BMW ( E39 ) 5 Series 525i 528i 530i 540i Sedan Sport Wagon 1997-2002 Workshop Service Repair Manual Pdf

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Model Variant: 525i, 528i, 530i, 540i Body Styles Covered: Sedan, Sport Wagon (Touring) Production Years: 1997-2002 Codes Engine Codes 525I: M50TU (early), M52B25, M54B25 Engine Codes 528I: M52B28 Engine Codes 530I: M54B30 Engine Codes 540I: M62B44, M62TU B44 👋 Introduction Market Position Vehicle Segment: Executive Mid-Size Sedan/Wagon (E-segment) Target Demographic: Consumers seeking luxury, performance, and practicality, often families or business professionals. Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS, Volvo S80/V70. Bmw E39 Strengths: Superior driving dynamics, refined engine options, high-quality interior, strong brand reputation for performance and engineering. Key Features Defining Characteristics: Balanced chassis, rear-wheel drive bias (optional xDrive on later models, but not typically E39), sophisticated suspension, intuitive controls. 📋 Manual Details Coverage Areas Documentation Type: Workshop Service Repair Manual Technician Level: Dealership Level (OEM) Page Count Estimated Page Count: Approximately 2000+ pages (comprehensive) Manual Type Manual Classification: Comprehensive Service and Repair Manual Language Language: English Format File Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Powertrain Systems: Engine mechanical (all variants), cooling system, fuel system, lubrication system, exhaust system, engine management (DME/ECU diagnostics and calibration). Transmission Drivetrain: Manual transmission (Getrag 260/6, Getrag 420G), Automatic transmission (ZF 5HP18, ZF 5HP19, ZF 5HP24, ZF 5HP30), clutch system, driveshafts, differential, axle shafts. Chassis Suspension Steering: Front suspension (double-wishbone, MacPherson strut), rear suspension (multi-link), steering system (hydraulic power steering, Servotronic), wheel bearings, alignment specifications. Brakes And Wheels: Brake system (ABS, DSC, EBD), brake caliper service, rotor replacement, brake fluid specifications, parking brake, wheel bolt torque specifications, tire sizes. Electrical System: Battery, charging system (alternator), starter motor, lighting system (headlights, taillights, interior), wiring diagrams, fuses, relays, ignition system, power windows, mirrors, seats, sunroof. Body And Interior: Body panel removal/installation, doors, hood, trunk, bumpers, glass replacement,...

Type: Car

공급업체:

Sku: 298771

Collections: ALL BMW

Tags: 1997 1998 1999 2000 2001 2002 525i 528i 530i 540i BMW Car Cars Misc Sedan Sport Wagon

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Variant:

525i, 528i, 530i, 540i

Body Styles Covered:

Sedan, Sport Wagon (Touring)

Production Years:

1997-2002

Codes

Engine Codes 525I:

M50TU (early), M52B25, M54B25

Engine Codes 528I:

M52B28

Engine Codes 530I:

M54B30

Engine Codes 540I:

M62B44, M62TU B44

👋 Introduction

Market Position

Vehicle Segment:

Executive Mid-Size Sedan/Wagon (E-segment)

Target Demographic:

Consumers seeking luxury, performance, and practicality, often families or business professionals.

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS, Volvo S80/V70.

Bmw E39 Strengths:

Superior driving dynamics, refined engine options, high-quality interior, strong brand reputation for performance and engineering.

Key Features

Defining Characteristics:

Balanced chassis, rear-wheel drive bias (optional xDrive on later models, but not typically E39), sophisticated suspension, intuitive controls.

📋 Manual Details

Coverage Areas

Documentation Type:

Workshop Service Repair Manual

Technician Level:

Dealership Level (OEM)

Page Count

Estimated Page Count:

Approximately 2000+ pages (comprehensive)

Manual Type

Manual Classification:

Comprehensive Service and Repair Manual

Language

Language:

English

Format

File Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Powertrain Systems:

Engine mechanical (all variants), cooling system, fuel system, lubrication system, exhaust system, engine management (DME/ECU diagnostics and calibration).

Transmission Drivetrain:

Manual transmission (Getrag 260/6, Getrag 420G), Automatic transmission (ZF 5HP18, ZF 5HP19, ZF 5HP24, ZF 5HP30), clutch system, driveshafts, differential, axle shafts.

