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BMW 525 525i 2002 Service Repair Workshop Manual

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$16.99
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🏷️ Basic Information Identification Make: BMW Model: 525i Year: 2002 Generation Chassis Code: E39 Codes Engine Code Common: M54B25 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Key Competitors:...
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斯库: 432739
BMW 525 525i 2002 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
525i
Year:
2002
Generation
Chassis Code:
E39
Codes
Engine Code Common:
M54B25
👋 Introduction
Market Position
Segment:
Executive Sedan
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type
Key Features
Vehicle Philosophy:
Blends luxury, performance, and advanced engineering characteristic of BMW's 'Ultimate Driving Machine' ethos.
Manual Value Proposition:
Provides professional-grade repair and maintenance information, empowering owners and independent mechanics to service the vehicle accurately and efficiently.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, as inferred from common practice)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnostics, timing, lubrication, cooling, fuel delivery, emissions control, exhaust systems
Engine Electrical:
Ignition system, starter, alternator, ECU, sensors, wiring diagrams
Transmission:
Automatic Transmission (e.g., GM 5L40-E), manual transmission, clutch, driveline, differential
Suspension Steering:
Front and rear suspension, steering gear, power steering system, wheel alignment
Brakes:
Hydraulic system, ABS, DSC, brake pads, rotors, calipers, parking brake
Body Interior:
Body panels, doors, windows, seats, trim, HVAC system, body electrical
Electrical Systems:
Lighting, power accessories, central locking, alarm system, instrument cluster, OBC (On-Board Computer)
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement
Troubleshooting:
Diagnostic procedures for common faults, DTC (Diagnostic Trouble Codes) interpretation, fault finding charts
Repair:
Step-by-step repair instructions for all major components and systems, component replacement, assembly/disassembly
Diagnostics:
Procedures for using diagnostic tools, reading sensor data, testing electrical circuits
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and component-level repair
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - typically searchable and bookmarked for easy navigation
Print Quality
Quality:
High resolution for clear text and diagrams
Binding Type
Binding:
N/A (for digital format)
Paper Type
Paper:
N/A (for digital format)
⚙️ Engine Specifications
Primary Engine
Engine Name:
BMW M54B25
Engine Type:
Inline 6-cylinder, Naturally Aspirated
Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
189 hp @ 6000 rpm
Torque:
245 Nm (181 lb-ft) @ 3500 rpm
Fuel System
Fuel Injection:
Multi-point Fuel Injection (Bosch Motronic ME7.2)
Fuel Type:
Premium Unleaded (91+ octane recommended)
Engine Components
Valvetrain:
Double Overhead Camshafts (DOHC), 24 valves, VANOS (Variable Valve Timing)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (Getrag Type G285)
Optional
Transmission Type:
5-speed Automatic Transmission (GM 5L40-E)
Features
Traction Control:
Available with Dynamic Stability Control (DSC)
Fluid Specifications
Automatic Transmission Fluid:
BMW LT-3 or equivalent (check specific model/transmission)
Fluid Capacities
Automatic Transmission Capacity:
Approx. 8.5 Liters (8.9 US quarts) - subject to exact procedure
📐 Dimensions
Exterior
Length:
4,770 mm (187.8 in)
Width:
1,799 mm (70.8 in)
Height:
1,436 mm (56.5 in)
Wheelbase
Wheelbase:
2,830 mm (111.4 in)
Weights
Curb Weight Manual:
Approx. 1,585 kg (3,494 lbs)
Curb Weight Automatic:
Approx. 1,610 kg (3,550 lbs)
Cargo
Trunk Capacity:
460 Liters (16.2 cu ft)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars (Driver and Passenger)
IIHS Side Impact:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Dsc:
Optional Dynamic Stability Control (DSC)
Passive Features
Airbags:
Frontal airbags for driver and passenger, optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters
💡 Technology Features
Infotainment
Head Unit:
BMW Business or Professional CD players with optional navigation system (MKIV).
Features:
Radio, CD player, optional cassette, optional navigation, optional premium audio system (e.g., Harman Kardon).
Driver Assistance
Traction Control:
Standard Traction Control (ASC+T) on some models, optional Dynamic Stability Control (DSC).
Connectivity
Telematics:
Optional Tele Aid system (early cellular-based emergency assistance).
Comfort Features
Climate Control:
Dual-zone automatic climate control
Seats:
Electrically adjustable front seats with memory function for driver's seat available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles or 12 months, depending on driving conditions and oil quality. Consult manual for specific Condition Based Service (CBS) indications.
Spark Plug Replacement:
Approximately every 60,000 miles (depending on spark plug type - standard vs. long-life)
Brake Fluid Flush:
Every 2 years (as per BMW recommendation)
Fluid Specifications
Engine Oil:
BMW LL-01 approved synthetic oil, typically SAE 5W-30 or 0W-30. Refer to manual for exact viscosity and spec.
Coolant:
BMW Blue Antifreeze/Coolant (G48 formulation), mixed 50/50 with distilled water
Power Steering Fluid:
Pentosin CHF 11S or equivalent BMW hydraulic fluid
Known Issues
Crankcase Ventilation:
CCV (Crankcase Ventilation) system can clog, leading to oil consumption, vacuum leaks, and rough idle.
Cooling System:
Plastic coolant expansion tank can become brittle and crack; water pump and thermostat failures are also common.
Oil Pan Gasket:
Oil pan gasket and valve cover gasket leaks are frequent due to age and material degradation.
ABS Asc Sensor Rings:
The ABS/ASC sensor rings on the driveshafts are prone to cracking or rusting, causing ABS/ASC warning lights.
Window Regulators:
Power window regulators can fail, particularly the plastic components.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW has a long-standing reputation for building sporty, luxurious, and technologically advanced automobiles since its founding in 1916.
Model Evolution
E39 Generation:
The E39 generation (1995-2003) is renowned for its superb chassis dynamics, improved interior quality, and advanced technology over its E34 predecessor. The 525i was a popular mid-range model in this lineup.
Production
Production Period:
The E39 5 Series was produced from 1995 to 2003, with the 525i variant featuring the M54 engine introduced in the later years of this generation (around 2000-2003).
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Car and Driver has consistently ranked the BMW 5 Series (including the E39 generation) on its annual '10Best' list for its excellent driving dynamics and overall refinement.
Automotive Journalism:
Praised by automotive journalists for its sophisticated chassis, powerful yet smooth inline-six engines, and high-quality interior.
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