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1997-2002 BMW 5-Series (E39) 525i 528i 530i 540i Sedan Sport Wagon Workshop Repair & Service Manual (1 002 Pages Searchable iPad-ready)

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🏷️ Basic Information Identification Make: BMW Model: 5-Series Chassis Code: E39 Body Styles: Sedan, Sport Wagon (Touring) Generation Generation: Fourth Generation (E39) Production Years: 1995-2003 (E39 Sedan), 1997-2004 (E39 Touring)...
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Sku: 213649
1997-2002 BMW 5-Series (E39) 525i 528i 530i 540i Sedan Sport Wagon Workshop Repair & Service Manual (1 002 Pages Searchable iPad-ready)
🏷️ Basic Information
Identification
Make:
BMW
Model:
5-Series
Chassis Code:
E39
Body Styles:
Sedan, Sport Wagon (Touring)
Generation
Generation:
Fourth Generation (E39)
Production Years:
1995-2003 (E39 Sedan), 1997-2004 (E39 Touring)
Codes
Specific Models Covered:
525i, 528i, 530i, 540i
👋 Introduction
Market Position
Segment:
Executive Sedan and Wagon
Bmw Positioning:
The E39 represented BMW's commitment to superior driving dynamics, advanced engineering, and luxurious appointments in the mid-size luxury segment.
Competitive Analysis
Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS, Jaguar S-Type
Key Features
Driving Dynamics:
Renowned for its balanced chassis, precise steering, and engaging driving experience, often lauded as a benchmark in its class.
Engineering Quality:
Robust build quality, high-quality materials, and sophisticated powertrain options.
Design Language:
Timeless, elegant exterior and interior design that has aged well.
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive workshop repair and service
Page Count
Page Count:
1,002
Manual Type
Manual Type:
Workshop Repair & Service Manual
Language
Language:
English
Format
Format:
PDF
Compatibility:
Searchable, Printable, iPad-ready
📖 Manual Coverage
Systems Covered
Engine:
Complete engine diagnostics, repair, overhaul, and tuning for all E39 variants (M52, M54, M62 families)
Fuel System:
Fuel injection, fuel pump, fuel filter, fuel pressure regulator, evaporative emission control (EVAP)
Ignition System:
Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensor, DME (Digital Motor Electronics)
Cooling System:
Radiator, water pump, thermostat, hoses, expansion tank, cooling fan operation
Exhaust System:
Exhaust manifolds, catalytic converters, mufflers, oxygen sensors, exhaust gas recirculation (EGR) system (where applicable)
Transmission Manual:
Clutch operation, transmission disassembly, assembly, fluid changes, seals, synchros
Transmission Automatic:
Automatic transmission (e.g., GM 5L40-E, ZF 5HP series) diagnostics, repair, fluid and filter service, solenoid operation
Drivetrain:
Driveshaft, CV joints, differential, rear axle assembly, wheel bearings
Suspension:
Front and rear suspension components, shock absorbers, struts, control arms, bushings, springs, anti-roll bars
Steering:
Power steering system, steering rack, tie rods, steering column, power steering fluid
Brakes:
Brake system diagnostics, hydraulic components, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pad/rotor replacement, brake fluid flush
Electrical System General:
Battery, alternator, starter motor, fuses, relays, wiring diagrams
Body Electrical:
Lighting systems (headlights, taillights, interior), power windows, power mirrors, central locking, horn
Climate Control:
HVAC (Heating, Ventilation, and Air Conditioning) system, refrigerant servicing, blower motor, evaporator, condenser, climate control module
Body And Interior:
Door panels, seat removal, dashboard removal, interior trim, exterior body panels, bumper repair, door glass replacement
Chassis And Frame:
Frame inspection, unibody structure analysis
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and top-offs
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment
Rebuilding Procedures:
Engine rebuild procedures, transmission rebuild procedures (where applicable)
Component Testing:
Testing of electrical components, sensors, actuators, and mechanical systems
Specifications:
Torque specifications, clearances, timing procedures, diagnostic values
Technical Depth
Depth Of Coverage:
Comprehensive (from basic maintenance to full engine and transmission rebuilds)
Diagnostic Capabilities:
Detailed diagnostic procedures and troubleshooting guides for complex systems
Wiring Diagrams:
Included for all major electrical systems
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval
Print Quality
Printability:
Printable pages for physical workshop use
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
525I Engine:
2.5L Inline-6 (M52TU/M54B25)
525I Horsepower:
189 hp @ 5900 rpm (M52TU), 192 hp @ 6000 rpm (M54)
