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BMW 5 Series E39 Service Repair Manual 1997-2002

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Code: E39 Codes Production Years Covered: 1997-2002 👋 Introduction Market Position Target Audience: BMW owners, independent repair shops, DIY enthusiasts Competitive Analysis Differentiation: Make, model, and year-specific; comprehensive coverage beyond generic manuals Key Features Delivery: Instant download, fast, easy, and secure Payment Options: Credit Card or PayPal 📋 Manual Details Coverage Areas Scope: Comprehensive workshop repair procedures Page Count Estimated Pages: Extensive (specific count not provided but implied to be comprehensive) Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (removal/installation, cylinder head/valve, cylinder/piston, crankcase, crankshaft/primary shaft), Clutch, Transmission, Gearshift Linkage, Sub transmission Chassis: Front Wheel/Suspension, Rear Wheel/Suspension, Hydraulic Brake Electrical: Battery/Charging System, Ignition System, Electric Starter, Switches, Rewiring Fuel System: Fuel pumps, fuel injectors, fuel pressure regulators, fuel lines, emissions control systems. Exhaust System: While not explicitly listed, general repair sections often cover exhaust manifold removal/installation and related components. Cooling System: Radiator, water pump, thermostat, hoses, heater core, fan clutch/electric fan operation. Steering System: Power steering pump, steering gear/rack, tie rods, steering column components. Body And Trim: Exterior body panel adjustments, interior trim removal/installation, door mechanisms, latch systems (implied by comprehensive repair scope). Procedures Included Maintenance: Lubrication, Inspection and Adjustment Repair: Rebuilding engine, comprehensive workshop repair procedures Diagnostics: Troubleshooting Troubleshooting Guides: Specific diagnostic flowcharts and symptom-based troubleshooting for common vehicle issues. Electrical Diagrams: Detailed wiring schematics for various vehicle systems, essential for diagnosing electrical faults. Technical Depth Depth: In-depth, covering all workshop repair procedures including engine rebuilds and electrical rewiring Component Rebuild: Extensive detail on rebuilding major components like engines, transmissions, and potentially differential units. 📊 Manual Specifications File Format Accessibility: Printable pages, viewable on screen Interactivity: Zoom in/out capability Searchability: PDF format typically allows for text searching, enhancing ease of use. Print Quality Quality: High-resolution diagrams and detailed text Binding Type Binding: Digital (PDF download) Paper Type Paper: Not applicable (digital format) ⚙️ Engine Specifications Primary Engine Engine Variants Covered: Assumed to cover common E39 engine options for 1997-2002 (e.g., M52/M54 inline-6, V8 variants might be included depending on specific manual detail) Common Engine Codes E39: M52B20, M52B25, M52B28 (2.0L, 2.5L, 2.8L inline-6), M54B22, M54B25, M54B30 (2.2L, 2.5L, 3.0L inline-6), M62B44, M62B46 (4.4L, 4.6L V8 - for 540i/M5) Performance Typical Performance Ranges: Covers repair and maintenance for engines producing power outputs ranging from approximately 170 hp to 340 hp depending on the specific engine variant. M54B30 Output: Approx. 228 hp @ 6000 rpm and 232 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Detailed procedures for fuel injection systems, fuel pumps, injectors, and fuel lines. Engine Management: Covers procedures related to the DME (Digital Motor Electronics) control unit and associated sensors. 🔧 Transmission Standard Transmission Types Covered: Details on both manual and automatic transmissions commonly found in the E39 5 Series. Optional Transmission Options: Covers repair and maintenance for various transmissions, likely including GM-sourced automatics and Getrag manuals. Automatic Transmission Models: Likely includes the GM 5L40-E (5-speed automatic) and ZF 5HPxx series (5-speed automatic). Manual Transmission Models: Likely includes Getrag 5-speed and 6-speed manual gearboxes. Features Transmission Operations: Includes troubleshooting, repair, and maintenance for gear selection, clutch operation, and transmission fluid services. 📐 Dimensions Exterior Typical Wheelbase: Approx. 113.4 inches (2880 mm) for most E39 sedans Typical Length: Approx. 191 inches (4850 mm) for most E39 sedans Typical Width: Approx. 71.5 inches (1816 mm) Typical Height: Approx. 57.0 inches (1450 mm) Weights Typical Curb Weight: Ranges from approx. 3500 lbs to over 4000 lbs depending on engine and equipment. 🛡️ Safety Features Ratings Crash Test Performance: The E39 platform generally performed well in its era's safety tests, though specific ratings for this manual's scope are not detailed. Active Features Braking System: Details on hydraulic brake systems, including ABS and likely DSC (Dynamic Stability Control) components. Passive Features Airbag System: While not explicitly listed, advanced repair manuals often include information related to the electrical systems powering airbags and pre-tensioners. 💡 Technology Features Infotainment Nav Professional: Manual likely covers diagnostic and troubleshooting of the BMW Professional navigation system and related audio components. Driver Assistance Cruise Control: Information on operation and potential repair of the cruise control system. Connectivity Telephone Preparation: Covers the integration and troubleshooting of early Bluetooth or cellular telephone interfaces if equipped. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system, depending on oil type and driving conditions. Spark Plug Replacement: Varies by engine, but commonly around 60,000-100,000 miles for long-life iridium plugs. Fluid Specifications Engine Oil Type: Typically BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) synthetic oil, viscosity dependent on climate (e.g., 5W-30, 5W-40). Coolant Type: BMW Blue Antifreeze/Coolant (G48 specification), a silicate-containing ethylene glycol-based coolant. Transmission Fluid: Specific ATF (Automatic Transmission Fluid) like Dexron...
