BMW 5 Series E39 Workshop Service Repair Manual 1997-2002 # 1
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Code: E39 Production Years: 1997-2002 👋 Introduction Market Position Target Audience: BMW E39 owners seeking to perform DIY repairs, maintenance, or tuning, as well as those preparing vehicles for sale. Competitive Analysis Value Proposition: Provides professional-grade information to save on repair costs and maintain vehicle condition. Positions itself as the 'ONLY' manual needed. Key Features Visual Aid: Features highly detailed exploded pictures to guide repair processes. User Friendliness: Designed for ease of use with step-by-step instructions. Accessibility: Instant download provides immediate access without shipping delays. 📋 Manual Details Coverage Areas Covered Models: 525i, 528i, 530i, 540i Covered Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Estimated Pages: Extensive (Implied by 'absolute wealth of information', 'entire vehicle from start to finish', 'step by step instruction & highly detailed exploded pictures') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive diagnosis, repair, overhaul, and tuning of all specified engine variants. Transmission Clutch: Detailed procedures for manual and automatic transmission servicing, repair, clutch replacement, and driveline components. Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications, and diagnosis of overheating issues. Fuel System: Fuel pump, injectors, fuel pressure, fuel filter replacement, and fuel tank servicing. Braking System: Front and rear brake systems, ABS, DSC, brake pad and rotor replacement, fluid bleeding, and caliper servicing. Suspension: Front and rear suspension components, control arms, shock absorbers, springs, alignment specifications, and steering system. Electrical System: Wiring diagrams, fuses, relays, battery, starter, alternator, lighting, power windows, climate control, and diagnostic troubleshooting. Bodywork Fixtures: Panel repair, interior trim removal, door mechanisms, bumpers, and general bodywork maintenance. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, and gasket replacement. Wheels Tires: Wheel specifications, tire pressure monitoring system (TPMS), tire rotation, and lug nut torque values. Technical Info: General technical specifications, torque values, fluid capacities, and diagnostic trouble codes (DTCs). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups, and inspection procedures. Repair: Step-by-step repair instructions for all major mechanical and electrical systems, including component removal and installation. Troubleshooting: Diagnostic procedures for identifying and resolving common and complex issues, including fault finding charts. Tuning: Guidance on performance enhancement and tuning-up procedures for various components. Technical Depth Depth: Comprehensive from basic user maintenance to in-depth mechanical repairs and diagnostics, comparable to professional mechanic resources. 📊 Manual Specifications File Format Digital Format: PDF Readability: Designed for viewing on Windows PC, Mac, tablets, and smartphones. Searchability: Likely searchable text content within the PDF, allowing for quick information retrieval. Print Quality Printability: Printable on demand, allowing for hardcopy creation of specific sections or the entire manual. Binding Type Digital Delivery: Instant Download via secure high-speed servers. Paper Type Digital Medium: N/A (Digital Product) ⚙️ Engine Specifications Primary Engine Engine Variants Covered: Inline-6 (M52TU, M54), V8 (M62TU) Engine 525I: M54B25 (2.5L Inline-6, approx. 189 hp @ 6000 rpm, 245 Nm torque @ 3500 rpm) Engine 528I: M52TUB28 (2.8L Inline-6, approx. 190 hp @ 5500 rpm, 280 Nm torque @ 3950 rpm) Engine 530I: M54B30 (3.0L Inline-6, approx. 225 hp @ 5900 rpm, 300 Nm torque @ 3500 rpm) Engine 540I: M62TUB44 (4.4L V8, approx. 290 hp @ 5400 rpm, 440 Nm torque @ 3600 rpm) Performance Vanos System: Double VANOS (Variable Valve Timing) system covered for M52TU and M54 engines. Fuel System Injection System: Electronic fuel injection (Bosch Motronic for most variants). Ignition System: Distributorless ignition (DIS) with individual coil-on-plug for M54 and M62TU. 