🏷️ Basic Information Identification Make: BMW Model: 5-Series Chassis Code: E39 Body Styles: Sedan, Sport Wagon (Touring) Generation Generation: Fourth Generation (E39) Production Years: 1995-2003 (E39 Sedan), 1997-2004 (E39 Touring) Codes Specific Models Covered: 525i, 528i, 530i, 540i 👋 Introduction Market Position Segment: Executive Sedan and Wagon Bmw Positioning: The E39 represented BMW's commitment to superior driving dynamics, advanced engineering, and luxurious appointments in the mid-size luxury segment. Competitive Analysis Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS, Jaguar S-Type Key Features Driving Dynamics: Renowned for its balanced chassis, precise steering, and engaging driving experience, often lauded as a benchmark in its class. Engineering Quality: Robust build quality, high-quality materials, and sophisticated powertrain options. Design Language: Timeless, elegant exterior and interior design that has aged well. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive workshop repair and service Page Count Page Count: 1,002 Manual Type Manual Type: Workshop Repair & Service Manual Language Language: English Format Format: PDF Compatibility: Searchable, Printable, iPad-ready 📖 Manual Coverage Systems Covered Engine: Complete engine diagnostics, repair, overhaul, and tuning for all E39 variants (M52, M54, M62 families) Fuel System: Fuel injection, fuel pump, fuel filter, fuel pressure regulator, evaporative emission control (EVAP) Ignition System: Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensor, DME (Digital Motor Electronics) Cooling System: Radiator, water pump, thermostat, hoses, expansion tank, cooling fan operation Exhaust System: Exhaust manifolds, catalytic converters, mufflers, oxygen sensors, exhaust gas recirculation (EGR) system (where applicable) Transmission Manual: Clutch operation, transmission disassembly, assembly, fluid changes, seals, synchros Transmission Automatic: Automatic transmission (e.g., GM 5L40-E, ZF 5HP series) diagnostics, repair, fluid and filter service, solenoid operation Drivetrain: Driveshaft, CV joints, differential, rear axle assembly, wheel bearings Suspension: Front and rear suspension components, shock absorbers, struts, control arms, bushings, springs, anti-roll bars Steering: Power steering system, steering rack, tie rods, steering column, power steering fluid Brakes: Brake system diagnostics, hydraulic components, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pad/rotor replacement, brake fluid flush Electrical System General: Battery, alternator, starter motor, fuses, relays, wiring diagrams Body Electrical: Lighting systems (headlights, taillights, interior), power windows, power mirrors, central locking, horn Climate Control: HVAC (Heating, Ventilation, and Air Conditioning) system, refrigerant servicing, blower motor, evaporator, condenser, climate control module Body And Interior: Door panels, seat removal, dashboard removal, interior trim, exterior body panels, bumper repair, door glass replacement Chassis And Frame: Frame inspection, unibody structure analysis Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and top-offs Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment Rebuilding Procedures: Engine rebuild procedures, transmission rebuild procedures (where applicable) Component Testing: Testing of electrical components, sensors, actuators, and mechanical systems Specifications: Torque specifications, clearances, timing procedures, diagnostic values Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to full engine and transmission rebuilds) Diagnostic Capabilities: Detailed diagnostic procedures and troubleshooting guides for complex systems Wiring Diagrams: Included for all major electrical systems 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval Print Quality Printability: Printable pages for physical workshop use Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine 525I Engine: 2.5L Inline-6 (M52TU/M54B25) 525I Horsepower: 189 hp @ 5900 rpm (M52TU), 192 hp @ 6000 rpm (M54) 525I Torque: 181 lb-ft @ 3950 rpm (M52TU), 199 lb-ft @ 3500 rpm (M54) 528I Engine: 2.8L Inline-6 (M52TU) 528I Horsepower: 193 hp @ 5500 rpm 528I Torque: 206 lb-ft @ 3950 rpm 530I Engine: 3.0L Inline-6 (M54B30) 530I Horsepower: 225 hp @ 5900 rpm 530I Torque: 214 lb-ft @ 3500 rpm 540I Engine: 4.4L V8 (M62TU) 540I Horsepower: 290 hp @ 5400 rpm 540I Torque: 324 lb-ft @ 3600 rpm Performance Engine Management: Bosch Motronic ECU (various versions depending on engine and year) Fuel System Fuel Type: Unleaded Gasoline (premium recommended) Fuel Delivery: Electronic Fuel Injection (EFI) 🔧 Transmission Standard 525I 528I 530I Standard Trans: 5-speed Manual (Getrag 260/6, Getrag 420G for later models) 540I Standard Trans: 5-speed Automatic (ZF 5HP30) Optional 525I 528I 530I Optional Trans: 5-speed Automatic (GM 5L40-E) 540I Optional Trans: 6-speed Manual (Getrag 420G) Features Automatic Features: Steptronic (manual shifting capability) 📐 Dimensions Exterior Length: Sedan: ~188.3 in (4783 mm), Wagon: ~190.4 in (4836 mm) Width: ~71.5 in (1816 mm) Height: Sedan: ~57.1 in (1450 mm), Wagon: ~57.6 in (1463 mm) Wheelbase: ~111.4 in (2830 mm) Weights Curb Weight: Varies by model and configuration, typically 3500-4000 lbs (1588-1814 kg) 🛡️ Safety Features Ratings NHTSA Front Crash Test: Likely achieved good ratings, as per BMW's safety standards of the era. Active Features ABS: Standard Anti-lock Braking System (ABS) Dsc: Optional Dynamic Stability Control (DSC) Traction Control: Automatic Stability Control...