Positioning:
Premium executive sedan and wagon, known for driving dynamics, luxury, and advanced engineering.
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS
Brand Philosophy:
Sheer Driving Pleasure (Freude am Fahren)
Audience:
Do-it-yourself enthusiasts and experienced mechanics seeking comprehensive repair and maintenance information.
Diy Savings:
Enables owners to perform repairs themselves, saving significant money on dealership labor costs.
Covered Models:
BMW 5 Series (E39) 525i, 528i, 530i, 540i Sedan, Sport Wagon
Covered Production Years:
1997, 1998, 1999, 2000, 2001, 2002
Type:
Service Repair Manual
Viewing Requirements:
Adobe PDF Reader
Compatibility:
All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android
Download Type:
Instant Download
Engine Mechanical:
Engine overhaul and rebuilding, timing belt replacement, engine performance, firing orders, serpentine belt routings with diagrams, timing belt service procedures
Brakes:
Brakes, brake servicing procedures
Suspension Steering:
Front end and alignment procedures and specifications, suspension, U-joint and CV-joint service procedures
Transmission:
Transmission removal and installation, transmission in-car servicing
Electrical Electronics:
Wiring diagrams, computer diagnostic trouble tree charts, computer diagnostic codes
Climate Control:
Air conditioning service and capacities
Diagnostics:
Trouble codes, troubleshooting and diagnostics
Repair Procedures:
All diagnostic and repair procedures, step-by-step instructions based on complete disassembly
Maintenance:
Factory maintenance schedules and charts, driving concerns
Engine Rebuilding:
Detailed procedures for engine overhaul and rebuilding.
Drive Shaft Service:
U-joint and CV-joint service procedures covered.
Depth:
Comprehensive: covers everything from basic maintenance to complete engine rebuilds, advanced diagnostics, and detailed troubleshooting.
Diagnostic Tools:
Guidance on interpreting diagnostic trouble codes and using diagnostic tools.
Visuals:
Detailed illustrations, diagrams, wiring schematics, hundreds of photos, vacuum diagrams.
Torque Specifications:
Complete torque specifications provided for all major components and fasteners.
Vacuum Diagrams:
Included
Diagnostic Charts:
Computer diagnostic trouble tree charts included for systematic fault finding.
Engine Options:
Inline-6 (M52/M54 families), V8 (M62 family)
525I Engine Details:
Approx. 2.5L Inline-6, ~189-192 hp, ~232-245 Nm torque (specifics vary by year/market and M52TU/M54B25)
528I Engine Details:
Approx. 2.8L Inline-6 (M52/M52TU), ~193-201 hp, ~280-285 Nm torque
530I Engine Details:
Approx. 3.0L Inline-6 (M54B30), ~225-231 hp, ~300-315 Nm torque
540I Engine Details:
Approx. 4.4L V8 (M62/M62TU), ~282-290 hp, ~440-460 Nm torque
Fuel Delivery:
Multi-point fuel injection (MPI)
Coolant Type:
BMW Blue Antifreeze/Coolant (or equivalent G48/G11)
Transmission Options:
5-speed Manual (Getrag 220 for I6, Getrag 420G for V8), 5-speed Automatic (Steptronic)
Automatic Transmission:
ZF 5HP18, 5HP19 (for I6), ZF 5HP24 (for V8)
Steptronic:
Manual shift mode available on automatic transmissions
Automatic Transmission Fluid:
Dexron III or ATF LT 71141 (for ZF transmissions, check specific application)
NHTSA Rating:
Generally good ratings for its era, though specific year data may vary.
Active Safety:
ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), Traction Control (ASC+T)
Passive Safety:
Front airbags, side airbags (optional/standard depending on trim), front and rear head protection system (HPS) curtain airbags (optional).
Infotainment System:
BMW Professional Radio, optional Navigation System (Mk III/IV), optional Hi-Fi or Harman Kardon sound systems.
Driver Assistance Features:
Cruise control, parking sensors (PDC - Park Distance Control), optional Xenon headlights with washers.
Connectivity Features:
Optional BMW Assist telematics system, Bluetooth hands-free connectivity (later models/options).
Oil Change Interval:
BMW Condition Based Service (CBS) system. Typically around 10,000-15,000 miles (16,000-24,000 km) or 12-24 months, depending on driving conditions.
Major Service Intervals:
Spark plugs typically at 60,000-100,000 miles, coolant flush at 3-5 years or specific mileage.
Engine Oil Specification:
SAE 5W-30 or 5W-40 synthetic oil meeting BMW LL-01 or LL-04 specifications (check specific model and year).
Coolant Capacity:
Approx. 9.5-10.5 liters (depending on engine and oil cooler)
Common Issues:
Cooling system (water pump, thermostat, hoses), VANOS system (variable valve timing), VANOS oil line leaks, oil separator/crankcase ventilation (CCV) system, rear subframe bushings, ABS/DSC sensor failures, pixelation on instrument cluster/radio displays, window regulator failures.
Brand History:
Bayerische Motoren Werke AG, founded 1916, renowned for luxury, performance, and engineering excellence.
E39 Generation:
The E39 generation succeeded the E34 and was produced from 1995 to 2003 (with the final facelift in 2000). It represented a significant leap in refinement, technology, and driving dynamics.
Production Period:
1995-2003 (International); 1997-2002 covered by this manual.
Manufacturing Locations:
Dingolfing, Germany; Rosslyn, South Africa; Regensburg, Germany; Graz, Austria (Magna Steyr for wagons)
