BMW E39 5251 5281 530i 540i Sedan Sport Wagon 1997 1998 1999 2000 2001 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series (E39) Codes Chassis Code: E39 Model Designations: 525i, 528i, 530i, 540i 👋 Introduction Market Position Segment: Executive Mid-size Luxury Sedan/Wagon Target Audience: Owners seeking detailed technical information for maintenance and repair, independent repair shops specializing in BMW Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type Key Features Vehicle Philosophy: BMW's 'Ultimate Driving Machine' ethos, blending comfort, performance, and advanced engineering for its era Manual Value Proposition: Provides essential technical data to maintain and repair the E39 platform effectively, reducing reliance on expensive dealership services. 📋 Manual Details Coverage Areas Body Styles Covered: Sedan, Sport Wagon (Touring) Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive E39 service manuals) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Systems: M52TU, M54, M62TU engines (mechanical, lubrication, cooling, fuel, exhaust, ignition, emission controls, engine management (DME)) Transmission Systems: 5-speed manual (Getrag 420G), 5-speed automatic (Steptronic - GM 5L40-E, ZF 5HP19, ZF 5HP24) Drivetrain Systems: Front axle, rear axle, differential, driveshafts, CV joints Suspension Systems: Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering system (hydraulic power steering, steering rack) Brake Systems: Hydraulic brake system, ABS, DSC (Dynamic Stability Control), EBD, brake pad/rotor replacement, caliper service, brake bleeding Electrical Systems: Battery, charging system, starter, lighting, wipers, horn, power windows, power locks, central locking, mirrors, seats, sunroof, climate control blower motor Body And Chassis: Body panels, doors, hood, trunk, bumpers, glass, interior trim, chassis components, rust prevention Climate Control HVAC: AC system, heating system, ventilation, automatic climate control, blower motor, cabin filter replacement Safety Systems: Airbags (SRS), seatbelt pre-tensioners, occupant restraint systems Diagnostic Systems: OBD-II diagnostics, fault codes, diagnostic procedures, troubleshooting guides for common malfunctions Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes Engine Repair: Head gasket replacement, timing chain/guide inspection and replacement, piston and ring service, valve stem seal replacement, engine mounts, oil pan gasket replacement, oil pump service Transmission Repair: Clutch replacement (manual), torque converter replacement (automatic), valve body service, seal replacement, transmission fluid and filter service Suspension And Steering Repair: Ball joint replacement, tie rod end replacement, control arm bushings replacement, shock absorber and strut replacement, steering rack replacement, power steering pump service Brake System Repair: Brake pad and rotor replacement, brake caliper rebuilding/replacement, brake line replacement, ABS module troubleshooting, brake bleeding procedures Electrical Troubleshooting: Wiring diagrams, component testing, diagnostic procedures for electrical faults, module replacement and programming (e.g., DME, ABS/DSC, GM/LCM) Bodywork And Interior: Door panel removal, seat removal, headliner replacement, body panel alignment, bumper repair, glass replacement HVAC Service: Evaporator core replacement, heater core replacement, AC system recharging, blower motor replacement, climate control module diagnostics Diagnostic And Troubleshooting: Step-by-step diagnostic flowcharts, identification of common problems and their causes, repair procedures for specific faults Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to complete engine/transmission rebuilds and complex electrical diagnostics) Diagnostic Tools Referenced: BMW proprietary diagnostic tools (e.g., DIS, ISTA/D - though this manual predates ISTA/D) Torque Specifications: Detailed torque specifications for all critical fasteners Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems Special Tools: Identification of required BMW special tools for specific procedures 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchable Text: Likely (depending on original source quality) Printable: Yes Print Quality Image Resolution: High resolution (typically for professional service manuals) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 525I: M54B25 (2.5L Inline-6) Engine Code 528I: M52TUB28 (2.8L Inline-6) Engine Code 530I: M54B30 (3.0L Inline-6) Engine Code 540I: M62TUB44 (4.4L V8) Performance Horsepower 525I: 189 hp @ 5900 rpm Torque 525I: 245 Nm (181 lb-ft) @ 3500 rpm Horsepower 528I: 190 hp @ 5500 rpm Torque 528I: 280 Nm (206 lb-ft) @ 3950 rpm Horsepower 530I: 225 hp @ 5900 rpm Torque 530I: 300 Nm (221 lb-ft) @ 3500 rpm Horsepower 540I: 282 hp @ 5400 rpm Torque 540I: 440 Nm (325 lb-ft) @ 3600 rpm Fuel System Fuel Injection: Multi-point Fuel Injection (MPI) with Bosch Motronic engine management Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) 🔧 Transmission Standard Transmission Standard 525I 530I: 5-speed manual (Getrag 420G) Transmission Standard 528I: 5-speed manual (Getrag 420G) Optional Transmission Optional 525I: 5-speed Steptronic automatic (GM 5L40-E) Transmission Optional 528I: 5-speed Steptronic automatic (ZF 5HP19) Transmission Optional 530I: 5-speed Steptronic automatic (GM 5L40-E) Transmission Optional 540I: 5-speed Steptronic automatic (ZF 5HP24) Features Steptronic Functionality: Allows manual gear selection via selector lever or steering wheel buttons (on some models) 📐 Dimensions Exterior Wheelbase: 2830 mm (111.4 in) Length Sedan: 4770 mm (187.8 in)...

