BMW 525i 528i 535i 540i 1997-2002 Service Repair Manual 1998 1999 2000 2001

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Generation Generation Designation: Fourth Generation Generation Years: 1995-2003 (global production) Codes Covered Models: 525i, 528i, 535i, 540i Covered Years: 1997, 1998, 1999, 2000, 2001, 2002 👋 Introduction Market Position Segment: Executive Sedan / Mid-size Luxury Sedan Positioning: The E39 5 Series was positioned as BMW's core executive sedan, known for its blend of performance, luxury, handling, and build quality, directly competing with Mercedes-Benz E-Class and Audi A6 of the era. Competitive Analysis Key Rivals: Mercedes-Benz W210 E-Class, Audi C5 A6, Lexus GS, Jaguar S-Type Key Features Handling Dynamics: Renowned for its balanced chassis, near-perfect weight distribution, and sophisticated suspension, offering a superior driving experience ('The Ultimate Driving Machine'). Build Quality: Exceptional German engineering and build quality, contributing to its longevity and desirability. Powertrain Refinement: Smooth and powerful inline-six and V8 engines, coupled with refined transmissions, provided effortless acceleration and cruising. Technology Integration: Early adoption of advanced electronic systems for engine management, safety (ABS, DSC), and comfort features. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Bodywork, Maintenance, Troubleshooting, Repair, Diagnostics Page Count Estimated Page Count: Over 2000 pages (typical for comprehensive factory-style manuals) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (M52B25, M52B28, M62B35, M62B44), Engine management (DME), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system Transmission: Manual (Getrag 420G), Automatic (Steptronic - GM 5L40-E, ZF 5HPxx series) Drivetrain: Driveshafts, Differential, Axles, Wheel bearings Suspension: Front suspension (McPherson strut, multi-link), Rear suspension (multi-link), Springs, Dampers, Bushings, Anti-roll bars Steering: Power assisted rack and pinion, Steering column, linkages Brakes: Front and rear disc brakes (vented/solid depending on model), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), Brake hydraulics, Parking brake Electrical: Battery, Charging system (alternator), Starting system, Lighting (headlights, taillights, interior), Fuses, Relays, Wiring diagrams, Body control module (BCM), Comfort electronics (windows, locks, mirrors, seats) HVAC: Air conditioning system, Heater core, Blower motor, Climate control unit, Recirculation system Bodywork: Body panels, Doors, Hood, Trunk, Bumpers, Glass, Seals, Interior trim, Seats Safety Systems: Airbags (SRS), Seatbelts, Pre-tensioners Procedures Included Scheduled Maintenance: Oil changes, Filter replacements (oil, air, fuel, cabin), Spark plug replacement, Coolant flush, Brake fluid flush, Transmission fluid changes Engine Repair: Engine overhaul, Head gasket replacement, Piston and ring replacement, Valve train servicing, Timing chain/belt service (if applicable), Component replacement (alternator, starter, water pump, radiator) Transmission Repair: Clutch replacement, Transmission overhaul (manual and automatic), Torque converter replacement, Gear selection mechanism repair Brake Repair: Brake pad and rotor replacement, Brake caliper service, Brake line replacement, ABS/DSC component testing and replacement Suspension Steering Repair: Shock absorber/strut replacement, Control arm bushing replacement, Ball joint replacement, Tie rod end replacement, Power steering pump and rack replacement Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, Component testing, Sensor diagnosis, ECU diagnostics (with appropriate tools) HVAC Service: Refrigerant system service, Component replacement (compressor, condenser, evaporator), Heater core replacement, Blend door actuator repair Body Panel Repair: Panel alignment, Door hinge and lock repair, Trunk lid service, Bumper repair/replacement Troubleshooting: Diagnostic flowcharts, Symptom-based troubleshooting guides, Error code interpretation Technical Specifications: Torque specifications for all fasteners, Lubricant types and capacities, Electrical system specifications, Diagnostic trouble codes (DTCs) Technical Depth Depth: Comprehensive: Covers everything from basic fluid changes and filter replacements to full engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repair. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (OCR processed) for quick information retrieval. Print Quality Image Resolution: High resolution for clear viewing of diagrams, schematics, and illustrations. Diagram Clarity: Detailed, clear, and accurate diagrams, schematics, and exploded views. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Quality: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine 525I: M52B25: 2.5L Inline-6, 192 hp @ 5900 rpm, 181 lb-ft @ 3950 rpm 528I: M52B28: 2.8L Inline-6, 190 hp @ 5300 rpm, 206 lb-ft @ 3950 rpm (early models), 193 hp @ 5500 rpm, 206 lb-ft @ 3500 rpm (later models with VANOS improvements) 535I: M62B35: 3.5L V8, 235 hp @ 5800 rpm, 243 lb-ft @ 3600 rpm 540I: M62B44: 4.4L V8, 282 hp @ 5400 rpm, 317 lb-ft @ 3600 rpm (early models), 290 hp @ 5400 rpm, 325 lb-ft @ 3600 rpm (later models with TU update) Performance 0-60 Mph Approx: 525i: ~7.0s, 528i: ~6.8s, 535i: ~6.5s, 540i: ~5.5s Fuel System Induction: Multi-point fuel injection (Bosch Motronic engine management) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Engine Features Variable Valve Timing: Double VANOS (Variable Valve Timing) on M52 and M62TU engines Cooling System: Pressurized, closed-loop coolant system with expansion tank and electric cooling fan (viscous fan clutch on some models). 🔧 Transmission Standard Transmission Options: 5-speed manual (Getrag 420G) available on 525i, 528i, and 540i. 5-speed automatic (Steptronic) optional on...

