🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E39

Model Variants Covered:

525i, 528i, 530i, 540i

Engine Codes 525I:

M52B25TU (2.5L I6)

Engine Codes 528I:

M52B28TU (2.8L I6)

Engine Codes 530I:

M54B30 (3.0L I6)

Engine Codes 540I:

M62B44TU (4.4L V8)

👋 Introduction

Positioning:

The E39 5 Series represented BMW's mid-luxury sedan, competing against rivals like the Mercedes-Benz E-Class and Audi A6. Known for its sophisticated handling, powerful engines, and driver-focused cockpit.

Comparison Points:

Excelled in driving dynamics, engine refinement, and build quality compared to many contemporaries.

Vehicle Highlights:

Balanced chassis, available inline-six and V8 engines, premium interior materials, sophisticated suspension design.

📋 Manual Details

Coverage Years:

1997, 1998, 1999, 2000, 2001, 2002

Estimated Page Count:

1500+

Type:

Factory Service Repair Manual

Language:

English

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, diagnosis, timing, lubrication, cooling, exhaust

Engine Management:

Fuel injection, ignition system, DME (Digital Motor Electronics), VANOS, emissions control

Transmission Manual:

Clutch, gearbox, shifter linkage, torque specifications, repair procedures

Transmission Automatic:

Steptronic transmission (GM 5L40-E/5HP series), hydraulic controls, electronic control unit, fluid service

Drivetrain:

Driveshafts, CV joints, differential, wheel bearings

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, bushings, alignment specifications

Steering:

Power steering system, steering rack, tie rods, steering column, troubleshooting

Brakes:

Front and rear brake systems (disc), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid specifications, bleeding procedures, caliper/rotor replacement

Electrical System:

12V battery, alternator, starter motor, wiring diagrams, fuse box locations, component testing

Body And Chassis:

Body panels, doors, windows, sunroof, exterior trim, interior trim, sound deadening

Climate Control:

HVAC system, A/C compressor, refrigerant, heater core, blower motor, climate control unit diagnostics

Safety Systems:

Airbags, seatbelt pretensioners, SRS control module

Lighting:

Headlights, taillights, interior lighting, bulb replacement, aiming

Infotainment And Electronics:

Radio, navigation system (optional), instrument cluster, power accessories (windows, locks, mirrors)

Maintenance Tasks:

Oil change, filter replacement, spark plug replacement, belt inspection/replacement, fluid checks and top-offs

Diagnostic Procedures:

Troubleshooting common faults, using diagnostic scan tools (e.g., DIS, GT1 - not included, but procedures described), DTC interpretation

Repair Procedures:

Component removal and installation, major component overhauls, system-specific repairs

Adjustment Procedures:

Throttle body synchronization, idle speed adjustment, headlight aiming

Engine Mechanical Procedures:

Cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing chain/guide replacement, oil pump removal/installation, oil pan gasket replacement.

Electrical Troubleshooting Procedures:

Detailed diagnostic flowcharts for common electrical faults, testing of sensors and actuators, wiring harness repair and continuity testing.

Chassis Component Replacement:

Ball joint replacement, control arm bushing replacement, wheel bearing replacement, shock absorber and strut replacement, steering rack seal replacement.

Body Repair Procedures:

Door panel removal, bumper cover replacement, headlight/taillight unit replacement, mirror replacement, sunroof mechanism servicing.

Depth:

Comprehensive, from basic scheduled maintenance to complete engine and transmission rebuilds, detailed diagnostics and electrical troubleshooting.

Diagnostic Tools Reference:

While not including the tools themselves, the manual describes diagnostic procedures that align with professional BMW diagnostic equipment like DIS or ISTA/P for fault code reading, module programming, and system calibration.

📊 Manual Specifications

Format Details:

Searchable PDF document with hyperlinked table of contents for easy navigation.

Quality:

High-resolution digital scans, clear diagrams and illustrations.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine:

M52B25TU (2.5L 24-valve DOHC Inline-6)

Horsepower 525I:

189 hp @ 5900 rpm (approx.)

Torque 525I:

181 lb-ft @ 3950 rpm (approx.)

Engine:

M52B28TU (2.8L 24-valve DOHC Inline-6)

Horsepower 528I:

190 hp @ 5500 rpm (approx.)

Torque 528I:

206 lb-ft @ 3950 rpm (approx.)

Engine:

M54B30 (3.0L 24-valve DOHC Inline-6)

Horsepower 530I:

225 hp @ 5900 rpm (approx.)

