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BMW 5 Series E39 Service Repair Workshop Manual 1997-2002

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Code: E39 Production Years Covered: 1997-2002 👋 Introduction Market Position Segment: Executive Sedan Competitors 1997 2002: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Volvo S80. Competitive Analysis Key Selling Points: Driving dynamics, luxurious interior, advanced engineering, performance options (M models). Key Features Manual Value Proposition: Provides in-depth technical data essential for DIY maintenance and professional repair, ensuring optimal performance and longevity of the vehicle. Superior to 'cheap, incomplete' alternatives. Manual Quality Claim: Explicitly positioned as a 'Best Manual Available On Tradebit!' and 'Complete Manual - No Missing Pages!' emphasizing comprehensive coverage and quality. 📋 Manual Details Coverage Areas Engine Variants Covered: 4-cylinder (M43/M52 variants), 6-cylinder (M52/M54 variants), V8 (M62 variants) Transmission Variants Covered: Manual (Getrag 220, ZF S5-310, ZF S6-370), Automatic (GM A5S 310Z, ZF 5HP19, ZF 5HP24, ZF 5HP30) Body Styles Covered: Sedan (4-door), Touring (Wagon/Estate - 5-door) Page Count Estimated Page Count: Extensive, often exceeding 1000 pages for comprehensive coverage Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel injection, ignition, emissions control, exhaust systems, cooling system, lubrication system, engine management systems (DME, VANOS), transmission (manual and automatic), clutch, driveshafts, differentials, axles. Chassis: Suspension (front and rear), steering system (hydraulic power steering), braking system (ABS, DSC, EBD), wheel bearings, subframes, chassis components. Electrical: Wiring diagrams, battery, alternator, starter, lighting systems, instrument cluster, climate control electronics, comfort electronics (windows, locks, seats, mirrors), infotainment system, SRS airbag system, immobilizer system (EWS), body control module (BCM). Body: Exterior body panels, interior trim, doors, hood, trunk, bumpers, glass, seals, body repair procedures. Climate Control: Manual and automatic climate control systems, including HVAC component diagnosis and repair, refrigerant handling. Procedures Included General Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement, brake pad and rotor replacement, tire rotation. Troubleshooting: Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for all major systems. Mechanical Repair: Engine component removal and installation (e.g., cylinder head, pistons, crankshaft), transmission overhaul, clutch replacement, suspension component replacement, steering rack repair/replacement, brake caliper/master cylinder overhaul. Electrical Diagnostics: Component testing, sensor troubleshooting, wiring harness repair, module programming (where applicable through external tools referenced). Body Repair: Dent removal, panel alignment, glass replacement, trim component installation. Timing Chain Replacement: Detailed procedures for timing chain and guide replacement on M52/M54 engines, a critical maintenance item. Technical Depth Depth: Comprehensive. Covers basic maintenance, in-depth diagnostics, component overhaul, and reassembly instructions. Includes torque specifications, clearances, and diagnostic flowcharts. Diagnostic Tools Referenced: References the use of BMW diagnostic tools like DIS (Diagnostic Information System) and GT1 for advanced electronic diagnostics. 📊 Manual Specifications File Format Searchable: Yes (if correctly generated PDF) Printable: Yes Text Searchability: High (designed for efficient searching of specific procedures or part numbers) Print Quality Image Clarity: High (ensuring clarity of diagrams and illustrations) Binding Type Digital Format: PDF Paper Type Digital Medium: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code Example I6: M52B28 (2.8L Inline-6) Engine Code Example V8: M62B44 (4.4L V8) Performance M52B28 Horsepower: 193 hp @ 5300 rpm M52B28 Torque: 206 lb-ft @ 3950 rpm M62B44 Horsepower: 282 hp @ 5400 rpm M62B44 Torque: 317 lb-ft @ 3600 rpm Fuel System Injection Type: Sequential Multi-Point Fuel Injection (Bosch Motronic) Recommended Fuel: Premium Unleaded Gasoline (91+ Octane) 🔧 Transmission Standard Transmission Type Early Models: 5-speed Manual (Getrag 220, ZF S5-310) Optional Transmission Type Automatic: 5-speed Automatic (ZF 5HP19, ZF 5HP24, ZF 5HP30) Features Smg Availability: Sequential Manual Gearbox (SMG) available on select M Sport models. 