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BMW 5 Series E39 Service Repair Manual 1997-2002
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Generation
Chassis Code:
E39
Codes
Production Years Covered:
1997-2002
👋 Introduction
Market Position
Target Audience:
BMW owners, independent repair shops, DIY enthusiasts
Competitive Analysis
Differentiation:
Make, model, and year-specific; comprehensive coverage beyond generic manuals
Key Features
Delivery:
Instant download, fast, easy, and secure
Payment Options:
Credit Card or PayPal
📋 Manual Details
Coverage Areas
Scope:
Comprehensive workshop repair procedures
Page Count
Estimated Pages:
Extensive (specific count not provided but implied to be comprehensive)
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (removal/installation, cylinder head/valve, cylinder/piston, crankcase, crankshaft/primary shaft), Clutch, Transmission, Gearshift Linkage, Sub transmission
Chassis:
Front Wheel/Suspension, Rear Wheel/Suspension, Hydraulic Brake
Electrical:
Battery/Charging System, Ignition System, Electric Starter, Switches, Rewiring
Fuel System:
Fuel pumps, fuel injectors, fuel pressure regulators, fuel lines, emissions control systems.
Exhaust System:
While not explicitly listed, general repair sections often cover exhaust manifold removal/installation and related components.
Cooling System:
Radiator, water pump, thermostat, hoses, heater core, fan clutch/electric fan operation.
Steering System:
Power steering pump, steering gear/rack, tie rods, steering column components.
Body And Trim:
Exterior body panel adjustments, interior trim removal/installation, door mechanisms, latch systems (implied by comprehensive repair scope).
Procedures Included
Maintenance:
Lubrication, Inspection and Adjustment
Repair:
Rebuilding engine, comprehensive workshop repair procedures
Diagnostics:
Troubleshooting
Troubleshooting Guides:
Specific diagnostic flowcharts and symptom-based troubleshooting for common vehicle issues.
Electrical Diagrams:
Detailed wiring schematics for various vehicle systems, essential for diagnosing electrical faults.
Technical Depth
Depth:
In-depth, covering all workshop repair procedures including engine rebuilds and electrical rewiring
Component Rebuild:
Extensive detail on rebuilding major components like engines, transmissions, and potentially differential units.
📊 Manual Specifications
File Format
Accessibility:
Printable pages, viewable on screen
Interactivity:
Zoom in/out capability
Searchability:
PDF format typically allows for text searching, enhancing ease of use.
Print Quality
Quality:
High-resolution diagrams and detailed text
Binding Type
Binding:
Digital (PDF download)
Paper Type
Paper:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Variants Covered:
Assumed to cover common E39 engine options for 1997-2002 (e.g., M52/M54 inline-6, V8 variants might be included depending on specific manual detail)
Common Engine Codes E39:
M52B20, M52B25, M52B28 (2.0L, 2.5L, 2.8L inline-6), M54B22, M54B25, M54B30 (2.2L, 2.5L, 3.0L inline-6), M62B44, M62B46 (4.4L, 4.6L V8 - for 540i/M5)
Performance
Typical Performance Ranges:
Covers repair and maintenance for engines producing power outputs ranging from approximately 170 hp to 340 hp depending on the specific engine variant.
