BMW 5 Series E39 1997-2002 Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Code: E39 Production Years: 1995-2003 (Global), 1997-2002 (Covered by Manual) Codes Manual Product Name: BMW 5 Series E39 1997-2002 Workshop Manual 👋 Introduction Market Position Positioning: The BMW E39 5 Series represented BMW's executive sedan and wagon offering, known for its blend of luxury, performance, and sophisticated engineering, competing with rivals like the Mercedes-Benz E-Class and Audi A6. Competitive Analysis Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type (X200) Key Features Vehicle Highlights: Renowned for its balanced chassis dynamics (often cited as one of the best handling sedans of its era), refined interior, powerful inline-six and V8 engines, and advanced features for its time. Manual Value Proposition Value: An essential resource for owners and independent mechanics seeking to maintain, diagnose, and repair the E39 5 Series, offering detailed procedures and technical data that exceed the scope of basic owner's manuals. 📋 Manual Details Coverage Areas Covered Models: 525i, 528i, 530i, 540i Sedan, Sport Wagon Covered Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Estimated Page Count: Extensive (Specific count not provided, but typical for comprehensive workshop manuals) Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English (Assumed based on typical product offerings, confirmation recommended) Format Format: Digital (Likely PDF, though physical copies may exist) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, EFI, Emission Control, Ignition, Cooling, Lubrication, Fuel System (EFI), Exhaust, Turbocharger (if applicable to specific models/years not detailed but often included) Transmission: Manual Transmission (Getrag S5D 250G, S6S 420G, ZF S5D 320Z), Automatic Transmission Unit Repair (A4S 270R, A4S 310R, A5S 360R, A5S 390R, A5S 325Z, A5S 560Z, A5S 440Z), Automatic Transaxle (Coverage may vary for AWD variants, though E39 was primarily RWD) Chassis: Brake, Steering, Front Axle and Suspension, Rear Axle and Suspension, Propeller Shaft, Clutch Bodywork: Body, Body Electrical, Air Conditioning, Collision Body Repair Manual Electrical: Electrical Wiring Diagrams, Charging, Battery, Starting, Body Electrical Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, inspection procedures Repair Overhaul: Engine rebuild, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and repair Diagnostics: Troubleshooting guides, fault code interpretation, diagnostic procedures for various systems Special Tools: SST and SSM (Special Service Tools and Special Service Measures) identification and usage Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including electrical schematics and body repair. 📊 Manual Specifications File Format Digital Format: PDF (Likely searchabl e, with hyperlinked sections for ease of navigation) Print Quality Print Readability: High resolution for clear text and diagrams, suitable for printing if required. Binding Type Physical Binding: N/A (Assuming digital format, but if printed, would typically be spiral-bound or perfect-bound for workshop use) Paper Type Physical Paper: N/A (Assuming digital format, but if printed, would be durable, high-quality paper suitable for workshop environments) ⚙️ Engine Specifications Primary Engine Engine Variants Covered: Inline-6: M52 (2.5L, 2.8L), M52 TU (2.5L, 2.8L), M54 (2.5L, 3.0L); V8: M62 (4.4L), M62 TU (4.4L) Performance 525I Engine Codes: M52B25 (1997-1998), M54B25 (2001-2002) 525I Horsepower: 189 hp (M52B25), 184 hp (M54B25) 525I Torque: 236 lb-ft (M52B25), 232 lb-ft (M54B25) 528I Engine Codes: M52B28 (1997-1998), M52TUB28 (1999-2000) 528I Horsepower: 190 hp (M52B28), 193 hp (M52TUB28) 528I Torque: 206 lb-ft (M52B28), 206 lb-ft (M52TUB28) 530I Engine Codes: M54B30 (2001-2002) 530I Horsepower: 225 hp 530I Torque: 214 lb-ft 540I Engine Codes: M62B44 (1997-2000), M62TUB44 (2001-2002) 540I Horsepower: 282 hp (M62B44), 290 hp (M62TUB44) 540I Torque: 317 lb-ft (M62B44), 324 lb-ft (M62TUB44) Fuel System Fuel Injection: Bosch Motronic electronic fuel injection (specific ECU varies by engine and year) Recommended Fuel: Premium Unleaded (91 octane or higher recommended for optimal performance) Engine Management ECU Control: Engine Control Unit (ECU) manages fuel injection, ignition timing, VANOS, and emission control systems. 🔧 Transmission Standard Manual Transmissions: Getrag S5D 250G (for 6-cylinder models), Getrag S6S 420G (for 540i and M5 models, though M5 not covered here), ZF S5D 320Z (some 6-cylinder applications) Optional Automatic Transmissions: A4S 270R, A4S 310R, A5S 360R, A5S 390R, A5S 325Z, A5S 560Z, A5S 440Z (ZF sourced, varying by engine and model year) Features Sport Modes: Many automatic transmissions offered a 'Steptronic' manual shifting mode, allowing driver control. Fluid Specs Manual Transmission Fluid: BMW recommends specific synthetic manual transmission fluids. Consult manual for exact specifications (e.g., Pentosin MTF LT-1/LT-2). Automatic Transmission Fluid: BMW ATF fluids are specified (e.g., Esso LT 71141 for many ZF transmissions). Crucial to use the correct fluid type. 📐 Dimensions Exterior Length: Approx. 4,819 mm (189.7 in) for Sedan, Approx. 4,847 mm (190.8 in) for Wagon Width: Approx. 1,798 mm (70.8 in) Height: Approx. 1,435 mm (56.5 in) for Sedan, Approx. 1,474 mm (58.0 in) for Wagon Wheelbase: Approx. 2,830 mm (111.4 in) Weights Curb Weight: Varies significantly by engine and body style, typically...