Torque 530I:

214 lb-ft @ 3500 rpm (approx.)

Engine:

M62B44TU (4.4L 32-valve DOHC V8)

Horsepower 540I:

282 hp @ 5400 rpm (approx.)

Torque 540I:

324 lb-ft @ 3600 rpm (approx.)

Injection Type:

Sequential Multi-Port Fuel Injection (SFI)

Recommended Fuel:

Premium Unleaded Gasoline (91+ octane)

ECU:

Bosch DME (e.g., MS42, MS43 for I6; MS43, MS43.1 for V8)

🔧 Transmission

Standard Transmission Type:

5-speed manual (Getrag 420G for I6, ZF S5-310Z for V8)

Optional Transmission Type:

5-speed automatic (GM 5L40-E for I6, ZF 5HP30/5HP24 for V8)

Steptronic:

Available on automatic transmissions, allowing manual gear selection.

📐 Dimensions

Wheelbase:

111.4 inches (2830 mm)

Length:

188.0 inches (4776 mm)

Width:

70.2 inches (1783 mm)

Height:

56.2 inches (1427 mm)

Curb Weight Approx:

3500 - 4000 lbs (1588 - 1814 kg) depending on engine and configuration

🛡️ Safety Features

NHTSA Front Impact Driver:

4 stars (1999-2001 models)

NHTSA Front Impact Passenger:

4 stars (1999-2001 models)

IIHS Front Offset Impact:

Good (for models tested)

Active Safety:

ABS, DSC (Dynamic Stability Control) standard on most models, Traction Control (ASC+T)

Passive Safety:

Front and side airbags, front seatbelt pretensioners, advanced crumple zones.

💡 Technology Features

Infotainment System:

BMW Professional Radio or Business CD player. Optional Professional Navigation system with integrated CD or DVD. Onboard computer providing trip data and vehicle status.

Driver Assistance Features:

Cruise control, parking sensors (optional), rain-sensing wipers (optional), automatic climate control.

Connectivity Options:

BMW Assist (telematics service) on select models, optional CD changer. Bluetooth integration was not common in early models but available on later facelifts or through aftermarket solutions.

🔧 Maintenance

Oil Change Interval:

Typically 7,500 - 15,000 miles or 12-24 months, depending on driving conditions and oil type (check Condition Based Service - CBS - on vehicles so equipped).

Transmission Fluid Service:

BMW historically stated 'lifetime' fill for automatic transmissions, but recommended inspection and potential replacement around 50,000-100,000 miles as a preventative measure, especially for critical components.

Coolant Change:

Every 2-4 years or as indicated by the service interval indicator. Use BMW Blue or Pink Antifreeze.

Engine Oil Type:

API SN/SP, ACEA A3/B4 or BMW LL-01 approved synthetic oil. Viscosity typically 0W-30, 5W-30, or 5W-40 depending on climate.

Coolant Type:

BMW Blue (G48 ethylene glycol based) or BMW Pink (40th Anniversary coolant) if updated, mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 4, Low Viscosity (LV), BMW part number 83 23 0 382 042 or equivalent.

Power Steering Fluid Type:

Pentosin CHF 11S or equivalent hydraulic fluid.

Automatic Transmission Fluid Type:

GM Lifeguard Fluid 5 (for GM 5L40-E) or ZF LifeguardFluid 5/6 (for ZF transmissions). Verify specific transmission fluid.

Common Problems:

Cooling system issues (water pump, thermostat, expansion tank leaks), VANOS solenoid failure, oil leaks (valve cover, oil pan gaskets), fuel pump failure, ABS sensor failure, window regulator failure, misfires on M54 engines (e.g., CCV system issues).

📚 Vehicle History

Heritage:

BMW has a long-standing reputation for building sporty, driver-oriented luxury sedans dating back to its post-war origins.

E39 Introduction:

The E39 generation replaced the E34 5 Series and was produced from 1995 to 2004 (though the covered range ends at 2002 for this manual). It was praised for its improved chassis dynamics and more modern amenities.

Production Location:

Dingolfing Plant, Germany

🏆 Awards & Recognition

Car And Driver 10 Best:

The E39 5 Series was a frequent recipient of Car and Driver's 10Best awards during its production run, lauded for its driving dynamics and overall excellence.

Edmunds Ratings:

Consistently received high ratings for performance, comfort, and quality from automotive review sites.