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BMW 5-series (E39) 1995 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5-series Chassis Code: E39 Model Year Coverage: 1995 👋 Introduction Market Position Segment: Executive/Luxury Sedan and Wagon (Touring) Competitive Analysis Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C4/C5), Lexus GS (JZS160). Key Features Design Philosophy: BMW's signature driving dynamics, sophisticated engineering, driver-focused cockpit, and high-quality interior appointments. Manual Value Proposition: Provides dealership-level accuracy and detail, enabling owners and independent technicians to perform complex repairs and maintenance with confidence, saving on dealership labor costs. 📋 Manual Details Coverage Areas Models Covered: All E39 5-series models manufactured in 1995, including sedan and touring variants. Repair Scope: Comprehensive A-Z repair coverage for all systems. Page Count Estimated Pages: Extensive (Exact page count not specified, but described as a complete dealership-level manual). Manual Type Type: Service and Repair Manual Language Language: English Format Format: Likely Print or Digital (PDF/EPUB) - often dealership-issued manuals are printed. 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, cooling system, exhaust system, engine management (DME), manual and automatic transmissions, driveline components (driveshafts, differentials). Chassis: Suspension (front and rear), steering system, braking system (including ABS), wheels and tires. Electrical: Engine control unit (ECU) and related sensors, lighting systems (headlights, taillights, interior), instrumentation and warning indicators, power accessories (windows, locks, mirrors), audio system, climate control system, body control module (BCM), starter, alternator. Body: Body panels, doors, latches, hinges, glass, sunroof, interior trim, bumper systems. Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks and top-offs, air filter replacement, spark plug replacement, brake pad and rotor replacement. Diagnostic Troubleshooting: Symptoms-based diagnostics, fault code interpretation (for applicable systems), specific component testing procedures, wiring diagrams for troubleshooting. Repair And Overhaul: Engine component replacement (e.g., head gaskets, pistons, crankshaft), transmission overhaul, brake caliper rebuild, suspension component replacement (e.g., control arms, shock absorbers), electrical component repair or replacement. Special Procedures: Air conditioning system servicing and refrigerant handling, airbag system safety precautions and removal/installation, fuel system pressure testing and component replacement, diagnostic tool usage (e.g., DIS). Technical Depth Depth: Complete factory-level technical specifications, repair procedures, and diagnostic information as used by authorized BMW technicians. 📊 Manual Specifications File Format Digital Format: If digital, typically a searchable PDF with high-resolution diagrams and schematics. Print Quality Print Quality: High quality, durable paper stock, clear text, and professional-grade diagrams. Binding Type Binding: Likely spiral-bound or comb-bound for lay-flat usability, or a robust hardbound for archival purposes. Paper Type Paper Type: Durable, possibly coated paper to withstand workshop conditions and repeated use. ⚙️ Engine Specifications Primary Engine Engine Code Examples: M52B20, M52B25, M52B28 (Inline-6 gasoline) Engine Configuration: Naturally aspirated Inline 6-cylinder, DOHC, 24 valves. Performance Typical Horsepower Range: 150 hp to 193 hp (depending on displacement: 2.0L, 2.5L, 2.8L). Typical Torque Range: 190 Nm to 280 Nm (depending on displacement). Fuel System Fuel Delivery: Multi-point fuel injection (MPI), Electronic Engine Management (DME) controlled. Cooling System Coolant Type: BMW Blue Coolant (G48 ethylene glycol based) - requires a 50/50 mix with distilled water. Capacity approx. 8.5 - 9.5 Liters. Lubrication Engine Oil Type Recommendation: SAE 5W-30 or 5W-40, API SJ or better, BMW Longlife-98 (LL-98) or Longlife-01 (LL-01) specification. Capacity approx. 6.5 Liters. 🔧 Transmission Standard Type E.G. 5Spd Manual: 5-speed manual transmission (e.g., Getrag S5D 250G). Optional Type E.G. 5Spd Auto: 5-speed automatic transmission (e.g., ZF 5HP18, 5HP19, 5HP24). Features Transmission Fluid Type Auto: ZF LifeguardFluid 5 (often specified as Dexron III compatible, but ZF fluid is preferred). Capacity approx. 7.5-8.5 Liters for a complete fill/flush. Transmission Fluid Type Manual: SAE 75W-90 synthetic gear oil, API GL-4 or GL-5. Capacity approx. 1.5 Liters. 📐 Dimensions Exterior Wheelbase: Approx. 2830 mm (111.4 in) Length: Approx. 4770 mm (187.8 in) Width: Approx. 1799 mm (70.8 in) Height: Approx. 1437 mm (56.6 in) Weights Curb Weight Range: Approx. 1500-1650 kg (3300-3640 lbs) depending on engine and equipment. Cargo Trunk Volume: Approx. 520 Liters (18.4 cu ft) for sedan. 🛡️ Safety Features Ratings IIHS Safety Ratings: Generally good frontal crash test ratings for its era, though specific data for 1995 E39 might be limited in retrospect compared to later models. Active Features Traction Control: Available Automatic Stability Control (ASC) or Automatic Stability Control + Traction (ASC+T). Braking System: Four-wheel disc brakes, ABS (Anti-lock Braking System) standard. Passive Features Airbags: Frontal airbags for driver and front passenger. Side airbags optional. Seatbelts: Three-point inertia-reel seatbelts with pretensioners for front seats. 💡 Technology Features Infotainment Radio Options: BMW Business CD, BMW Professional CD, optional navigation system (MK I or MK II) with early generation displays. Climate Control: Optional automatic climate control with dual-zone functionality. Manual climate control also available. Driver Assistance Cruise Control: Standard cruise control system. Parking Sensors: Optional Park Distance Control (PDC) system, typically front and rear. Connectivity Phone Integration: Optional integrated Bluetooth preparation or cradle for mobile phones. 🔧 Maintenance Service Intervals Oil Change Interval:...