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Typ: Car

Anbieter:

Art.-Nr: 471484

Sammlungen: ALL BMW Material Handling

Verfügbarkeit: Auf Lager

Stichworte: 1997 1998 1999 2000 2001 2002 5 Series E39 BMW Car Getrag Industrial Equipment & Tools Material Handling Transmissions Gearboxes Vehicle Parts & Accessories

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Generation

Chassis Code:

Production Years:

1995-2003 (Global), 1997-2002 (Covered by Manual)

Codes

Manual Product Name:

BMW 5 Series E39 1997-2002 Workshop Manual

👋 Introduction

Market Position

Positioning:

The BMW E39 5 Series represented BMW's executive sedan and wagon offering, known for its blend of luxury, performance, and sophisticated engineering, competing with rivals like the Mercedes-Benz E-Class and Audi A6.

Competitive Analysis

Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type (X200)

Key Features

Vehicle Highlights:

Renowned for its balanced chassis dynamics (often cited as one of the best handling sedans of its era), refined interior, powerful inline-six and V8 engines, and advanced features for its time.

Manual Value Proposition

Value:

An essential resource for owners and independent mechanics seeking to maintain, diagnose, and repair the E39 5 Series, offering detailed procedures and technical data that exceed the scope of basic owner's manuals.

📋 Manual Details

Coverage Areas

Covered Models:

525i, 528i, 530i, 540i Sedan, Sport Wagon

Covered Years:

1997, 1998, 1999, 2000, 2001, 2002

Page Count

Estimated Page Count:

Extensive (Specific count not provided, but typical for comprehensive workshop manuals)

Manual Type

Type:

Workshop Manual / Service Manual / Repair Manual

Language

Language:

English (Assumed based on typical product offerings, confirmation recommended)

Format

Format:

Digital (Likely PDF, though physical copies may exist)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, EFI, Emission Control, Ignition, Cooling, Lubrication, Fuel System (EFI), Exhaust, Turbocharger (if applicable to specific models/years not detailed but often included)

Transmission:

Manual Transmission (Getrag S5D 250G, S6S 420G, ZF S5D 320Z), Automatic Transmission Unit Repair (A4S 270R, A4S 310R, A5S 360R, A5S 390R, A5S 325Z, A5S 560Z, A5S 440Z), Automatic Transaxle (Coverage may vary for AWD variants, though E39 was primarily RWD)

Chassis:

