🏷️ Basic Information Identification Make: BMW Model: 5-Series Chassis Code: E39 Product Name: 1997-2002 BMW E39 5-series Service Workshop Repair Manual 👋 Introduction Market Position Category: Premium Mid-size Luxury Sedan/Wagon Target Audience: Owners seeking detailed DIY repair and maintenance, independent repair shops Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Volvo S80 Key Features Vehicle Design: Rear-wheel drive platform, balanced chassis, refined driving dynamics, high-quality interior materials Manual Value Proposition: Provides comprehensive, dealership-level repair information for DIYers and professionals. 📋 Manual Details Coverage Areas Covered Models: 525i, 528i, 530i, 540i Sedan, Sport Wagon Covered Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Total Pages: 759 Manual Type Type: Workshop Repair Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, diagnosis, timing, lubrication, cooling, fuel injection, emission controls Transmission Manual: Manual gearbox repair, clutch system, linkage adjustments Transmission Automatic: Automatic transmission diagnosis, repair, fluid service, valve body issues Drivetrain: Driveshaft, CV joints, differential, rear axle assembly Suspension: Front and rear suspension components, struts, shocks, bushings, alignment procedures Steering: Power steering system, steering rack, steering column, linkages Brakes: Hydraulic system, ABS, DSC, brake pads, rotors, calipers, bleeding procedures Electrical System: Battery, charging system, starter, ignition, lighting, power windows, locks, seats, mirrors Body And Chassis: Body panels, doors, hoods, trunks, bumpers, interior trim, structural components Heating Ventilation Air Conditioning: HVAC system diagnosis and repair, climate control, refrigerant service Safety Systems: Airbag system, seatbelts, passive safety features Diagnostic Troubleshooting: Extensive troubleshooting guides, fault codes, diagnostic procedures Procedures Included Preventative Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Routine Repairs: Replacement of common wear items, belt replacement, spark plug service Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement Diagnostic Testing: Step-by-step diagnostic routines for all major systems Wiring Diagrams: Comprehensive electrical schematics for all circuits Torque Specifications: Detailed torque values for all critical fasteners Special Tools: Identification and usage of specialized tools required for certain procedures Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Print Quality Printable: Printable without any restriction Binding Type Type: Digital Download (PDF) Paper Type Format Details: Requires Adobe PDF Reader ⚙️ Engine Specifications Primary Engine 525I: M54B25, 2.5L Inline-6, VANOS 528I: M52TU B28, 2.8L Inline-6, VANOS (later M54B30 for 2001+ 530i) 530I: M54B30, 3.0L Inline-6, VANOS 540I: M62TU B44, 4.4L V8, VANOS Performance 525I Hp: 189 hp @ 5900 rpm (M54) 528I Hp: 193 hp @ 5500 rpm (M52TU) 530I Hp: 225 hp @ 5900 rpm (M54) 540I Hp: 290 hp @ 5400 rpm (M62TU) Fuel System Injection Type: Sequential Multi-Point Fuel Injection (S M P I) Recommended Fuel: Premium Unleaded Gasoline (91 Octane or higher) 🔧 Transmission Standard 525I 528I 530I: 5-speed Manual (Getrag S5D 250G) 540I: 5-speed Automatic (Steptronic) Optional 525I 528I 530I: 5-speed Automatic (Steptronic) 540I: 6-speed Manual (Getrag S6S 420G) Features Steptronic: Driver-selectable manual shifting mode for automatic transmissions 📐 Dimensions Exterior Wheelbase: Approx. 111.4 inches (2830 mm) Length: Approx. 188.5 inches (4788 mm) Weights Curb Weight Min: Approx. 3571 lbs (1620 kg) for 525i Curb Weight Max: Approx. 3891 lbs (1765 kg) for 540i Sedan 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (driver and passenger) Active Features Traction Control: ASC+T (Automatic Stability Control + Traction) Stability Control: DSC (Dynamic Stability Control) available on later models/trims Passive Features Airbags: Front airbags, side airbags (optional/standard on later models) Seatbelts: 3-point inertia-reel seat belts with pretensioners 💡 Technology Features Infotainment Head Unit Options: Business CD, Professional CD RDS, Navigation systems (MK I, II, III) Audio Systems: Harmon Kardon premium sound system available Driver Assistance Cruise Control: Standard cruise control system Parking Assistance: Rear Park Distance Control (PDC) available Connectivity Phone Integration: BMW Assist telematics system and integrated phone options on later models 🔧 Maintenance Service Intervals Oil Change: Variable Service Interval (VSI) based on driving conditions, typically 10,000-15,000 miles or annually Brake Fluid: Every 2 years Coolant: BMW Blue Coolant (G48), first change at 4 years, then every 2 years Spark Plugs: M54: 100,000 miles; M62TU: 100,000 miles Fluid Specifications Engine Oil: BMW Longlife-01 (LL-01) or LL-98 specification, SAE 0W-30 or 5W-30 Synthetic Transmission Fluid Auto: LT 71141 (Dexron III compatible, but LT 71141 is preferred for longevity) Transmission Fluid Manual: G50 or G52 gear oil specification Power Steering Fluid: Pentosin CHF 11S or BMW PSF L Known Issues Cooling System: Plastic expansion tank cracks, water pump failure, thermostat housing leaks Valve Cover Gasket: Common oil leaks due to failing gaskets and PCV system Oil Pan Gasket: Oil leaks often occur on the oil pan gasket Suspension Components: Wear on control arm bushings, ball joints, and tie rods ABS/Dsc Sensor Failure: Wheel speed sensors can fail, triggering ABS and DSC warning lights Pixel Display...