Chassis Suspension Steering:

Front suspension (double-wishbone, MacPherson strut), rear suspension (multi-link), steering system (hydraulic power steering, Servotronic), wheel bearings, alignment specifications.

Brakes And Wheels:

Brake system (ABS, DSC, EBD), brake caliper service, rotor replacement, brake fluid specifications, parking brake, wheel bolt torque specifications, tire sizes.

Electrical System:

Battery, charging system (alternator), starter motor, lighting system (headlights, taillights, interior), wiring diagrams, fuses, relays, ignition system, power windows, mirrors, seats, sunroof.

Body And Interior:

Body panel removal/installation, doors, hood, trunk, bumpers, glass replacement, interior trim, seats, dashboard, climate control system (HVAC), infotainment system (CCC/Business/Professional).

Safety Systems:

Airbag system (SRS), seat belts, safety features, diagnostic procedures for safety systems.

Procedures Included

Maintenance Procedures:

Routine maintenance (oil changes, filter replacements), fluid level checks and top-offs, spark plug replacement, belt replacement, brake pad/rotor replacement, battery service.

Diagnostic Procedures:

Troubleshooting guides, diagnostic trouble codes (DTCs) and their meanings, symptom-based diagnostics, electrical troubleshooting using wiring diagrams, OBD-II diagnostics.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation for all major systems, including engine component overhaul, transmission rebuild, suspension component replacement, brake system repairs, electrical component troubleshooting and replacement.

Special Procedures:

Catalytic converter replacement, EGR system service (if applicable), ABS/DSC module troubleshooting, airbag system diagnosis, climate control refrigerant handling.

Technical Depth

Depth Of Information:

Complete engine rebuild specifications, transmission overhaul procedures, detailed electrical schematics, torque specifications for all fasteners, diagnostic flowcharts, component testing procedures.

📊 Manual Specifications

File Format

Searchability:

Searchable text within PDF for quick information retrieval.

Printability:

Printable pages for on-site workshop use.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations.

Binding Type

Digital Format:

PDF (Portable Document Format)

Paper Type

Physical Manual Comparison:

Digital equivalent to professionally printed, bound workshop manuals used by BMW dealerships.

⚙️ Engine Specifications

Primary Engine

525I Engine:

2.5L Inline-6 (M54B25) - 189 hp @ 6000 rpm, 181 lb-ft @ 3500 rpm. Earlier models: M52B25 (168-189 hp).

528I Engine:

2.8L Inline-6 (M52B28) - 190 hp @ 5500 rpm, 206 lb-ft @ 3950 rpm.

530I Engine:

3.0L Inline-6 (M54B30) - 225 hp @ 5900 rpm, 214 lb-ft @ 3500 rpm.

540I Engine:

4.4L V8 (M62TU B44) - 290 hp @ 5400 rpm, 324 lb-ft @ 3600 rpm.

Performance

0 60 Mph 530I:

Approximately 6.3 seconds (manual transmission).

0 60 Mph 540I:

Approximately 5.6 seconds (manual transmission).

Fuel System

Fuel Delivery:

Sequential multi-point fuel injection (Bosch Motronic)

Recommended Fuel:

Premium Unleaded gasoline (91 octane or higher recommended)

🔧 Transmission

Standard

Standard Transmission Early Models:

5-speed manual (Getrag 260/6 for 6-cyl, Getrag 420G for M54 engines).

Standard Transmission Late Models:

5-speed Steptronic automatic transmission (ZF 5HP18/19/24).

Optional

Optional Transmission 540I:

6-speed manual (Getrag 420G).

Features

Steptronic Functionality:

Allows manual selection of gears via shifter or steering wheel buttons (on some models).

Transmission Fluid Type:

BMW LT-3 or ZF Lifeguardfluid 5 (for automatic transmissions).