Brake, Steering, Front Axle and Suspension, Rear Axle and Suspension, Propeller Shaft, Clutch

Bodywork:

Body, Body Electrical, Air Conditioning, Collision Body Repair Manual

Electrical:

Electrical Wiring Diagrams, Charging, Battery, Starting, Body Electrical

Procedures Included

Maintenance:

Routine maintenance, fluid changes, filter replacements, inspection procedures

Repair Overhaul:

Engine rebuild, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and repair

Diagnostics:

Troubleshooting guides, fault code interpretation, diagnostic procedures for various systems

Special Tools:

SST and SSM (Special Service Tools and Special Service Measures) identification and usage

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including electrical schematics and body repair.

📊 Manual Specifications

File Format

Digital Format:

PDF (Likely searchabl e, with hyperlinked sections for ease of navigation)

Print Quality

Print Readability:

High resolution for clear text and diagrams, suitable for printing if required.

Binding Type

Physical Binding:

N/A (Assuming digital format, but if printed, would typically be spiral-bound or perfect-bound for workshop use)

Paper Type

Physical Paper:

N/A (Assuming digital format, but if printed, would be durable, high-quality paper suitable for workshop environments)

⚙️ Engine Specifications

Primary Engine

Engine Variants Covered:

Inline-6: M52 (2.5L, 2.8L), M52 TU (2.5L, 2.8L), M54 (2.5L, 3.0L); V8: M62 (4.4L), M62 TU (4.4L)

Performance

525I Engine Codes:

M52B25 (1997-1998), M54B25 (2001-2002)

525I Horsepower:

189 hp (M52B25), 184 hp (M54B25)

525I Torque:

236 lb-ft (M52B25), 232 lb-ft (M54B25)

528I Engine Codes:

M52B28 (1997-1998), M52TUB28 (1999-2000)

528I Horsepower:

190 hp (M52B28), 193 hp (M52TUB28)

528I Torque:

206 lb-ft (M52B28), 206 lb-ft (M52TUB28)

530I Engine Codes:

M54B30 (2001-2002)

530I Horsepower:

225 hp

530I Torque:

214 lb-ft

540I Engine Codes:

M62B44 (1997-2000), M62TUB44 (2001-2002)

540I Horsepower:

282 hp (M62B44), 290 hp (M62TUB44)

540I Torque:

317 lb-ft (M62B44), 324 lb-ft (M62TUB44)

Fuel System

Fuel Injection:

Bosch Motronic electronic fuel injection (specific ECU varies by engine and year)

Recommended Fuel:

Premium Unleaded (91 octane or higher recommended for optimal performance)

Engine Management

ECU Control:

Engine Control Unit (ECU) manages fuel injection, ignition timing, VANOS, and emission control systems.

🔧 Transmission

Standard

Manual Transmissions:

Getrag S5D 250G (for 6-cylinder models), Getrag S6S 420G (for 540i and M5 models, though M5 not covered here), ZF S5D 320Z (some 6-cylinder applications)

Optional

Automatic Transmissions:

A4S 270R, A4S 310R, A5S 360R, A5S 390R, A5S 325Z, A5S 560Z, A5S 440Z (ZF sourced, varying by engine and model year)

Features

Sport Modes:

Many automatic transmissions offered a 'Steptronic' manual shifting mode, allowing driver control.

Fluid Specs

Manual Transmission Fluid:

BMW recommends specific synthetic manual transmission fluids. Consult manual for exact specifications (e.g., Pentosin MTF LT-1/LT-2).

Automatic Transmission Fluid:

BMW ATF fluids are specified (e.g., Esso LT 71141 for many ZF transmissions). Crucial to use the correct fluid type.

📐 Dimensions

Exterior

Length:

Approx. 4,819 mm (189.7 in) for Sedan, Approx. 4,847 mm (190.8 in) for Wagon

Width:

Approx. 1,798 mm (70.8 in)

Height:

Approx. 1,435 mm (56.5 in) for Sedan, Approx. 1,474 mm (58.0 in) for Wagon

Wheelbase:

Approx. 2,830 mm (111.4 in)

Weights

Curb Weight:

Varies significantly by engine and body style, typically ranging from ~3,500 lbs to ~4,000+ lbs.

