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BMW 5 Series (E39) 525i 528i 530i 540i Sedan Sport Wagon Service & Repair Manual 1997 1998 1999 2000 2001 2002

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Code: E39 Production Years: 1995-2003 (E39 platform) Codes Covered Variants: 525i, 528i, 530i, 540i Body Styles: Sedan, Sport Wagon (Touring) 👋 Introduction Market Position Segment: Executive Sedan and Mid-Size Luxury Wagon Philosophy: The E39 generation represented BMW's commitment to driving dynamics, advanced engineering, and luxurious comfort. Competitive Analysis Key Rivals: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS. Key Features Handling: Renowned for its balanced chassis, sophisticated multi-link suspension, and precise steering, providing a 'driver's car' experience. Engines: Smooth and powerful inline-six and V8 engines known for their performance and refinement. Interior Quality: High-quality materials, ergonomic design, and a driver-focused cockpit. Availability: Offered in both sedan and practical wagon (Touring) body styles, broadening its appeal. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive service, repair, and maintenance for E39 5 Series Sedan and Sport Wagon models. Page Count Estimated Pages: 1500+ Manual Type Type: Factory-level Service and Repair Manual Language Primary Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system. Drivetrain: Manual transmission, automatic transmission, clutch, driveshafts, differentials, axles. Chassis: Suspension (front and rear), steering system, brakes (ABS, DSC, parking brake), wheels, tires. Electrical: Wiring diagrams, lighting, battery, alternator, starter, fuses, relays, engine control unit (ECU), body control module (BCM). Body And Interior: Body panels, doors, windows, seats, HVAC, SRS (airbag) system, interior trim, sound system. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement. Diagnostics: Troubleshooting guides, symptom-based diagnostics, error code interpretation (OBD-II), electrical system diagnostics. Repair: Engine overhaul, transmission repair, suspension component replacement, brake caliper rebuild, electrical component repair. Installation: Component replacement procedures for all major systems. Technical Depth Depth: Highly detailed, from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures and specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable, allowing for quick finding of specific topics. Print Quality Printability: High-resolution, suitable for printing individual sections or the entire manual. Binding Type Binding Style: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine 525I Engine: M54B25: 2.5-liter (2494cc) DOHC 24-valve Inline-6 528I Engine: M52TU B28: 2.8-liter (2793cc) DOHC 24-valve Inline-6 530I Engine: M54B30: 3.0-liter (2979cc) DOHC 24-valve Inline-6 540I Engine: M62B44: 4.4-liter (4398cc) DOHC 32-valve V8 Performance 525I Horsepower: 189 hp @ 6000 rpm 528I Horsepower: 190 hp @ 5500 rpm 530I Horsepower: 225 hp @ 5900 rpm 540I Horsepower: 282 hp @ 5400 rpm 525I Torque: 191 lb-ft @ 3500 rpm 528I Torque: 206 lb-ft @ 3950 rpm 530I Torque: 214 lb-ft @ 3500 rpm 540I Torque: 324 lb-ft @ 3600 rpm Fuel System Injection Type: Sequential Multi-Point Fuel Injection (SEFI) Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended) Cooling System Coolant Type: BMW Blue Antifreeze/Coolant (G48) 🔧 Transmission Standard 525I/528I/530I: 5-speed Manual Transmission (Getrag S5D 250G for 525i/528i, GS5-39DZ for 530i) 540I: 6-speed Manual Transmission (Getrag S6S 420G) Optional All Models: 5-speed Automatic Transmission (ZF 5HP18 for 525i/528i, ZF 5HP30 for 540i, GM A5S360R for 530i) Features Automatic Transmission: Steptronic feature allowing manual gear selection. Fluid Specifications Manual Transmission Fluid: BMW MTF LT-2 or equivalent GL-4/GL-5 rated gear oil. Automatic Transmission Fluid: BMW ATF LT-4 or ZF Lifeguardfluid 5 (LF-01). 📐 Dimensions Exterior Length: Sedan: Approx. 190.4 inches (4836 mm); Wagon: Approx. 191.5 inches (4864 mm) Width: Approx. 71.1 inches (1806 mm) Height: Sedan: Approx. 56.7 inches (1440 mm); Wagon: Approx. 55.8 inches (1417 mm) Wheelbase: Approx. 111.4 inches (2830 mm) Cargo Wagon Cargo Volume: Approx. 21.8 cu ft with rear seats up, 64.5 cu ft with rear seats folded. Weights Curb Weight: Ranges from approx. 3461 lbs (1570 kg) for 525i to approx. 3792 lbs (1720 kg) for 540i. Gross Vehicle Weight Rating: Varies by model, consult manual for specific figures. 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (driver and passenger) IIHS Side Impact: Good (for vehicles equipped with side airbags) Active Features Stability Control: Dynamic Stability Control (DSC) available on most models. Traction Control: Automatic Stability Control and Traction (ASC+T) standard on many models. ABS: Anti-lock Braking System (ABS) standard on all models. Passive Features Airbags: Frontal airbags (driver and passenger), optional front side-impact airbags, optional head protection airbags. Seatbelts: 3-point inertia-reel seatbelts with front seatbelt pretensioners and force limiters. 💡 Technology Features Infotainment Radio Options: BMW Business CD, BMW Professional RDS, optional CD changer. Navigation: Optional BMW Professional Navigation system (MK III or MK IV). Driver Assistance Parking Sensors: Park Distance Control (PDC) optional. Cruise Control: Standard cruise control system. Connectivity Bluetooth: Optional Bluetooth hands-free system available on later models. Onboard Computer: Standard OBC providing fuel economy, range, and trip data. 🔧 Maintenance Service Intervals Oil Change Interval: BMW Condition Based Service (CBS) system or approx....