🔧 Transmission Standard Transmission Type Std I6: 5-speed Manual (Getrag 260/6 or ZF S5-31) Optional Transmission Type Opt I6: 5-speed Automatic (ZF 5HP19) Transmission Type Std V8: 5-speed Automatic (ZF 5HP30) Features Transmission Fluid Spec Auto: Dexron III or equivalent (consult specific BMW fluid recommendations for optimal performance and longevity). Clutch Type: Hydraulically operated single dry plate clutch (for manual transmission models). 📐 Dimensions Exterior Wheelbase: Approx. 2830 mm (111.4 in) Length: Approx. 4770 mm (187.8 in) Width: Approx. 1790 mm (70.5 in) Height: Approx. 1430 mm (56.3 in) Weights Curb Weight Range: Approx. 1500 - 1700 kg (3300 - 3750 lbs) depending on model and equipment. Wheel Bolt Pattern: 5x120 mm 🛡️ Safety Features Ratings NHTSA Rating: 4-star front, 5-star side for driver and passenger (for comparable E39 models). Active Features ABS: Standard Anti-lock Braking System (ABS). Asc T: Automatic Stability Control + Traction (ASC+T) standard on many models, optional on others. Dsc: Dynamic Stability Control (DSC) available on later models. Passive Features Airbags: Driver and passenger front airbags, side airbags, and head protection system (optional on some models). Seatbelts: Pretensioning front seatbelts with force limiters. 💡 Technology Features Infotainment Head Unit: BMW Business CD, BMW Professional CD, or BMW Navigation systems (e.g., MKIII, MKIV). Audio System: Standard Hi-Fi system, optional Harman Kardon Logic 7...
BMW E39 owners seeking to perform DIY repairs, maintenance, or tuning, as well as those preparing vehicles for sale.
Competitive Analysis
Value Proposition:
Provides professional-grade information to save on repair costs and maintain vehicle condition. Positions itself as the 'ONLY' manual needed.
Key Features
Visual Aid:
Features highly detailed exploded pictures to guide repair processes.
User Friendliness:
Designed for ease of use with step-by-step instructions.
Accessibility:
Instant download provides immediate access without shipping delays.
📋 Manual Details
Coverage Areas
Covered Models:
525i, 528i, 530i, 540i
Covered Years:
1997, 1998, 1999, 2000, 2001, 2002
Page Count
Estimated Pages:
Extensive (Implied by 'absolute wealth of information', 'entire vehicle from start to finish', 'step by step instruction & highly detailed exploded pictures')
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive diagnosis, repair, overhaul, and tuning of all specified engine variants.
Transmission Clutch:
Detailed procedures for manual and automatic transmission servicing, repair, clutch replacement, and driveline components.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant specifications, and diagnosis of overheating issues.
Fuel System:
Fuel pump, injectors, fuel pressure, fuel filter replacement, and fuel tank servicing.
Braking System:
Front and rear brake systems, ABS, DSC, brake pad and rotor replacement, fluid bleeding, and caliper servicing.
Suspension:
Front and rear suspension components, control arms, shock absorbers, springs, alignment specifications, and steering system.
Electrical System:
Wiring diagrams, fuses, relays, battery, starter, alternator, lighting, power windows, climate control, and diagnostic troubleshooting.
Bodywork Fixtures:
Panel repair, interior trim removal, door mechanisms, bumpers, and general bodywork maintenance.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, and gasket replacement.
Wheels Tires:
Wheel specifications, tire pressure monitoring system (TPMS), tire rotation, and lug nut torque values.
Technical Info:
General technical specifications, torque values, fluid capacities, and diagnostic trouble codes (DTCs).
Double VANOS (Variable Valve Timing) system covered for M52TU and M54 engines.
Fuel System
Injection System:
Electronic fuel injection (Bosch Motronic for most variants).
Ignition System:
Distributorless ignition (DIS) with individual coil-on-plug for M54 and M62TU.
🔧 Transmission
Standard
Transmission Type Std I6:
5-speed Manual (Getrag 260/6 or ZF S5-31)
Optional
Transmission Type Opt I6:
5-speed Automatic (ZF 5HP19)
Transmission Type Std V8:
5-speed Automatic (ZF 5HP30)
Features
Transmission Fluid Spec Auto:
Dexron III or equivalent (consult specific BMW fluid recommendations for optimal performance and longevity).