📐 Dimensions

Exterior

Length:

Sedan: Approx. 190.6 inches (4841 mm)

Width:

Approx. 71.0 inches (1803 mm)

Height:

Sedan: Approx. 57.0 inches (1448 mm), Wagon: Approx. 57.5 inches (1460 mm)

Wheelbase:

Approx. 111.4 inches (2830 mm)

Interior

Front Headroom:

Approx. 38.6 inches (980 mm)

Rear Legroom:

Approx. 35.8 inches (909 mm)

Cargo

Sedan Trunk Volume:

Approx. 15.0 cu ft (425 liters)

Wagon Cargo Volume Seats Up:

Approx. 22.0 cu ft (620 liters)

Weights

Curb Weight 525I:

Approx. 3570 lbs (1619 kg)

Curb Weight 540I:

Approx. 3880 lbs (1760 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (Driver & Passenger)

IIHS Side Impact:

Good (for applicable model years)

Active Features

Standard Safety Features:

Anti-lock Braking System (ABS), Traction Control System (ASC+T), Dynamic Stability Control (DSC) on later models.

Optional Safety Features:

Xenon headlights, Parking Distance Control (PDC).

Passive Features

Airbag System:

Front dual-stage airbags, front side-impact airbags, optional head protection system (HPS).

Seatbelts:

Three-point inertia-reel seat belts with pretensioners for all seating positions.

💡 Technology Features

Infotainment

Head Unit Options:

BMW Business CD, BMW Professional CD, Navigation system (CCC or MkIV).

Audio Systems:

Standard 10-speaker system, optional Harman Kardon surround sound system.

Driver Assistance

Advanced Features:

Park Distance Control (PDC), Cruise Control, Rain-sensing wipers (optional).

Connectivity

Optional Connectivity:

On-board computer, Bluetooth integration (via aftermarket solutions or specific factory options).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable, typically every 7,500 to 15,000 miles or 12-24 months (dependent on driving conditions and oil quality, based on Condition Based Service - CBS).

Spark Plug Replacement:

M54 engines: Approx. 100,000 miles (using long-life spark plugs). M52/M62: Approx. 60,000-100,000 miles.

Coolant Flush:

Every 2-4 years or 30,000-60,000 miles.

Fluid Specifications

Engine Oil Capacity 6Cyl:

Approx. 6.5-7.0 quarts (6.2-6.6 liters) - SAE 5W-30 or 5W-40 synthetic recommended (BMW Longlife-01 or LL-04).

Engine Oil Capacity V8:

Approx. 7.0-7.5 quarts (6.6-7.1 liters) - SAE 5W-30 or 5W-40 synthetic recommended (BMW Longlife-01 or LL-04).

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 formulation).

Brake Fluid Type:

DOT 4 (low viscosity or high performance recommended).

Known Issues

Common Failures Cooling System:

Plastic expansion tank cracking, water pump failure (plastic impeller), thermostat housing leaks, radiator leaks.

Common Failures Ignition Engine:

Valve cover gasket leaks (oil smell), CCV (Crankcase Ventilation) system failure leading to oil consumption/leaks, VANOS solenoid issues (especially on M54 engines), ignition coil and spark plug degradation.

Common Failures Suspension Steering:

Front control arm bushings (bushings can tear), tie rod ends, sway bar links, rear shock mount failures.

Common Failures Electrical:

ABS/DSC wheel speed sensor failures, headlight leveling sensor issues, alternator failure, fuel pump failure, LCM (Light Control Module) issues, pixilation on instrument cluster LCD.

Common Failures Body:

Sagging headliner, pixelation in the instrument cluster, door seal degradation.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure - emphasis on performance, handling, and driver engagement.

Model Evolution

E39 Predecessor:

BMW E34 5 Series (1988-1996)

E39 Successor:

BMW E60 5 Series (2004-2010)

E39 Facelift:

Significant facelift in 2001 (model year 2001.5), introducing updated engines (M54 series), revised headlights and taillights, and updated interior features.

Production

Manufacturing Locations:

Dingolfing, Germany (primary), Rosslyn, South Africa (assembly).

Production Volume:

Over 1 million units produced worldwide.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

Named to Car and Driver's 10Best list multiple times during its production run.

Ward Best Engines:

The M54 inline-6 engines (2.5L and 3.0L) were recognized for their smoothness and efficiency.

Ratings

Vehicle Reviews General:

Widely praised for its driving dynamics, build quality, and comfortable interior, often considered a benchmark in its class.

Certifications

Manual Quality Certification:

OEM standard, mirroring the technical documentation used by certified BMW technicians.