk, bumpers, glass replacement.

Body Interior:

Seat removal, dashboard disassembly, trim panel removal, interior lighting.

Heating Ventilation Air Conditioning HVAC:

Compressor service, refrigerant charging, evaporator and heater core replacement, blower motor.

Lighting System:

Headlights, taillights, interior lights, bulb replacement, ballast diagnostics.

Instrument Panel:

Gauge cluster removal and repair, indicator lights, warning systems.

Audio Visual System:

Radio removal, speaker replacement, iDrive system troubleshooting, amplifier servicing.

Comfort Systems:

Power seats, sunroof operation, keyless entry, central locking.

Safety Systems Airbags:

Airbag module replacement, sensor diagnostics, seat belt pre-tensioners.

Safety Systems ABS Dsc:

ABS/DSC module diagnostics, wheel speed sensors, hydraulic unit repair.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement.

Major Engine Repair:

Head gasket replacement, piston and ring replacement, crankshaft and camshaft servicing.

Transmission Service:

Fluid and filter replacement, internal component repair, mechatronics unit diagnosis.

Brake Replacement:

Front and rear brake pad and rotor replacement, brake fluid flush and bleeding.

Suspension Repair:

Component replacement (struts, control arms, ball joints), wheel bearing replacement.

Electrical Diagnostics:

Troubleshooting electrical faults, using diagnostic tools, component testing.

Body Repair:

Dent removal, panel alignment, door and window regulator repair.

Ac System Service:

Refrigerant recovery and charging, leak detection, component replacement.

Troubleshooting Guides:

Systematic fault finding for common and complex issues, diagnostic trouble codes (DTCs).

Torque Specifications:

Detailed torque values for all critical fasteners.

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine and transmission rebuilds).

📊 Manual Specifications

File Format

Format:

Searchable Text:

Printable:

Print Quality

Quality:

High-resolution scans with clear diagrams and text.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

N54B30

Engine Type:

3.0L Twin-Turbocharged Inline-6

Displacement:

2979 cc (181.7 cu in)

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 (407 Nm) @ 1400-5000 rpm

Fuel System

Fuel Delivery:

Direct Injection (High-Pressure Fuel Injection)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Oil Type:

SAE 5W-30 Synthetic (BMW Longlife-01 or LL-01FE approved)

Engine Oil Capacity

Capacity With Filter:

6.9 US quarts (6.5 liters)

🔧 Transmission

Standard

Type:

6-speed Manual Transmission (SMG availability for some markets/years not detailed here, but this manual covers the core 535xi)

Optional

Type:

6-speed Automatic Transmission (with Steptronic and paddle shifters)

Features

Drivetrain System:

xDrive All-Wheel Drive (Active Intelligent AWD System)

Transmission Fluid Type

Automatic:

BMW ATF LT-5 or equivalent (check specific vehicle VIN for exact specification)

Transmission Fluid Capacity

Automatic:

Approximately 9.5 US quarts (9.0 liters)

📐 Dimensions

Exterior E60

Length:

191.1 inches (4855 mm)

Width:

72.7 inches (1847 mm)

Height:

58.0 inches (1473 mm)

Exterior E61

Length:

192.4 inches (4887 mm)

Width:

72.7 inches (1847 mm)

Height:

57.3 inches (1455 mm)

Wheelbase

Wheelbase:

116.4 inches (2956 mm)

Wheel Bolt Pattern:

5x120 mm

Center Bore:

72.5 mm

Weights

Curb Weight Approx:

4000-4200 lbs (1814-1905 kg), varies by configuration.

Cargo E60

Trunk Volume:

14.0 cu ft (396 liters)

Cargo E61

Cargo Volume Seats Up:

27.9 cu ft (790 liters)

Cargo Volume Seats Down:

60.6 cu ft (1715 liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (2007 Model Year)

NHTSA Front Impact Passenger:

5-Star (2007 Model Year)

NHTSA Side Impact Front Seat:

5-Star (2007 Model Year)

NHTSA Side Impact Rear Seat:

5-Star (2007 Model Year)

IIHS Top Safety Pick:

Yes (for various model years within this range, subject to specific testing criteria)

Active Features

Traction Control:

Dynamic Traction Control (DTC), Dynamic Stability Control (DSC), xDrive AWD.

