Segment:
Executive Luxury Mid-size Sedan and Wagon
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS, Jaguar S-Type
E39 Advantages:
Renowned for driving dynamics, build quality, advanced engineering, and sophisticated design
Platform Philosophy:
Driver-focused, balanced chassis, rear-wheel drive bias (optional xDrive for some markets/variants, though less common on these specific models)
Technological Advancements:
Introduction of CAN bus network, advanced engine management, optional iDrive infotainment system (later models)
Engine:
Full diagnostics, repair, and overhaul for M52, M54, M62 engines (including VANOS, ignition, fuel injection, cooling, lubrication)
Transmission:
Service and repair for Automatic (e.g., GM 5L40-E, ZF 5HP19, ZF 5HP24) and Manual transmissions
Drivetrain:
Driveshafts, differentials, axles, wheel bearings, clutch (manual)
Suspension:
Front and rear suspension components, struts, shocks, control arms, bushings, sway bars, self-leveling rear suspension (if equipped)
Steering:
Power steering system, steering rack, tie rods, steering column, steering angle sensor
Brakes:
Hydraulic system, ABS, DSC (Dynamic Stability Control), EBD, brake calipers, rotors, pads, brake fluid, parking brake
Electrical:
Complete wiring diagrams, ECU diagnostics, starter, alternator, battery, lighting systems (headlights, taillights, interior), fuses, relays, power windows, locks, mirrors
HVAC:
Air conditioning system, heater core, blower motor, climate control module, cabin filter, refrigerant
Bodywork:
Body panel removal and installation, door mechanisms, hood, trunk lid, bumpers, glass replacement, interior trim
Safety Systems:
Airbag system, seatbelt pretensioners, SRS module diagnostics
Infotainment:
Radio, navigation system (if equipped), speaker systems, antenna
Preventative Maintenance:
Oil changes, filter replacements, spark plug replacement, coolant flush, brake fluid service, belt inspections
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system fault finding
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment
Overhaul Rebuild:
Detailed instructions for engine, transmission, and component rebuilds
Wheel Alignment:
Specifications for camber, caster, and toe angles
Diagnostic Procedures:
Procedures for using diagnostic tools and interpreting data
Special Tools:
Identification and usage of BMW-specific and common tools required for repairs
Depth Level:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, complex electrical diagnostics
Diagnostic Complexity:
Advanced: Includes detailed diagnostic flowcharts and parameter explanations for DME, EWS, ABS/DSC modules
Torque Specifications:
Detailed torque values for all critical fasteners and components
Schematics:
Detailed electrical wiring diagrams for all systems
525I:
M54B25 (2.5L Inline-6), 189 hp @ 6000 rpm, 180 lb-ft @ 3500 rpm
528I:
M52TU B28 (2.8L Inline-6), 190 hp @ 5300 rpm, 206 lb-ft @ 3950 rpm
530I:
M54B30 (3.0L Inline-6), 225 hp @ 5900 rpm, 214 lb-ft @ 3500 rpm
540I:
M62TU B44 (4.4L V8), 290 hp @ 5400 rpm, 324 lb-ft @ 3600 rpm
Compression Ratio 525I:
10.2:1
Compression Ratio 540I:
10.0:1
Fuel Injection:
Sequential Multi-Point Fuel Injection (MPI) with Bosch Motronic or Siemens engine management
Fuel Type:
Premium Unleaded Gasoline (91+ Octane Recommended)
Engine Control Unit ECUs:
DME (Digital Motor Electronics) for inline-6, M62-specific ECUs for V8
525I 528I 530I:
5-speed Manual (Getrag 220) or 5-speed Automatic (GM 5L40-E)
540I:
5-speed Automatic (ZF 5HP24) or 6-speed Manual (Getrag S6-40Z)
All Models:
Various 5-speed Automatic transmissions depending on engine and market
Automatic Features:
Steptronic manual shift mode available on most automatic transmissions
Automatic Transmission Fluid:
BMW ATF LT-71141, Dexron III/VI (check specific transmission)
Manual Transmission Fluid:
BMW MTF-LT-2 or equivalent SAE 75W-90 GL-4/GL-5 gear oil
Oil Change Interval:
Typically 7,500-10,000 miles (12,000-16,000 km) or as indicated by the Condition Based Service (CBS) system
Spark Plug Replacement:
100,000 miles (160,000 km) for M54 engines; consult manual for M52/M62
Coolant Flush:
Every 2 years or 30,000 miles (48,000 km)
Brake Fluid Flush:
Every 2 years, regardless of mileage
Engine Oil Capacity 525I 530I:
6.5 quarts (6.2 liters) with filter, SAE 0W-30 or 5W-30 BMW LL-01 approved oil
Engine Oil Capacity 540I:
7.0 quarts (6.6 liters) with filter, SAE 5W-40 BMW LL-01 approved oil
Coolant Type:
BMW Blue Antifreeze/Coolant (G48) or equivalent HOAT coolant, mixed 50/50 with distilled water
Power Steering Fluid:
Pentosin CHF 11S or compatible hydraulic fluid
Cooling System:
Plastic coolant expansion tanks can become brittle and crack; water pump failure (plastic impeller)
Vanos:
Seals can degrade, leading to rough idle and reduced low-end torque (especially on M52TU and M54)
Oil Leaks:
Valve cover gasket, oil pan gasket, oil filter housing gasket are common leak points
Suspension Components:
Control arm bushings (specifically the front tension strut bushings), ball joints, and tie rod ends wear out over time
ABS/Dsc Sensors:
Wheel speed sensors can fail, triggering ABS/DSC warning lights
Mass Airflow Sensor (Maf):
Can become dirty or fail, affecting engine performance and fuel economy
Bmw Philosophy:
Sheer Driving Pleasure, engineering excellence, performance, and luxury
E39 Introduction:
Introduced in 1995 (Europe) and 1996 (North America) as a successor to the E34 5 Series
E39 Facelift Lci:
Mid-cycle facelift (LCI) introduced in 2000 with revised headlights, taillights, bumpers, and interior updates
E39 Engine Updates:
Transition from M52/M62 to M54/M62TU engines for improved performance and emissions
Production Years:
1995-2003 (E39 platform)
Manufacturing Locations:
Dingolfing, Germany; Rosslyn, South Africa; Magna Steyr, Austria
Notable Variants:
M5 (E39) - high-performance model (not covered by this specific manual)
