🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variants Covered: 525i, 528i, 540i Codes Chassis Code: E39 Production Years Covered: 1997-2002 👋 Introduction Market Position Vehicle Segment: Executive Sedan, Luxury Mid-size Sedan. Target Audience: Owners seeking to maintain and repair their E39 5 Series, DIY enthusiasts, independent workshops. Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS, Jaguar S-Type. Key Features Vehicle Platform: The E39 platform is renowned for its excellent chassis dynamics, refined ride, and build quality. Manual Value Proposition: Offers a single, consolidated resource for all repair and maintenance needs, saving time and money compared to individual service bulletins. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Page Count Page Count: Hundreds of Pages (Specific count not provided, but implies comprehensive coverage) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed engine disassembly, assembly, overhaul, diagnostics for M50, M52, M62 engines. Engine Management: Ignition system, fuel injection, emissions control, ECU diagnosis, DME function. Transmission Manual: Service, repair, and overhaul procedures for Getrag 5-speed and 6-speed manual transmissions. Transmission Automatic: Service and repair procedures for ZF 5HP19 (for 525i/528i) and ZF 5HP30 (for 540i) automatic transmissions. Drivetrain: Driveshaft, differential, axles, wheel bearings, universal joints. Suspension: Front and rear suspension components, struts, shocks, control arms, ball joints, bushings, steering linkage. Brakes: Hydraulic system, ABS, DSC, brake calipers, rotors, pads, lines, bleeding procedures. Steering: Power steering system, steering rack, pump, hoses, alignment specifications. Electrical System: Battery, charging system, starter, lighting, fuses, relays, wiring diagrams. Body And Interior: Body panels, doors, windows, sunroof, seats, dashboard, trim. HVAC: Heating, ventilation, air conditioning system diagnosis and repair. Safety Systems: Airbags, seatbelt pre-tensioners, SRS system. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks, inspections, lubrication points. Diagnostics: Troubleshooting guides, common fault codes, diagnostic procedures for all major systems. Repair Procedures: Step-by-step instructions for component replacement, system overhaul, and major repairs. Rebuilding: Comprehensive guides for engine and transmission rebuilding. Refurbishment: Guidance on restoring various vehicle components and systems. Restoration: Detailed information applicable to the restoration of E39 models. Technical Depth Depth Level: Complete Workshop Manual level covering all aspects from routine maintenance to in-depth mechanical and electrical repair. 📊 Manual Specifications File Format File Format Type: PDF Searchable Text: Likely searchable, as is standard for high-quality PDF manuals. Printable: Assumed printable for ease of use in a workshop environment. Document Structure: Includes a comprehensive Table of Contents for efficient navigation. Print Quality Image Resolution: High resolution images and diagrams expected for clarity. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine 525I: 3.0L M54B30 I6 (for later models, earlier 2.5L M52TU) Engine 528I: 2.8L M52B28/M52TU I6 Engine 540I: 4.4L M62 V8 Performance Horsepower 525I M54: 225 hp @ 6000 rpm (approx.) Torque 525I M54: 214 lb-ft @ 3500 rpm (approx.) Horsepower 528I M52Tu: 193 hp @ 5300 rpm (approx.) Torque 528I M52Tu: 206 lb-ft @ 3950 rpm (approx.) Horsepower 540I M62: 282 hp @ 5400 rpm (approx.) Torque 540I M62: 324 lb-ft @ 3600 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Bosch Motronic DME. Fuel Type: Premium Unleaded Gasoline (91+ octane recommended). 🔧 Transmission Standard 525I 528I Standard Transmission: 5-speed manual (e.g., Getrag 260Z) 540I Standard Transmission: 6-speed manual (e.g., Getrag 420G) Optional 525I 528I Optional Transmission: 5-speed automatic (ZF 5HP19) 540I Optional Transmission: 5-speed automatic (ZF 5HP30) Features Transmission Fluid 5Hp19: BMW ATF JWS 3309 (Mobil ATF 3309) or equivalent. Transmission Fluid 5Hp30: BMW ATF LT71141 or equivalent. Transmission Fluid Manual: GL-4 or GL-5 manual transmission fluid as specified by BMW. 📐 Dimensions Exterior Wheelbase: 113.4 inches (2880 mm) Length: 188.4 - 190.3 inches (4785 - 4834 mm) depending on model/year Width: 70.2 inches (1783 mm) Height: 56.7 inches (1440 mm) Weights Curb Weight 525I: 3461 lbs (1570 kg) (approx.) Curb Weight 528I: 3571 lbs (1620 kg) (approx.) Curb Weight 540I: 3814 lbs (1730 kg) (approx.) Wheel Bolt Pattern: 5x120 mm Center Bore: 72.5 mm 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (for earlier models, later testing may vary) IIHS Side Impact: Good (for models tested) Active Features Traction Control: ASC+T (Automatic Stability Control and Traction) or DSC (Dynamic Stability Control) optional/standard depending on year/model. ABS: Standard Anti-lock Braking System (ABS). Passive Features Airbags: Frontal airbags, optional side airbags. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Navigation System: BMW Professional Navigation System (optional). Audio System: BMW Business CD, BMW Professional CD RDS, optional Harman Kardon sound system. Driver Assistance Parking Assist: Park Distance Control (PDC) - front and rear sensors (optional). Cruise Control: Standard cruise control, optional Active Cruise Control (ACC) on some models. Connectivity Bluetooth: Optional Bluetooth phone integration available from ~2001 onwards. Telematics: BMW Assist (telematics system) available on later models....