525I Torque:
181 lb-ft @ 3950 rpm (M52TU), 199 lb-ft @ 3500 rpm (M54)
528I Engine:
2.8L Inline-6 (M52TU)
528I Horsepower:
193 hp @ 5500 rpm
528I Torque:
206 lb-ft @ 3950 rpm
530I Engine:
3.0L Inline-6 (M54B30)
530I Horsepower:
225 hp @ 5900 rpm
530I Torque:
214 lb-ft @ 3500 rpm
540I Engine:
4.4L V8 (M62TU)
540I Horsepower:
290 hp @ 5400 rpm
540I Torque:
324 lb-ft @ 3600 rpm
Performance
Engine Management:
Bosch Motronic ECU (various versions depending on engine and year)
Fuel System
Fuel Type:
Unleaded Gasoline (premium recommended)
Fuel Delivery:
Electronic Fuel Injection (EFI)
🔧 Transmission
Standard
525I 528I 530I Standard Trans:
5-speed Manual (Getrag 260/6, Getrag 420G for later models)
540I Standard Trans:
5-speed Automatic (ZF 5HP30)
Optional
525I 528I 530I Optional Trans:
5-speed Automatic (GM 5L40-E)
540I Optional Trans:
6-speed Manual (Getrag 420G)
Features
Automatic Features:
Steptronic (manual shifting capability)
📐 Dimensions
Exterior
Length:
Sedan: ~188.3 in (4783 mm), Wagon: ~190.4 in (4836 mm)
Width:
~71.5 in (1816 mm)
Height:
Sedan: ~57.1 in (1450 mm), Wagon: ~57.6 in (1463 mm)
Wheelbase:
~111.4 in (2830 mm)
Weights
Curb Weight:
Varies by model and configuration, typically 3500-4000 lbs (1588-1814 kg)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Likely achieved good ratings, as per BMW's safety standards of the era.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Dsc:
Optional Dynamic Stability Control (DSC)
Traction Control:
Automatic Stability Control (ASC) or DSC
Passive Features
Airbags:
Front airbags, optional side airbags
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD, optional CD/Cassette with navigation (MK series).
Audio System:
Optional Harman Kardon sound system.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Sensors:
Optional Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional Bluetooth preparation for mobile phones.
Other Tech
Rain Sensing Wipers:
Optional rain sensor for automatic wiper activation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles or as indicated by the Condition Based Service (CBS) system.
Air Filter Replacement:
Every 30,000 miles or as needed based on driving conditions.
Cabin Filter Replacement:
Every 15,000 - 30,000 miles or annually.
Spark Plug Replacement:
M52TU/M54: ~100,000 miles. M62TU: ~60,000 miles (depending on plug type).
Brake Fluid Flush:
Every 2 years regardless of mileage.
Fluid Specifications
Engine Oil:
BMW Longlife-98 (LL-98) or Longlife-01 (LL-01) synthetic oil, typically SAE 5W-30 or 5W-40.
Coolant:
BMW Blue coolant or equivalent ethylene glycol-based antifreeze, mixed 50/50 with distilled water.
Transmission Fluid Auto:
GM Dexron III/VI for GM transmissions, ZF Lifeguardfluid5 or equivalent for ZF transmissions (check specific model).
Transmission Fluid Manual:
BMW MTF LT-1 or equivalent manual transmission fluid (check specific type).
Power Steering Fluid:
BMW Power Steering Fluid or Pentosin CHF 11S (check owner's manual).
Known Issues
Cooling System Failures:
Plastic cooling system components (e.g., expansion tank, thermostat housing, water pump impellers) are prone to cracking and failure due to age and heat cycles.
Oil Vanos Seals:
Degradation of VANOS (Variable Valve Timing) O-rings can lead to rough idle, loss of power, and increased fuel consumption.
Oil Pan Gasket:
Leaking oil pan gaskets are common due to aging seals.
Ccv System:
Crankcase Ventilation (CCV) system failure can lead to oil consumption and pressure issues.
Window Regulators:
Plastic components in window regulator mechanisms can break, leading to inoperable windows.
ABS Wheel Speed Sensors:
Failure of ABS wheel speed sensors can trigger ABS and DSC warning lights.
Ignition Coils And Spark Plugs:
While generally reliable, these components do wear and can cause misfires.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's long-standing reputation for building sporty, driver-focused luxury vehicles.
Model Evolution
E39 Introduction:
The E39 replaced the E34 generation, introducing a more aerodynamic design and significantly improved chassis dynamics and technology.
Facelift:
The E39 received a significant facelift in 2000, introducing updated headlights (angel eyes), taillights, bumpers, and interior refinements. The M54 engines also replaced the M52TU for most models.
Production
Manufacturing Locations:
Mainly produced in Dingolfing, Germany.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E39 5-Series was a frequent recipient of Car and Driver's '10Best' awards during its production run, a testament to its exceptional driving dynamics and overall excellence.
Ward'S Auto:
Recognized for its engineering and interior quality by automotive publications.
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