📐 Dimensions Exterior Wheelbase Inches: 111.4 inches Length Inches: 191.1 inches Width Inches: 70.2 inches Height Inches: 57.0 inches Weights Curb Weight Lbs Approx: 3500 - 4000 lbs (depending on engine/options) 🛡️ Safety Features Ratings NHTSA Front Driver Side: 5-Star (for models tested) NHTSA Front Passenger Side: 5-Star (for models tested) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Dynamic Stability Control (DSC) / Traction Control System (ASC+T) Passive Features Airbags: Front dual-stage airbags, optional side-impact airbags. Seatbelts: Pretensioning front seatbelts with force limiters. 💡 Technology Features Infotainment Head Unit: BMW Professional Radio/Cassette or optional CD player with integrated navigation system (Business or Professional). Audio System: Optional Harman Kardon premium sound system. Driver Assistance Parking Sensors: Optional Park Distance Control (PDC) front and rear. Cruise Control: Standard cruise control. Connectivity Phone Integration: Optional Bluetooth hands-free phone system. 🔧 Maintenance Service Intervals Oil Change Interval Miles: Typically 7,500 - 15,000 miles (depending on oil type and driving conditions, as per Condition Based Service - CBS). Spark Plug Replacement Miles: 60,000 - 100,000 miles (depending on spark plug type: standard vs. long-life iridium). Brake Fluid Flush Years: Every 2 years (regardless of mileage). Fluid Specifications Engine Oil Viscosity: BMW Longlife-01 (LL-01) approved...
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BMW 5 Series E39 Service Repair Workshop Manual 1997-2002
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Generation
Chassis Code:
E39
Production Years Covered:
1997-2002
👋 Introduction
Market Position
Segment:
Executive Sedan
Competitors 1997 2002:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Volvo S80.
Competitive Analysis
Key Selling Points:
Driving dynamics, luxurious interior, advanced engineering, performance options (M models).
Key Features
Manual Value Proposition:
Provides in-depth technical data essential for DIY maintenance and professional repair, ensuring optimal performance and longevity of the vehicle. Superior to 'cheap, incomplete' alternatives.
Manual Quality Claim:
Explicitly positioned as a 'Best Manual Available On Tradebit!' and 'Complete Manual - No Missing Pages!' emphasizing comprehensive coverage and quality.
📋 Manual Details
Coverage Areas
Engine Variants Covered:
4-cylinder (M43/M52 variants), 6-cylinder (M52/M54 variants), V8 (M62 variants)
Transmission Variants Covered:
Manual (Getrag 220, ZF S5-310, ZF S6-370), Automatic (GM A5S 310Z, ZF 5HP19, ZF 5HP24, ZF 5HP30)
Body Styles Covered:
Sedan (4-door), Touring (Wagon/Estate - 5-door)
Page Count
Estimated Page Count:
Extensive, often exceeding 1000 pages for comprehensive coverage
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel injection, ignition, emissions control, exhaust systems, cooling system, lubrication system, engine management systems (DME, VANOS), transmission (manual and automatic), clutch, driveshafts, differentials, axles.
Chassis:
Suspension (front and rear), steering system (hydraulic power steering), braking system (ABS, DSC, EBD), wheel bearings, subframes, chassis components.
Electrical:
Wiring diagrams, battery, alternator, starter, lighting systems, instrument cluster, climate control electronics, comfort electronics (windows, locks, seats, mirrors), infotainment system, SRS airbag system, immobilizer system (EWS), body control module (BCM).
Body:
Exterior body panels, interior trim, doors, hood, trunk, bumpers, glass, seals, body repair procedures.
Climate Control:
Manual and automatic climate control systems, including HVAC component diagnosis and repair, refrigerant handling.
Procedures Included
General Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement, brake pad and rotor replacement, tire rotation.
Troubleshooting:
Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for all major systems.
Mechanical Repair:
Engine component removal and installation (e.g., cylinder head, pistons, crankshaft), transmission overhaul, clutch replacement, suspension component replacement, steering rack repair/replacement, brake caliper/master cylinder overhaul.
Electrical Diagnostics:
Component testing, sensor troubleshooting, wiring harness repair, module programming (where applicable through external tools referenced).
Body Repair:
Dent removal, panel alignment, glass replacement, trim component installation.
Timing Chain Replacement:
Detailed procedures for timing chain and guide replacement on M52/M54 engines, a critical maintenance item.
Technical Depth
Depth:
Comprehensive. Covers basic maintenance, in-depth diagnostics, component overhaul, and reassembly instructions. Includes torque specifications, clearances, and diagnostic flowcharts.