Gross Vehicle Weight Rating:

Refer to vehicle's VIN plate or owner's manual for specific GVWR.

Towing Capacity:

Not typically advertised or recommended for US models, but European variants may have specifications. Consult local regulations and manual.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-star (for models equipped with side airbags, as per original testing for similar vehicles of the era)

IIHS Side Impact:

Good (for models equipped with side airbags)

Active Features

Braking System:

Anti-lock Braking System (ABS) standard. Optional Dynamic Stability Control (DSC) on later models.

Traction Control:

Automatic Stability Control (ASC) or Automatic Stability Control + Traction (ASC+T) standard on most models.

Passive Features

Airbags:

Driver and front passenger airbags standard. Optional side-impact airbags for front occupants, and rear side airbags on some models.

Seatbelts:

Pretensioning front seatbelts, three-point rear seatbelts.

💡 Technology Features

Infotainment

Audio System:

Available premium audio systems (e.g., Harman Kardon), CD player, AM/FM radio. Navigation system available on some models.

Display Interface:

Central LCD display in dashboard for OBC (On-Board Computer), climate control, and radio information. No iDrive system in the E39 generation.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Connectivity

Phone Integration:

Optional Bluetooth mobile phone preparation with car kit on later models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW's Condition Based Service (CBS) system or typically every 7,500-10,000 miles / 1 year, whichever comes first. Always refer to the manual for specific intervals based on driving conditions.

Transmission Fluid Interval:

Manual: Lifetime fluid is often stated, but changing every 60,000-100,000 miles is recommended for longevity. Automatic: BMW historically stated 'lifetime' but fluid degradation occurs; changing around 50,000-80,000 miles is advisable for continued smooth operation.

Coolant Interval:

BMW Longlife coolant typically requires replacement every 2-4 years or 30,000-50,000 miles.

Fluid Specifications

Engine Oil Spec:

BMW Longlife-01 (LL-01) or Longlife-98 (LL-98) approved synthetic oil, typically 0W-40 or 5W-40 viscosity. Check manual for specific engine requirements.

Coolant Spec:

BMW Blue Longlife Antifreeze/Coolant (G48 formulation) or equivalent.

Brake Fluid Spec:

DOT 4 low-viscosity brake fluid.

Known Issues

Common Problems:

VANOS seals degradation (particularly on M52/M54 engines), cooling system component failure (plastic expansion tank, water pump, thermostat), oil leaks (valve cover gaskets, oil pan gaskets), ignition coil failure, ABS/DSC sensor issues, window regulator failures, PIEZO injectors (on some later M62TU V8s), subframe cracking (rare but documented).

Maintenance Schedule Highlights:

Regular inspection of drive belts, hoses, suspension bushings, and exhaust system. Spark plug replacement as per schedule (e.g., 60,000 miles for iridium plugs). Check for oil leaks diligently.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long-standing reputation for building driver-focused luxury vehicles with a focus on performance and engineering excellence, dating back to the early 20th century.

Model Evolution

E39 Lineage:

The E39 succeeded the E34 5 Series and was replaced by the E60 5 Series. It is often considered a high point for the 5 Series in terms of design and driving dynamics before the introduction of iDrive.

Production

Manufacturing Locations:

Primarily manufactured in Dingolfing, Germany. Some assembly may have occurred in other global locations.

Global Sales:

The E39 was a significant global sales success for BMW, solidifying the 5 Series' position in the executive car market.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E39 5 Series was frequently named to Car and Driver's 10Best list during its production run, highlighting its exceptional driving dynamics and overall package.

Ratings

Jd Power Dependability:

J.D. Power ratings varied by model year and specific vehicle, but the E39 was generally considered a reliable luxury vehicle, though with some characteristic German engineering quirks.

Certifications

Epa Fuel Economy:

EPA estimates varied by engine and transmission, typically ranging from 16-19 MPG city and 23-28 MPG highway. Specific figures for each variant are available through official sources.