1997-2002 BMW 5 Series (E39) Factory Service/Repair/ Workshop Manual (1997 1998 1999 2000 2001 2002)

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Model Years Covered: 1997-2002 Body Styles Covered: Sedan, Sport Wagon (Touring) Specific Models Covered: 525i, 528i, 530i, 540i Generation Generation Code: E39 Production Start Year: 1995 Production End Year: 2003 👋 Introduction Market Position Vehicle Class: Executive Mid-size Sedan / Wagon Target Audience: Premium market segment Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type Key Features Design Philosophy: The E39 represented a significant evolution in BMW's design language, known for its refined styling, robust build quality, and emphasis on driving dynamics. Manual Utility: Provides in-depth knowledge for DIY owners and independent repair shops to maintain and repair the E39 accurately and efficiently. 📋 Manual Details Coverage Areas Primary Coverage: Maintenance, Service, Diagnosis, Repair Detailed Systems Coverage: Engine, Transmission, Suspension, Steering, Brakes, Body, Body Equipment, Electrical System, Equipment and Accessories, Electrical Wiring Diagrams Page Count Estimated Page Count: Extensive (Typical for factory service manuals, often 1000+ pages) Manual Type Manual Classification: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format File Format: PDF Download Type: Instant Download Compatibility: All Versions of Windows & Mac Requirements Software Requirements: Adobe PDF Reader, WinZip (for extraction) Printability Print Capability: Printable 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, internal component repair (pistons, rings, bearings, valves, camshafts, crankshaft), cylinder head service, timing systems (chains, guides, tensioners), lubrication system, cooling system. Engine Management: Fuel injection systems (DME - Digital Motor Electronics), ignition systems, emission control systems (secondary air, EVAP), sensor testing and replacement, diagnostic trouble codes (DTCs). Transmission Manual: Clutch operation and adjustment, gearbox overhaul, shift mechanism. Transmission Automatic: Identification of automatic transmission types (e.g., GM 5L40-E, ZF 5HP19, ZF 5HP30), fluid and filter changes, torque converter service, valve body diagnostics, electronic control module (EGS) integration. Drivetrain: Driveshafts, CV joints, differential service and repair, rear axle assemblies. Suspension: Front and rear suspension component replacement (struts, shocks, control arms, bushings, ball joints, tie rod ends), wheel bearing service, alignment specifications. Steering: Power steering system components (pump, hoses, rack and pinion), steering column adjustments, steering angle sensor. Brakes: Hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), ABS/DSC (Dynamic Stability Control) system components, brake pad and rotor replacement, brake fluid specifications and bleeding procedures, parking brake system. Body Exterior: Panel removal and installation (fenders, doors, hood, trunk lid), bumper repair and replacement, mirror assembly, glass replacement, sunroof mechanisms. Body Interior: Trim panel removal, seat adjustments and removal, dashboard components, headliner, door panels, carpet replacement. Body Equipment: Door locks and latches, window regulators and motors, exterior lighting, interior lighting, wipers and washer systems, horn, antennas. Electrical System General: Battery and charging system diagnostics, starter motor, alternator testing and replacement, fuses and relays identification and testing. Electrical System Modules: Body Control Module (BCM), DME, EGS, ABS/DSC module, instrument cluster diagnostics and repair. Comfort Systems: Climate control (HVAC) system diagnostics, blower motor, HVAC control panel, A/C refrigerant service, heated seats, power seats. Safety Systems: Airbag system diagnostics and SRS (Supplemental Restraint System) component replacement, seatbelt service. Electrical Wiring Diagrams: Complete, system-specific wiring diagrams for all major electrical components and circuits. Procedures Included Maintenance Procedures: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid flushes, differential fluid changes, transmission fluid and filter service. Diagnostic Procedures: Troubleshooting guides for common problems, symptom-based diagnostics, electrical system fault finding, engine performance analysis. Repair Procedures: Component replacement, overhaul instructions for major assemblies, body panel repair, interior trim repair, electrical component repair. Adjustment Procedures: Clutch adjustment, headlight aiming, parking brake adjustment, idle speed adjustment. Installation Procedures: Installation of factory accessories, replacement of major components. Technical Depth Depth Of Information: Comprehensive (Factory level detail) Detail Level: Step-by-step instructions, exploded views, diagrams, torque specifications, service limits, special tool requirements. Diagnostic Approach: Includes diagnostic trouble code (DTC) interpretation and guided troubleshooting trees. 📊 Manual Specifications File Format Document Quality: High Resolution, Clear Text and Images Print Quality Print Fidelity: Designed for clear home printing Binding Type Digital Format: Not Applicable (Digital Download) Paper Type Digital Format: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine 525I Engine Code: M50/M52/M54 (depending on specific year and market) Displacement: 2.5 Liters (2494 cc) Configuration: Inline-6 Cylinder Valvetrain: DOHC (Dual Overhead Camshafts), 24 valves Horsepower Range: 189 - 192 hp @ 5900 - 6000 rpm Torque Range: 181 - 184 lb-ft @ 3900 - 4200 rpm Primary Engine 528I Engine Code: M52/M54 Displacement: 2.8 Liters (2793 cc) Configuration: Inline-6 Cylinder Horsepower: 190 hp @ 5300 rpm Torque: 206 lb-ft @ 3950 rpm Primary Engine 530I Engine Code: M54 Displacement: 3.0 Liters (2979 cc) Configuration: Inline-6 Cylinder Horsepower: 225 hp @ 5900 rpm Torque: 214 lb-ft @ 3500 rpm Primary Engine 540I Engine Code: M62/M62TU Displacement: 4.4 Liters (4398 cc) Configuration: V8 Cylinder Valvetrain: DOHC, 32 valves...