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BMW 5 Series (E39) 525i 528i 530i 540i Sedan Sport Wagon Service & Repair Manual 1997 1998 1999 2000 2001 2002
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Generation
Chassis Code:
E39
Production Years:
1995-2003 (E39 platform)
Codes
Covered Variants:
525i, 528i, 530i, 540i
Body Styles:
Sedan, Sport Wagon (Touring)
👋 Introduction
Market Position
Segment:
Executive Sedan and Mid-Size Luxury Wagon
Philosophy:
The E39 generation represented BMW's commitment to driving dynamics, advanced engineering, and luxurious comfort.
Competitive Analysis
Key Rivals:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS.
Key Features
Handling:
Renowned for its balanced chassis, sophisticated multi-link suspension, and precise steering, providing a 'driver's car' experience.
Engines:
Smooth and powerful inline-six and V8 engines known for their performance and refinement.
Interior Quality:
High-quality materials, ergonomic design, and a driver-focused cockpit.
Availability:
Offered in both sedan and practical wagon (Touring) body styles, broadening its appeal.
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive service, repair, and maintenance for E39 5 Series Sedan and Sport Wagon models.
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory-level Service and Repair Manual
Language
Primary Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system.
Drivetrain:
Manual transmission, automatic transmission, clutch, driveshafts, differentials, axles.
Chassis:
Suspension (front and rear), steering system, brakes (ABS, DSC, parking brake), wheels, tires.
Electrical:
Wiring diagrams, lighting, battery, alternator, starter, fuses, relays, engine control unit (ECU), body control module (BCM).
Body And Interior:
Body panels, doors, windows, seats, HVAC, SRS (airbag) system, interior trim, sound system.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, error code interpretation (OBD-II), electrical system diagnostics.
Repair:
Engine overhaul, transmission repair, suspension component replacement, brake caliper rebuild, electrical component repair.
Installation:
Component replacement procedures for all major systems.
Technical Depth
Depth:
Highly detailed, from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable, allowing for quick finding of specific topics.
Print Quality
Printability:
High-resolution, suitable for printing individual sections or the entire manual.
Binding Type
Binding Style:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
525I Engine:
M54B25: 2.5-liter (2494cc) DOHC 24-valve Inline-6
528I Engine:
M52TU B28: 2.8-liter (2793cc) DOHC 24-valve Inline-6
530I Engine:
M54B30: 3.0-liter (2979cc) DOHC 24-valve Inline-6
540I Engine:
M62B44: 4.4-liter (4398cc) DOHC 32-valve V8
Performance
525I Horsepower:
189 hp @ 6000 rpm
528I Horsepower:
190 hp @ 5500 rpm
530I Horsepower:
225 hp @ 5900 rpm
540I Horsepower:
282 hp @ 5400 rpm
525I Torque:
191 lb-ft @ 3500 rpm
528I Torque:
206 lb-ft @ 3950 rpm
530I Torque:
214 lb-ft @ 3500 rpm
540I Torque:
324 lb-ft @ 3600 rpm
Fuel System
Injection Type:
Sequential Multi-Point Fuel Injection (SEFI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane Recommended)
Cooling System
Coolant Type:
BMW Blue Antifreeze/Coolant (G48)
🔧 Transmission
Standard
525I/528I/530I:
5-speed Manual Transmission (Getrag S5D 250G for 525i/528i, GS5-39DZ for 530i)
540I:
6-speed Manual Transmission (Getrag S6S 420G)
Optional
All Models:
5-speed Automatic Transmission (ZF 5HP18 for 525i/528i, ZF 5HP30 for 540i, GM A5S360R for 530i)
Features
Automatic Transmission:
Steptronic feature allowing manual gear selection.