M54B30 Output:
Approx. 228 hp @ 6000 rpm and 232 lb-ft @ 3500 rpm
Fuel System
Fuel Delivery:
Detailed procedures for fuel injection systems, fuel pumps, injectors, and fuel lines.
Engine Management:
Covers procedures related to the DME (Digital Motor Electronics) control unit and associated sensors.
🔧 Transmission
Standard
Transmission Types Covered:
Details on both manual and automatic transmissions commonly found in the E39 5 Series.
Optional
Transmission Options:
Covers repair and maintenance for various transmissions, likely including GM-sourced automatics and Getrag manuals.
Automatic Transmission Models:
Likely includes the GM 5L40-E (5-speed automatic) and ZF 5HPxx series (5-speed automatic).
Manual Transmission Models:
Likely includes Getrag 5-speed and 6-speed manual gearboxes.
Features
Transmission Operations:
Includes troubleshooting, repair, and maintenance for gear selection, clutch operation, and transmission fluid services.
📐 Dimensions
Exterior
Typical Wheelbase:
Approx. 113.4 inches (2880 mm) for most E39 sedans
Typical Length:
Approx. 191 inches (4850 mm) for most E39 sedans
Typical Width:
Approx. 71.5 inches (1816 mm)
Typical Height:
Approx. 57.0 inches (1450 mm)
Weights
Typical Curb Weight:
Ranges from approx. 3500 lbs to over 4000 lbs depending on engine and equipment.
🛡️ Safety Features
Ratings
Crash Test Performance:
The E39 platform generally performed well in its era's safety tests, though specific ratings for this manual's scope are not detailed.
Active Features
Braking System:
Details on hydraulic brake systems, including ABS and likely DSC (Dynamic Stability Control) components.
Passive Features
Airbag System:
While not explicitly listed, advanced repair manuals often include information related to the electrical systems powering airbags and pre-tensioners.
💡 Technology Features
Infotainment
Nav Professional:
Manual likely covers diagnostic and troubleshooting of the BMW Professional navigation system and related audio components.
Driver Assistance
Cruise Control:
Information on operation and potential repair of the cruise control system.
Connectivity
Telephone Preparation:
Covers the integration and troubleshooting of early Bluetooth or cellular telephone interfaces if equipped.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500-15,000 miles or as indicated by the Condition Based Service (CBS) system, depending on oil type and driving conditions.
Spark Plug Replacement:
Varies by engine, but commonly around 60,000-100,000 miles for long-life iridium plugs.
Fluid Specifications
Engine Oil Type:
Typically BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) synthetic oil, viscosity dependent on climate (e.g., 5W-30, 5W-40).
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 specification), a silicate-containing ethylene glycol-based coolant.
Transmission Fluid:
Specific ATF (Automatic Transmission Fluid) like Dexron III/VI for automatics, and appropriate gear oil for manuals. Exact part numbers/specifications are within the manual.
Brake Fluid Type:
DOT 4 BMW Super-11 or equivalent.
Power Steering Fluid:
BMW PSF-V or Pentosin CHF 11 S for some models, or ATF for others. Manual provides specific requirements.
Known Issues
Common E39 Complaints:
Cooling system leaks (plastic components), VANOS seal issues (engine performance), window regulator failures, oil pan gasket leaks, ABS/DSC sensor failures, suspension component wear (control arms).
Differential Leaks:
Rear main seal and differential seal leaks are common service items detailed in such manuals.
Technical Specifications
Brake Rotor Sizes:
Varies by model, e.g., front rotors could be around 324mm or 334mm for larger engine models.
Tire Sizes:
Common sizes include 205/55R16, 215/55R16, 225/50R17, 235/45R17, etc., depending on trim and wheel option.
Wheel Bolt Pattern:
5x120mm
Lug Nut Torque:
140 Nm (103 lb-ft)
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Represents BMW's commitment to luxury, performance, and driver engagement in the executive sedan segment.
Model Evolution
E39 Development:
The E39 succeeded the E34 and introduced significant advancements in chassis design, electronics, and engine technology for its time.
Production
Production Period:
1995-2003 (though the manual covers the 1997-2002 market segment)
🏆 Awards & Recognition
Recognitions
Car And Driver 5Best:
The E39 5 Series was a frequent recipient of Car and Driver's '10Best' award during its production run, highlighting its class-leading dynamics and refinement.
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