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

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Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Body Style: Sedan, Sport Wagon Product Name: 1997-2002 BMW 5 Series (E39) 525i 528i 530i 540i Sedan Sport Wagon...

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Description

Basic Information
Identification
Make:	BMW
Model:	5 Series
Chassis Code:	E39
Body Style:	Sedan, Sport Wagon
Product Name:	1997-2002 BMW 5 Series (E39) 525i 528i 530i 540i Sedan Sport Wagon Complete Workshop Service Repair Manual

Introduction
Market Position
Positioning:	The E39 5 Series represented BMW's executive sedan and wagon offering, known for its blend of luxury, performance, and advanced technology for its time.
Competitive Analysis
Key Competitors:	Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type.
Key Features Vehicle
Chassis Design:	Sophisticated multi-link suspension, excellent weight distribution, and a focus on driver engagement.
Engine Options:	Smooth inline-six engines and powerful V8 engines, offering a range of performance characteristics.
Key Features Manual
Value Proposition:	An indispensable resource for owners and independent repair shops seeking to maintain, diagnose, and repair the E39 5 Series effectively.
Comprehensiveness:	Covers nearly all aspects of vehicle maintenance and repair, providing OEM-level detail.

Manual Details
Coverage Areas
Specific Models Covered:	525i, 528i, 530i, 540i
Production Years Covered:	1997, 1998, 1999, 2000, 2001, 2002
Page Count
Estimated Page Count:	Extensive (typically 2000+ pages for a complete workshop manual of this era)
Manual Type
Manual Type:	Complete Workshop Service and Repair Manual
Language
Language:	English
Format
Format:	Digital (likely PDF, often searchable and printable)

Manual Coverage
Systems Covered
Engine:	Detailed diagnostics, repair, overhaul for M50/M52/M62 engines (including VANOS, ignition, fuel injection, cooling, exhaust)
Transmission:	Automatic (GM 5L40-E, ZF 5HP19, ZF 5HP24, ZF 5HP30) and Manual (Getrag 6-speed) transmission repair, diagnostics, fluid changes
Drivetrain:	Driveshaft, differential, axle shafts, wheel bearings, AWD (xDrive if applicable for specific regional models, though less common on E39 initially)
Suspension:	Front (McPherson struts, control arms, sway bar), Rear (multi-link, shock absorbers, springs, sway bar), bushings, alignment
Steering:	Power steering system, steering rack, tie rods, steering column, wheel alignment
Brakes:	Hydraulic system, ABS, DSC (Dynamic Stability Control), EBD, brake calipers, rotors, pads, parking brake, bleeding procedures
Electrical System:	Battery, alternator, starter, wiring diagrams, fuses, relays, lighting, horn, power windows, locks, mirrors, seats
Body And Chassis:	Body panels, doors, hood, trunk, bumpers, sunroof, interior trim, sound deadening, chassis lubrication
HVAC:	Air conditioning, heating, climate control system, blower motor, refrigerant, evaporator, condenser, cabin filter
Fuel System:	Fuel pump, fuel filter, injectors, fuel lines, fuel tank, EVAP system
Exhaust System:	Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors
Safety Systems:	Airbags, seat belts, SRS control module, crash sensors
Instrumentation And Controls:	Dashboard, instrument cluster, warning lights, switches, steering wheel controls
Infotainment And Electronics:	Radio, CD player, navigation system (if equipped), speakers, antenna, park distance control (PDC), onboard computer (OBC)
Procedures Included
Routine Maintenance:	Oil change, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, spark plug replacement
Diagnostic Procedures:	Troubleshooting common symptoms, fault code retrieval and interpretation (e.g., via OBD-II, BMW specific codes), component testing
Repair And Overhaul:	Engine rebuilds, transmission repairs, suspension component replacement, brake caliper rebuilds, electrical component repair
Scheduled Maintenance:	Detailed intervals and procedures for long-term upkeep
Component Replacement:	Step-by-step guides for replacing major and minor components
Technical Specifications Lookup:	Torque values, clearances, fluid capacities, diagnostic parameters
Technical Depth
Depth Of Coverage:	Comprehensive, from basic maintenance to complete engine and transmission overhauls
Diagnostic Focus:	Detailed diagnostic flowcharts, component testing, and symptom-based troubleshooting
Wiring Diagrams:	Detailed, system-specific wiring schematics with component identification
Special Tools:	Identification of specific tools required for certain procedures

