Segment:
Executive/Mid-size Luxury Sedan
Target Audience:
Discerning buyers seeking a blend of performance, luxury, and advanced engineering.
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type.
Driving Dynamics:
Renowned for its balanced chassis, precise steering, and engaging driving experience ('The Ultimate Driving Machine').
Interior Appointments:
High-quality materials, ergonomic design, comfortable seating, advanced (for its time) features like iDrive (later models) and premium audio options.
Powertrain Refinement:
Smooth inline-six engines known for their power delivery and durability.
Engine Mechanical:
Engine construction, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel injection system, ignition system, exhaust system, engine diagnostics, performance tuning.
Transmission Manual:
Clutch, gearbox disassembly and assembly, shifting mechanisms, driveshafts, differential.
Transmission Automatic:
Torque converter, valve body, planetary gear sets, hydraulic control systems, electronic control unit (ECU) interface, diagnostic procedures.
Brakes:
Hydraulic system, ABS (Anti-lock Braking System) components and diagnostics, brake pads, rotors, calipers, brake lines, parking brake.
Suspension:
Front and rear suspension components (struts, shock absorbers, control arms, bushings, sway bars), steering system (power steering rack, pump, hoses), wheel alignment specifications.
Electrical System:
Battery, alternator, starter motor, wiring diagrams, lighting system (headlights, taillights, interior), fuse box layout, relays, diagnostic connector (OBD-II).
Climate Control:
HVAC system operation, refrigerant charging, blower motor, A/C compressor, heater core, climate control module diagnostics.
Body And Interior:
Body panel removal and installation, door mechanisms, windows, seats, dashboard, trim panels, convertible top (if applicable, though not for 525i E39), sound deadening.
Safety Systems:
Airbag system (SRS - Supplemental Restraint System) components, sensors, control module, seatbelt mechanisms.
Routine Maintenance:
Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid level checks and top-offs, tire rotations, brake inspections.
Repair And Overhaul:
Engine rebuild procedures, transmission overhaul, suspension component replacement, brake system repairs, cooling system repairs, fuel system servicing, electrical component replacement.
Diagnostics And Troubleshooting:
Step-by-step troubleshooting guides for common and uncommon issues, diagnostic trouble codes (DTCs) interpretation, use of diagnostic tools (e.g., BMW GT1, INPA).
Special Tools:
Identification and usage instructions for specialized BMW tools required for specific repairs.
Wiring Diagrams:
Detailed electrical schematics for all major systems.
Depth:
Comprehensive: Covers everything from basic fluid checks and filter replacements to full engine and transmission overhauls, advanced electrical diagnostics, and bodywork.
NHTSA Front Impact:
Not explicitly rated by NHTSA for this specific year/model in available records, but generally considered strong for its era.
IIHS Side Impact:
Not explicitly rated by IIHS for this specific year/model in available records.
ABS:
Standard Anti-lock Braking System
Asc:
Optional Automatic Stability Control (ASC+T)
Traction Control:
Available
Airbags:
Frontal airbags for driver and passenger, optional side-impact airbags.
Seatbelts:
3-point inertia-reel seat belts with pretensioners and force limiters
Chassis Design:
Reinforced safety cell, crumple zones.
Oil Change Interval:
Every 7,500 - 15,000 miles (12,000 - 24,000 km) or annually, depending on driving conditions and oil type used (BMW's Condition Based Service - CBS system).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as per CBS.
Cabin Filter Replacement:
Every 15,000 miles (24,000 km) or annually.
Spark Plug Replacement:
Every 60,000 - 100,000 miles (96,000 - 160,000 km) for long-life iridium plugs (check specific plug type).
Engine Oil:
BMW Longlife-98 (LL-98) or Longlife-01 (LL-01) approved synthetic oil, SAE 5W-30 or 5W-40 recommended.
Coolant:
BMW Blue Antifreeze/Coolant (G48) or equivalent, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 (ISO 4925 Class 4) synthetic brake fluid. Replace every 2 years.
Common Problems:
Vibration issues (driveshaft flex disc, guibo), cooling system leaks (water pump, thermostat housing, hoses), ABS/DSC sensor failures, VANOS system (variable camshaft timing) issues, oil pan gasket leaks, headliner sagging, pixelation on instrument cluster/radio displays.
Repair Focus:
The manual will provide detailed procedures for addressing these common issues, including diagnostic steps and parts replacement instructions.
Brand Focus:
BMW has a long-standing reputation for engineering excellence, performance, and luxury automobiles.
E39 Introduction:
The E39 generation of the 5 Series was introduced in 1995 (1996 model year in North America) and ran until 2003.
E39 Facelift:
Facelifted in 2000 (for the 2001 model year), featuring updated headlights (angel eyes), taillights, bumpers, and interior refinements.
Production Years Covered:
1997-2002 (specific to this manual)
Manufacturing Locations:
Primarily Dingolfing, Germany; also plants in Austria, Mexico, and Egypt.
