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BMW 5 Series E39 Sedan Sport Wagon Service Repair Manual 1997-2002

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Body Styles Covered: Sedan, Sport Wagon (Touring) Production Years Covered: 1997-2002 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, BMW owners seeking detailed information Competitive Analysis Value Proposition: Cost savings through DIY repairs, access to factory-level information Key Features Ease Of Use: Easy-to-follow, step-by-step instructions suitable for any skill level Completeness: Comprehensive coverage mirroring official workshop manuals Keywords Tags: BMW 5, BMW E39, repair, Manual 📋 Manual Details Coverage Areas Overall Coverage: Complete workshop/service manual Page Count Estimated Page Count: Extensive (specific count not provided, but described as 'complete' and 'extremely detailed') Manual Type Type: Service/Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Full engine service, repair, and overhaul Fuel System: Fuel injection and ignition system diagnostics and repair Transmission: Clutch and gearbox service and repair Drivetrain: Drive axles, differentials (implied within gearbox/suspension) Suspension: Complete suspension system service, repair, and alignment Steering: Steering system service and repair Brakes: Braking system diagnostics, repair, and maintenance Wheels: Wheel and tire service, bolt patterns Electrical: Complete electrical system diagnostics, wiring diagrams, component testing Bodywork: Bodywork repair and maintenance Climate Control: Air temperature control system service and repair Exhaust: Implied within engine and general repair Cooling: Implied within engine and general repair Procedures Included Maintenance: Routine maintenance (e.g., spark plug changes), fluid changes Diagnostics: Troubleshooting and diagnostic procedures for all systems Repair: Step-by-step repair instructions for major and minor components Rebuilding: Engine rebuilding procedures Installation: Component installation procedures Adjustments: System adjustments and calibrations Technical Depth Depth: Comprehensive, from basic maintenance to full engine rebuilds Illustrations Diagrams: Detailed step-by-step diagrams, exploded views, electrical diagrams Data Technical Data: Includes torque settings, fluid capacities, technical specifications Parts Spare Parts: Illustrations of spare parts 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF (common for digital manuals) Print Quality Printability: All pages are printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Common Engines Covered: Likely covers M52, M54, M62, S62 (4-cylinder, 6-cylinder, and V8 variants common in E39, though specific engines are not listed, a complete manual would cover all factory options for the years) Performance Power Output Range: Varies by engine (e.g., 170 hp to 400 hp for M52/M54/M62/S62) Torque Range: Varies by engine (e.g., 181 lb-ft to 431 lb-ft for M52/M54/M62/S62) Fuel System Fuel Delivery: Fuel injection (likely Bosch Motronic variants for the era) Cooling Cooling System: Coolant capacity and service procedures Lubrication Oil Capacity: Engine oil capacity and recommended specifications (e.g., BMW Longlife-01) Spark Plugs Spark Plug Type: Specific spark plug part numbers and torque specifications 🔧 Transmission Standard Standard Transmission Type: 5-speed manual (Getrag or ZF) Optional Optional Transmission Type: 5-speed automatic (Steptronic, likely ZF 5HP19 or 5HP24) Features Clutch Service: Clutch replacement and adjustment procedures Fluid Specs Transmission Fluid Type: Specific automatic transmission fluid (ATF) and manual transmission fluid (MTF) specifications 📐 Dimensions Exterior Wheelbase Sedan: Approx. 115.4 inches (2931 mm) Wheelbase Wagon: Approx. 115.4 inches (2931 mm) Length Sedan: Approx. 191.1 inches (4854 mm) Length Wagon: Approx. 193.3 inches (4910 mm) Width: Approx. 70.2 inches (1783 mm) Height Sedan: Approx. 57.2 inches (1453 mm) Height Wagon: Approx. 57.7 inches (1466 mm) Weights Curb Weight: Varies by model (approx. 3500 - 4000 lbs / 1588 - 1814 kg) Cargo Cargo Volume Wagon: Approx. 