Manual Specifications
File Format
File Format:	PDF (typically)
Searchability:	Likely includes searchable text for quick information retrieval
Print Quality
Print Quality:	High-resolution scans suitable for printing key sections or the entire manual
Binding Type
Binding Type:	N/A (Digital format)
Paper Type
Paper Type:	N/A (Digital format)

Engine Specifications
Primary Engine 525I
Engine Code:	M52TU B25
Displacement:	2.5 Liters (2494 cc)
Configuration:	Inline 6-cylinder, DOHC, 24 valves
Horsepower:	189 hp @ 5900 rpm
Torque:	181 lb-ft @ 3500 rpm
Fuel System:	Multi-point fuel injection (Bosch Motronic)
Primary Engine 528I
Engine Code:	M52TU B28
Displacement:	2.8 Liters (2793 cc)
Configuration:	Inline 6-cylinder, DOHC, 24 valves
Horsepower:	193 hp @ 5500 rpm
Torque:	206 lb-ft @ 3500 rpm
Fuel System:	Multi-point fuel injection (Bosch Motronic)
Primary Engine 530I
Engine Code:	M54 B30
Displacement:	3.0 Liters (2979 cc)
Configuration:	Inline 6-cylinder, DOHC, 24 valves
Horsepower:	225 hp @ 5900 rpm
Torque:	214 lb-ft @ 3500 rpm
Fuel System:	Multi-point fuel injection (Bosch Motronic ME 7.2)
Primary Engine 540I
Engine Code:	M62TU B44
Displacement:	4.4 Liters (4398 cc)
Configuration:	V8, DOHC, 32 valves
Horsepower:	290 hp @ 5400 rpm
Torque:	324 lb-ft @ 3600 rpm
Fuel System:	Multi-point fuel injection (Bosch Motronic ME 7.2)
Performance
Note:	Performance figures are approximate and may vary based on transmission, vehicle condition, and specific market.

Transmission
Standard 525I 528I 530I
Standard Transmission:	5-speed Manual (Getrag 420G for later models/some markets)
Optional 525I 528I 530I
Optional Transmission:	5-speed Automatic (GM 5L40-E)
Standard 540I
Standard Transmission:	5-speed Automatic (ZF 5HP24)
Optional 540I
Optional Transmission:	6-speed Manual (Getrag 420G, rare in North America)
Features
Traction Control:	ASC+T (Automatic Stability Control + Traction) or DSC (Dynamic Stability Control) depending on year and options.
Fluid Specifications
Automatic Transmission Fluid Type:	BMW ATF LT-3 or equivalent (check specific vehicle documentation, e.g., ZF LifeguardFluid 5)
Manual Transmission Fluid Type:	BMW MTF LT-2 or equivalent (e.g., Castrol TWS Motorsport 75W-90 or similar spec)

Dimensions
Exterior Sedan
Length:	Approx. 188.5 inches (4788 mm)
Width:	Approx. 71.0 inches (1803 mm)
Height:	Approx. 57.0 inches (1448 mm)
Exterior Wagon
Length:	Approx. 190.2 inches (4831 mm)
Width:	Approx. 71.0 inches (1803 mm)
Height:	Approx. 57.8 inches (1468 mm)
Weights
Curb Weight Range:	Approx. 3500-3900 lbs (1588-1769 kg), varies by model and options
Gross Vehicle Weight Rating:	Varies by model, refer to vehicle specific plate.
Cargo Wagon
Cargo Volume Seats Up:	Approx. 23.7 cubic feet (671 L)
Cargo Volume Seats Down:	Approx. 57.4 cubic feet (1625 L)
Wheels And Tires
Wheelbase:	115.4 inches (2931 mm)
Wheel Bolt Pattern:	5 x 120 mm
Common Tire Sizes:	225/60R16, 235/45R17, 235/40R18 (depending on trim and options)

Safety Features
Ratings
NHTSA Front Impact Rating:	4/5 stars (for most models)
IIHS Offset Frontal Crash Rating:	Good (for models tested)
Active Features
ABS:	Standard Anti-lock Braking System
Traction Control:	ASC+T or DSC (Dynamic Stability Control) - standard on later models/higher trims
Brake Assist:	Available on some models
Passive Features
Airbags:	Frontal airbags, front side-impact airbags, optional rear side-impact airbags
Seatbelts:	Three-point inertia-reel seatbelts with pre-tensioners
Head Restraints:	Active head restraints on front seats (on some models/years)