Braking Assistance:

Anti-lock Braking System (ABS), Brake Assist.

Passive Features

Airbags:

Front airbags, front side-impact airbags, head protection system (curtain airbags).

Seat Belts:

Pre-tensioning seat belts with force limiters.

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for Children).

💡 Technology Features

Infotainment

System Name:

iDrive (CCC or CIC depending on production date and options)

Features:

Navigation, climate control, audio system, Bluetooth connectivity, vehicle settings management.

Display Type:

Central LCD screen (6.5", 8.8", or 10.2" depending on options).

Driver Assistance

Cruise Control:

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

Parking Assistance:

Front and Rear Park Distance Control (PDC), optional rearview camera.

Lighting Technology:

Xenon Adaptive Headlights with automatic leveling and cornering function.

Connectivity

Bluetooth:

Integrated Bluetooth for hands-free calling and audio streaming.

Usb Aux:

Optional USB/Audio interface for music playback and charging.

🔧 Maintenance

Service Intervals Oil

Engine Oil Change:

Variable Service Interval (Condition Based Service - CBS), typically around 10,000-15,000 miles or 1 year, whichever comes first.

Service Intervals Filters

Engine Oil Filter:

Replace with every oil change.

Engine Air Filter:

Inspect every 15,000-30,000 miles, replace as needed.

Cabin Air Filter:

Replace every 15,000-30,000 miles or annually.

Service Intervals Fluids

Transmission Fluid Auto:

BMW typically lists transmission fluid as 'lifetime' for this era, but regular inspection and change (e.g., 60,000-100,000 miles) is highly recommended for longevity.

Brake Fluid:

Replace every 2 years, regardless of mileage.

Coolant:

BMW Blue Antifreeze/Coolant (G48 specification), typically lasts 4 years or 100,000 miles, then every 2 years.

Fluid Specifications

Power Steering Fluid:

Pentosin CHF 11S or equivalent approved fluid.

Known Issues

N54 Engine Common Problems:

High-pressure fuel pump (HPFP) failure, vacuum leak issues (boost leaks), ignition coil and spark plug issues, oil pan gasket leaks, valve cover gasket leaks.

Electrical Common Problems:

Water pump failure (electric), starter issues, headlight ballast failure, sensor failures (e.g., ABS sensors).

Transmission Common Problems:

Mechatronics unit issues in automatic transmissions, clunking from AWD system due to worn U-joints or transfer case.

Suspension Common Problems:

Worn control arm bushings, strut mounts, and sway bar links leading to noise and poor handling.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

Founded in 1916, renowned for engineering excellence, performance-oriented vehicles, and luxury appointments.

Model Evolution

5 Series History:

The 5 Series represents BMW's mid-size executive offering, evolving through multiple generations to balance sportiness and comfort.

E60 Generation:

The E60 generation (2004-2010) marked a significant design shift under Chris Bangle's influence, introducing advanced technology and a more dynamic chassis.

E60 Introduction Of Xidrive:

The 'xi' designation signified the introduction of BMW's xDrive all-wheel-drive system to the 5 Series, enhancing its appeal in markets with varied weather conditions.

Production

Production Location:

Dingolfing, Germany; Spartanburg, South Carolina, USA (for some variants).

🏆 Awards & Recognition

Recognitions

Ward 2008 10Best Engines:

The N54 engine received the Ward's 10 Best Engines award for its performance and technology.

Consumer Reports:

Generally rated well for driving dynamics and performance, but can have lower predicted reliability ratings for some years/components.

Insurance Institute For Highway Safety IIHS:

Awarded 'Top Safety Pick' for multiple years within this generation, indicating strong crash test performance.