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Tipo: Car

Fabricante:

Sku: 478934

Coleções: ALL BMW

Disponibilidade: Em estoque

Tag: 1997 1998 1999 2000 2001 2002 5251 5281 530i 540i BMW Car Cars E39 Misc

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series (E39)

Codes

Chassis Code:

Model Designations:

525i, 528i, 530i, 540i

👋 Introduction

Market Position

Segment:

Executive Mid-size Luxury Sedan/Wagon

Target Audience:

Owners seeking detailed technical information for maintenance and repair, independent repair shops specializing in BMW

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type

Key Features

Vehicle Philosophy:

BMW's 'Ultimate Driving Machine' ethos, blending comfort, performance, and advanced engineering for its era

Manual Value Proposition:

Provides essential technical data to maintain and repair the E39 platform effectively, reducing reliance on expensive dealership services.

📋 Manual Details

Coverage Areas

Body Styles Covered:

Sedan, Sport Wagon (Touring)

Page Count

Estimated Page Count:

Approximately 1500-2000 pages (typical for comprehensive E39 service manuals)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

M52TU, M54, M62TU engines (mechanical, lubrication, cooling, fuel, exhaust, ignition, emission controls, engine management (DME))

Transmission Systems:

5-speed manual (Getrag 420G), 5-speed automatic (Steptronic - GM 5L40-E, ZF 5HP19, ZF 5HP24)

Drivetrain Systems:

Front axle, rear axle, differential, driveshafts, CV joints

Suspension Systems:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering system (hydraulic power steering, steering rack)

Brake Systems:

Hydraulic brake system, ABS, DSC (Dynamic Stability Control), EBD, brake pad/rotor replacement, caliper service, brake bleeding

Electrical Systems:

Battery, charging system, starter, lighting, wipers, horn, power windows, power locks, central locking, mirrors, seats, sunroof, climate control blower motor

Body And Chassis:

Body panels, doors, hood, trunk, bumpers, glass, interior trim, chassis components, rust prevention

Climate Control HVAC:

AC system, heating system, ventilation, automatic climate control, blower motor, cabin filter replacement

Safety Systems:

Airbags (SRS), seatbelt pre-tensioners, occupant restraint systems

Diagnostic Systems:

OBD-II diagnostics, fault codes, diagnostic procedures, troubleshooting guides for common malfunctions

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes

Engine Repair:

Head gasket replacement, timing chain/guide inspection and replacement, piston and ring service, valve stem seal replacement, engine mounts, oil pan gasket replacement, oil pump service

Transmission Repair:

Clutch replacement (manual), torque converter replacement (automatic), valve body service, seal replacement, transmission fluid and filter service

Suspension And Steering Repair:

Ball joint replacement, tie rod end replacement, control arm bushings replacement, shock absorber and strut replacement, steering rack replacement, power steering pump service

Brake System Repair:

Brake pad and rotor replacement, brake caliper rebuilding/replacement, brake line replacement, ABS module troubleshooting, brake bleeding procedures

Electrical Troubleshooting:

