Era:
Late 1990s / Early 2000s luxury market
Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160).
Vehicle Focus:
Sporty handling, refined interiors, powerful inline-six engines, technological advancements for its time.
Manual Value Proposition:
Provides comprehensive DIY repair and maintenance information for owners looking to maintain their E39 525i, saving on dealership costs and ensuring proper upkeep.
Engine:
Engine mechanicals, cooling system, lubrication system, fuel system, ignition system, engine control unit (ECU), emissions control.
Transmission:
Manual transmission (Getrag 220/250), Automatic transmission (ZF 5HP18/5HP19/5HP24), clutch system, driveshafts, differentials.
Brakes:
Brake system diagnosis and repair, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid specifications, rotor and pad replacement, caliper service.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering rack, power steering system.
Electrical:
Complete wiring diagrams, fuse box locations and functions, battery, alternator, starter motor, lighting systems, horn, wipers, power windows, central locking, dashboard indicators, diagnostic connector (OBD-II).
Body Chassis:
Body panel repair, door mechanisms, interior trim removal, bumpers, glass replacement, chassis lubrication, rust prevention.
Climate Control:
HVAC (Heating, Ventilation, Air Conditioning) system diagnosis and repair, refrigerant types, compressor service, climate control module.
Maintenance:
Routine service, oil changes, filter replacements, spark plug replacement, fluid checks and changes, brake pad/rotor replacement, belt replacement.
Repair:
Engine tune-up, cooling system repair, fuel injector service, transmission service, brake caliper rebuild, suspension component replacement, electrical component diagnosis and replacement.
Troubleshooting:
Step-by-step diagnostic procedures for common and complex issues, fault code interpretation, electrical circuit tracing.
Diagnostics:
On-board diagnostics (OBD-II) interpretation, using diagnostic tools, reading error codes, live data analysis.
Depth:
Comprehensive coverage from basic maintenance to in-depth engine and transmission overhauls, including detailed torque specifications and repair sequences.
Quality:
High-resolution, searchable PDF with clear diagrams and illustrations.
Searchable:
Yes, full text search capability.
Printable:
Yes, individual pages or sections can be printed.
Binding:
Not applicable (Digital PDF download)
Paper Type:
Not applicable (Digital PDF download)
Engine Type:
Inline-6 Cylinder, DOHC, 24 valves
Engine Codes Prefacelift:
M50B25TU (for early 97) or M52B25 (2.5L)
Engine Codes Facelift:
M54B25 (2.5L, Vanos, Valvetronic)
Displacement:
2494 cc (2.5 Liters)
Horsepower M52B25:
168-170 hp @ 5500-5800 rpm
Horsepower M54B25:
184 hp @ 6000 rpm
Torque M52B25:
181 lb-ft (245 Nm) @ 3900-4200 rpm
Torque M54B25:
175 lb-ft (237 Nm) @ 3500 rpm
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic 5.2/5.2.1 for M52, MS43/MS43.1 for M54)
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Vanos:
Double VANOS (Variable Valve Timing) on M52TU and M54 engines.
Valvetronic:
Valvetronic (variable valve lift) on M54 engines.
Transmission Type:
5-Speed Manual (Getrag 220 on early models, Getrag 250 on later models)
Transmission Type:
5-Speed Automatic (ZF 5HP18/5HP19 on M52/M52TU, ZF 5HP24 on M54)
Automatic Features:
Steptronic (manual shifting mode) available on some automatic transmissions.
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent (check manual for specific PN)
Automatic Transmission Fluid:
ZF Lifeguardfluid 5 or equivalent (check manual for specific PN)
Length:
Approx. 188.2 inches (4780 mm)
Width:
Approx. 71.0 inches (1803 mm)
Height:
Approx. 57.4 inches (1458 mm)
Wheelbase:
Approx. 111.4 inches (2830 mm)
Curb Weight:
Approx. 3500-3700 lbs (1588-1678 kg), varies by transmission and options.
Gross Vehicle Weight Rating:
Refer to vehicle's VIN plate or manual.
NHTSA Front Impact:
4-star (driver), 4-star (passenger) (US spec, approximate for era)
IIHS Side Impact:
Good (US spec, approximate for era)
Dsc:
Dynamic Stability Control (optional on some early models, standard on later models)
Traction Control:
Available as part of DSC or as a separate system (ASC+T).
Airbags:
Driver and front passenger airbags standard. Side airbags available.
Seatbelts:
Front 3-point automatic locking retractors with pre-tensioners and force limiters. Rear 3-point seatbelts.
Head Unit:
BMW Professional RDS or Business CD radios. Optional navigation system (MK series). Cassette player standard, CD changer optional.
Display:
Central OBC (On-Board Computer) display in instrument cluster, often prone to 'dead pixels'. Optional color LCD for navigation.
Parking Sensors:
Park Distance Control (PDC) available as an option.
Bluetooth:
Available via optional BMW Bluetooth car kits or aftermarket integrations.
Headlights:
Halogen reflectors standard. Xenon Adaptive Headlights optional on facelift models.
Oil Change Interval:
BMW Condition Based Service (CBS) system or approx. every 7,500 - 15,000 miles (12,000 - 24,000 km) depending on driving conditions and oil type used. Consult manual for specific CBS reset procedures.
Air Filter Replacement:
Approx. every 30,000 miles (48,000 km) or as per CBS.
Spark Plug Replacement:
Approx. every 60,000 miles (96,000 km) for standard plugs, or 100,000 miles (160,000 km) for long-life plugs (e.g., platinum/iridium).
Engine Oil Type:
BMW Longlife-01 (LL-01) compliant synthetic oil, typically 5W-30 or 0W-40. Check manual for specific viscosity recommendations based on climate.
Engine Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 (BMW Super DOT 4 recommended).
Common Problems:
Coolant expansion tank leaks, cracked vacuum hoses, VANOS solenoids/seals, oil filter housing gasket leaks, fuel pump failure, ABS/DSC sensor issues, sticky pixels on the instrument cluster OBC display, worn suspension bushings.
Oil Sludge:
Risk of oil sludge formation in M54 engines if oil changes are neglected or incorrect oil is used. Regular maintenance is crucial.
Bmw Philosophy:
Bayerische Motoren Werke AG, renowned for performance, engineering, and luxury in automobiles.
E39 Introduction:
The E39 generation of the 5 Series was introduced in 1995 (as a 1996 model in some markets) and replaced the E34. The 525i variant was a core model offering a balance of performance and efficiency.
Facelift:
A significant facelift occurred for the 2001 model year, featuring updated headlights (angel eyes/halos), taillights, bumpers, and the introduction of the M54 engine with Valvetronic technology.
Production Period:
1995-2003 (E39 generation). This manual covers the 1997-2002 model years.
Manufacturing Plants:
Primarily Dingolfing, Germany, with some assembly in other locations globally.
