🏷️ Basic Information

Make:

BMW

Model:

5 Series (E39)

Model Variants:

525i, 528i, 530i, 540i

Chassis Code:

E39

Production Years Covered:

1997-2002

👋 Introduction

Market Segment:

Mid-size luxury sedan executive car segment.

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Volvo S80.

Driving Dynamics:

Renowned for BMW's signature balanced chassis, precise steering, and engaging driving experience.

Interior Quality:

High-quality materials, ergonomic design, and comfortable seating, characteristic of BMW luxury.

Powertrain Options:

Smooth inline-six and V8 engines offering a blend of performance and refinement.

📋 Manual Details

Coverage Scope:

All repairs A-Z, all models and variants within the specified production years.

Estimated Page Count:

Likely over 1000 pages (typical for comprehensive BMW service manuals of this era).

Manual Type:

Service and Repair Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed diagnostics, repair, and overhaul procedures for all engines (M52TU, M54, M62/M62TU). Includes timing, valve train, cooling, lubrication, fuel delivery, and exhaust systems.

Engine Electrical:

Engine control units (ECUs), ignition system, fuel injection systems (DME), sensors, actuators, and wiring diagrams for engine management.

Transmission:

Repair and maintenance for both manual (Getrag S5D 250G, ZF S5-14) and automatic transmissions (GM A5S 310R, ZF 5HP19, ZF 5HP24, ZF 5HP30). Includes fluid changes, torque converter, and electronic controls.

Drivetrain:

Front axle, rear axle differential, driveshafts, CV joints, and driveshaft carrier bearing.

Suspension:

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

Brakes:

Brake system diagnostics, repair, ABS, DSC (Dynamic Stability Control), brake fluid specifications, pad and rotor replacement, caliper overhaul, and bleeding procedures.

Steering:

Power steering system, steering rack, tie rods, steering column, and wheel alignment specifications.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass, seals, chassis components, corrosion protection, and underbody structure.

Electrical System:

Comprehensive wiring diagrams, battery, charging system, lighting (headlights, taillights, interior), starter motor, and accessory circuits.

Climate Control:

HVAC system diagnostics, repair, refrigerant handling (R134a), compressor, evaporator, condenser, blower motor, and control modules.

Infotainment And Comfort:

Radio, navigation system (if equipped), speaker replacement, power windows, central locking, seat adjustment, and comfort electronics.

Scheduled Maintenance:

Detailed maintenance schedules, oil change intervals, filter replacements (oil, air, cabin, fuel), spark plug replacement, and fluid checks.

Troubleshooting:

Systematic diagnostic procedures, common fault codes (DTCs), symptom-based troubleshooting, and electrical system diagnostics.

Repair And Rebuild:

Step-by-step repair instructions for major components such as engine rebuilds, transmission overhauls, suspension and brake component replacements, and bodywork repairs.

Component Replacement:

Instructions for replacing specific parts like alternators, starter motors, fuel pumps, water pumps, radiators, EGR valves (if applicable), oxygen sensors, and more.

Electrical Diagnostics:

Detailed wiring diagrams, component testing procedures, and troubleshooting of electrical faults.

Technical Depth:

Comprehensive, suitable for professional technicians and experienced DIY enthusiasts. Covers everything from basic fluid changes to full engine and transmission rebuilds.

📊 Manual Specifications

File Format:

PDF

Searchability:

Likely text-searchable PDF for quick access to information.

Print Quality:

High-resolution scans, designed for clear viewing and printing of diagrams and text.

Binding Type:

Not applicable (digital PDF format).

Paper Type:

Not applicable (digital PDF format).

⚙️ Engine Specifications

Engine Code:

M54B25 (post-2000), M52TUB25 (pre-2000)

Displacement:

2.5 Liters (2494 cc)

Horsepower:

184-189 hp @ 5900-6000 rpm (varies by year and specific engine code)

Torque:

235-245 Nm (173-181 lb-ft) @ 3500-4200 rpm

Engine Code:

M52TUB28 (post-2000), M52B28 (pre-2000)

Displacement:

2.8 Liters (2793 cc)

Horsepower:

190-193 hp @ 5500-5800 rpm

Torque:

280-285 Nm (207-210 lb-ft) @ 3600-3950 rpm

Engine Code:

M54B30

Displacement:

3.0 Liters (2979 cc)

Horsepower:

225-228 hp @ 5900-6000 rpm

Torque:

300-303 Nm (221-224 lb-ft) @ 3500-4500 rpm

Engine Code:

M62B44 (pre-2000), M62TUB44 (post-2000)

Displacement:

4.4 Liters (4398 cc)

Horsepower:

282 hp (M62) / 290 hp (M62TU) @ 5400-6000 rpm

Torque:

440 Nm (325 lb-ft) (M62) / 460 Nm (339 lb-ft) (M62TU) @ 3600-4000 rpm

Engine Technology:

Aluminum block and cylinder heads, VANOS (variable valve timing) on M52TU and M54/M62TU engines, Sequential Fuel Injection (SFI).

