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

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🏷️ Basic Information Identification Make: BMW Model: 5 Series (E39) Engine Variants: 525i, 528i, 530i, 540i Body Styles: Sedan, Sport Wagon Codes Chassis Code: E39 👋 Introduction Market Position Positioning: Premium executive sedan and wagon, known for driving dynamics, luxury, and advanced engineering. Competitive Analysis Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS Key Features Brand Philosophy: Sheer Driving Pleasure (Freude am Fahren) Target Audience Audience: Do-it-yourself enthusiasts and experienced mechanics seeking comprehensive repair and maintenance information. Value Proposition Diy Savings: Enables owners to perform repairs themselves, saving significant money on dealership labor costs. 📋 Manual Details Coverage Areas Covered Models: BMW 5 Series (E39) 525i, 528i, 530i, 540i Sedan, Sport Wagon Covered Production Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Total Pages: 1002 Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF Viewing Requirements: Adobe PDF Reader Compatibility: All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android Features Searchable: Yes Bookmarked: Yes Download Type: Instant Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul and rebuilding, timing belt replacement, engine performance, firing orders, serpentine belt routings with diagrams, timing belt service procedures Brakes: Brakes, brake servicing procedures Suspension Steering: Front end and alignment procedures and specifications, suspension, U-joint and CV-joint service procedures Transmission: Transmission removal and installation, transmission in-car servicing Electrical Electronics: Wiring diagrams, computer diagnostic trouble tree charts, computer diagnostic codes Climate Control: Air conditioning service and capacities Body Interior: Sunroof Diagnostics: Trouble codes, troubleshooting and diagnostics Procedures Included Repair Procedures: All diagnostic and repair procedures, step-by-step instructions based on complete disassembly Maintenance: Factory maintenance schedules and charts, driving concerns Engine Rebuilding: Detailed procedures for engine overhaul and rebuilding. Drive Shaft Service: U-joint and CV-joint service procedures covered. Technical Depth Depth: Comprehensive: covers everything from basic maintenance to complete engine...

Type: Car

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Sku: 532745

Collections: ALL BMW

Tags: 5 Series BMW

제품 이형 상품

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series (E39)

Engine Variants:

525i, 528i, 530i, 540i

Body Styles:

Sedan, Sport Wagon

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

Premium executive sedan and wagon, known for driving dynamics, luxury, and advanced engineering.

Competitive Analysis

Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS

Key Features

Brand Philosophy:

Sheer Driving Pleasure (Freude am Fahren)

Target Audience

Audience:

Do-it-yourself enthusiasts and experienced mechanics seeking comprehensive repair and maintenance information.

Value Proposition

Diy Savings:

Enables owners to perform repairs themselves, saving significant money on dealership labor costs.

📋 Manual Details

Coverage Areas

Covered Models:

BMW 5 Series (E39) 525i, 528i, 530i, 540i Sedan, Sport Wagon

Covered Production Years:

1997, 1998, 1999, 2000, 2001, 2002

Page Count

Total Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

File Format:

Viewing Requirements:

Adobe PDF Reader

Compatibility:

All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android

Features

Searchable:

Bookmarked:

Download Type:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul and rebuilding, timing belt replacement, engine performance, firing orders, serpentine belt routings with diagrams, timing belt service procedures

Brakes:

Brakes, brake servicing procedures

Suspension Steering:

Front end and alignment procedures and specifications, suspension, U-joint and CV-joint service procedures

Transmission:

Transmission removal and installation, transmission in-car servicing

Electrical Electronics:

Wiring diagrams, computer diagnostic trouble tree charts, computer diagnostic codes

Climate Control:

Air conditioning service and capacities

Body Interior:

Sunroof

Diagnostics:

Trouble codes, troubleshooting and diagnostics

Procedures Included

Repair Procedures:

All diagnostic and repair procedures, step-by-step instructions based on complete disassembly

Maintenance:

Factory maintenance schedules and charts, driving concerns

Engine Rebuilding:

Detailed procedures for engine overhaul and rebuilding.

Drive Shaft Service:

U-joint and CV-joint service procedures covered.

Technical Depth

Depth:

Comprehensive: covers everything from basic maintenance to complete engine rebuilds, advanced diagnostics, and detailed troubleshooting.

Diagnostic Tools:

Guidance on interpreting diagnostic trouble codes and using diagnostic tools.

Illustrations

Visuals:

Detailed illustrations, diagrams, wiring schematics, hundreds of photos, vacuum diagrams.