21.8 - 30.2 cu ft (expandable) Wheels Tires Wheel Bolt Pattern: 5x120 Common Tire Sizes: e.g., 225/55R16, 235/45R17, 245/40R18 (varies by trim and options) 🛡️ Safety Features Ratings NHTSA Ratings: Refer to specific model year reports, generally good for its era Active Features Traction Control: ASR (Anti-Slip Regulation) / Traction Control System (TCS) Stability Control: DSC (Dynamic Stability Control) available on later models/trims Passive Features Airbags: Frontal airbags, side airbags (optional/standard depending on trim) Seatbelts: Pretensioning front seatbelts 💡 Technology Features Infotainment Nav System: BMW Professional Navigation System (MKIII/MKIV) available Audio: Harman Kardon sound system option Driver Assistance Parking Sensors: Park Distance Control (PDC) front and rear available Connectivity Phone Integration: Bluetooth phone preparation available 🔧 Maintenance Service Intervals Oil Change Interval: BMW Extended Service Intervals (e.g., 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used, via Condition Based Service - CBS) Spark Plug Replacement: e.g., 60,000 miles for standard plugs, 100,000 miles for long-life plugs (varies by engine) Transmission Fluid Change: BMW often cited as 'lifetime' for automatic transmissions, but recommended to change around 50,000-100,000 miles by independent specialists. Fluid Specifications Engine Oil Specification: BMW Longlife-01 (LL-01) or LL-98 recommended (e.g., SAE 0W-40, 5W-30, 5W-40 depending on engine and climate) Coolant Type: BMW Blue Ethylene Glycol based coolant (G48) Brake Fluid Type: DOT 4 (low viscosity for ABS systems) Known Issues Cooling System: Plastic expansion tank failures, water pump issues, radiator leaks...
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Sku: 319485
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BMW 5 Series E39 Sedan Sport Wagon Service Repair Manual 1997-2002
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E39
Body Styles Covered:
Sedan, Sport Wagon (Touring)
Production Years Covered:
1997-2002
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent repair shops, BMW owners seeking detailed information
Competitive Analysis
Value Proposition:
Cost savings through DIY repairs, access to factory-level information
Key Features
Ease Of Use:
Easy-to-follow, step-by-step instructions suitable for any skill level
Completeness:
Comprehensive coverage mirroring official workshop manuals
Keywords
Tags:
BMW 5, BMW E39, repair, Manual
📋 Manual Details
Coverage Areas
Overall Coverage:
Complete workshop/service manual
Page Count
Estimated Page Count:
Extensive (specific count not provided, but described as 'complete' and 'extremely detailed')
Manual Type
Type:
Service/Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Full engine service, repair, and overhaul
Fuel System:
Fuel injection and ignition system diagnostics and repair
Transmission:
Clutch and gearbox service and repair
Drivetrain:
Drive axles, differentials (implied within gearbox/suspension)
Suspension:
Complete suspension system service, repair, and alignment
Steering:
Steering system service and repair
Brakes:
Braking system diagnostics, repair, and maintenance
Wheels:
Wheel and tire service, bolt patterns
Electrical:
Complete electrical system diagnostics, wiring diagrams, component testing
Bodywork:
Bodywork repair and maintenance
Climate Control:
Air temperature control system service and repair
Exhaust:
Implied within engine and general repair
Cooling:
Implied within engine and general repair
Procedures Included
Maintenance:
Routine maintenance (e.g., spark plug changes), fluid changes
Diagnostics:
Troubleshooting and diagnostic procedures for all systems
Repair:
Step-by-step repair instructions for major and minor components
Rebuilding:
Engine rebuilding procedures
Installation:
Component installation procedures
Adjustments:
System adjustments and calibrations
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine rebuilds
Illustrations
Diagrams:
Detailed step-by-step diagrams, exploded views, electrical diagrams
Data
Technical Data:
Includes torque settings, fluid capacities, technical specifications
Parts
Spare Parts:
Illustrations of spare parts
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF (common for digital manuals)
Print Quality
Printability:
All pages are printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Common Engines Covered:
Likely covers M52, M54, M62, S62 (4-cylinder, 6-cylinder, and V8 variants common in E39, though specific engines are not listed, a complete manual would cover all factory options for the years)
