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BMW 525 525i 1997 Workshop Repair Service Manual

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$17.99
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🏷️ Basic Information Identification Make: BMW Model: 525i Model Variant: 525 Year: 1997 Codes Chassis Code: E39 Engine Code Identifier: M52B25 👋 Introduction Market Position Segment: Executive Sedan Reputation: Renowned...
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BMW 525 525i 1997 Workshop Repair Service ManualBMW 525 525i 1997 Workshop Repair Service ManualBMW 525 525i 1997 Workshop Repair Service ManualBMW 525 525i 1997 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
525i
Model Variant:
525
Year:
1997
Codes
Chassis Code:
E39
Engine Code Identifier:
M52B25
👋 Introduction
Market Position
Segment:
Executive Sedan
Reputation:
Renowned for driving dynamics, build quality, and advanced engineering for its era
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C4/C5), Lexus GS, Jaguar S-Type
Key Features
Driving Dynamics:
Rear-wheel drive, balanced chassis, responsive steering
Powertrain Refinement:
Smooth inline-six engine, characteristic BMW performance
Build Quality:
Solid construction, high-quality interior materials
📋 Manual Details
Coverage Areas
Engine:
All variants
Transmission:
All types (Manual, Automatic)
Trim Levels:
All included
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, emissions control
Drivetrain:
Transmission (manual & automatic), clutch, driveshafts, differentials, axles
Chassis:
Suspension (front & rear), steering system, braking system (ABS included), wheels, tires
Electrical:
Battery, starting system, charging system, lighting, instruments, comfort systems, infotainment (basic), body control modules, wiring diagrams
Body:
Body panels, doors, windows, glass, interior trim, HVAC system, exterior trim
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups
Repair:
Engine overhaul, transmission overhaul, brake system repair, suspension component replacement, electrical component diagnosis and repair
Troubleshooting:
Diagnostic procedures, fault code interpretation, symptom-based troubleshooting guides
Diagnostics:
Engine management diagnostics, ABS system diagnostics, component testing
Technical Depth
Depth:
Comprehensive, from basic maintenance to detailed component overhaul and diagnostics
Wiring Diagrams:
Detailed electrical system wiring diagrams included
Torque Specifications:
All critical torque specifications for fasteners
Special Tools:
Identification and usage of specialized BMW tools where applicable
📊 Manual Specifications
File Format
Format:
Searchable PDF
Printability:
Printable pages
Accessibility:
Hyperlinked chapters for easy navigation
Print Quality
Image Resolution:
High-resolution images and diagrams
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Name:
M52B25 (VANOS)
Configuration:
2.5-liter Inline 6-cylinder
Displacement:
2494 cc
Bore X Stroke:
84 mm x 90 mm
Compression Ratio:
10.0:1
Performance
Horsepower:
168 hp @ 5500 rpm
Torque:
181 lb-ft @ 3950 rpm
Fuel System
Fuel Delivery:
Bosch Motronic M5.2 Engine Management System, Sequential Multi-Port Fuel Injection (MPI)
Recommended Fuel:
Premium Unleaded (91 Octane or higher recommended)
Other
Valvetrain:
DOHC (Double Overhead Camshafts), 4 valves per cylinder
Timing:
Double VANOS (Variable Valve Timing on intake and exhaust camshafts)
🔧 Transmission
Standard
Type:
5-speed Manual (Getrag 260/6)
Optional
Type:
5-speed Automatic (ZF 5HP18/5HP19)
Features
Manual:
Hydraulically actuated clutch
Automatic:
Adaptive shift control, Comfort/Sport modes
Fluid Type
Manual Transmission Fluid:
BMW ATF (or equivalent, e.g., Castrol TAF-X / SAF-XO)
Automatic Transmission Fluid:
BMW ATF LT-3 (or equivalent, e.g., Pentosin ATF1)
📐 Dimensions
Exterior
Length:
4,769 mm (187.8 in)
Width:
1,799 mm (70.8 in)
Height:
1,436 mm (56.5 in)
Wheelbase:
2,830 mm (111.4 in)
Weights
Curb Weight:
1,530-1,580 kg (3,373-3,483 lbs) depending on options
Gross Vehicle Weight Rating:
Approx. 2,070 kg (4,564 lbs)
Cargo
Trunk Volume:
460 L (16.2 cu ft)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (for comparable models/years)
IIHS Offset Crash Test:
Good (for comparable models/years)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Automatic Stability Control (ASC+T)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners
Body Structure:
Reinforced passenger cell, crumple zones
💡 Technology Features
Infotainment
Radio:
Factory AM/FM stereo with cassette player and CD changer option. BMW Professional RDS sound system available.
Navigation:
Optional BMW Business or Professional Navigation System with CRT screen.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Sensors:
Optional rear Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional integrated mobile phone preparation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles (12,000-16,000 km) or as indicated by the vehicle's condition-based service (CBS) system.
Spark Plug Replacement:
Approximately every 60,000 to 100,000 miles (96,000-160,000 km) for platinum or iridium plugs, depending on type.
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Transmission Fluid Change:
Manual: 'Lifetime' but recommended every 60,000 miles (96,000 km). Automatic: Recommended every 50,000-60,000 miles (80,000-96,000 km), especially in severe use.
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) or LL-98 approved synthetic oil, typically 5W-30 or 0W-40.
Engine Oil Capacity:
6.5 Liters (6.9 US Quarts)
Coolant:
BMW Blue/Green Coolant (G48) or equivalent ethylene glycol-based coolant with corrosion inhibitors.
Known Issues
Cooling System:
Plastic expansion tank, water pump, and radiator hoses can become brittle and leak over time. Thermostat housing also prone to cracking.
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing gasket are common leak points.
Suspension:
Front control arm bushings and ball joints wear out, leading to knocking noises and imprecise handling. Rear subframe bushings can also deteriorate.
Electrical:
Mass airflow sensor (MAF), idle control valve (ICV), and ABS wheel speed sensors can fail. Pixelated LCD displays in instrument clusters are a common issue.
Interior:
Headliner fabric can sag, door panel vapor barriers can fail causing water leaks into the cabin.
Common Repairs
Vanos Unit:
The VANOS system can develop issues with seals or solenoids, affecting engine performance and idle stability.
Ccv System:
The Crankcase Ventilation (CCV) system can clog, leading to increased oil pressure and leaks.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Long-standing reputation for sporty luxury sedans and advanced engineering.
Model Evolution
E39 Introduction:
The E39 generation replaced the E34 5 Series, launching in 1995 (Europe) and 1996 (North America). Known for significant improvements in chassis dynamics, refinement, and technology over its predecessor.
E39 Generation Characteristics:
Significant emphasis on weight reduction using aluminum in suspension and body components, leading to improved handling and ride comfort. Introduction of advanced electronics and safety features.
Production
Production Years:
1995-2003 (E39 platform)
Manufacturing Locations:
Dingolfing, Germany; Rosslyn, South Africa; Araquari, Brazil; Kaliningrad, Russia
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E39 5 Series (including 525i and 540i variants) was a consistent recipient of Car and Driver's 10Best list during its production years, praised for its handling and balance.
Automotive Journalism:
Widely acclaimed by automotive journalists for its blend of luxury, performance, and handling prowess.
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