🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E39

Body Style:

Sedan, Sport Wagon

Product Name:

1997-2002 BMW 5 Series (E39) 525i 528i 530i 540i Sedan Sport Wagon Complete Workshop Service Repair Manual

👋 Introduction

Positioning:

The E39 5 Series represented BMW's executive sedan and wagon offering, known for its blend of luxury, performance, and advanced technology for its time.

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type.

Chassis Design:

Sophisticated multi-link suspension, excellent weight distribution, and a focus on driver engagement.

Engine Options:

Smooth inline-six engines and powerful V8 engines, offering a range of performance characteristics.

Value Proposition:

An indispensable resource for owners and independent repair shops seeking to maintain, diagnose, and repair the E39 5 Series effectively.

Comprehensiveness:

Covers nearly all aspects of vehicle maintenance and repair, providing OEM-level detail.

📋 Manual Details

Specific Models Covered:

525i, 528i, 530i, 540i

Production Years Covered:

1997, 1998, 1999, 2000, 2001, 2002

Estimated Page Count:

Extensive (typically 2000+ pages for a complete workshop manual of this era)

Manual Type:

Complete Workshop Service and Repair Manual

Language:

English

Format:

Digital (likely PDF, often searchable and printable)

📖 Manual Coverage

Engine:

Detailed diagnostics, repair, overhaul for M50/M52/M62 engines (including VANOS, ignition, fuel injection, cooling, exhaust)

Transmission:

Automatic (GM 5L40-E, ZF 5HP19, ZF 5HP24, ZF 5HP30) and Manual (Getrag 6-speed) transmission repair, diagnostics, fluid changes

Drivetrain:

Driveshaft, differential, axle shafts, wheel bearings, AWD (xDrive if applicable for specific regional models, though less common on E39 initially)

Suspension:

Front (McPherson struts, control arms, sway bar), Rear (multi-link, shock absorbers, springs, sway bar), bushings, alignment

Steering:

Power steering system, steering rack, tie rods, steering column, wheel alignment

Brakes:

Hydraulic system, ABS, DSC (Dynamic Stability Control), EBD, brake calipers, rotors, pads, parking brake, bleeding procedures

Electrical System:

Battery, alternator, starter, wiring diagrams, fuses, relays, lighting, horn, power windows, locks, mirrors, seats

Body And Chassis:

Body panels, doors, hood, trunk, bumpers, sunroof, interior trim, sound deadening, chassis lubrication

HVAC:

Air conditioning, heating, climate control system, blower motor, refrigerant, evaporator, condenser, cabin filter

Fuel System:

Fuel pump, fuel filter, injectors, fuel lines, fuel tank, EVAP system

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors

Safety Systems:

Airbags, seat belts, SRS control module, crash sensors

Instrumentation And Controls:

Dashboard, instrument cluster, warning lights, switches, steering wheel controls

Infotainment And Electronics:

Radio, CD player, navigation system (if equipped), speakers, antenna, park distance control (PDC), onboard computer (OBC)

Routine Maintenance:

Oil change, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, spark plug replacement

Diagnostic Procedures:

Troubleshooting common symptoms, fault code retrieval and interpretation (e.g., via OBD-II, BMW specific codes), component testing

Repair And Overhaul:

Engine rebuilds, transmission repairs, suspension component replacement, brake caliper rebuilds, electrical component repair

Scheduled Maintenance:

Detailed intervals and procedures for long-term upkeep

Component Replacement:

Step-by-step guides for replacing major and minor components

Technical Specifications Lookup:

Torque values, clearances, fluid capacities, diagnostic parameters

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and transmission overhauls

Diagnostic Focus:

Detailed diagnostic flowcharts, component testing, and symptom-based troubleshooting

Wiring Diagrams:

Detailed, system-specific wiring schematics with component identification

Special Tools:

Identification of specific tools required for certain procedures

📊 Manual Specifications

File Format:

