Model Variant:
525i, 528i, 530i, 540i
Model Years Covered:
1997, 1998, 1999, 2000, 2001, 2002
Engine Codes Covered:
M50, M52, M54 (Specific variants dependent on sub-model year)
Vehicle Segment:
Executive Sedan / Luxury Mid-Size
Target Audience:
Owners seeking to maintain and repair their BMW E39, DIY enthusiasts, independent repair shops.
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160)
Manual Benefit:
Provides comprehensive, year and model-specific repair and maintenance information, reducing reliance on expensive dealership service.
Ease Of Use:
Easy-to-follow detailed instructions and step-by-step diagrams.
Delivery Method:
Instant digital download, eliminating shipping delays.
Engine Mechanical:
Engine removal/installation, cylinder head/valve, cylinder/piston, crankcase, crankshaft/primary shaft, lubrication, inspection and adjustment
Fuel System:
Fuel system components, fuel delivery, fuel injection (specifics depend on engine variant)
Transmission Manual:
Clutch, gearshift linkage, sub-transmission (if applicable), transmission removal/installation, overhaul (specifics depend on transmission type)
Transmission Automatic:
Service procedures, fluid capacities, general repair (specifics depend on transmission type)
Suspension Steering:
Front wheel/suspension, rear wheel/suspension, alignment specifications
Brakes:
Hydraulic brake system, components, service, bleeding procedures
Electrical Charging:
Battery/charging system, alternator, starter motor, wiring diagrams
Electrical Ignition:
Ignition system components, service, troubleshooting
Electrical Components:
Switches, relays, lighting, comfort systems (details vary)
Body Chassis:
General body repairs, exterior trim, interior trim (specifics may be limited in scope)
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair:
Component replacement, system overhauls, internal engine/transmission repairs
Diagnostics:
Troubleshooting guides, symptom-based problem solving
Wiring:
Complete electrical diagrams for troubleshooting and repair
Technical Features:
Explanation of specific vehicle technologies relevant to repair
Depth Of Coverage:
Comprehensive: From basic maintenance and fluid checks to full engine and transmission rebuilds, including electrical system diagnostics.
Engine Type:
Inline 6-cylinder (525i, 528i, 530i), V8 (540i)
Displacement 525I:
2.5 Liters (e.g., 2494cc)
Displacement 528I:
2.8 Liters (e.g., 2793cc)
Displacement 530I:
3.0 Liters (e.g., 2979cc)
Displacement 540I:
4.4 Liters (e.g., 4398cc) - M62 V8
Horsepower 525I Early:
Approx. 189 hp @ 5900 rpm
Horsepower 528I:
Approx. 193 hp @ 5500 rpm (Later models 240 hp)
Horsepower 530I:
Approx. 225 hp @ 5900 rpm
Horsepower 540I:
Approx. 282 hp @ 5400 rpm (Later models 290 hp)
Torque 540I:
Approx. 310 lb-ft @ 3600 rpm (Later models 325 lb-ft)
Fuel Injection Type:
Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Emission Controls:
Catalytic Converter, On-Board Diagnostics (OBD-II)
Transmission Type Standard 6Cyl:
5-speed Manual (Getrag 260/6, ZF S5-31)
Transmission Type Standard 8Cyl:
5-speed Manual (ZF S5-31)
Transmission Type Optional 6Cyl:
5-speed Steptronic Automatic (GM A5S 325Z, ZF 5HP19)
Transmission Type Optional 8Cyl:
5-speed Steptronic Automatic (ZF 5HP24)
Steptronic Functionality:
Allows manual gear selection via shifter or steering wheel buttons (on select models).
Rear Differential:
Standard Open Differential; Limited Slip Differential (LSD) often optional or on specific performance models (M5).
NHTSA Frontal Impact:
Generally rated well for its era, often 4 or 5 stars (specific ratings vary by year and test conditions).
Traction Control:
Standard on most models (ASC+T or DSC).
Stability Control:
Dynamic Stability Control (DSC) became more prevalent in later years.
ABS:
Anti-lock Braking System (ABS) standard.
Airbags:
Frontal airbags, side airbags (often optional or standard depending on year/trim).
Seatbelts:
Three-point seatbelts with pretensioners.
Radio Options:
Various BMW Business and Professional CD/Radio head units, optional navigation systems (e.g., MKIII/MKIV).
Speaker Systems:
Standard 6-speaker systems, optional HiFi or Harman Kardon premium audio.
Cruise Control:
Standard on all models.
Parking Sensors:
Optional Park Distance Control (PDC) front and rear.
Phone Integration:
Optional Bluetooth hands-free system (may require specific adapter or cradle).
Oil Change Interval:
Typically every 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system, depending on driving conditions and oil type.
Spark Plug Replacement:
Approximately every 100,000 miles for iridium or platinum plugs; shorter intervals for older plug types.
Coolant Flush:
Every 2-4 years or per manufacturer recommendation.
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-04 approved synthetic oil, typically 5W-30 or 5W-40 depending on climate and engine variant.
Transmission Fluid Manual:
MTF LT-2 or equivalent (specific part number recommended by manual).
Transmission Fluid Automatic:
ATF LT 3 or equivalent (specific part number recommended by manual).
Coolant Specification:
BMW Blue Coolant (G48) or equivalent antifreeze/coolant mixture.
Brake Fluid Specification:
DOT 4 Low Viscosity (LV) or DOT 4 Plus.
Common Wear Items:
Cooling system components (water pump, thermostat, hoses), VANOS system (on 6-cylinder engines), suspension bushings, wheel bearings, ignition coils, oil separator (CCV).
Electrical Quirks:
Pixelated instrument cluster displays, door seal water leaks, ABS/DSC sensor failures.
Bmw Philosophy:
Ultimate Driving Machine, emphasis on performance, luxury, and engineering.
E39 Generation:
Third generation of the BMW 5 Series, known for its refined chassis, improved handling, and enhanced luxury over its predecessor (E34).
Facelift:
Mid-cycle facelift occurred around 2000, introducing updated headlights, taillights, bumpers, and interior trim.
Production Period:
1995-2003 (Global), 1997-2002 specific to this manual's coverage.
Assembly Locations:
Dingolfing, Germany; Rosslyn, South Africa; Graz, Austria (for some variants).
