Category:
Premium Mid-size Luxury Sedan/Wagon
Target Audience:
Owners seeking detailed DIY repair and maintenance, independent repair shops
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Volvo S80
Vehicle Design:
Rear-wheel drive platform, balanced chassis, refined driving dynamics, high-quality interior materials
Manual Value Proposition:
Provides comprehensive, dealership-level repair information for DIYers and professionals.
Covered Models:
525i, 528i, 530i, 540i Sedan, Sport Wagon
Covered Years:
1997, 1998, 1999, 2000, 2001, 2002
Type:
Workshop Repair Service Manual
Engine Mechanical:
Complete engine overhaul, diagnosis, timing, lubrication, cooling, fuel injection, emission controls
Transmission Manual:
Manual gearbox repair, clutch system, linkage adjustments
Transmission Automatic:
Automatic transmission diagnosis, repair, fluid service, valve body issues
Drivetrain:
Driveshaft, CV joints, differential, rear axle assembly
Suspension:
Front and rear suspension components, struts, shocks, bushings, alignment procedures
Steering:
Power steering system, steering rack, steering column, linkages
Brakes:
Hydraulic system, ABS, DSC, brake pads, rotors, calipers, bleeding procedures
Electrical System:
Battery, charging system, starter, ignition, lighting, power windows, locks, seats, mirrors
Body And Chassis:
Body panels, doors, hoods, trunks, bumpers, interior trim, structural components
Heating Ventilation Air Conditioning:
HVAC system diagnosis and repair, climate control, refrigerant service
Safety Systems:
Airbag system, seatbelts, passive safety features
Diagnostic Troubleshooting:
Extensive troubleshooting guides, fault codes, diagnostic procedures
Preventative Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Routine Repairs:
Replacement of common wear items, belt replacement, spark plug service
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement
Diagnostic Testing:
Step-by-step diagnostic routines for all major systems
Wiring Diagrams:
Comprehensive electrical schematics for all circuits
Torque Specifications:
Detailed torque values for all critical fasteners
Special Tools:
Identification and usage of specialized tools required for certain procedures
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds
525I:
M54B25, 2.5L Inline-6, VANOS
528I:
M52TU B28, 2.8L Inline-6, VANOS (later M54B30 for 2001+ 530i)
530I:
M54B30, 3.0L Inline-6, VANOS
540I:
M62TU B44, 4.4L V8, VANOS
525I Hp:
189 hp @ 5900 rpm (M54)
528I Hp:
193 hp @ 5500 rpm (M52TU)
530I Hp:
225 hp @ 5900 rpm (M54)
540I Hp:
290 hp @ 5400 rpm (M62TU)
Injection Type:
Sequential Multi-Point Fuel Injection (S M P I)
Recommended Fuel:
Premium Unleaded Gasoline (91 Octane or higher)
Head Unit Options:
Business CD, Professional CD RDS, Navigation systems (MK I, II, III)
Audio Systems:
Harmon Kardon premium sound system available
Cruise Control:
Standard cruise control system
Parking Assistance:
Rear Park Distance Control (PDC) available
Phone Integration:
BMW Assist telematics system and integrated phone options on later models
Oil Change:
Variable Service Interval (VSI) based on driving conditions, typically 10,000-15,000 miles or annually
Brake Fluid:
Every 2 years
Coolant:
BMW Blue Coolant (G48), first change at 4 years, then every 2 years
Spark Plugs:
M54: 100,000 miles; M62TU: 100,000 miles
Engine Oil:
BMW Longlife-01 (LL-01) or LL-98 specification, SAE 0W-30 or 5W-30 Synthetic
Transmission Fluid Auto:
LT 71141 (Dexron III compatible, but LT 71141 is preferred for longevity)
Transmission Fluid Manual:
G50 or G52 gear oil specification
Power Steering Fluid:
Pentosin CHF 11S or BMW PSF L
Cooling System:
Plastic expansion tank cracks, water pump failure, thermostat housing leaks
Valve Cover Gasket:
Common oil leaks due to failing gaskets and PCV system
Oil Pan Gasket:
Oil leaks often occur on the oil pan gasket
Suspension Components:
Wear on control arm bushings, ball joints, and tie rods
ABS/Dsc Sensor Failure:
Wheel speed sensors can fail, triggering ABS and DSC warning lights
Pixel Display Failure:
Instrument cluster LCD display can lose pixels
Misfires:
Coil packs and spark plug wires (on earlier M52) can fail, leading to misfires