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Sku: 402595

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Tags: 1997 1998 1999 2000 2001 2002 5 Series 5 Series (E39) BMW Car Cars

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Years Covered:

1997-2002

Body Styles Covered:

Sedan, Sport Wagon (Touring)

Specific Models Covered:

525i, 528i, 530i, 540i

Generation

Generation Code:

Production Start Year:

Production End Year:

👋 Introduction

Market Position

Vehicle Class:

Executive Mid-size Sedan / Wagon

Target Audience:

Premium market segment

Competitive Analysis

Key Competitors:

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

Key Features

Design Philosophy:

The E39 represented a significant evolution in BMW's design language, known for its refined styling, robust build quality, and emphasis on driving dynamics.

Manual Utility:

Provides in-depth knowledge for DIY owners and independent repair shops to maintain and repair the E39 accurately and efficiently.

📋 Manual Details

Coverage Areas

Primary Coverage:

Maintenance, Service, Diagnosis, Repair

Detailed Systems Coverage:

Engine, Transmission, Suspension, Steering, Brakes, Body, Body Equipment, Electrical System, Equipment and Accessories, Electrical Wiring Diagrams

Page Count

Estimated Page Count:

Extensive (Typical for factory service manuals, often 1000+ pages)

Manual Type

Manual Classification:

Factory Service Manual / Workshop Manual / Repair Manual

Language

Language:

English

Format

File Format:

Download Type:

Instant Download

Compatibility:

All Versions of Windows & Mac

Requirements

Software Requirements:

Adobe PDF Reader, WinZip (for extraction)

Printability

Print Capability:

Printable

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures, internal component repair (pistons, rings, bearings, valves, camshafts, crankshaft), cylinder head service, timing systems (chains, guides, tensioners), lubrication system, cooling system.

Engine Management:

Fuel injection systems (DME - Digital Motor Electronics), ignition systems, emission control systems (secondary air, EVAP), sensor testing and replacement, diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch operation and adjustment, gearbox overhaul, shift mechanism.

Transmission Automatic:

Identification of automatic transmission types (e.g., GM 5L40-E, ZF 5HP19, ZF 5HP30), fluid and filter changes, torque converter service, valve body diagnostics, electronic control module (EGS) integration.

Drivetrain:

Driveshafts, CV joints, differential service and repair, rear axle assemblies.

Suspension:

Front and rear suspension component replacement (struts, shocks, control arms, bushings, ball joints, tie rod ends), wheel bearing service, alignment specifications.

Steering:

Power steering system components (pump, hoses, rack and pinion), steering column adjustments, steering angle sensor.

Brakes:

Hydraulic system (master cylinder, brake lines, calipers, wheel cylinders), ABS/DSC (Dynamic Stability Control) system components, brake pad and rotor replacement, brake fluid specifications and bleeding procedures, parking brake system.

