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BMW 525 525i 1997 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 525i Model Variant: 525 Year: 1997 Codes Chassis Code: E39 Engine Code Identifier: M52B25 👋 Introduction Market Position Segment: Executive Sedan Reputation: Renowned...
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UGS: 434757
Mots clés: 1997 525 525i BMW Car Cars Misc
BMW 525 525i 1997 Workshop Repair Service ManualBMW 525 525i 1997 Workshop Repair Service ManualBMW 525 525i 1997 Workshop Repair Service ManualBMW 525 525i 1997 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
525i
Model Variant:
525
Year:
1997
Codes
Chassis Code:
E39
Engine Code Identifier:
M52B25
👋 Introduction
Market Position
Segment:
Executive Sedan
Reputation:
Renowned for driving dynamics, build quality, and advanced engineering for its era
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C4/C5), Lexus GS, Jaguar S-Type
Key Features
Driving Dynamics:
Rear-wheel drive, balanced chassis, responsive steering
Powertrain Refinement:
Smooth inline-six engine, characteristic BMW performance
Build Quality:
Solid construction, high-quality interior materials
📋 Manual Details
Coverage Areas
Engine:
All variants
Transmission:
All types (Manual, Automatic)
Trim Levels:
All included
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, emissions control
Drivetrain:
Transmission (manual & automatic), clutch, driveshafts, differentials, axles
Chassis:
Suspension (front & rear), steering system, braking system (ABS included), wheels, tires
Electrical:
Battery, starting system, charging system, lighting, instruments, comfort systems, infotainment (basic), body control modules, wiring diagrams
Body:
Body panels, doors, windows, glass, interior trim, HVAC system, exterior trim
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups
Repair:
Engine overhaul, transmission overhaul, brake system repair, suspension component replacement, electrical component diagnosis and repair
Troubleshooting:
Diagnostic procedures, fault code interpretation, symptom-based troubleshooting guides
Diagnostics:
Engine management diagnostics, ABS system diagnostics, component testing
Technical Depth
Depth:
Comprehensive, from basic maintenance to detailed component overhaul and diagnostics
Wiring Diagrams:
Detailed electrical system wiring diagrams included
Torque Specifications:
All critical torque specifications for fasteners
Special Tools:
Identification and usage of specialized BMW tools where applicable
📊 Manual Specifications
File Format
Format:
Searchable PDF
Printability:
Printable pages
Accessibility:
Hyperlinked chapters for easy navigation
Print Quality
Image Resolution:
High-resolution images and diagrams
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Name:
M52B25 (VANOS)
Configuration:
2.5-liter Inline 6-cylinder
Displacement:
2494 cc
Bore X Stroke:
84 mm x 90 mm
Compression Ratio:
10.0:1
Performance
Horsepower:
168 hp @ 5500 rpm
Torque:
181 lb-ft @ 3950 rpm
Fuel System
Fuel Delivery:
Bosch Motronic M5.2 Engine Management System, Sequential Multi-Port Fuel Injection (MPI)
Recommended Fuel:
Premium Unleaded (91 Octane or higher recommended)
Other
Valvetrain:
DOHC (Double Overhead Camshafts), 4 valves per cylinder
Timing:
Double VANOS (Variable Valve Timing on intake and exhaust camshafts)
🔧 Transmission
Standard
Type:
5-speed Manual (Getrag 260/6)
Optional
Type:
5-speed Automatic (ZF 5HP18/5HP19)
Features
Manual:
Hydraulically actuated clutch
Automatic:
Adaptive shift control, Comfort/Sport modes
Fluid Type
Manual Transmission Fluid:
BMW ATF (or equivalent, e.g., Castrol TAF-X / SAF-XO)
Automatic Transmission Fluid:
BMW ATF LT-3 (or equivalent, e.g., Pentosin ATF1)
📐 Dimensions
Exterior
Length:
4,769 mm (187.8 in)
Width:
1,799 mm (70.8 in)
Height:
1,436 mm (56.5 in)
Wheelbase:
2,830 mm (111.4 in)
Weights
Curb Weight:
1,530-1,580 kg (3,373-3,483 lbs) depending on options
Gross Vehicle Weight Rating:
Approx. 2,070 kg (4,564 lbs)
Cargo
Trunk Volume:
460 L (16.2 cu ft)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (for comparable models/years)
IIHS Offset Crash Test:
Good (for comparable models/years)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Automatic Stability Control (ASC+T)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners
Body Structure:
Reinforced passenger cell, crumple zones
💡 Technology Features
Infotainment
Radio:
Factory AM/FM stereo with cassette player and CD changer option. BMW Professional RDS sound system available.
Navigation:
Optional BMW Business or Professional Navigation System with CRT screen.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Sensors:
Optional rear Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional integrated mobile phone preparation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles (12,000-16,000 km) or as indicated by the vehicle's condition-based service (CBS) system.
Spark Plug Replacement:
Approximately every 60,000 to 100,000 miles (96,000-160,000 km) for platinum or iridium plugs, depending on type.
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Transmission Fluid Change:
Manual: 'Lifetime' but recommended every 60,000 miles (96,000 km). Automatic: Recommended every 50,000-60,000 miles (80,000-96,000 km), especially in severe use.
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) or LL-98 approved synthetic oil, typically 5W-30 or 0W-40.
Engine Oil Capacity:
6.5 Liters (6.9 US Quarts)
Coolant:
BMW Blue/Green Coolant (G48) or equivalent ethylene glycol-based coolant with corrosion inhibitors.
Known Issues
Cooling System:
Plastic expansion tank, water pump, and radiator hoses can become brittle and leak over time. Thermostat housing also prone to cracking.
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing gasket are common leak points.
Suspension:
Front control arm bushings and ball joints wear out, leading to knocking noises and imprecise handling. Rear subframe bushings can also deteriorate.
Electrical:
Mass airflow sensor (MAF), idle control valve (ICV), and ABS wheel speed sensors can fail. Pixelated LCD displays in instrument clusters are a common issue.
Interior:
Headliner fabric can sag, door panel vapor barriers can fail causing water leaks into the cabin.
Common Repairs
Vanos Unit:
The VANOS system can develop issues with seals or solenoids, affecting engine performance and idle stability.
Ccv System:
The Crankcase Ventilation (CCV) system can clog, leading to increased oil pressure and leaks.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Long-standing reputation for sporty luxury sedans and advanced engineering.
Model Evolution
E39 Introduction:
The E39 generation replaced the E34 5 Series, launching in 1995 (Europe) and 1996 (North America). Known for significant improvements in chassis dynamics, refinement, and technology over its predecessor.
E39 Generation Characteristics:
Significant emphasis on weight reduction using aluminum in suspension and body components, leading to improved handling and ride comfort. Introduction of advanced electronics and safety features.
Production
Production Years:
1995-2003 (E39 platform)
Manufacturing Locations:
Dingolfing, Germany; Rosslyn, South Africa; Araquari, Brazil; Kaliningrad, Russia
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E39 5 Series (including 525i and 540i variants) was a consistent recipient of Car and Driver's 10Best list during its production years, praised for its handling and balance.
Automotive Journalism:
Widely acclaimed by automotive journalists for its blend of luxury, performance, and handling prowess.
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