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BMW 5-series (E39) 1995 Service and Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5-series
Chassis Code:
E39
Model Year Coverage:
1995
👋 Introduction
Market Position
Segment:
Executive/Luxury Sedan and Wagon (Touring)
Competitive Analysis
Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C4/C5), Lexus GS (JZS160).
Key Features
Design Philosophy:
BMW's signature driving dynamics, sophisticated engineering, driver-focused cockpit, and high-quality interior appointments.
Manual Value Proposition:
Provides dealership-level accuracy and detail, enabling owners and independent technicians to perform complex repairs and maintenance with confidence, saving on dealership labor costs.
📋 Manual Details
Coverage Areas
Models Covered:
All E39 5-series models manufactured in 1995, including sedan and touring variants.
Repair Scope:
Comprehensive A-Z repair coverage for all systems.
Page Count
Estimated Pages:
Extensive (Exact page count not specified, but described as a complete dealership-level manual).
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Likely Print or Digital (PDF/EPUB) - often dealership-issued manuals are printed.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals, fuel system, cooling system, exhaust system, engine management (DME), manual and automatic transmissions, driveline components (driveshafts, differentials).
Chassis:
Suspension (front and rear), steering system, braking system (including ABS), wheels and tires.
Electrical:
Engine control unit (ECU) and related sensors, lighting systems (headlights, taillights, interior), instrumentation and warning indicators, power accessories (windows, locks, mirrors), audio system, climate control system, body control module (BCM), starter, alternator.
Body:
Body panels, doors, latches, hinges, glass, sunroof, interior trim, bumper systems.
Procedures Included
Routine Maintenance:
Oil and filter changes, fluid level checks and top-offs, air filter replacement, spark plug replacement, brake pad and rotor replacement.
Diagnostic Troubleshooting:
Symptoms-based diagnostics, fault code interpretation (for applicable systems), specific component testing procedures, wiring diagrams for troubleshooting.
Repair And Overhaul:
Engine component replacement (e.g., head gaskets, pistons, crankshaft), transmission overhaul, brake caliper rebuild, suspension component replacement (e.g., control arms, shock absorbers), electrical component repair or replacement.
Special Procedures:
Air conditioning system servicing and refrigerant handling, airbag system safety precautions and removal/installation, fuel system pressure testing and component replacement, diagnostic tool usage (e.g., DIS).
Technical Depth
Depth:
Complete factory-level technical specifications, repair procedures, and diagnostic information as used by authorized BMW technicians.
📊 Manual Specifications
File Format
Digital Format:
If digital, typically a searchable PDF with high-resolution diagrams and schematics.
Print Quality
Print Quality:
High quality, durable paper stock, clear text, and professional-grade diagrams.
Binding Type
Binding:
Likely spiral-bound or comb-bound for lay-flat usability, or a robust hardbound for archival purposes.
Paper Type
Paper Type:
Durable, possibly coated paper to withstand workshop conditions and repeated use.
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
M52B20, M52B25, M52B28 (Inline-6 gasoline)
Engine Configuration:
Naturally aspirated Inline 6-cylinder, DOHC, 24 valves.
Performance
Typical Horsepower Range:
150 hp to 193 hp (depending on displacement: 2.0L, 2.5L, 2.8L).
Typical Torque Range:
190 Nm to 280 Nm (depending on displacement).
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI), Electronic Engine Management (DME) controlled.
Cooling System
Coolant Type:
BMW Blue Coolant (G48 ethylene glycol based) - requires a 50/50 mix with distilled water. Capacity approx. 8.5 - 9.5 Liters.