PDF (typically)

Searchability:

Likely includes searchable text for quick information retrieval

Print Quality:

High-resolution scans suitable for printing key sections or the entire manual

Binding Type:

N/A (Digital format)

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Engine Code:

M52TU B25

Displacement:

2.5 Liters (2494 cc)

Configuration:

Inline 6-cylinder, DOHC, 24 valves

Horsepower:

189 hp @ 5900 rpm

Torque:

181 lb-ft @ 3500 rpm

Fuel System:

Multi-point fuel injection (Bosch Motronic)

Engine Code:

M52TU B28

Displacement:

2.8 Liters (2793 cc)

Configuration:

Inline 6-cylinder, DOHC, 24 valves

Horsepower:

193 hp @ 5500 rpm

Torque:

206 lb-ft @ 3500 rpm

Fuel System:

Multi-point fuel injection (Bosch Motronic)

Engine Code:

M54 B30

Displacement:

3.0 Liters (2979 cc)

Configuration:

Inline 6-cylinder, DOHC, 24 valves

Horsepower:

225 hp @ 5900 rpm

Torque:

214 lb-ft @ 3500 rpm

Fuel System:

Multi-point fuel injection (Bosch Motronic ME 7.2)

Engine Code:

M62TU B44

Displacement:

4.4 Liters (4398 cc)

Configuration:

V8, DOHC, 32 valves

Horsepower:

290 hp @ 5400 rpm

Torque:

324 lb-ft @ 3600 rpm

Fuel System:

Multi-point fuel injection (Bosch Motronic ME 7.2)

Note:

Performance figures are approximate and may vary based on transmission, vehicle condition, and specific market.

🔧 Transmission

Standard Transmission:

5-speed Manual (Getrag 420G for later models/some markets)

Optional Transmission:

5-speed Automatic (GM 5L40-E)

Standard Transmission:

5-speed Automatic (ZF 5HP24)

Optional Transmission:

6-speed Manual (Getrag 420G, rare in North America)

Traction Control:

ASC+T (Automatic Stability Control + Traction) or DSC (Dynamic Stability Control) depending on year and options.

Automatic Transmission Fluid Type:

BMW ATF LT-3 or equivalent (check specific vehicle documentation, e.g., ZF LifeguardFluid 5)

Manual Transmission Fluid Type:

BMW MTF LT-2 or equivalent (e.g., Castrol TWS Motorsport 75W-90 or similar spec)

📐 Dimensions

Length:

Approx. 188.5 inches (4788 mm)

Width:

Approx. 71.0 inches (1803 mm)

Height:

Approx. 57.0 inches (1448 mm)

Length:

Approx. 190.2 inches (4831 mm)

Width:

Approx. 71.0 inches (1803 mm)

Height:

Approx. 57.8 inches (1468 mm)

Curb Weight Range:

Approx. 3500-3900 lbs (1588-1769 kg), varies by model and options

Gross Vehicle Weight Rating:

Varies by model, refer to vehicle specific plate.

Cargo Volume Seats Up:

Approx. 23.7 cubic feet (671 L)

Cargo Volume Seats Down:

Approx. 57.4 cubic feet (1625 L)

Wheelbase:

115.4 inches (2931 mm)

Wheel Bolt Pattern:

5 x 120 mm

Common Tire Sizes:

225/60R16, 235/45R17, 235/40R18 (depending on trim and options)

🛡️ Safety Features

NHTSA Front Impact Rating:

4/5 stars (for most models)

IIHS Offset Frontal Crash Rating:

Good (for models tested)

ABS:

Standard Anti-lock Braking System

Traction Control:

ASC+T or DSC (Dynamic Stability Control) - standard on later models/higher trims

Brake Assist:

Available on some models

Airbags:

Frontal airbags, front side-impact airbags, optional rear side-impact airbags

Seatbelts:

Three-point inertia-reel seatbelts with pre-tensioners

Head Restraints:

Active head restraints on front seats (on some models/years)

💡 Technology Features

Head Unit Options:

BMW Business CD, BMW Professional CD RDS, optional navigation system (Mk III/Mk IV).

