1997-2002 BMW 5 series E39 525i 528i 530i 540i Factory Service Repair Manual 1998 1999 2000 2001

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002 Specific Models Covered: 525i, 528i, 530i, 540i 👋 Introduction...

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Type: Car

Vendor:

Sku: 319001

Tags: 1997 1998 1999 2000 2001 2002 5 Series 525i 528i 530i 540i BMW Car Cars

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Years Covered:

1997, 1998, 1999, 2000, 2001, 2002

Specific Models Covered:

525i, 528i, 530i, 540i

👋 Introduction

Market Position

Segment:

Executive Sedan

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (S160)

Key Features

Platform Philosophy:

Sporty handling, refined comfort, advanced engineering

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

ENGLISH

File Format:

PDF/ZIP

Compatibility:

WIN/MAC/LINUX

Availability:

Instant Download

📖 Manual Coverage

Systems Covered

General Data And Maintenance:

Included

Engine:

Included

Transmission:

Included

Suspension:

Included

Steering:

Included

Brakes:

Included

Body:

Included

Body Equipment:

Included

Equipment And Accessories:

Included

Procedures Included

Repair Procedures:

Comprehensive

Service Procedures:

Comprehensive

Technical Depth

Depth:

Factory level, suitable for DIY and professional mechanics

📊 Manual Specifications

File Specifications

File Type:

Compression Format:

Software Requirement:

Unzipping software (e.g., WinRAR)

⚙️ Engine Specifications

Primary Engine 525I

Engine Code:

M54B25 (from late 2000) / M52TU B25

Displacement:

2.5 Liters (2494 cc)

Configuration:

Inline 6-cylinder, DOHC, 24 valves

Horsepower Approx:

189 hp @ 6000 rpm (M54B25)

Torque Approx:

236 lb-ft @ 3500 rpm (M54B25)

Primary Engine 528I

Engine Code:

M52TU B28

Displacement:

2.8 Liters (2793 cc)

Configuration:

Inline 6-cylinder, DOHC, 24 valves

Horsepower Approx:

190 hp @ 5500 rpm

Torque Approx:

206 lb-ft @ 3950 rpm

Primary Engine 530I

Engine Code:

M54B30

Displacement:

3.0 Liters (2979 cc)

Configuration:

Inline 6-cylinder, DOHC, 24 valves

Horsepower Approx:

225 hp @ 6000 rpm

Torque Approx:

214 lb-ft @ 3500 rpm

Primary Engine 540I

Engine Code:

M62TU V8

Displacement:

4.4 Liters (4398 cc)

Configuration:

V8, DOHC, 32 valves

Horsepower Approx:

290 hp @ 5400 rpm

Torque Approx:

324 lb-ft @ 3600 rpm

Performance

Valvetrain:

Double Overhead Camshaft (DOHC), 4 valves per cylinder

Fuel System:

Multi-point Fuel Injection (MPI)

Engine Management:

Siemens MS42/MS43 ECU (varied by model year and engine)

🔧 Transmission

Standard Transmission

525I/528I/530I:

5-speed Manual (e.g., Getrag 260/5 or 420G)

540I:

5-speed Automatic (e.g., ZF 5HP30)

Optional Transmission

525I/528I/530I:

5-speed Automatic (e.g., ZF 5HP18/5HP19)

540I:

6-speed Manual (e.g., ZF S6-40Z)

📐 Dimensions

Exterior

Length Approx:

188.2 inches (4780 mm)

Width Approx:

70.2 inches (1783 mm)

Height Approx:

57.3 inches (1455 mm)

Wheelbase Approx:

111.4 inches (2830 mm)

Weights

Curb Weight Range Approx:

3500 - 3900 lbs (1588 - 1769 kg) depending on model and configuration

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (1997-1998 models)

NHTSA Front Impact Passenger:

4 Stars (1997-1998 models)

IIHS Side Impact:

Acceptable (models with optional side airbags)

Active Features

Brakes:

4-wheel Anti-lock Braking System (ABS), vented discs front/rear

Traction Control:

Dynamic Stability Control (DSC) on most models

Passive Features

Airbags:

Front dual airbags, optional front side airbags

Body Structure:

Reinforced passenger cell, crumple zones

💡 Technology Features

Infotainment

Navigation:

Optional factory navigation system (CCC later replaced by iDrive in later generations).

Audio System:

High-fidelity BMW Professional radio, optional CD changer, Harman Kardon sound system.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Assistance:

Optional rear parking sensors (Park Distance Control - PDC).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500-10,000 miles or 1 year, depending on driving conditions and oil quality (refer to manual for specific recommendations based on CBS).

Coolant Change Interval:

BMW Longlife coolant, often recommended for 30,000-60,000 miles or as per condition monitoring.

Spark Plug Replacement:

Varies by engine and spark plug type; typically 60,000-100,000 miles.

Fluid Specifications

Engine Oil Specification M54:

API SJ/SL, ACEA A3/B3 or A3/B4, SAE 5W-30 or 5W-40 (BMW LL-01 approved preferred)

Engine Oil Specification M62Tu:

API SJ/SL, ACEA A3/B3 or A3/B4, SAE 5W-40 (BMW LL-01 approved preferred)

Transmission Fluid Automatic Zf:

ZF LifeguardFluid 5 (or equivalent Dexron III/Mercon equivalent if specified in older manuals)

Transmission Fluid Manual:

SAE 75W-90 GL-4 or GL-5

Brake Fluid Specification:

DOT 4

Known Issues

Cooling System:

Plastic coolant expansion tanks prone to cracking, water pump failures, thermostat housing leaks.

Suspension:

Control arm bushings, thrust arms, ball joints, rear subframe bushings wear out.

Electrical:

Window regulators, door lock actuators, VANOS solenoid issues, ABS/DSC sensor failures.

Engine:

Oil separator (CCV) system clogging (M54), valve cover gasket leaks, oil pan gasket leaks.

📚 Vehicle History

Brand Heritage

Manufacturer:

Bayerische Motoren Werke AG (BMW)

Model Evolution

E39 Introduction:

Launched in 1995 (for the 1996 model year in Europe, 1997 in North America) as the successor to the E34.

E39 Facelift:

Mid-cycle refresh (LCI) introduced in 2000, featuring updated headlights (Angel Eyes), taillights, bumpers, and revised interior/engine options.

Production

Production Period:

1995-2003 (sedan), 1996-2004 (touring)

Production Locations

Primary Assembly:

Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Named to Car and Driver's 10Best list multiple times during its production run.