Lubrication
Engine Oil Type Recommendation:
SAE 5W-30 or 5W-40, API SJ or better, BMW Longlife-98 (LL-98) or Longlife-01 (LL-01) specification. Capacity approx. 6.5 Liters.
🔧 Transmission
Standard
Type E.G. 5Spd Manual:
5-speed manual transmission (e.g., Getrag S5D 250G).
Optional
Type E.G. 5Spd Auto:
5-speed automatic transmission (e.g., ZF 5HP18, 5HP19, 5HP24).
Features
Transmission Fluid Type Auto:
ZF LifeguardFluid 5 (often specified as Dexron III compatible, but ZF fluid is preferred). Capacity approx. 7.5-8.5 Liters for a complete fill/flush.
Transmission Fluid Type Manual:
SAE 75W-90 synthetic gear oil, API GL-4 or GL-5. Capacity approx. 1.5 Liters.
📐 Dimensions
Exterior
Wheelbase:
Approx. 2830 mm (111.4 in)
Length:
Approx. 4770 mm (187.8 in)
Width:
Approx. 1799 mm (70.8 in)
Height:
Approx. 1437 mm (56.6 in)
Weights
Curb Weight Range:
Approx. 1500-1650 kg (3300-3640 lbs) depending on engine and equipment.
Cargo
Trunk Volume:
Approx. 520 Liters (18.4 cu ft) for sedan.
🛡️ Safety Features
Ratings
IIHS Safety Ratings:
Generally good frontal crash test ratings for its era, though specific data for 1995 E39 might be limited in retrospect compared to later models.
Active Features
Traction Control:
Available Automatic Stability Control (ASC) or Automatic Stability Control + Traction (ASC+T).
Braking System:
Four-wheel disc brakes, ABS (Anti-lock Braking System) standard.
Passive Features
Airbags:
Frontal airbags for driver and front passenger. Side airbags optional.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners for front seats.
💡 Technology Features
Infotainment
Radio Options:
BMW Business CD, BMW Professional CD, optional navigation system (MK I or MK II) with early generation displays.
Climate Control:
Optional automatic climate control with dual-zone functionality. Manual climate control also available.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Sensors:
Optional Park Distance Control (PDC) system, typically front and rear.
Connectivity
Phone Integration:
Optional integrated Bluetooth preparation or cradle for mobile phones.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable Service Indicator (VSI) system, typically 10,000-15,000 miles (15,000-25,000 km) or annually, whichever comes first, depending on driving conditions. Refer to VSI system for exact timing.
Major Service Intervals:
Inspect/replace spark plugs (approx. 60,000 miles), inspect/replace coolant (approx. 2-4 years or 30,000-50,000 miles), inspect brake fluid (every 2 years).
Fluid Specifications
Power Steering Fluid:
BMW Power Steering Fluid (or Pentosin CHF 11S/CHF 202). Capacity approx. 1.2 Liters.
Brake Fluid:
DOT 4 (or DOT 4 PLUS for improved performance). Capacity approx. 1 Liter.
Known Issues
Cooling System:
Plastic expansion tank cracking, water pump failure (plastic impeller often breaks), thermostat housing leaks. Regular inspection recommended.
Suspension:
Front control arm bushings (vibration and steering wander), rear subframe bushings (clunks, separation), sway bar links and bushings (clunks).
Electrical:
Ignition coil failures, mass airflow sensor (MAF) issues, ABS sensor failures, Pixelfehler (pixelated displays) in the instrument cluster, VANOS (Variable Valve Timing) solenoids and seals.
Interior:
Headliner sagging, door panel creaks, driver's seat bolster wear.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's legacy of building sporty, driver-focused luxury vehicles, emphasizing performance and engineering excellence.
Model Evolution
E39 Introduction:
The E39 generation of the 5-series debuted in 1995 for the 1996 model year in Europe, and slightly later in North America. It represented a significant advancement in chassis design, aerodynamics, and technology over its E34 predecessor.
E39 Era Focus:
This generation focused on improved ride comfort, enhanced safety, and a more refined driving experience while retaining BMW's characteristic handling prowess.
Production
Production Period:
1995-2003 (for E39 generation).
Key Manufacturing Locations:
Dingolfing, Germany; Rosslyn, South Africa; Graz, Austria (for Touring models).
🏆 Awards & Recognition
Recognitions
Car And Driver Best 10:
The E39 5-series was a consistent recipient of Car and Driver's '10Best' list during its production run, often cited for its balance of luxury, performance, and handling.
Ratings
World Car Of The Year:
While not explicitly winning 'World Car of the Year' for 1995, the E39 generation was highly regarded in automotive press for its class-leading attributes.
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