🏷️ Basic Information

Make:

BMW

Model:

525i

Model Code:

E39

Production Years Covered By Manual:

1997, 1998, 1999, 2000, 2001, 2002

Engine Codes:

M50B25TU (early), M52B25, M52TUB25

👋 Introduction

Market Segment:

Executive Sedan

Target Audience:

Owners, independent repair shops, DIY enthusiasts seeking in-depth repair knowledge.

Competitors:

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

Vehicle Philosophy:

Focus on driving dynamics, luxury, and sophisticated engineering.

Manual Advantage:

Provides the detailed technical information necessary for authentic BMW maintenance and repair, crucial for preserving performance and longevity.

📋 Manual Details

Manual Scope:

Comprehensive Workshop Service and Repair

Page Count:

1002

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete engine diagnostics, disassembly, assembly, timing, cooling system, lubrication system, fuel delivery, ignition system, emissions control.

Transmission:

Manual and automatic transmission service, overhaul, diagnosis, fluid specifications, shift control systems.

Drivetrain:

Driveshafts, CV joints, differential, rear axle assembly, wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, struts, control arms, bushings, alignment specifications, troubleshooting.

Brakes:

Hydraulic system, ABS, DSC (Dynamic Stability Control), brake pad replacement, rotor resurfacing/replacement, caliper service, bleeding procedures.

Steering:

Power steering system, steering rack, tie rods, steering column, diagnosis and repair.

Electrical System:

Battery, charging system, starter, lighting, body electronics, instrument cluster, power windows, locks, mirrors, diagnosis using wiring diagrams.

Climate Control:

HVAC system, A/C system diagnosis and recharge, heater core, blower motor, climate control unit.

Body And Chassis:

Exterior panels, interior trim, doors, windows, bumpers, underbody, rust prevention, body repair procedures.

Safety Systems:

Airbag system (SRS) diagnosis and replacement, seat belt mechanisms.

Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt replacement, brake service, tire rotation.

Repair:

Detailed step-by-step repair instructions for all major mechanical and electrical components.

Troubleshooting:

Diagnostic charts and symptom-based troubleshooting guides for common and complex issues.

Diagnostics:

OBD-II diagnostic procedures, fault code interpretation, sensor testing, ECU diagnostics.

Rebuilds:

Engine and transmission rebuild procedures with component specifications and tolerances.

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values.

Depth:

Comprehensive, from basic maintenance to complete engine/transmission overhauls and advanced electrical diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text enabled

Printability:

Printable pages

Image Resolution:

High resolution for clear diagrams and illustrations

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Inline 6-cylinder, DOHC, 24-valve

Displacement:

2.5 Liters (2494 cc)

Engine Code Common:

M52B25 / M52TUB25

Horsepower Peak:

189 hp @ 5900 rpm (approximate, varies slightly by market/year)

Torque Peak:

245 Nm / 181 lb-ft @ 3950 rpm (approximate)

Engine Management System:

Bosch Motronic (various versions like ME 7.2)

Fuel Type:

Unleaded Gasoline (Premium recommended)

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-Point Injection (MPI)

Valvetrain:

Double Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing) on intake camshaft.

🔧 Transmission

Transmission Type Standard:

5-speed Manual (Getrag 260/5, later ZF S5-31)

Transmission Type Optional:

5-speed Automatic (Steptronic, GM 5L40-E)

Automatic Features:

Steptronic manual shifting mode.

Automatic Transmission Fluid:

Dexron III / Mercon equivalent (e.g., BMW Part No. 83 22 0 031 307)

Manual Transmission Fluid:

MTF LT-2 or equivalent (e.g., BMW Part No. 83 22 9 408 092)

📐 Dimensions

Length:

~4770 mm / 187.8 in

Width:

~1800 mm / 70.9 in

Height:

~1435 mm / 56.5 in

Curb Weight:

~1500-1600 kg / 3300-3520 lbs (varies by transmission and options)

Wheelbase:

~2830 mm / 111.4 in

🛡️ Safety Features

NHTSA Front Impact:

4-star (driver), 4-star (passenger) for E39 platform

IIHS Side Impact:

Good (for E39 platform)

Traction Control:

ASC+T (Automatic Stability Control and Traction) often standard or optional.

Stability Control:

DSC (Dynamic Stability Control) available on later models.

Braking System:

ABS (Anti-lock Braking System) standard, EBD (Electronic Brake-force Distribution).

Airbags:

Frontal airbags (driver and passenger), side airbags (optional), head airbags (optional).

Seatbelts:

Pretensioners and force limiters on front seat belts.

💡 Technology Features

Audio System:

BMW Business/Professional CD radios, optional Harman Kardon audio system.

Navigation:

Optional BMW Navigation system (MKII/MKIII era) with CRT or LCD screen.

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Cruise Control:

Standard electronic cruise control.

Phone Integration:

Optional Bluetooth preparation with ULF module for hands-free calling (on later models).

🔧 Maintenance

Oil Change Interval:

BMW Condition Based Service (CBS) typically around 10,000-15,000 miles or 12-24 months. Refer to manual for specific CBS prompts.

Spark Plug Replacement:

Approx. 100,000 miles (Long-Life Platinum/Iridium spark plugs).

Coolant Flush:

Every 2-4 years or as indicated by CBS. Use BMW Blue Coolant (G48).

Engine Oil Type:

API SJ or higher, ACEA A3/B3, BMW LL-98 (synthetic). Viscosity: 5W-30 or 5W-40 recommended.

Engine Oil Capacity:

Approx. 6.5 liters (6.9 US quarts) with filter.

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 standard)

Brake Fluid:

DOT 4 (low viscosity recommended, BMW Part No. 81 22 9 400 803)

Common Problems:

Cooling system (plastic expansion tank, water pump, hoses), VANOS unit, oil pan gasket leaks, ABS/DSC sensor failures, fuel pump, ignition coils, window regulators, CCV system (crankcase ventilation).

Oil Pan Gasket Issue:

Prone to drying out and leaking over time, requiring significant labor to replace.

Vanos Reliability:

Seals can degrade, leading to rough idle and loss of low-end torque.

📚 Vehicle History

Brand Legacy:

BMW's reputation for sporty luxury sedans and engineering excellence.

Generation Name:

E39

Introduction Year:

1995 (global), 1996 (North America)

Facelift:

2000 (LCI - Life Cycle Impulse), featuring updated headlights (angel eyes), taillights, bumpers, and interior enhancements.

Production Start:

1995

Production End:

2003

Manufacturing Locations:

Germany (Dingolfing), Austria, South Africa, Egypt, Russia, Thailand, Indonesia, Malaysia, Vietnam, India.

🏆 Awards & Recognition

Car And Driver Best:

Car and Driver's 10 Best Cars list multiple times during its production run.

European Car Of The Year:

While not a winner, the E39 platform was highly regarded in its class.

Safety Certification:

Meets or exceeds all relevant federal motor vehicle safety standards (FMVSS) for its model years.