Fluid Specifications
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent GL-4/GL-5 rated gear oil.
Automatic Transmission Fluid:
BMW ATF LT-4 or ZF Lifeguardfluid 5 (LF-01).
📐 Dimensions
Exterior
Length:
Sedan: Approx. 190.4 inches (4836 mm); Wagon: Approx. 191.5 inches (4864 mm)
Width:
Approx. 71.1 inches (1806 mm)
Height:
Sedan: Approx. 56.7 inches (1440 mm); Wagon: Approx. 55.8 inches (1417 mm)
Wheelbase:
Approx. 111.4 inches (2830 mm)
Cargo
Wagon Cargo Volume:
Approx. 21.8 cu ft with rear seats up, 64.5 cu ft with rear seats folded.
Weights
Curb Weight:
Ranges from approx. 3461 lbs (1570 kg) for 525i to approx. 3792 lbs (1720 kg) for 540i.
Gross Vehicle Weight Rating:
Varies by model, consult manual for specific figures.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (driver and passenger)
IIHS Side Impact:
Good (for vehicles equipped with side airbags)
Active Features
Stability Control:
Dynamic Stability Control (DSC) available on most models.
Traction Control:
Automatic Stability Control and Traction (ASC+T) standard on many models.
ABS:
Anti-lock Braking System (ABS) standard on all models.
Passive Features
Airbags:
Frontal airbags (driver and passenger), optional front side-impact airbags, optional head protection airbags.
Seatbelts:
3-point inertia-reel seatbelts with front seatbelt pretensioners and force limiters.
💡 Technology Features
Infotainment
Radio Options:
BMW Business CD, BMW Professional RDS, optional CD changer.
Navigation:
Optional BMW Professional Navigation system (MK III or MK IV).
Driver Assistance
Parking Sensors:
Park Distance Control (PDC) optional.
Cruise Control:
Standard cruise control system.
Connectivity
Bluetooth:
Optional Bluetooth hands-free system available on later models.
Onboard Computer:
Standard OBC providing fuel economy, range, and trip data.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system or approx. 10,000-15,000 miles (16,000-24,000 km) depending on driving conditions. Manual details CBS reset procedures.
Spark Plug Replacement:
Approx. 100,000 miles (160,000 km) for M54 engines (long-life spark plugs).
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Capacity 525I/530I:
6.5 quarts (6.2 liters) of synthetic 5W-30 or 5W-40.
Engine Oil Capacity 540I:
7.0 quarts (6.6 liters) of synthetic 0W-40 or 5W-40.
Coolant Capacity:
Approx. 8.5 quarts (8.0 liters)
Power Steering Fluid:
Pentosin CHF 11S or equivalent.
Known Issues
Cooling System:
Plastic coolant expansion tanks are prone to cracking; water pump and thermostat failure.
Valve Cover Gasket:
Oil leaks from valve cover gaskets and oil pan gaskets due to age and brittle seals.
ABS Wheel Speed Sensors:
Common failure leading to ABS and DSC warning lights.
Crankshaft Position Sensor:
Failure can cause intermittent starting issues or stalling.
Window Regulators:
Plastic components in window regulator mechanisms can break.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for performance, luxury, and engineering excellence.
Model Evolution
E39 Introduction:
The E39 replaced the E34 and introduced significant improvements in chassis dynamics, interior comfort, and technology.
Updates:
Mid-cycle refresh in 2000 brought updated styling, new engines (M54 series), and improved features.
Production
Manufacturing Location:
Dingolfing, Germany; Rosslyn, South Africa; Graz, Austria (Magna Steyr for wagons).
Total Production:
Over 1.5 million units produced worldwide.
🏆 Awards & Recognition
Recognitions
Car And Driver Best List:
Car and Driver named the 5 Series to its annual 10Best list multiple times during its production run.
Ratings
Edmunds User Reviews:
Consistently high ratings for performance, comfort, and build quality among owners.
Certifications
Build Quality:
Recognized for robust construction and long-term durability when properly maintained.
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