Audio System:

Standard 10-speaker Hi-Fi system, optional Harman Kardon surround sound system.

Stability Control:

Available ASC+T or the more advanced DSC (Dynamic Stability Control) system.

Parking Assistance:

Park Distance Control (PDC) sensors (front and rear on later models).

Onboard Computer:

Onboard Computer (OBC) providing information on fuel economy, range, average speed, and system checks.

Telematics:

Optional BMW Assist telematics system (cellular phone integration, emergency services).

Climate Control:

Automatic climate control with dual-zone temperature settings, pollen filter.

Seating:

Standard power-adjustable front seats, optional comfort seats with memory, heated seats.

🔧 Maintenance

Engine Oil Change Interval:

Typically every 7,500 to 10,000 miles or annually, or as indicated by the onboard computer (Service Interval Indicator - SII) using synthetic oil.

Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000 to 30,000 miles or as needed based on driving conditions.

Cabin Air Filter Replacement:

Every 15,000 to 30,000 miles or annually.

Coolant Flush:

Every 30,000 to 60,000 miles or 2-4 years.

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Spark Plug Replacement M52Tu M54:

Approx. 60,000 miles (using long-life spark plugs).

Spark Plug Replacement M62Tu:

Approx. 100,000 miles (using long-life spark plugs).

Engine Oil Type:

Synthetic SAE 5W-30 or 5W-40 meeting BMW LL-01 specification (or older LL-98 for some early models, consult manual).

Engine Oil Capacity:

525i/528i/530i: Approx. 6.5-7.0 quarts (6.2-6.6 L); 540i: Approx. 7.0-7.5 quarts (6.6-7.1 L). Refer to manual for exact fill.

Coolant Type:

BMW Blue Coolant (G48) or approved equivalent.

Power Steering Fluid Type:

Pentosin CHF 11S or equivalent approved fluid.

Cooling System Failures:

Plastic expansion tank leaks, water pump failure (plastic impeller), thermostat housing leaks.

Oil Leaks:

Valve cover gasket, oil pan gasket, oil filter housing gasket, CCV system leaks.

Suspension Wear:

Control arm bushings, ball joints, sway bar links, rear subframe bushings.

Electrical Gremlins:

ABS/DSC module failures, headlight leveling issues, instrument cluster pixelation (LCD displays).

Vanos System:

Wear in the VANOS solenoids and seals can lead to rough idle, loss of power, and increased fuel consumption.

E39 Specific Issues:

Sagging headliner, pixelated OBC displays, heater control valve failure, ABS speed sensor failures.

📚 Vehicle History

Bmw Philosophy:

BMW's reputation for building driver-focused, well-engineered automobiles with a focus on performance and luxury.

E39 Introduction:

Launched in 1995 (as a 1996 model in some markets), the E39 replaced the E34 and was produced until 2003. It represented a significant technological and design advancement.

Mid-Cycle Refresh:

The E39 received a facelift in 2000, which included updated headlights (angel eyes), taillights, bumpers, interior trim, and the introduction of the M54 engines.

Manufacturing Locations:

Primarily Dingolfing, Germany. Some assembly may have occurred in other BMW facilities or through contract manufacturing.

Sales Figures:

The E39 was a highly successful model for BMW, with over one million units produced worldwide.

🏆 Awards & Recognition

Car And Driver 10 Best:

The E39 5 Series was frequently named to Car and Driver's 10 Best lists during its production run, a testament to its engineering and driving dynamics.

Consumer Reports Ratings:

Generally received good to excellent ratings for performance, comfort, and reliability, with some model years and specific issues noted.

Euro Ncapsafety Rating:

4 stars for adult occupant protection (for models tested).