Specifications

Torque Specifications:

Complete torque specifications provided for all major components and fasteners.

Vacuum Diagrams:

Included

Diagnostic Charts:

Computer diagnostic trouble tree charts included for systematic fault finding.

📊 Manual Specifications

File Format

Quality:

High quality, complete and intact, no missing/corrupt pages.

Print Quality

Usability:

Printable, zoomable.

Binding Type

Binding:

Digital (PDF Download)

Paper Type

Paper:

N/A (Digital Format)

Accessibility

Digital Storage:

Can be saved to hard-drive, burned to CD-ROM.

⚙️ Engine Specifications

Primary Engine

Engine Options:

Inline-6 (M52/M54 families), V8 (M62 family)

Performance

525I Engine Details:

Approx. 2.5L Inline-6, ~189-192 hp, ~232-245 Nm torque (specifics vary by year/market and M52TU/M54B25)

528I Engine Details:

Approx. 2.8L Inline-6 (M52/M52TU), ~193-201 hp, ~280-285 Nm torque

530I Engine Details:

Approx. 3.0L Inline-6 (M54B30), ~225-231 hp, ~300-315 Nm torque

540I Engine Details:

Approx. 4.4L V8 (M62/M62TU), ~282-290 hp, ~440-460 Nm torque

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI)

Cooling System

Coolant Type:

BMW Blue Antifreeze/Coolant (or equivalent G48/G11)

🔧 Transmission

Standard

Transmission Options:

5-speed Manual (Getrag 220 for I6, Getrag 420G for V8), 5-speed Automatic (Steptronic)

Optional

Automatic Transmission:

ZF 5HP18, 5HP19 (for I6), ZF 5HP24 (for V8)

Features

Steptronic:

Manual shift mode available on automatic transmissions

Fluid Specifications

Automatic Transmission Fluid:

Dexron III or ATF LT 71141 (for ZF transmissions, check specific application)

📐 Dimensions

Exterior

Wheelbase:

Approx. 113.4 inches (2880 mm)

Weights

Curb Weight:

Varies by model, approx. 3500-3900 lbs (1588-1769 kg)

🛡️ Safety Features

Ratings

NHTSA Rating:

Generally good ratings for its era, though specific year data may vary.

Active Features

Active Safety:

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

Passive Features

Passive Safety:

Front airbags, side airbags (optional/standard depending on trim), front and rear head protection system (HPS) curtain airbags (optional).

💡 Technology Features

Infotainment

Infotainment System:

BMW Professional Radio, optional Navigation System (Mk III/IV), optional Hi-Fi or Harman Kardon sound systems.

Driver Assistance

Driver Assistance Features:

Cruise control, parking sensors (PDC - Park Distance Control), optional Xenon headlights with washers.

Connectivity

Connectivity Features:

Optional BMW Assist telematics system, Bluetooth hands-free connectivity (later models/options).

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system. Typically around 10,000-15,000 miles (16,000-24,000 km) or 12-24 months, depending on driving conditions.

Major Service Intervals:

Spark plugs typically at 60,000-100,000 miles, coolant flush at 3-5 years or specific mileage.

Fluid Specifications

Engine Oil Specification:

SAE 5W-30 or 5W-40 synthetic oil meeting BMW LL-01 or LL-04 specifications (check specific model and year).

Coolant Capacity:

Approx. 9.5-10.5 liters (depending on engine and oil cooler)

Known Issues

Common Issues:

Cooling system (water pump, thermostat, hoses), VANOS system (variable valve timing), VANOS oil line leaks, oil separator/crankcase ventilation (CCV) system, rear subframe bushings, ABS/DSC sensor failures, pixelation on instrument cluster/radio displays, window regulator failures.

📚 Vehicle History

Brand Heritage

Brand History:

Bayerische Motoren Werke AG, founded 1916, renowned for luxury, performance, and engineering excellence.

Model Evolution

E39 Generation:

The E39 generation succeeded the E34 and was produced from 1995 to 2003 (with the final facelift in 2000). It represented a significant leap in refinement, technology, and driving dynamics.

Production

Production Period:

1995-2003 (International); 1997-2002 covered by this manual.

Manufacturing Locations

Manufacturing Locations:

Dingolfing, Germany; Rosslyn, South Africa; Regensburg, Germany; Graz, Austria (Magna Steyr for wagons)

🏆 Awards & Recognition

Recognitions

Automotive Journal Awards:

Consistently praised by automotive critics for its chassis, handling, comfort, and build quality. Often cited as a benchmark in its class for driving dynamics.