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Sku: 475985

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Tags: 1997 1998 1999 2000 2001 2002 525i 528i 535i 540i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Generation

Generation Designation:

Fourth Generation

Generation Years:

1995-2003 (global production)

Codes

Covered Models:

525i, 528i, 535i, 540i

Covered Years:

1997, 1998, 1999, 2000, 2001, 2002

👋 Introduction

Market Position

Segment:

Executive Sedan / Mid-size Luxury Sedan

Positioning:

The E39 5 Series was positioned as BMW's core executive sedan, known for its blend of performance, luxury, handling, and build quality, directly competing with Mercedes-Benz E-Class and Audi A6 of the era.

Competitive Analysis

Key Rivals:

Mercedes-Benz W210 E-Class, Audi C5 A6, Lexus GS, Jaguar S-Type

Key Features

Handling Dynamics:

Renowned for its balanced chassis, near-perfect weight distribution, and sophisticated suspension, offering a superior driving experience ('The Ultimate Driving Machine').

Build Quality:

Exceptional German engineering and build quality, contributing to its longevity and desirability.

Powertrain Refinement:

Smooth and powerful inline-six and V8 engines, coupled with refined transmissions, provided effortless acceleration and cruising.

Technology Integration:

Early adoption of advanced electronic systems for engine management, safety (ABS, DSC), and comfort features.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Bodywork, Maintenance, Troubleshooting, Repair, Diagnostics

Page Count

Estimated Page Count:

Over 2000 pages (typical for comprehensive factory-style manuals)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanicals (M52B25, M52B28, M62B35, M62B44), Engine management (DME), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system

Transmission:

Manual (Getrag 420G), Automatic (Steptronic - GM 5L40-E, ZF 5HPxx series)

Drivetrain:

Driveshafts, Differential, Axles, Wheel bearings

Suspension:

Front suspension (McPherson strut, multi-link), Rear suspension (multi-link), Springs, Dampers, Bushings, Anti-roll bars

Steering:

Power assisted rack and pinion, Steering column, linkages

Brakes:

Front and rear disc brakes (vented/solid depending on model), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), Brake hydraulics, Parking brake

Electrical:

Battery, Charging system (alternator), Starting system, Lighting (headlights, taillights, interior), Fuses, Relays, Wiring diagrams, Body control module (BCM), Comfort electronics (windows, locks, mirrors, seats)

HVAC:

Air conditioning system, Heater core, Blower motor, Climate control unit, Recirculation system

Bodywork:

Body panels, Doors, Hood, Trunk, Bumpers, Glass, Seals, Interior trim, Seats

Safety Systems:

Airbags (SRS), Seatbelts, Pre-tensioners

Procedures Included

Scheduled Maintenance:

Oil changes, Filter replacements (oil, air, fuel, cabin), Spark plug replacement, Coolant flush, Brake fluid flush, Transmission fluid changes

Engine Repair:

Engine overhaul, Head gasket replacement, Piston and ring replacement, Valve train servicing, Timing chain/belt service (if applicable), Component replacement (alternator, starter, water pump, radiator)

Transmission Repair:

Clutch replacement, Transmission overhaul (manual and automatic), Torque converter replacement, Gear selection mechanism repair

