Bmw E39 5 Series Workshop Service Repair Manual 1995-2003
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Model Years Covered: 1995-2003 Codes Vin Decoder Reference: BMW VIN decoder required for specific model/engine identification within E39 range. 👋 Introduction Market Position Positioning: A definitive resource for BMW E39 owners and independent repair facilities, replicating the information provided to official service centers. Competitive Analysis Value Proposition: Offers complete coverage for all E39 models and engines, differentiating itself through its comprehensiveness and professional service shop equivalency. Key Features Accessibility: Works on all computers (PC & Mac) and mobile devices (Tablets, Phones - iPhone, Apple, Android, Windows Phone). Delivery: Instant download, no shipping costs, no waiting for physical media. Guarantee: Same-day money-back guarantee if unsatisfied. 📋 Manual Details Coverage Areas All Models: Yes All Engines: Yes Page Count Estimated Pages: Thousands (as stated in product description) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul and rebuilding, timing belt replacement, engine performance, firing orders, detailed specifications. Engine Management: Trouble codes, computer diagnostic codes, engine performance tuning. Drivetrain: Transmission information, gearbox service, U-joint and CV-joint service procedures. Suspension Steering: Front end procedures and specifications, suspension system service. Brakes: Brake system service and repair procedures, torque specifications. Electrical Electronics: Wiring diagrams, computer diagnostic codes, troubleshooting and diagnostics. Climate Control: Air conditioning system service, climate control system repair. Body Interior: Sunroof service, body workshop procedures. Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel lines. Cooling System: Radiator, water pump, thermostat, cooling fans, coolant hoses, expansion tank. Exhaust System: Exhaust manifolds, catalytic converters, mufflers, exhaust pipes, oxygen sensors. Wheels Tires: Wheel specifications, tire pressure recommendations, alignment procedures. Procedures Included Diagnostics: Troubleshooting and diagnostics, computer diagnostic codes. Repair: Engine overhaul and rebuilding, timing belt replacement, brake repair, clutch service, exhaust system repair, U-joint/CV-joint service, general repair procedures. Maintenance: Factory maintenance schedules and charts, serpentine belt routings, driving concerns. Clutch Service: Complete clutch replacement procedures, including hydraulic system service, will be detailed for manual transmission models. Exhaust Service: Repair and replacement of exhaust components, including catalytic converters and mufflers. Climate Control Service: Service procedures for the heating, ventilation, and air conditioning (HVAC) system, including refrigerant handling and component replacement. Body Repair: Workshop procedures for body panel repair, alignment, and potentially rust prevention. Torque Specifications: Comprehensive torque specifications for all critical fasteners across various systems. Serpentine Belt: Diagrams and instructions for serpentine belt replacement and routing. Driving Concerns: Troubleshooting common driving issues and providing solutions. Light Replacement: Procedures for replacing headlamps, taillights, and interior lighting. Wiper System: Service and replacement of wiper arms, blades, and washer system components. Instrument Cluster: Diagnosing and repairing issues with the instrument cluster, gauges, and warning lights. Locking System: Service and repair of central locking, door locks, and key fob systems. Window Mechanisms: Repair and replacement of power window regulators and motors. Technical Depth Depth: Comprehensive, covering routine maintenance to major component overhauls and diagnostics. Electrical Diagrams Detail: Extensive and detailed wiring diagrams for all electrical systems, crucial for diagnosing complex issues. 📊 Manual Specifications File Format PDF Features: Zoomable for detailed parts viewing, printable pages. Searchability: PDF format generally allows for text searching if the PDF is text-based, enhancing usability. Print Quality Illustrations: Hundreds of illustrations provided. