Segment:
Executive Sedan / Mid-size Luxury Sedan
Reputation:
Known for driving dynamics, build quality, and sophisticated engineering.
Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Cadillac CTS, Volvo S80
Vehicle Appeal:
Balance of performance, comfort, and luxury. Strong driver engagement.
Usefulness:
Provides dealership-level repair and maintenance information, essential for DIY enthusiasts and independent repair shops.
Models Covered:
All E39 5-series models including 525i, 530i, 540i, M5
Regions Covered:
Global (specifications may vary slightly by market)
Estimated Page Count:
1500+
Type:
Factory Service Manual / Repair Manual
Format:
Digital (likely PDF or similar e-format)
Powertrain:
Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, engine management (DME/ECU), clutch, transmission (manual & automatic), drivetrain (driveshafts, differentials), AWD (xDrive if applicable)
Chassis:
Suspension (front & rear), steering system, braking system (ABS, DSC), wheels & tires
Electrical:
Battery, charging system, starting system, lighting (headlights, taillights, interior), instrumentation, body electronics (power windows, locks, mirrors), climate control electronics, infotainment system wiring, SRS airbag system, basic troubleshooting of common electrical faults
Bodywork:
Body panels, doors, hood, trunk, bumpers, exterior trim, interior trim, HVAC system (controls, ducting, actuators), basic body repair procedures
Maintenance:
Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, drive belt replacement, air filter replacement, cabin filter replacement
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics for various systems
Repair:
Component removal & installation, engine rebuilding procedures, transmission overhaul, suspension component replacement, brake caliper/rotor service, electrical component diagnosis and repair, body panel alignment and repair
Specifications:
Torque specifications for all fasteners, fluid capacities and types, electrical system voltages and schematics, component dimensions and tolerances
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and detailed electrical schematics)
Engine Code Common:
M54 (for 525i, 530i), M62 (for 540i)
Engine Type:
Inline-6 (525i, 530i), V8 (540i)
Displacement 525I:
2.5 Liters (2494 cc)
Displacement 530I:
3.0 Liters (2979 cc)
Displacement 540I:
4.4 Liters (4398 cc)
Horsepower 525I:
184 hp @ 6000 rpm
Torque 525I:
175 lb-ft @ 3500 rpm
Horsepower 530I:
225 hp @ 5900 rpm
Torque 530I:
214 lb-ft @ 3500 rpm
Horsepower 540I:
290 hp @ 5400 rpm
Torque 540I:
324 lb-ft @ 3600 rpm
Injection Type:
Electronic Fuel Injection (EFI), Sequential Multi-port Injection (MPI)
Fuel Grade Recommended:
Premium Unleaded (91 octane or higher)
Transmission Type 525I 530I:
5-speed Manual (Getrag S5D 250G)
Transmission Type 540I:
6-speed Manual (Getrag S6S 420G)
Transmission Type 525I 530I:
5-speed Automatic (Steptronic - GM 5L40-E)
Transmission Type 540I:
5-speed Automatic (Steptronic - ZF 5HP30)
Drivetrain:
Rear-Wheel Drive (RWD)
Length:
Approx. 190.6 inches (4841 mm)
Width:
Approx. 71.1 inches (1806 mm)
Height:
Approx. 57.1 inches (1450 mm)
Wheelbase:
Approx. 111.4 inches (2830 mm)
Curb Weight Approx 525I:
3500-3600 lbs (1588-1633 kg)
Curb Weight Approx 540I:
3800-3900 lbs (1724-1769 kg)
NHTSA Front Impact:
5-star (driver and passenger)
IIHS Side Impact:
Good (for vehicles tested)
Traction Control:
Traction Control System (TCS) / Dynamic Stability Control (DSC)
ABS:
Anti-lock Braking System (ABS)
Stability Control:
Standard DSC (Dynamic Stability Control)
Airbags:
Frontal airbags (driver & passenger), side airbags (front occupants), optional head protection airbags (front & rear)
Seatbelts:
3-point seat belts with pretensioners and force limiters
System Name:
BMW Professional Radio, optional Navigation System (MKIV), optional Harman Kardon audio system
User Interface:
iDrive controller introduced later in the E39 lifecycle (around 2001-2002), but many 2004 models still feature the earlier button-based interface or a simpler infotainment screen.
Features:
Cruise Control, Parking Sensors (Park Distance Control - PDC), Xenon Headlights with Halos (optional)
Features:
Onboard Computer, Tele Aid (telematics system, availability varies by market)
Oil Change Interval:
Typically every 7,500-10,000 miles or annually, depending on driving conditions and oil used. BMW's Condition Based Service (CBS) system would monitor this.
Spark Plug Replacement:
M54 engines: ~100,000 miles. M62 engines: ~60,000 miles.
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles.
Engine Oil Type M54:
SAE 5W-30 Synthetic, meeting BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) specification
Engine Oil Type M62:
SAE 5W-40 or 5W-30 Synthetic, meeting BMW Longlife-98 (LL-98) or Longlife-01 (LL-01) specification
Coolant:
BMW Blue or Purple Antifreeze/Coolant (G48 type), mixed 50/50 with distilled water
Brake Fluid:
DOT 4 or DOT 4 PLUS
Transmission Fluid Auto Gm5L40E:
Dexron III or Dexron VI
Transmission Fluid Auto Zf5Hp30:
Esso LT 71141 or equivalent synthetic ATF
Common Failures:
Cooling system (ốn-O-ring failure, water pump, thermostat, expansion tank), VANOS solenoids/seals, oil pan gasket leaks, ABS/DSC sensor failures, ignition coil failures, fuel pump, sagging headliner, CCV system failure (M54), window regulator failures, blower motor resistor.
Maintenance Focus:
Preventative maintenance is key. The manual will detail how to address or prevent these common issues.
Bmw Legacy:
BMW is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, engineering, and driver connection.
E39 Introduction:
The E39 generation of the 5-series debuted in 1995 (for the 1996 model year) and represented a significant evolution in luxury, technology, and chassis dynamics.
E39 Facelift:
The E39 received a facelift in 2000, which included updated headlights (angel eyes), taillights, bumpers, and interior refinements, making the 2004 model a late-stage, highly refined version.
Production Years:
1995-2003 (European launch), 1996-2003 (North American launch). The 2004 model year in North America primarily consisted of remaining 2003 production vehicles, with some minor year-specific updates.
Manufacturing Locations:
Dingolfing, Germany; Spartanburg, South Carolina, USA (for some models).
Car And Driver 10Best:
Car and Driver 10 Best list multiple times during its production run.
Consumer Reports Ratings:
Generally received good to excellent ratings for performance and handling, with mixed reviews on reliability depending on the specific component and maintenance history.
Safety Certifications:
Met all US Federal Motor Vehicle Safety Standards (FMVSS) for 2004.