Brake Repair:

Brake pad and rotor replacement, Brake caliper service, Brake line replacement, ABS/DSC component testing and replacement

Suspension Steering Repair:

Shock absorber/strut replacement, Control arm bushing replacement, Ball joint replacement, Tie rod end replacement, Power steering pump and rack replacement

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, Component testing, Sensor diagnosis, ECU diagnostics (with appropriate tools)

HVAC Service:

Refrigerant system service, Component replacement (compressor, condenser, evaporator), Heater core replacement, Blend door actuator repair

Body Panel Repair:

Panel alignment, Door hinge and lock repair, Trunk lid service, Bumper repair/replacement

Troubleshooting:

Diagnostic flowcharts, Symptom-based troubleshooting guides, Error code interpretation

Technical Specifications:

Torque specifications for all fasteners, Lubricant types and capacities, Electrical system specifications, Diagnostic trouble codes (DTCs)

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid changes and filter replacements to full engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repair.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text (OCR processed) for quick information retrieval.

Print Quality

Image Resolution:

High resolution for clear viewing of diagrams, schematics, and illustrations.

Diagram Clarity:

Detailed, clear, and accurate diagrams, schematics, and exploded views.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Quality:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

525I:

M52B25: 2.5L Inline-6, 192 hp @ 5900 rpm, 181 lb-ft @ 3950 rpm

528I:

M52B28: 2.8L Inline-6, 190 hp @ 5300 rpm, 206 lb-ft @ 3950 rpm (early models), 193 hp @ 5500 rpm, 206 lb-ft @ 3500 rpm (later models with VANOS improvements)

535I:

M62B35: 3.5L V8, 235 hp @ 5800 rpm, 243 lb-ft @ 3600 rpm

540I:

M62B44: 4.4L V8, 282 hp @ 5400 rpm, 317 lb-ft @ 3600 rpm (early models), 290 hp @ 5400 rpm, 325 lb-ft @ 3600 rpm (later models with TU update)

Performance

0-60 Mph Approx:

525i: ~7.0s, 528i: ~6.8s, 535i: ~6.5s, 540i: ~5.5s

Fuel System

Induction:

Multi-point fuel injection (Bosch Motronic engine management)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Engine Features

Variable Valve Timing:

Double VANOS (Variable Valve Timing) on M52 and M62TU engines

Cooling System:

Pressurized, closed-loop coolant system with expansion tank and electric cooling fan (viscous fan clutch on some models).

🔧 Transmission

Standard

Transmission Options:

5-speed manual (Getrag 420G) available on 525i, 528i, and 540i. 5-speed automatic (Steptronic) optional on all models.

Optional

Automatic Transmission:

GM 5L40-E (5-speed automatic with Steptronic) for 6-cylinder models; ZF 5HPxx series (5-speed automatic with Steptronic) for V8 models.

Features

Steptronic:

Manual shifting mode allowing driver control over gear selection.

Fluid Specifications

Manual Transmission Fluid:

BMW recommends specific synthetic manual transmission fluid (e.g., BMW MTF LT-2, Shell TF 0800, or equivalent). Capacity varies by model.

Automatic Transmission Fluid:

Dexron III or Dexron VI compatible ATF. Consult manual for specific BMW PN. Capacity varies by model (e.g., ~8-10 liters for a complete fluid change).

📐 Dimensions

Exterior

Length:

Approx. 188.5 inches (4788 mm)

Width:

Approx. 71.0 inches (1803 mm)

Height:

Approx. 56.0 inches (1422 mm)

Wheelbase:

Approx. 111.4 inches (2830 mm)

Interior

Front Headroom:

Approx. 38.7 inches (983 mm)

Rear Headroom:

Approx. 38.3 inches (970 mm)

Front Legroom:

Approx. 41.7 inches (1059 mm)

Rear Legroom:

Approx. 34.7 inches (881 mm)

Cargo

Trunk Volume:

Approx. 17.7 cu ft (501 liters)

Weights

Curb Weight:

Approx. 3500 - 3900 lbs (1588 - 1769 kg) depending on engine and options.

Gross Vehicle Weight Rating:

Varies by model, typically around 4600 - 5000 lbs.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (for driver and front passenger in 1997-1999 models where tested).

IIHS Side Impact:

Good (for models tested, though comprehensive side-impact testing was less standardized in earlier years).