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Available Engines Overview: The E39 generation offered a range of inline-4, inline-6, and V8 gasoline engines, as well as inline-6 diesel engines. This manual covers all of them, including variants like the M52, M54, M62, and the S62 in the M5. Specific engine displacements and power outputs would vary by model. Performance Performance Data Availability: Detailed performance specifications, horsepower, and torque figures for each engine variant are expected to be included. Fuel System Fuel Injection Type: Bosch Motronic fuel injection systems (specific variants vary by engine) are comprehensively detailed. Timing System Timing Method: Timing belt and timing chain service procedures are covered, depending on the specific engine model. Engine Variants Inline 4: e.g., M43B19 (1.9L) Inline 6 Petrol: e.g., M52B20 (2.0L), M52B25 (2.5L), M52B28 (2.8L), M54B22 (2.2L), M54B25 (2.5L), M54B30 (3.0L) V8 Petrol: e.g., M62B35 (3.5L), M62B44 (4.4L), S62B50 (5.0L - M5) Inline 6 Diesel: e.g., M57D25 (2.5L), M57D30 (3.0L) 🔧 Transmission Standard Standard Transmission: Manual transmissions (e.g., Getrag 5-speed and 6-speed for some models) were available. Optional Optional Transmission: Automatic transmissions (e.g., ZF 5HP series) were widely available and are thoroughly covered. Features Transmission Service: Includes service procedures, fluid capacities, and specifications for both manual and automatic transmissions. 📐 Dimensions Exterior Body Styles: Sedan (4-door) and Touring (5-door wagon) body styles are covered. Weights Curb Weight Range: Curb weights varied significantly by engine and options, typically ranging from approximately 3,300 lbs to over 4,000 lbs. 🛡️ Safety...
BMW VIN decoder required for specific model/engine identification within E39 range.
👋 Introduction
Market Position
Positioning:
A definitive resource for BMW E39 owners and independent repair facilities, replicating the information provided to official service centers.
Competitive Analysis
Value Proposition:
Offers complete coverage for all E39 models and engines, differentiating itself through its comprehensiveness and professional service shop equivalency.
Key Features
Accessibility:
Works on all computers (PC & Mac) and mobile devices (Tablets, Phones - iPhone, Apple, Android, Windows Phone).
Delivery:
Instant download, no shipping costs, no waiting for physical media.
Guarantee:
Same-day money-back guarantee if unsatisfied.
📋 Manual Details
Coverage Areas
All Models:
Yes
All Engines:
Yes
Page Count
Estimated Pages:
Thousands (as stated in product description)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul and rebuilding, timing belt replacement, engine performance, firing orders, detailed specifications.
Troubleshooting and diagnostics, computer diagnostic codes.
Repair:
Engine overhaul and rebuilding, timing belt replacement, brake repair, clutch service, exhaust system repair, U-joint/CV-joint service, general repair procedures.
Maintenance:
Factory maintenance schedules and charts, serpentine belt routings, driving concerns.
Clutch Service:
Complete clutch replacement procedures, including hydraulic system service, will be detailed for manual transmission models.
Exhaust Service:
Repair and replacement of exhaust components, including catalytic converters and mufflers.
Climate Control Service:
Service procedures for the heating, ventilation, and air conditioning (HVAC) system, including refrigerant handling and component replacement.
Body Repair:
Workshop procedures for body panel repair, alignment, and potentially rust prevention.
Torque Specifications:
Comprehensive torque specifications for all critical fasteners across various systems.
Serpentine Belt:
Diagrams and instructions for serpentine belt replacement and routing.
Driving Concerns:
Troubleshooting common driving issues and providing solutions.
Light Replacement:
Procedures for replacing headlamps, taillights, and interior lighting.
Wiper System:
Service and replacement of wiper arms, blades, and washer system components.
Instrument Cluster:
Diagnosing and repairing issues with the instrument cluster, gauges, and warning lights.
Locking System:
Service and repair of central locking, door locks, and key fob systems.
Window Mechanisms:
Repair and replacement of power window regulators and motors.
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major component overhauls and diagnostics.
Electrical Diagrams Detail:
Extensive and detailed wiring diagrams for all electrical systems, crucial for diagnosing complex issues.
📊 Manual Specifications
File Format
PDF Features:
Zoomable for detailed parts viewing, printable pages.
Searchability:
PDF format generally allows for text searching if the PDF is text-based, enhancing usability.