Performance
Power Output Range:
Varies by engine (e.g., 170 hp to 400 hp for M52/M54/M62/S62)
Torque Range:
Varies by engine (e.g., 181 lb-ft to 431 lb-ft for M52/M54/M62/S62)
Fuel System
Fuel Delivery:
Fuel injection (likely Bosch Motronic variants for the era)
Cooling
Cooling System:
Coolant capacity and service procedures
Lubrication
Oil Capacity:
Engine oil capacity and recommended specifications (e.g., BMW Longlife-01)
Spark Plugs
Spark Plug Type:
Specific spark plug part numbers and torque specifications
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual (Getrag or ZF)
Optional
Optional Transmission Type:
5-speed automatic (Steptronic, likely ZF 5HP19 or 5HP24)
Features
Clutch Service:
Clutch replacement and adjustment procedures
Fluid Specs
Transmission Fluid Type:
Specific automatic transmission fluid (ATF) and manual transmission fluid (MTF) specifications
📐 Dimensions
Exterior
Wheelbase Sedan:
Approx. 115.4 inches (2931 mm)
Wheelbase Wagon:
Approx. 115.4 inches (2931 mm)
Length Sedan:
Approx. 191.1 inches (4854 mm)
Length Wagon:
Approx. 193.3 inches (4910 mm)
Width:
Approx. 70.2 inches (1783 mm)
Height Sedan:
Approx. 57.2 inches (1453 mm)
Height Wagon:
Approx. 57.7 inches (1466 mm)
Weights
Curb Weight:
Varies by model (approx. 3500 - 4000 lbs / 1588 - 1814 kg)
Cargo
Cargo Volume Wagon:
Approx. 21.8 - 30.2 cu ft (expandable)
Wheels Tires
Wheel Bolt Pattern:
5x120
Common Tire Sizes:
e.g., 225/55R16, 235/45R17, 245/40R18 (varies by trim and options)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Refer to specific model year reports, generally good for its era
Active Features
Traction Control:
ASR (Anti-Slip Regulation) / Traction Control System (TCS)
Stability Control:
DSC (Dynamic Stability Control) available on later models/trims
Passive Features
Airbags:
Frontal airbags, side airbags (optional/standard depending on trim)
Seatbelts:
Pretensioning front seatbelts
💡 Technology Features
Infotainment
Nav System:
BMW Professional Navigation System (MKIII/MKIV) available
Audio:
Harman Kardon sound system option
Driver Assistance
Parking Sensors:
Park Distance Control (PDC) front and rear available
Connectivity
Phone Integration:
Bluetooth phone preparation available
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Extended Service Intervals (e.g., 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used, via Condition Based Service - CBS)
Spark Plug Replacement:
e.g., 60,000 miles for standard plugs, 100,000 miles for long-life plugs (varies by engine)
Transmission Fluid Change:
BMW often cited as 'lifetime' for automatic transmissions, but recommended to change around 50,000-100,000 miles by independent specialists.
Fluid Specifications
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-98 recommended (e.g., SAE 0W-40, 5W-30, 5W-40 depending on engine and climate)
Coolant Type:
BMW Blue Ethylene Glycol based coolant (G48)
Brake Fluid Type:
DOT 4 (low viscosity for ABS systems)
Known Issues
Cooling System:
Plastic expansion tank failures, water pump issues, radiator leaks
Suspension:
Control arm bushings, ball joints, sway bar links wear
Electrical:
ABS/DSC sensor failures, alternator issues, VANOS solenoids (on M54/M62)
Engine:
Oil pan gasket leaks, CCV system clogs (M54)
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Focus on driving dynamics ('The Ultimate Driving Machine'), build quality, and technology
Model Evolution
E39 Generation:
Fifth generation of the BMW 5 Series, known for its refinement, handling, and balance of luxury and sportiness. Introduced in 1995 for the 1996 model year in Europe, 1997 in North America. Major facelift in 2000.
Facelift Impact:
2000 facelift brought updated engines (M54 series), new headlights, taillights, bumpers, and interior trim changes.
Production
Production Period:
1996–2003 (globally), with 1997-2002 covered by this manual.
Manufacturing Locations:
Germany (Dingolfing)
🏆 Awards & Recognition
Recognitions
Car And Driver 5 Best Cars:
Car and Driver 10 Best Cars list multiple times (e.g., 1998, 1999, 2000, 2001, 2002)
Ratings
Consumer Reports:
Generally well-rated for performance and driving dynamics, though some model years/engines had specific reliability concerns highlighted by Consumer Reports.
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