Body Exterior:

Panel removal and installation (fenders, doors, hood, trunk lid), bumper repair and replacement, mirror assembly, glass replacement, sunroof mechanisms.

Body Interior:

Trim panel removal, seat adjustments and removal, dashboard components, headliner, door panels, carpet replacement.

Body Equipment:

Door locks and latches, window regulators and motors, exterior lighting, interior lighting, wipers and washer systems, horn, antennas.

Electrical System General:

Battery and charging system diagnostics, starter motor, alternator testing and replacement, fuses and relays identification and testing.

Electrical System Modules:

Body Control Module (BCM), DME, EGS, ABS/DSC module, instrument cluster diagnostics and repair.

Comfort Systems:

Climate control (HVAC) system diagnostics, blower motor, HVAC control panel, A/C refrigerant service, heated seats, power seats.

Safety Systems:

Airbag system diagnostics and SRS (Supplemental Restraint System) component replacement, seatbelt service.

Electrical Wiring Diagrams:

Complete, system-specific wiring diagrams for all major electrical components and circuits.

Procedures Included

Maintenance Procedures:

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

Diagnostic Procedures:

Troubleshooting guides for common problems, symptom-based diagnostics, electrical system fault finding, engine performance analysis.

Repair Procedures:

Component replacement, overhaul instructions for major assemblies, body panel repair, interior trim repair, electrical component repair.

Adjustment Procedures:

Clutch adjustment, headlight aiming, parking brake adjustment, idle speed adjustment.

Installation Procedures:

Installation of factory accessories, replacement of major components.

Technical Depth

Depth Of Information:

Comprehensive (Factory level detail)

Detail Level:

Step-by-step instructions, exploded views, diagrams, torque specifications, service limits, special tool requirements.

Diagnostic Approach:

Includes diagnostic trouble code (DTC) interpretation and guided troubleshooting trees.

📊 Manual Specifications

File Format

Document Quality:

High Resolution, Clear Text and Images

Print Quality

Print Fidelity:

Designed for clear home printing

Binding Type

Digital Format:

Not Applicable (Digital Download)

Paper Type

Digital Format:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine 525I

Engine Code:

M50/M52/M54 (depending on specific year and market)

Displacement:

2.5 Liters (2494 cc)

Configuration:

Inline-6 Cylinder

Valvetrain:

DOHC (Dual Overhead Camshafts), 24 valves

Horsepower Range:

189 - 192 hp @ 5900 - 6000 rpm

Torque Range:

181 - 184 lb-ft @ 3900 - 4200 rpm

Primary Engine 528I

Engine Code:

M52/M54

Displacement:

2.8 Liters (2793 cc)

Configuration:

Inline-6 Cylinder

Horsepower:

190 hp @ 5300 rpm

Torque:

206 lb-ft @ 3950 rpm

Primary Engine 530I

Engine Code:

Displacement:

3.0 Liters (2979 cc)

Configuration:

Inline-6 Cylinder

Horsepower:

225 hp @ 5900 rpm

Torque:

214 lb-ft @ 3500 rpm

Primary Engine 540I

Engine Code:

M62/M62TU

Displacement:

4.4 Liters (4398 cc)

Configuration:

V8 Cylinder

Valvetrain:

DOHC, 32 valves

Horsepower:

282 - 290 hp @ 5400 - 5800 rpm

Torque:

317 - 325 lb-ft @ 3600 - 3700 rpm

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Delivery:

Electronic Fuel Injection (EFI)

Ignition System:

Distributorless Ignition System (DIS) / Coil-on-Plug

🔧 Transmission

Standard

525I/528I/530I (Early):

5-Speed Manual Getrag S5D 250G

530I (Later)/540I:

5-Speed Automatic ZF 5HP19 (530i) / ZF 5HP30 (540i)

Optional

525I/528I/530I (Early):

5-Speed Automatic GM 5L40-E

540I:

6-Speed Manual Getrag S5D 310Z

Features

Automatic Transmission Features:

Steptronic (manual shifting capability)

📐 Dimensions

Exterior

Wheelbase:

111.4 inches (2830 mm)

Length:

188.0 - 190.6 inches (4775 - 4841 mm) (Sedan)

Width:

70.2 inches (1783 mm)

Height:

57.0 - 57.5 inches (1448 - 1460 mm) (Sedan)

Weights

Curb Weight Range:

3500 - 3900 lbs (approx.)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4/5 Stars (for models tested)

IIHS Side Impact:

Good (for models tested)

Active Features

Stability Control:

DSC (Dynamic Stability Control) available on most models

Traction Control:

ASC+T (Automatic Stability Control + Traction) available

Braking System:

ABS (Anti-lock Braking System) standard

Passive Features

Airbags:

Frontal airbags (driver and passenger), optional side airbags

Seatbelts:

3-point seatbelts with pretensioners

💡 Technology Features

Infotainment

Available Systems:

BMW Business CD, BMW Professional CD, optional navigation system (MK series), optional CD changer.

