E39 Market Segment:
Executive/Luxury Mid-size Sedan and Wagon
Target Audience For Manual:
BMW owners, independent repair shops, automotive enthusiasts
E39 Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type
Driving Dynamics:
Renowned for balanced chassis, RWD platform, and engaging driving experience
Build Quality:
High level of German engineering and build quality
Design Evolution:
Sleek, timeless design with a significant facelift in 2001 (LCI)
Engine Mechanical:
Engine overhaul, cylinder head, pistons, crankshaft, timing, lubrication, cooling, fuel injection, emission controls
Engine Electrical:
Ignition system, sensors (MAF, O2, Crankshaft, Camshaft), Engine Control Module (ECM) diagnostics, wiring diagrams
Transmission Manual:
Clutch, gearbox overhaul, shift mechanism, driveshafts
Transmission Automatic:
Automatic transmission (e.g., GM 5L40-E, ZF 5HP) overhaul, torque converter, transmission control unit (TCU), fluid service
Drivetrain:
Differential, rear axle, driveshafts, universal joints
Suspension:
Front and rear suspension components (struts, control arms, bushings, springs, shocks), alignment specifications
Steering:
Power steering system, steering rack, tie rods, steering column
Brakes:
Brake system (front/rear discs, calipers, master cylinder, ABS, DSC), brake fluid specifications, bleeding procedures
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting, fuses, relays, body control module (BCM), comfort electronics
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, blower motor, climate control unit
Bodywork Exterior:
Body panels, doors, hood, trunk, bumpers, glass, trim
Bodywork Interior:
Interior trim, seats, dashboard, airbags, seat belts
Diagnostics:
On-Board Diagnostics (OBD-II) procedures, fault code interpretation, troubleshooting charts
Routine Maintenance:
Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, belt inspection/replacement
Major Repairs:
Engine rebuild, transmission overhaul, suspension component replacement, brake caliper replacement, radiator replacement
Electrical Diagnostics:
Tracing electrical faults, testing components, understanding wiring diagrams
Troubleshooting:
Step-by-step guides for diagnosing common and uncommon issues
Component Replacement:
Detailed instructions for replacing virtually any component
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems
Depth Of Coverage:
Complete workshop level, suitable for professional technicians and advanced DIYers
Diagnostic Tools Mention:
Likely references BMW's proprietary diagnostic systems (e.g., DIS, ISTA) and generic OBD-II tools
Torque Specifications:
Detailed torque values for all critical fasteners
Special Tools:
Lists required BMW special tools for specific procedures
Engine Lineup Overview:
Inline-6 (M50, M52, M54) and V8 (M62, M62TU) gasoline engines
525I Engine Displacement:
2.5 Liters (approx. 2494cc)
525I Horsepower Range:
189 hp to 192 hp
528I Engine Displacement:
2.8 Liters (approx. 2793cc)
528I Horsepower Range:
190 hp to 193 hp
530I Engine Displacement:
3.0 Liters (approx. 2979cc)
540I Engine Displacement:
4.4 Liters (approx. 4398cc)
540I Horsepower Range:
282 hp (M62) to 290 hp (M62TU)
Fuel Delivery:
Bosch Motronic Engine Management System, Fuel Injection
Recommended Fuel:
Premium Unleaded Gasoline (91 Octane or higher)
Standard Transmission 525I 528I 530I:
5-speed Manual (Getrag 260/6 or similar)
Standard Transmission 540I:
5-speed Automatic (ZF 5HP30)
Optional Transmission 525I 528I 530I:
5-speed Automatic (GM 5L40-E)
Optional Transmission 540I:
6-speed Manual (Getrag 420G) available on some models
Traction Control:
ASC+T (Automatic Stability Control and Traction) or DSC (Dynamic Stability Control) on later models
NHTSA Frontal Crash Rating:
4-star (driver) / 5-star (passenger) for early models
IIHS Side Impact Rating:
Good (for comparable models of the era)
Stability Control:
Available ASC+T and DSC (Dynamic Stability Control)
Traction Control:
Standard on most models
ABS:
Standard Anti-lock Braking System
Airbags:
Frontal airbags, optional side airbags, optional head protection airbags (HPS)
Seatbelts:
Pretensioner seatbelts with force limiters
Headrests:
Active headrests on some later models
Oil Change Interval:
BMW Condition Based Service (CBS) system, typically 10,000-15,000 miles or annually, whichever comes first.
Microfilter Replacement:
Typically every 2 years or 20,000-30,000 miles
Spark Plug Replacement:
M54 engines: ~100,000 miles. M52/M50: ~60,000 miles. M62: ~100,000 miles.
Coolant Flush:
BMW recommends replacing coolant every 4 years or 60,000 miles
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-04 (for diesels, not applicable here), typically 5W-30 or 5W-40 synthetic
Transmission Fluid Automatic:
Specific to transmission type (e.g., GM Dexron III/VI for 5L40-E, ZF Lifeguardfluid5 for 5HP30). Manual requires ATF or gear oil depending on type.
Brake Fluid:
DOT 4 (BMW recommends DOT 4 HP)
Coolant:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)
Cooling System:
Plastic coolant expansion tank failure, water pump failure (plastic impeller), thermostat housing leaks
Vanos System:
Vanous (Variable Valve Timing) rattle on startup, particularly with M52TU and M54 engines due to worn seals or solenoids
Oil Leaks:
Valve cover gasket, oil pan gasket, oil filter housing gasket
Suspension Bushings:
Wear in front control arm bushings (RTABS), rear trailing arm bushings
Ignition System:
Coil-on-plug ignition system issues, spark plug well oil contamination
ABS Asc Sensors:
Failure of ABS/ASC wheel speed sensors leading to warning lights and system malfunction
Power Window Regulators:
Plastic components in window regulators can break
Pixel Display Failure:
Instrument cluster LCD screen dead pixels
