🏷️ Basic Information

Make:

BMW

Model:

5 Series

Model Variant:

525i

Chassis Code:

E39

Engine Code:

M52B25 (specific variant may vary slightly across years)

👋 Introduction

Class:

Executive/Luxury Sedan

Target Audience:

Owners of BMW E39 525i seeking to perform DIY maintenance and repairs, professional mechanics, and automotive enthusiasts.

Competitors:

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

Manual Value:

Provides comprehensive, factory-level information essential for maintaining and repairing the BMW E39 525i, saving significant costs compared to dealership servicing.

Vehicle Reputation:

The E39 generation is renowned for its excellent driving dynamics, sophisticated design, and robust build quality.

📋 Manual Details

Supported Years:

1997, 1998, 1999, 2000, 2001, 2002

Estimated Pages:

1000+

Type:

Service and Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine Mechanical:

Detailed repair and overhaul procedures for the M52B25 inline-six engine, including cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, and cooling system.

Engine Management:

Diagnosis and repair of the DME (Digital Motor Electronics) control system, fuel injection, ignition system, emission controls, and sensor functions.

Transmission Manual:

Repair and overhaul of the Getrag 5-speed manual transmission, clutch assembly, driveshafts, and differential.

Transmission Automatic:

Diagnosis, repair, and overhaul of the ZF 5HP19 electronic automatic transmission, including torque converter, valve body, and transmission control module (TCM).

Suspension:

Front and rear suspension components, including struts, shocks, control arms, bushings, springs, sway bars, and alignment specifications.

Steering:

Power steering system diagnosis and repair, including pump, hoses, steering rack, and steering column.

Brakes:

Hydraulic brake system, including master cylinder, brake lines, calipers, pads, rotors, ABS (Anti-lock Braking System) components, and DSC (Dynamic Stability Control) where applicable.

Electrical System:

Comprehensive wiring diagrams, fuse box locations, relay functions, battery, charging system, starter, lighting, and all electrical accessories.

Body And Chassis:

Body panel repair, door mechanisms, glass replacement, interior trim removal and installation, and chassis component checks.

HVAC:

Climate control system diagnosis and repair, including AC compressor, refrigerant, heater core, blower motor, and control modules.

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid changes, and other scheduled service tasks.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting guides, fault code interpretation, and component testing.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds, and electrical system repairs.

Component Replacement:

Detailed step-by-step instructions for replacing virtually every major and minor component in the vehicle.

Special Tools:

Identification and usage instructions for specialized BMW tools required for specific repair procedures.

Depth:

Comprehensive; covers everything from basic maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics and troubleshooting.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Print Quality:

High-resolution digital scans suitable for printing individual pages or the entire manual.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated Inline-Six Cylinder

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

10.2:1

Valve Train:

DOHC, 24 Valves (4 per cylinder), VANOS (Variable Valve Timing)

Horsepower:

170 hp @ 5500 rpm (approx.)

Torque:

245 Nm (181 lb-ft) @ 3950 rpm (approx.)

Fuel Delivery:

Multi-point Fuel Injection (Bosch Motronic)

Fuel Type:

Unleaded Gasoline (Premium Unleaded Recommended)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) - typically 50/50 mix with distilled water.

🔧 Transmission

Type:

5-Speed Manual Transmission (Getrag S5D 250G)

Type:

5-Speed Automatic Transmission (ZF 5HP19)

Transmission Fluid Manual:

BMW MTF-LT-1 or equivalent (check specific year/model).

Transmission Fluid Automatic:

ZF Lifeguardfluid 5 (or equivalent for 5HP19 transmission).

📐 Dimensions

Length:

4,774 mm (188.0 in)

Width:

1,799 mm (70.8 in)

Height:

1,435 mm (56.5 in)

Wheelbase:

2,830 mm (111.4 in)

Curb Weight:

1,540 - 1,610 kg (3,395 - 3,549 lbs) depending on transmission and options.

🛡️ Safety Features

NHTSA Front Impact:

4-star driver, 4-star passenger (for early E39 models).

ABS:

Standard on all models.

Dsc:

Optional or standard on later models (Dynamic Stability Control).

Airbags:

Front dual-stage airbags, optional front side airbags.

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Head Unit:

BMW Business CD or Professional RDS with optional CD changer.

Navigation:

Optional BMW Navigation system (MKII/MKIII) with CRT display.

Cruise Control:

Standard electronic cruise control.

Phone Prep:

Optional Bluetooth or older cellular phone integration (depending on year and package).

🔧 Maintenance

Oil Change Interval:

Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used (BMW Service Indicator system).

Transmission Fluid Change Interval Manual:

BMW stated 'lifetime' but recommended service every 60,000-100,000 miles by enthusiasts/specialists.

Transmission Fluid Change Interval Automatic:

BMW stated 'lifetime' but recommended service every 50,000-80,000 miles by enthusiasts/specialists.

Coolant Change Interval:

Every 2-4 years or as indicated by the service indicator.

Engine Oil Viscosity:

SAE 5W-30 or 5W-40 (BMW LL-01 approved synthetic oil highly recommended).

Engine Oil Capacity:

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

Brake Fluid Type:

DOT 4 (or DOT 4 LV for newer specs if compatible).

Cooling System:

Plastic coolant expansion tanks can become brittle and crack; water pumps and thermostats are common failure points.

Suspension:

Control arm bushings, sway bar links, and front thrust arm bushings are wear items.

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and oil filter housing gaskets are prone to leakage.

Electrical:

Abs sensor failures, pixelated instrument cluster displays, and blower motor resistor failures are common.

Ignition System:

Coil packs and spark plug wires (if applicable to specific M52 variant) can fail, leading to misfires.

📚 Vehicle History

Bmw Philosophy:

BMW's reputation for building driver-focused, high-performance luxury sedans with advanced engineering.

E39 Introduction:

The E39 generation of the 5 Series was introduced in 1995 (for model year 1996 in Europe, 1997 in North America) and succeeded the E34. The 525i was a key model in the lineup.

E39 Facelift:

The E39 received a significant facelift in 2000 (for model year 2001) with updated headlights, taillights, bumpers, and interior revisions.

Production Years:

1997-2003 (for North American market, 1995-2004 globally)

Manufacturing Locations:

Dingolfing, Germany; also assembled in other international locations.

🏆 Awards & Recognition

Car And Driver 5Best:

The E39 5 Series, including variants like the 525i, was a frequent recipient of Car and Driver's '10Best' awards during its production run, lauded for its driving dynamics and refinement.