Speaker Systems:

Standard 6-speaker system, optional Hi-Fi audio system.

Driver Assistance

Parking Assistance:

Optional rear parking sensors (Park Distance Control - PDC)

Cruise Control:

Standard cruise control

Connectivity

Onboard Computer:

Central Information Display (CID) in instrument cluster

Optional Features:

Onboard phone system (GSM/CDMA), heated steering wheel.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 7,500 - 15,000 miles (or as indicated by the Condition Based Service - CBS system for later models, though manual may specify fixed intervals).

Engine Air Filter:

Every 30,000 - 60,000 miles, or as needed based on conditions.

Cabin Air Filter:

Every 15,000 - 30,000 miles, or annually.

Spark Plugs:

Typically every 60,000 miles (e.g., for M54 engines with iridium plugs).

Brake Fluid Flush:

Every 2 years (regardless of mileage).

Coolant Flush:

Every 3-4 years or 50,000-60,000 miles for long-life coolant.

Fluid Specifications

Engine Oil 5W-30:

API SG/SH or ACEA A2/A3, BMW Longlife-98 specification (e.g., Castrol Syntec 5W-30 or equivalent)

Coolant:

BMW Blue Antifreeze/Coolant Concentrate (G48 ethylene glycol based), mixed 50/50 with distilled water.

Brake Fluid:

DOT 4

Power Steering Fluid:

Pentosin CHF 11S (Green) or compatible synthetic hydraulic fluid.

Automatic Transmission Fluid Gm:

Dexron III/VI or equivalent

Automatic Transmission Fluid Zf:

ZF Lifeguardfluid 5 (Texaco ETL-7045E or equivalent)

Manual Transmission Fluid:

GL-4 (specific viscosity will vary based on BMW spec, typically 75W-90)

Differential Fluid:

Hypoid gear oil GL-5 (specific viscosity will vary based on BMW spec, typically 75W-90)

Known Issues

Cooling System:

Plastic coolant expansion tank can crack, water pump failure, thermostat housing leaks.

Suspension:

Front control arm bushings wear out, rear subframe bushings can tear, strut mount failure.

Electrical:

LCM (Light Control Module) failure, ABS/DSC sensor failures, dead pixels in instrument cluster, vapor canister purge valve failure (EVAP system).

Engine M52/M54:

CCV (Crankcase Ventilation) system clogging leading to oil leaks/consumption, VANOS (Variable Valve Timing) solenoids and seals, oil separator issues.

Engine M62/M62Tu:

Timing chain tensioner failure (especially pre-TU models), Nikasil cylinder liner wear (early models), valley pan gasket leaks.

Automatic Transmission:

GM 5L40-E can develop harsh shifts or failure due to worn solenoids or torque converter issues. ZF transmissions are generally robust but require proper fluid maintenance.

Body:

Rust in wheel wells, rocker panels, and door bottoms. Headlight lens hazing.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW has a long-standing reputation for engineering excellence, performance ('The Ultimate Driving Machine'), and luxury.

Model Evolution

E39 Development:

The E39 was the fourth generation of the 5 Series, succeeding the E34. It was praised for its improved handling, comfort, and technology over its predecessor.

Mid-Cycle Refresh:

A significant facelift occurred for the 2001 model year, featuring updated headlights (angel eyes), taillights, bumpers, and introduction of the M54 engines.

Production

Manufacturing Locations:

Germany (Dingolfing plant) and South Africa

Production Volume:

Over 600,000 units produced globally

🏆 Awards & Recognition

Recognitions

Car And Driver Awards:

Car and Driver's 10 Best Cars list for multiple years during its production run.

Consumer Ratings:

Consistently received high ratings for build quality, performance, and refinement from automotive journalists and owners.