🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Generation: Fourth Generation Model Years Covered: 1997-2002 Codes Engine Codes Implied: M52B25, M52B28, M62B44, M62B46 (for 540i variants, including M-Sport/M5) Chassis Codes Implied: E39 (specific to sedan and touring/wagon variants) 👋 Introduction Market Position Market Position: The E39 5 Series represented BMW's mid-size luxury sedan and wagon offering, known for its superior driving dynamics, refined interiors, and advanced technology for its era, competing against rivals like the Mercedes-Benz E-Class and Audi A6. Competitive Analysis Competitive Analysis: The E39 was lauded for its balanced chassis, powerful inline-six and V8 engines, and driver-focused cockpit. This workshop manual provides the necessary depth to maintain and repair these sophisticated vehicles, ensuring their performance characteristics are preserved. Key Features Key Features: Digital format for convenient access and printing, detailed illustrations, numbered step-by-step instructions, troubleshooting guides, and comprehensive coverage of all major vehicle systems. 📋 Manual Details Coverage Areas Coverage Areas: North America, Europe, and Global markets where E39 was sold Page Count Page Count: Hundreds of pages (exact count not specified, but implied to be extensive) Manual Type Manual Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, Engine management, Fuel system, Ignition system, Cooling system, Exhaust system, Clutch, Transmission (manual and automatic), Driveline, Suspension (front and rear), Steering system, Brakes (ABS, DSC), Body (interior and exterior), Electrical system (lighting, accessories, power features), HVAC system, SRS (airbag) system, Diagnostic procedures Bodywork Interior: Trim removal and installation, seat adjustment mechanisms, dashboard components, door panel removal, headliner servicing. Bodywork Exterior: Fender removal, bumper cover installation, headlight and taillight replacement, door hinge adjustment, trunk lid and hood alignment. Procedures Included Procedures Included: Scheduled maintenance, Routine checks, Lubrication, Oil changes, Filter replacements (air, oil, fuel, cabin), Spark plug replacement, Belt replacement, Brake pad and rotor replacement, Suspension component repair (shocks, struts, bushings), Steering system repair, Engine diagnostics and repair, Transmission servicing and repair, Electrical troubleshooting, Wiring diagram interpretation, Body panel repair and replacement, Climate control system servicing, Drivetrain component repair, Exhaust system repair, Diagnostic trouble code (DTC) interpretation and resolution, Complete engine overhaul, Timing belt/chain replacement (where applicable by engine variant), Head gasket replacement Head Gasket Replacement: Detailed step-by-step instructions for removing cylinder heads, replacing head gaskets, and reassembling the engine, including torque specifications and crucial alignment procedures. Timing Chain Maintenance: Includes procedures for inspecting and replacing timing chain guides and tensioners on applicable engines, a critical maintenance item for long-term engine health. Technical Depth Technical Depth: Comprehensive, ranging from basic owner maintenance tasks to complex mechanical and electrical system repairs, suitable for DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable without restriction, allowing users to print specific sections or the entire manual as needed. Binding Type Binding Type: Digital Download (PDF) - No physical binding Paper Type Paper Type: Not Applicable (Digital Format) Software Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Variants Covered: Inline-6 (2.5L, 2.8L) and V8 (4.4L, 4.6L M-tuned for 540i variants) Performance 525I Engine Power: Approx. 189 hp @ 5900 rpm (M52TU B25) 528I Engine Power: Approx. 190 hp @ 5300 rpm (M52TU B28) 530I Engine Power: Approx. 225 hp @ 5900 rpm (M54 B30) 540I Engine Power: Approx. 282 hp @ 5400 rpm (M62 B44TU) 530I Engine Torque: Approx. 225 lb-ft @ 3500 rpm (M54 B30) 540I Engine Torque: Approx. 324 lb-ft @ 3600 rpm (M62 B44TU) Fuel System Fuel System Type: Electronic Fuel Injection (EFI) with Bosch Motronic engine management Engine Maintenance Timing Chain Intervals: No scheduled replacement (designed for the life of the engine with proper maintenance), but inspection and potential tensioner/guide replacement is covered. Spark Plug Replacement Interval: Approximately 100,000 miles (or as specified in the manual, varies by engine) 🔧 Transmission Standard Standard Transmission Offered: 5-speed Manual Transmission (Getrag 280/370) Optional Optional Transmission Offered: 5-speed Automatic Transmission (GM 5L40-E for 6-cyl, ZF 5HP30/5HP24 for V8) Features Transmission Fluid Type: BMW ATF Dexron III/VI (for GM 5L40-E), ZF Lifeguardfluid 5 (for ZF 5HP series) - manual specifies exact BMW part numbers Maintenance Automatic Transmission Fluid Change Interval: BMW initially recommended 'lifetime' fluid, but later revised to recommend fluid and filter changes approximately every 60,000 miles for optimal longevity. Manual details the procedure. 📐 Dimensions Exterior Wheelbase Sedan: 111.4 inches (2830 mm) Length Sedan: 188.7 inches (4793 mm) Width Sedan: 70.2 inches (1783 mm) Height Sedan: 56.6 inches (1438 mm) Wheelbase Wagon: 111.4 inches (2830 mm) Weights Curb Weight 528I: Approximately 3571 lbs (1620 kg) Curb Weight 540I: Approximately 3858 lbs (1750 kg) Gross Vehicle Weight Rating: Varies by model, detailed in manual Cargo Cargo Volume Sedan: Approx. 15.0 cubic feet Cargo Volume Wagon: Approx. 21.8 cubic feet (rear seats...