Print Quality
Illustrations:
Hundreds of illustrations provided.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Available Engines Overview:
The E39 generation offered a range of inline-4, inline-6, and V8 gasoline engines, as well as inline-6 diesel engines. This manual covers all of them, including variants like the M52, M54, M62, and the S62 in the M5. Specific engine displacements and power outputs would vary by model.
Performance
Performance Data Availability:
Detailed performance specifications, horsepower, and torque figures for each engine variant are expected to be included.
Fuel System
Fuel Injection Type:
Bosch Motronic fuel injection systems (specific variants vary by engine) are comprehensively detailed.
Timing System
Timing Method:
Timing belt and timing chain service procedures are covered, depending on the specific engine model.
Manual transmissions (e.g., Getrag 5-speed and 6-speed for some models) were available.
Optional
Optional Transmission:
Automatic transmissions (e.g., ZF 5HP series) were widely available and are thoroughly covered.
Features
Transmission Service:
Includes service procedures, fluid capacities, and specifications for both manual and automatic transmissions.
📐 Dimensions
Exterior
Body Styles:
Sedan (4-door) and Touring (5-door wagon) body styles are covered.
Weights
Curb Weight Range:
Curb weights varied significantly by engine and options, typically ranging from approximately 3,300 lbs to over 4,000 lbs.
🛡️ Safety Features
Ratings
Crash Test Data:
While specific NHTSA/IIHS ratings for all years/trims may not be in this manual, it will detail safety system components and repair procedures.
Active Features
Active Safety Systems:
ABS (Anti-lock Braking System), ASC+T (Automatic Stability Control + Traction), DSC (Dynamic Stability Control) where applicable, are covered.
Passive Features
Passive Safety Systems:
Airbag systems, seatbelt pre-tensioners, and structural integrity aspects related to repair are detailed.
💡 Technology Features
Infotainment
Infotainment Systems:
Details on the Professional Radio, Business CD, and optional Navigation systems (CCC, MK series navigation computers) and their components may be included.
Driver Assistance
Driver Assistance Features:
Information on features like cruise control, parking sensors (PDC), and the integration of ABS/ASC/DSC systems.
Connectivity
Connectivity Features:
Details related to On-Board Computer (OBC) functions, diagnostic ports (OBD-II), and potentially early Bluetooth integration (car phone systems) may be covered.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable Service Interval (VSI) system indicated oil change needs based on driving conditions; typically 7,500-15,000 miles or annually.
Major Service Points:
Details on spark plug replacement, coolant flushes, brake fluid changes, and other scheduled maintenance items are covered.
Fluid Specifications
Engine Oil Specification:
Specific BMW Longlife-01 (LL-01) or Longlife-98 (LL-98) approved synthetic oils, typically 0W-30, 0W-40, 5W-30, or 5W-40 depending on engine and ambient temperature. Manual will specify precise grades and viscosities.
Coolant Specification:
BMW Blue Coolant (G48 ethylene glycol based antifreeze) or equivalent meeting BMW specifications.
Transmission Fluid Specifications:
Specific ATF fluids for automatic transmissions (e.g., Esso LT 71141 for ZF 5HP) and gear oil specifications for manual transmissions will be detailed.
Known Issues
Common E39 Problems:
Common E39 issues that the manual would assist in diagnosing and repairing include: Cooling system components (water pump, thermostat, hoses), VANOS system, oil leaks (valve cover gaskets, oil pan gaskets), ABS wheel speed sensors, rear shock mounts, blower motor resistor, ignition coils, and various suspension bushings.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
The 5 Series has a long-standing reputation for sporty handling, luxurious interiors, and advanced engineering.
Model Evolution
E39 Development:
The E39, succeeding the E34, introduced significant advancements in chassis design, electronics, and engine technology, including wider use of aluminum in its suspension components for improved handling.
Production
Manufacturing Locations:
Primarily produced in Dingolfing, Germany, with some assembly possibly occurring in other BMW facilities worldwide.
🏆 Awards & Recognition
Recognitions
Automotive Awards E39:
The E39 5 Series was widely acclaimed for its driving dynamics, comfort, and build quality, often featuring on 'Car of the Year' lists and 'Ten Best Cars' lists from various automotive publications during its production run.