Technology Features
Infotainment
Head Unit Options:	BMW Business CD, BMW Professional CD RDS, optional navigation system (Mk III/Mk IV).
Audio System:	Standard 10-speaker Hi-Fi system, optional Harman Kardon surround sound system.
Driver Assistance
Stability Control:	Available ASC+T or the more advanced DSC (Dynamic Stability Control) system.
Parking Assistance:	Park Distance Control (PDC) sensors (front and rear on later models).
Connectivity
Onboard Computer:	Onboard Computer (OBC) providing information on fuel economy, range, average speed, and system checks.
Telematics:	Optional BMW Assist telematics system (cellular phone integration, emergency services).
Comfort Features
Climate Control:	Automatic climate control with dual-zone temperature settings, pollen filter.
Seating:	Standard power-adjustable front seats, optional comfort seats with memory, heated seats.

Maintenance
Service Intervals Oil
Engine Oil Change Interval:	Typically every 7,500 to 10,000 miles or annually, or as indicated by the onboard computer (Service Interval Indicator - SII) using synthetic oil.
Service Intervals Filters
Oil Filter Replacement:	With every oil change.
Air Filter Replacement:	Every 15,000 to 30,000 miles or as needed based on driving conditions.
Cabin Air Filter Replacement:	Every 15,000 to 30,000 miles or annually.
Service Intervals Fluids
Coolant Flush:	Every 30,000 to 60,000 miles or 2-4 years.
Brake Fluid Flush:	Every 2 years, regardless of mileage.
Service Intervals Spark Plugs
Spark Plug Replacement M52Tu M54:	Approx. 60,000 miles (using long-life spark plugs).
Spark Plug Replacement M62Tu:	Approx. 100,000 miles (using long-life spark plugs).
Fluid Specifications
Engine Oil Type:	Synthetic SAE 5W-30 or 5W-40 meeting BMW LL-01 specification (or older LL-98 for some early models, consult manual).
Engine Oil Capacity:	525i/528i/530i: Approx. 6.5-7.0 quarts (6.2-6.6 L); 540i: Approx. 7.0-7.5 quarts (6.6-7.1 L). Refer to manual for exact fill.
Coolant Type:	BMW Blue Coolant (G48) or approved equivalent.
Power Steering Fluid Type:	Pentosin CHF 11S or equivalent approved fluid.
Known Issues
Cooling System Failures:	Plastic expansion tank leaks, water pump failure (plastic impeller), thermostat housing leaks.
Oil Leaks:	Valve cover gasket, oil pan gasket, oil filter housing gasket, CCV system leaks.
Suspension Wear:	Control arm bushings, ball joints, sway bar links, rear subframe bushings.
Electrical Gremlins:	ABS/DSC module failures, headlight leveling issues, instrument cluster pixelation (LCD displays).
Vanos System:	Wear in the VANOS solenoids and seals can lead to rough idle, loss of power, and increased fuel consumption.
E39 Specific Issues:	Sagging headliner, pixelated OBC displays, heater control valve failure, ABS speed sensor failures.

Vehicle History
Brand Heritage
Bmw Philosophy:	BMW's reputation for building driver-focused, well-engineered automobiles with a focus on performance and luxury.
Model Evolution
E39 Introduction:	Launched in 1995 (as a 1996 model in some markets), the E39 replaced the E34 and was produced until 2003. It represented a significant technological and design advancement.
Mid-Cycle Refresh:	The E39 received a facelift in 2000, which included updated headlights (angel eyes), taillights, bumpers, interior trim, and the introduction of the M54 engines.
Production
Manufacturing Locations:	Primarily Dingolfing, Germany. Some assembly may have occurred in other BMW facilities or through contract manufacturing.
Sales Figures:	The E39 was a highly successful model for BMW, with over one million units produced worldwide.

Awards & Recognition
Recognitions
Car And Driver 10 Best:	The E39 5 Series was frequently named to Car and Driver's 10 Best lists during its production run, a testament to its engineering and driving dynamics.
Ratings
Consumer Reports Ratings:	Generally received good to excellent ratings for performance, comfort, and reliability, with some model years and specific issues noted.
Certifications
Euro Ncapsafety Rating:	4 stars for adult occupant protection (for models tested).