I have BMW 525 D E60, 2004, 177 hp. My father lost the first key and we’re currently using the 2nd key. I bought a blank key and a local locksmith cut it . We’re able to lock/unlock the door manually, but nothing else, which is kinda expected, because I haven’t programmed it. For only program one or even 10 CAS2 keys, Autohex II is soothing luxury. Xhorse VVDI2 is verified working by an increasing number of users and its price drops down to 1186 EUR. Yanhua Mini ACDP is the cheapest working one and the price is less than 800EUR.
1st option: Expensive one Autohex II
Buy Autohex II BMW Full Package tool and program the key yourself. I guarantee you can do it by obd! I am 100% sure it is a very good tool but not worth to buy just for 1 car (also not worth for 10 cars).
2nd option: Xhorse VVDI2
I have BMW key with CAS2 and I make key in 2 minutes if cas 2 or cas 3 with Xhorse VVDI2 tool. If cas3+ then need around 15 minutes. I was making keys on all versions.
no need to remove cas on this car it is very simple 2 minutes job with vvdi2 tool. You can buy tool for 1186 EUR for sale
Look this Google search – BMW FLASH Digital Kaos
7 pages with ask for help for BMW CAS modules – almost all of them after use VVDI2 and other Chinese tools by OBD
Also, you’d better read some locksmiths’ option : Your Cas module is able to do via OBD but safest way is removing and direct connection with some tool for that job.
3rd option: Yanhua Mini ACDP BMW package
Besides, Yanhua Mini ACDP BMW package is also a decent key programmer for BMW all systems (CAS1 -4+, FEM & BDC) and its price is less than 800USD.
Read this article which lists what BMW immobilizer system ACDP works with:
Hope it helps.