Clutch Type:
Hydraulically operated single dry plate clutch (for manual transmission models).
📐 Dimensions
Exterior
Wheelbase:
Approx. 2830 mm (111.4 in)
Length:
Approx. 4770 mm (187.8 in)
Width:
Approx. 1790 mm (70.5 in)
Height:
Approx. 1430 mm (56.3 in)
Weights
Curb Weight Range:
Approx. 1500 - 1700 kg (3300 - 3750 lbs) depending on model and equipment.
Wheel Bolt Pattern:
5x120 mm
🛡️ Safety Features
Ratings
NHTSA Rating:
4-star front, 5-star side for driver and passenger (for comparable E39 models).
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Asc T:
Automatic Stability Control + Traction (ASC+T) standard on many models, optional on others.
Dsc:
Dynamic Stability Control (DSC) available on later models.
Passive Features
Airbags:
Driver and passenger front airbags, side airbags, and head protection system (optional on some models).
Seatbelts:
Pretensioning front seatbelts with force limiters.
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD, or BMW Navigation systems (e.g., MKIII, MKIV).
Audio System:
Standard Hi-Fi system, optional Harman Kardon Logic 7 audio system.
Driver Assistance
Parking Sensors:
Park Distance Control (PDC) front and rear available on many models.
Cruise Control:
Standard cruise control.
Connectivity
Phone Integration:
Optional Bluetooth hands-free system with cradle integration.
Navigation:
Optional BMW On-Board Navigation system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used. The Condition Based Service (CBS) system will often indicate specific intervals.
Spark Plug Replacement:
Approximately 60,000 miles for standard spark plugs, potentially longer for iridium or platinum plugs. Refer to specific engine and plug type.
Coolant Flush:
Recommended every 2-4 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Spec:
BMW Longlife-01 (LL-01) or BMW Longlife-98 (LL-98) compliant synthetic oil, typically SAE 5W-30 or 5W-40 depending on climate and engine.
Brake Fluid Spec:
DOT 4 (BMW recommends their own high-performance brake fluid).
Power Steering Fluid Spec:
Pentosin CHF 11S or equivalent, or BMW's recommended power steering fluid.
Known Issues
Cooling System Leaks:
Common issues include plastic expansion tanks cracking, coolant hoses degrading, and water pump failures.
Oil Gasket Leaks:
Valve cover gasket and oil pan gasket leaks are frequent due to age and material degradation.
Suspension Wear:
Control arm bushings, ball joints, and tie rod ends are common wear items, leading to steering looseness or clunks.
Electrical Gremlins:
Water ingress into ABS/DSC modules, LCM (Light Control Module) failures, and frayed wiring harnesses can cause various electrical problems.
Ccv System Clogging:
Crankcase Ventilation (CCV) system on M54 engines can become clogged, leading to oil leaks and increased crankcase pressure.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Reputation for 'The Ultimate Driving Machine', emphasizing performance, luxury, and engineering excellence.
Model Evolution
E39 Introduction:
The E39 generation of the 5 Series was introduced in 1995 (as a 1996 model in some markets), succeeding the E34. The 1997-2002 timeframe reflects the North American market introduction and subsequent model year updates.
Facelift:
A significant facelift occurred in 2000 (for the 2001 model year) with updated styling (headlights, taillights, bumpers) and introduction of the M54 engines.
Production
Production Locations:
Primarily manufactured in Dingolfing, Germany.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The E39 5 Series was frequently recognized on Car and Driver's '10Best' list during its production run for its driving dynamics and overall excellence.
Ward Top10 Engines:
The M54 inline-six engines were often lauded for their smooth power delivery and efficiency.
Ratings
Consumer Reports Reliability:
While specific reliability ratings can vary by year and powertrain, the E39 is generally considered a solid and well-engineered vehicle, though some common wear items should be anticipated.