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Fuel Delivery:

Bosch Motronic Electronic Fuel Injection.

🔧 Transmission

525I/528I/530I:

5-speed Getrag manual (S5D 250G) or 5-speed ZF automatic (5HP19)

540I:

5-speed ZF automatic (5HP24/5HP30) - Manual transmission optional on early models, rare.

540I Manual:

6-speed Getrag manual (S6S 420G) available on certain markets/years for 540i.

Automatic Transmission Features:

Steptronic (manual shifting mode), adaptive shift programs.

📐 Dimensions

Length:

Approx. 4770-4790 mm (187.8-188.6 in)

Width:

Approx. 1800 mm (70.9 in)

Height:

Approx. 1435-1440 mm (56.5-56.7 in)

Wheelbase:

Approx. 2830 mm (111.4 in)

Curb Weight:

Approx. 1550-1750 kg (3417-3858 lbs) depending on engine and options.

🛡️ Safety Features

NHTSA Front Crash Test:

5-star rating (for models tested).

Stability Control:

Standard on most models: DSC (Dynamic Stability Control).

Traction Control:

Standard: ASC+T (Automatic Stability Control and Traction).

Brakes:

Four-wheel Anti-lock Braking System (ABS).

Airbags:

Front airbags, side airbags, and optional head airbags (Side Curtain Airbags).

Seatbelts:

Front and rear seat belts with pre-tensioners and force limiters.

💡 Technology Features

Head Unit Options:

Various BMW Business, Professional, and Navigation systems with CD players, cassette decks, and available DSP (Digital Sound Processor) audio.

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

Optional Park Distance Control (PDC).

Phone Integration:

Optional Bluetooth hands-free preparation with cradle.

🔧 Maintenance

Oil Change Interval:

Typically 10,000-15,000 miles (15,000-25,000 km) or every 12 months, as indicated by the Condition Based Service (CBS) system (on later models within the range) or manufacturer recommendation.

Spark Plug Replacement:

Around 60,000 miles (100,000 km) for standard plugs; iridium plugs may last longer (consult manual for specific engine).

Coolant Flush:

Typically every 2-4 years or 30,000-60,000 miles.

Engine Oil:

BMW Longlife-01 (LL-01) approved synthetic oil, typically 5W-30 or 5W-40.

Transmission Fluid Auto:

Refer to ZF LifeguardFluid specifications for specific ZF transmissions (e.g., LT-3/ATF3 for 5HP series).

Transmission Fluid Manual:

GL-4 or GL-5 gear oil (specific viscosity recommended by BMW).

Brake Fluid:

DOT 4 Low Viscosity (LV) or equivalent.

Coolant:

BMW Blue Antifreeze/Coolant (G48 formulation) mixed with distilled water.

Cooling System:

Plastic coolant expansion tank can become brittle and crack; water pump failure (especially plastic impeller versions).

Valve Cover Gasket:

Common oil leaks from the valve cover gasket and spark plug well seals.

Oil Pan Gasket:

Oil leaks from the oil pan gasket are also common.

ABS Wheel Speed Sensors:

ABS/DSC warning lights due to failing wheel speed sensors.

Ccv System:

Crankcase Ventilation (CCV) system failure (especially on M54 engines) leading to oil consumption and vacuum leaks.

Misfires:

Ignition coil failures and spark plug issues can cause misfires.

Transmission Problems Auto:

Mechatronic seal leaks in automatic transmissions can cause harsh shifting or loss of drive.

📚 Vehicle History

Bmw Legacy:

BMW's long-standing reputation for building driver-focused luxury sedans with advanced engineering.

E39 Introduction:

The E39 generation succeeded the E34 and introduced significant advancements in chassis design, technology, and comfort. It was produced from 1995 to 2003 globally, with the facelift occurring in 2000.

Manufacturing Locations:

Primarily Dingolfing, Germany.

🏆 Awards & Recognition

Car And Driver Five Best:

Consistently ranked on Car and Driver's '10Best' list during its production run.

Consumers Reports Reliability:

Generally good reliability ratings from consumer organizations for its era, though specific components can be prone to wear.