Active Features

Standard Anti-lock Braking System

Optional or Standard Dynamic Stability Control (later models and higher trims often included DSC).

Traction Control:

Often integrated with DSC or available as a separate system (ASC+T).

Passive Features

Airbags:

Driver and front passenger airbags, side airbags (optional on some models, standard on later/higher trims).

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

Body Structure:

Reinforced passenger safety cell with energy-absorbing crumple zones.

💡 Technology Features

Infotainment

Nav System:

Optional BMW Professional Navigation System with CD-ROM based maps (Mk I, Mk II, Mk III units).

Audio System:

Standard BMW Business CD or optional BMW Professional CD/radio with premium Hi-Fi systems (e.g., Logic 7).

Climate Control:

Standard manual climate control or optional Automatic Climate Control (ACC) with dual-zone temperature settings.

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Cruise Control:

Standard cruise control.

Headlights:

Halogen projector headlights. Optional Xenon HID headlights with automatic leveling and headlight washers.

Connectivity

Phone Integration:

Optional Bluetooth or cradle-based cellular phone integration (often requires specific phone models).

Auxiliary Input:

Not standard; aftermarket solutions required for audio input.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles or annually, whichever comes first. BMW's 'Condition Based Service' (CBS) system monitors oil life.

Air Filter Replacement:

Recommended every 20,000-30,000 miles or as needed based on driving conditions.

Cabin Air Filter Replacement:

Recommended every 10,000-15,000 miles or annually.

Spark Plug Replacement:

Inline-6 (M52): ~60,000 miles. V8 (M62): ~100,000 miles (with Long Life plugs).

Coolant Flush Interval:

Every 2-4 years or 30,000-60,000 miles, depending on coolant type.

Brake Fluid Flush Interval:

Every 2 years (recommended by most manufacturers and BMW).

Fluid Specifications

Engine Oil Spec:

BMW Longlife-01 (LL-01) or BMW Longlife-98 (LL-98) synthetic oil. Viscosity typically 5W-30 or 5W-40. Consult manual for specific engine requirements.

Coolant Spec:

BMW Blue Coolant (G48) or compatible ethylene glycol-based coolant. Mix 50/50 with distilled water.

Power Steering Fluid:

BMW Power Steering Fluid (e.g., Pentosin CHF 11S or equivalent). DO NOT use generic ATF.

Brake Fluid Spec:

DOT 4 (or DOT 4 Plus/Super DOT 4) low-viscosity brake fluid.

Known Issues

Common Problems 6Cyl:

Coolant expansion tank leaks, PCV valve issues (leading to oil consumption/smoke), Vanos solenoids/seals, Oil separator issues, Cooling fan clutch failure, Ignition coil failures, Water pump (plastic impeller failure), Differential seals, Front control arm bushings, Rear subframe bushings.

Common Problems V8:

Coolant leaks (especially aluminum pipes and gaskets), Oil pan gaskets, Valve stem seals, Spark plug well seals, Timing chain tensioners/guides (on early M62), Crankshaft position sensor failure, ABS/DSC sensor issues, Heater core failure, Pik Pik sound from VANOS on startup.

Electrical Issues:

LCM (Light Control Module) failures, Window regulator failures, Pixels on instrument cluster display (LCD degradation), Door seal water ingress (affecting electronics).

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long-standing reputation for producing sporty luxury sedans with a focus on driving dynamics and engineering excellence, dating back to the Neue Klasse era and continuing with the 5 Series line.

Model Evolution

E39 Introduction:

The E39 generation of the 5 Series was introduced in 1995 as a successor to the E34. It represented a significant step forward in design, technology, and refinement.

E39 Updates:

Mid-cycle refresh in 2000 brought updated headlights (angel eyes), taillights, bumpers, and interior trim. The M62 V8 engines were also updated to 'TU' (Technical Update) spec, offering more power and efficiency.

Production

Production Period:

1995-2003 (global production). Manual covers model years 1997-2002.

Manufacturing Locations:

Primary manufacturing in Dingolfing, Germany. Some assembly also took place in South Africa, Egypt, Russia, Thailand, and other locations.

🏆 Awards & Recognition

Recognitions

Car And Driver:

Car and Driver 10 Best list multiple times during its production run.

Auto Motor Und Sport:

Frequent class wins and high ratings in comparison tests by prominent automotive publications.

Ratings

Overall Reputation:

Widely regarded as one of the best handling and most satisfying driving sedans of its era, with a strong emphasis on build quality and driver engagement.