🏷️ Basic Information

Make:

BMW

Model:

525i

Model Variant:

525

Year:

1996

Chassis Code:

E39

👋 Introduction

Segment:

Executive Sedan

Target Audience:

Performance-oriented luxury car buyers, DIY enthusiasts, independent repair shops.

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C4/C5), Lexus GS300.

Vehicle Philosophy:

BMW's signature 'Ultimate Driving Machine' ethos, offering a balance of luxury, performance, and driver engagement.

Manual Value Proposition:

Provides detailed, actionable information for owners and technicians to maintain and repair the E39 525i, ensuring longevity and optimal performance.

📋 Manual Details

Regions Covered:

Global (primarily North American and European specifications)

Models Covered:

BMW 525i (E39 chassis), All Engines, All Trim Levels, All Transmission Types

Estimated Page Count:

1500+

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

M50B25 (2.5L Inline-6), Engine mechanical, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system, ignition system, exhaust system, engine management (DME).

Transmission:

Manual (Getrag 260/5 or 260/6) and Automatic (ZF 5HP18, 5HP19). Clutch, gearbox, driveshafts, differentials, torque converter, transmission control.

Brakes:

Front ventilated discs, rear solid discs (standard), ABS (Anti-lock Braking System) including ABS/ASC+T (Automatic Stability Control + Traction) sensors, hydraulic lines, master cylinder, calipers, parking brake.

Suspension Steering:

Front MacPherson struts, rear multi-link independent suspension, control arms, shock absorbers, springs, anti-roll bars, steering rack, power steering system, steering column.

Electrical Electronics:

Battery, alternator, starter motor, wiring diagrams (comprehensive), fuses, relays, lighting system (headlights, taillights, interior), instrument cluster, power windows, mirrors, central locking, OBC (On-Board Computer).

Body Chassis:

Body construction, structural components, doors, hood, trunk lid, bumpers, body panels, rust prevention, jacking points, towing points, chassis identification.

Climate Control:

HVAC system, blower motor, evaporator, condenser, refrigerant circuits, climate control unit, actuators, heater core, air conditioning.

Safety Restraints:

Airbag system (driver and passenger), seat belts, pre-tensioners.

Maintenance:

Routine maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad/rotor replacement, tire rotation.

Troubleshooting:

Diagnostic procedures for engine performance, electrical faults, transmission issues, braking system problems, climate control malfunctions.

Repair:

Detailed step-by-step repair instructions for major components and systems, including engine disassembly/reassembly, transmission overhaul, suspension component replacement, brake caliper rebuilding, electrical component diagnosis and replacement.

Diagnostics:

Fault code reading and interpretation (OBD-II compliant for 1996 models), sensor testing, actuator testing, circuit analysis.

Specification Data:

Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic values.

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, and advanced electrical system diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Text-searchable PDF

Print Option:

Printable

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

M50B25

Engine Type:

Naturally Aspirated Inline-6 (I6)

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

10.0:1

Valvetrain:

Dual Overhead Camshafts (DOHC), 24 valves (4 per cylinder), VANOS (Variable Valve Timing) on intake camshaft.

Horsepower Bhp:

189 bhp @ 5900 rpm

Torque Lb Ft:

181 lb-ft @ 4200 rpm

Fuel Delivery:

Multi-point fuel injection (Bosch Motronic 5.2 DME)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

🔧 Transmission

Transmission Type:

5-Speed Manual (Getrag 260/6)

Transmission Type:

5-Speed Automatic (ZF 5HP18)

Manual Clutch:

Hydraulically actuated single dry plate clutch.

Automatic Control:

Electronic Transmission Control (ETC) with Sport/Comfort modes.

📐 Dimensions

Length:

188.2 inches (4780 mm)

Width:

70.2 inches (1783 mm)

Height:

57.0 inches (1448 mm)

Wheelbase:

111.4 inches (2830 mm)

Curb Weight:

3571 - 3704 lbs (1620 - 1680 kg) depending on transmission

🛡️ Safety Features

NHTSA Front Impact:

4-Star (Driver), 4-Star (Passenger)

IIHS Front Offset:

Good

ABS:

Standard

Traction Control:

ASC+T (Optional on some early models, standard on later ones, often linked with ABS)

Airbags:

Driver and front passenger airbags

Seatbelts:

Front pretensioned seatbelts, rear 3-point seatbelts.

💡 Technology Features

Radio System:

BMW Business CD or Professional RDS radio with cassette player, optional CD changer. Basic analog tuning.

Onboard Computer:

Multi-function OBC with functions like average speed, fuel consumption, range, and diagnostic fault codes.

Cruise Control:

Standard cruise control system.

Telematics:

Pre-wiring for optional cellular telephone integration.

🔧 Maintenance

Oil Change Interval:

Every 7,500 - 10,000 miles or annually, whichever comes first (or per Condition Based Service - CBS indicators).

Spark Plug Replacement:

Approx. 60,000 miles (refer to manual for specific plug type and gap).

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles.

Engine Oil Type:

BMW Longlife-98 specification, SAE 5W-30 or 5W-40 synthetic oil (check owner's manual for exact specification and viscosity for climate).

Engine Oil Capacity:

Approx. 6.5 US quarts (6.2 Liters) with filter change.

Coolant Type:

BMW Blue antifreeze (G48 ethylene glycol based), mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 4

Power Steering Fluid:

BMW ATF Dexron III or equivalent (check specific model year recommendations).

Transmission Fluid Manual:

GL-4 SAE 75W-90 synthetic gear oil.

Transmission Fluid Automatic:

BMW ATF JWS 3309 (or equivalent for ZF 5HP18/19).

Cooling System:

Plastic coolant expansion tank can become brittle and crack; water pump impeller can fail (especially plastic ones); radiator leaks; thermostat housing leaks.

Suspension:

Front lower control arm bushings and ball joints wear out, leading to steering looseness and tire wear; rear subframe bushings can also degrade.

Electrical:

ABS/ASC sensor failures leading to warning lights; headlight/taillight condensation; OBC display pixelation (dead pixels); door seal moisture ingress impacting electronics.

Engine Management:

VANOS solenoid or seal issues can cause rough idle or low-end torque loss; Mass Air Flow (MAF) sensor failures; Ignition coil failures (especially in later years or if not replaced with updated versions).

Interior:

Headliner sagging; dashboard creaks; climate control blower motor resistor failure.

📚 Vehicle History

Bmw Philosophy:

Founded in 1916, BMW has a long history of producing high-quality, performance-oriented vehicles, particularly known for its inline-6 engines and rear-wheel-drive platforms.

E39 Introduction:

The E39 generation of the 5 Series was introduced in 1995 (as a 1996 model year in North America) succeeding the E34. It represented a significant leap in design, technology, and refinement.

E39 525I Positioning:

The 525i served as a mid-range model within the E39 lineup, offering a balance of performance and luxury, positioned below the 528i and 540i.

E39 Production Years:

1995-2003 (Global)

🏆 Awards & Recognition

Car And Driver 10Best:

The E39 generation 5 Series (including variants like the 525i) was frequently recognized on Car and Driver's 10Best lists for its segment-defining handling, refinement, and performance.

Jd Power Initial Quality:

Typically received strong initial quality ratings for its class, reflecting BMW's commitment to build quality.