Diagnostic Tools Referenced:
References the use of BMW diagnostic tools like DIS (Diagnostic Information System) and GT1 for advanced electronic diagnostics.
📊 Manual Specifications
File Format
Searchable:
Yes (if correctly generated PDF)
Printable:
Yes
Text Searchability:
High (designed for efficient searching of specific procedures or part numbers)
Print Quality
Image Clarity:
High (ensuring clarity of diagrams and illustrations)
Binding Type
Digital Format:
PDF
Paper Type
Digital Medium:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code Example I6:
M52B28 (2.8L Inline-6)
Engine Code Example V8:
M62B44 (4.4L V8)
Performance
M52B28 Horsepower:
193 hp @ 5300 rpm
M52B28 Torque:
206 lb-ft @ 3950 rpm
M62B44 Horsepower:
282 hp @ 5400 rpm
M62B44 Torque:
317 lb-ft @ 3600 rpm
Fuel System
Injection Type:
Sequential Multi-Point Fuel Injection (Bosch Motronic)
Recommended Fuel:
Premium Unleaded Gasoline (91+ Octane)
🔧 Transmission
Standard
Transmission Type Early Models:
5-speed Manual (Getrag 220, ZF S5-310)
Optional
Transmission Type Automatic:
5-speed Automatic (ZF 5HP19, ZF 5HP24, ZF 5HP30)
Features
Smg Availability:
Sequential Manual Gearbox (SMG) available on select M Sport models.
📐 Dimensions
Exterior
Wheelbase Inches:
111.4 inches
Length Inches:
191.1 inches
Width Inches:
70.2 inches
Height Inches:
57.0 inches
Weights
Curb Weight Lbs Approx:
3500 - 4000 lbs (depending on engine/options)
🛡️ Safety Features
Ratings
NHTSA Front Driver Side:
5-Star (for models tested)
NHTSA Front Passenger Side:
5-Star (for models tested)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Dynamic Stability Control (DSC) / Traction Control System (ASC+T)
Passive Features
Airbags:
Front dual-stage airbags, optional side-impact airbags.
Seatbelts:
Pretensioning front seatbelts with force limiters.
💡 Technology Features
Infotainment
Head Unit:
BMW Professional Radio/Cassette or optional CD player with integrated navigation system (Business or Professional).
Audio System:
Optional Harman Kardon premium sound system.
Driver Assistance
Parking Sensors:
Optional Park Distance Control (PDC) front and rear.
Cruise Control:
Standard cruise control.
Connectivity
Phone Integration:
Optional Bluetooth hands-free phone system.
🔧 Maintenance
Service Intervals
Oil Change Interval Miles:
Typically 7,500 - 15,000 miles (depending on oil type and driving conditions, as per Condition Based Service - CBS).
Spark Plug Replacement Miles:
60,000 - 100,000 miles (depending on spark plug type: standard vs. long-life iridium).
Brake Fluid Flush Years:
Every 2 years (regardless of mileage).
Fluid Specifications
Engine Oil Viscosity:
BMW Longlife-01 (LL-01) approved oils, typically 0W-40 or 5W-30 depending on ambient temperature.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 specification) mixed with distilled water (50/50 ratio).
Transmission Fluid Auto:
Dexron III (for GM transmissions) or Esso LT 71141 (for ZF transmissions).
Known Issues
Cooling System:
Plastic expansion tanks can crack; water pumps and thermostats are common failure points.
Suspension:
Control arm bushings, ball joints, and tie rod ends wear over time leading to steering looseness and premature tire wear.
Electrical:
Heater control valve failure (common 'pisspot' leak), ABS/DSC sensor failures, pixelation on instrument cluster displays.
Vanos:
Failure of the VANOS (Variable Valve Timing) system seals can lead to rough idle, power loss, and increased fuel consumption.
Oil Pan Gasket:
Oil pan gasket leaks are common due to age and heat exposure.
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, engineering, and driver engagement.
Model Evolution
E39 Introduction:
The E39 replaced the E34 5 Series and was praised for its improved handling, ride comfort, and refined interior.
E39 Facelift:
Facelifted in 2000 (model year 2001) with updated headlights, taillights, bumpers, and interior trim.
Production
Manufacturing Locations:
Germany (Dingolfing), South Africa, Egypt, Thailand, Russia, Ukraine, Vietnam, Indonesia.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Named to Car and Driver's 10Best list multiple times during its production run.
Popular Mechanics:
Recognized for its engineering and driving dynamics by automotive publications.
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