Wiring diagrams, component testing, diagnostic procedures for electrical faults, module replacement and programming (e.g., DME, ABS/DSC, GM/LCM)

Bodywork And Interior:

Door panel removal, seat removal, headliner replacement, body panel alignment, bumper repair, glass replacement

HVAC Service:

Evaporator core replacement, heater core replacement, AC system recharging, blower motor replacement, climate control module diagnostics

Diagnostic And Troubleshooting:

Step-by-step diagnostic flowcharts, identification of common problems and their causes, repair procedures for specific faults

Technical Depth

Depth Of Coverage:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds and complex electrical diagnostics)

Diagnostic Tools Referenced:

BMW proprietary diagnostic tools (e.g., DIS, ISTA/D - though this manual predates ISTA/D)

Torque Specifications:

Detailed torque specifications for all critical fasteners

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems

Special Tools:

Identification of required BMW special tools for specific procedures

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchable Text:

Likely (depending on original source quality)

Printable:

Print Quality

Image Resolution:

High resolution (typically for professional service manuals)

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 525I:

M54B25 (2.5L Inline-6)

Engine Code 528I:

M52TUB28 (2.8L Inline-6)

Engine Code 530I:

M54B30 (3.0L Inline-6)

Engine Code 540I:

M62TUB44 (4.4L V8)

Performance

Horsepower 525I:

189 hp @ 5900 rpm

Torque 525I:

245 Nm (181 lb-ft) @ 3500 rpm

Horsepower 528I:

190 hp @ 5500 rpm

Torque 528I:

280 Nm (206 lb-ft) @ 3950 rpm

Horsepower 530I:

225 hp @ 5900 rpm

Torque 530I:

300 Nm (221 lb-ft) @ 3500 rpm

Horsepower 540I:

282 hp @ 5400 rpm

Torque 540I:

440 Nm (325 lb-ft) @ 3600 rpm

Fuel System

Fuel Injection:

Multi-point Fuel Injection (MPI) with Bosch Motronic engine management

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

🔧 Transmission

Standard

Transmission Standard 525I 530I:

5-speed manual (Getrag 420G)

Transmission Standard 528I:

5-speed manual (Getrag 420G)

Optional

Transmission Optional 525I:

5-speed Steptronic automatic (GM 5L40-E)

Transmission Optional 528I:

5-speed Steptronic automatic (ZF 5HP19)

Transmission Optional 530I:

5-speed Steptronic automatic (GM 5L40-E)

Transmission Optional 540I:

5-speed Steptronic automatic (ZF 5HP24)

Features

Steptronic Functionality:

Allows manual gear selection via selector lever or steering wheel buttons (on some models)

📐 Dimensions

Exterior

Wheelbase:

2830 mm (111.4 in)

Length Sedan:

4770 mm (187.8 in)

Width:

1790 mm (70.5 in)

Height Sedan:

1430 mm (56.3 in)

Height Wagon:

1440 mm (56.7 in)

Cargo

Trunk Capacity Sedan:

Approx. 510 L (18.0 cu ft)

Cargo Capacity Wagon:

Approx. 460 L (16.2 cu ft) with rear seats up, expandable to Approx. 1500 L (53.0 cu ft) with rear seats folded

Weights

Curb Weight Range:

Approx. 1570 kg - 1830 kg (3461 lbs - 4034 lbs) depending on engine and configuration

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

4 stars (Driver), 5 stars (Passenger) - for similar era BMWs

IIHS Side Impact:

Good (for well-equipped models of the era)

Active Features

Standard Stability Control:

DSC (Dynamic Stability Control) or ASC+T (Automatic Stability Control + Traction) on most models

Standard Anti-lock Braking System (ABS)

Traction Control:

Standard Traction Control (ASC)

Passive Features

Airbags:

Frontal airbags, optional side airbags (for front and rear occupants on some models)

Seatbelts:

Three-point inertia-reel seatbelts with pre-tensioners and force limiters

Head Restraints:

Active head restraints (on front seats)

💡 Technology Features

Infotainment

Head Unit Options:

BMW Business CD, BMW Professional CD RDS, BMW Navigation System (MK III/MK IV)

Display Technology:

Central Information Display (CID) in the dashboard for vehicle status, navigation, and radio information. Instrument cluster display (OBC/SID).

Driver Assistance

Parking Assistance:

Optional Park Distance Control (PDC) front and rear sensors.

Cruise Control:

Standard cruise control, often with steering wheel controls.

Connectivity

Phone Integration:

Optional Bluetooth preparation with integrated mobile phone functionality via cradle or direct pairing (depending on year and options).

Audio Interface:

Optional CD changer, cassette player (standard on many early models), AM/FM radio.

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system typically recommends oil changes based on driving conditions, often around 10,000-15,000 miles or annually. Refer to manual for specific CBS reset procedures.

Coolant Change Interval:

Every 2 years or 30,000 miles, whichever comes first (BMW Blue Coolant).

Brake Fluid Change Interval:

Every 2 years, regardless of mileage.

Transmission Fluid Change:

Lifetime fluid designation by BMW, but periodic changes (e.g., every 50,000-70,000 miles) are highly recommended for longevity, especially for automatics.

Fluid Specifications

Engine Oil Type:

API SN, ACEA A3/B4, BMW Longlife-01 (e.g., Castrol EDGE Professional OE 5W-30, Mobil 1 5W-30)

Engine Oil Capacity 525I 530I:

Approx. 6.5 Liters (6.9 US Quarts)

Engine Oil Capacity 528I:

Approx. 6.5 Liters (6.9 US Quarts)

Engine Oil Capacity 540I:

Approx. 7.5 Liters (7.9 US Quarts)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 type), 50/50 mixture with distilled water.

Power Steering Fluid:

Pentosin CHF 11S or Pentosin CHF 202 (Green fluid)

Automatic Transmission Fluid:

GM 5L40-E: Dexron III H / Dexron VI; ZF 5HP19: Esso LT 71141; ZF 5HP24: Mobil ATF LT 71141 (Specific fluid crucial for transmission life).

Manual Transmission Fluid:

Typically ATF Dexron III or equivalent, consult manual for exact spec (e.g., Pentosin MTF LT-1).

Known Issues

Cooling System:

Plastic coolant expansion tank prone to cracking, water pump failure (especially plastic impeller), thermostat housing leaks.

Engine M54:

Vanos seal wear, CCV (Crankcase Ventilation) system clogging leading to oil leaks and rough idle, DISA valve flap failure, oil filter housing gasket leaks.

Engine M62Tu:

Timing chain guides and tensioners wear, Vanos system issues, valve stem seal degradation, cooling system issues similar to inline-6.

Suspension And Steering:

Front control arm bushings and ball joints wear (leading to wandering), rear subframe bushings can detach, steering rack leaks, tie rod end wear.

Electrical:

Heated Oxygen Sensor (O2 sensor) failures, MAF (Mass Air Flow) sensor issues, LCM (Light Control Module) issues, ABS/DSC sensor failures, dead pixels in instrument cluster (OBC/SID).

Interior:

Headliner sagging, leather seat wear, fading pixels in instrument cluster.

Automatic Transmission:

Clunking or harsh shifts, solenoid failures, torque converter issues (especially ZF units).

📚 Vehicle History

Brand Heritage

Bmw Philosophy History:

BMW's reputation for 'Sheer Driving Pleasure' established through performance-oriented engineering and motorsport heritage.

Model Evolution

E39 Introduction:

Introduced in 1995 (for the 1996 model year) in Europe, launched in North America in late 1996 for the 1997 model year. Replaced the E34 5 Series.

E39 Facelift:

Mid-cycle facelift ('LCI' - Life Cycle Impulse) introduced in September 2000 for the 2001 model year, featuring updated styling (headlights, taillights, bumpers) and technological improvements.

Production

Production Years:

1997-2003 (North America market, production ended in 2003)

Production Locations:

Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

E39 5 Series models frequently appeared on Car and Driver's 10Best lists during its production run, highlighting its blend of performance and luxury.

Motor Trend Car Of The Year Contender:

Often considered a benchmark in its class and a strong contender in automotive awards.

Certifications

Epa Fuel Economy Estimates:

Varies by model and year, typically ranging from 16-19 MPG city / 24-28 MPG highway.