BMW 5-series (E39) 2003 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5-series Chassis Code: E39 Model Year: 2003 Applicable Model Years Within Generation: 1996-2003 Codes Internal Bmw Project Code: E39 👋 Introduction Market Position Vehicle Market Segment: Executive/Luxury Sedan and Wagon Competitive Analysis Key Competitors E39 Era: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type, Volvo S80 Key Features E39 Generation Highlights: Exceptional driving dynamics (often lauded as a driver's car), refined interior, advanced engineering, available V8 engines, robust construction Manual Value Proposition Manual Benefit: Provides factory-level diagnostic and repair information, enabling accurate and efficient maintenance and repair, saving time and money compared to dealership service. Manual Authenticity Manual Origin: Exact same manual used by dealership technicians 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (Likely PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection, ignition, lubrication, cooling, exhaust, emissions control, engine management (DME), timing systems Transmission Systems: Manual and automatic transmissions, clutch, driveshafts, differentials, CV joints Braking Systems: Front and rear brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid, parking brake Suspension Steering: Front and rear suspension (MacPherson strut, multi-link), steering systems (rack and pinion), power steering Electrical Electronics: Battery, charging system, starter, lighting, instruments, body electronics module (BE/GM), comfort modules, diagnostic systems (OBD-II), wiring diagrams HVAC Systems: Heating, ventilation, and air conditioning (HVAC), climate control, refrigerant systems Body Chassis: Body construction, panels, doors, windows, interior trim, bumpers, chassis components, corrosion protection Safety Systems: Airbags, seatbelt systems, passive safety features Procedures Included Maintenance Procedures: Scheduled maintenance (oil changes, filter replacements, inspections), fluid level checks and top-offs, belt replacement, spark plug replacement Repair Procedures: Engine component repair/replacement (e.g., head gasket, pistons), transmission overhaul, brake caliper/rotor replacement, suspension arm/bush replacement, electrical component diagnosis and repair, HVAC component repair Troubleshooting: Diagnostic fault codes (DTCs), symptom-based troubleshooting guides, electrical circuit testing, fuel system diagnostics Diagnostics: OBD-II diagnostics, BMW-specific diagnostic procedures, sensor testing, actuator testing Technical Depth Depth Of Information: Comprehensive, from basic maintenance to complete overhaul and advanced diagnostics Data Specificity: Vehicle-specific technical data, torque specifications, clearances, timing settings, electrical schematics Tool Requirements: Special tools and equipment required for specific repairs 📊 Manual Specifications File Format Digital File Type: PDF Print Quality Resolution And Clarity: High resolution for clear diagrams and text Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Searchability Text Searchability: Fully searchable text for quick information retrieval ⚙️ Engine Specifications Primary Engine Options 2003 Model Year Engine Variant 1 Code: M54B25 Engine Variant 1 Displacement: 2.5 Liters (2494 cc) Engine Variant 1 Configuration: Inline 6-cylinder (I6), DOHC, 24 valves Engine Variant 1 Horsepower: 189 hp @ 6000 rpm Engine Variant 1 Torque: 236 Nm (174 lb-ft) @ 3500 rpm Engine Variant 2 Code: M54B30 Engine Variant 2 Displacement: 3.0 Liters (2979 cc) Engine Variant 2 Configuration: Inline 6-cylinder (I6), DOHC, 24 valves Engine Variant 2 Horsepower: 225 hp @ 6000 rpm Engine Variant 2 Torque: 289 Nm (213 lb-ft) @ 3500 rpm Engine Variant 3 Code: M62TU V8 (for 540i) Engine Variant 3 Displacement: 4.4 Liters (4398 cc) Engine Variant 3 Configuration: V8, DOHC, 32 valves, VANOS Engine Variant 3 Horsepower: 290 hp @ 5400 rpm Engine Variant 3 Torque: 440 Nm (325 lb-ft) @ 3600 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Bosch Motronic ME7.x) Technical Features Engine Management: Digital Motor Electronics (DME) with diagnostic capabilities Valve Control: Double VANOS (Variable Valve Timing) on M54 and M62TU engines 🔧 Transmission Standard Transmission 525I 530I Standard: 5-speed manual transmission (Getrag GS5-39DZ) Optional Transmission 525I 530I Optional: 5-speed automatic transmission (ZF 5HP19) 540I Optional: 5-speed automatic transmission (ZF 5HP24) Transmission Features Automatic Transmission Features: Steptronic (manual shifting mode) Fluid Specifications Manual Transmission Fluid: BMW MTF LT-2 (or equivalent specification) Automatic Transmission Fluid 5Hp19: Dexron III Automatic Transmission Fluid 5Hp24: Dexron III 📐 Dimensions Exterior Sedan Length Sedan: 4770 mm (187.8 in) Width Sedan: 1799 mm (70.8 in) Height Sedan: 1436 mm (56.5 in) Wheelbase Sedan: 2830 mm (111.4 in) Exterior Wagon Length Wagon: 4795 mm (188.8 in) Width Wagon: 1799 mm (70.8 in) Height Wagon: 1454 mm (57.2 in) Wheelbase Wagon: 2830 mm (111.4 in) Weights Curb Weight 525I Manual: Approx. 1550 kg (3417 lbs) Curb Weight 530I Automatic: Approx. 1580 kg (3483 lbs) Curb Weight 540I Automatic: Approx. 1680 kg (3704 lbs) Gvw Gross Vehicle Weight Rating: Varies by model, consult manual for specific figure Cargo Trunk Volume Sedan: Approx. 520 liters (18.4 cu ft) Cargo Volume Wagon: Approx. 460-1550 liters (16.2-54.7 cu ft) with rear seats folded 🛡️ Safety Features Ratings NHTSA Front Impact Rating: Good (for comparable models of the era) IIHS Side Impact Rating: Good (for comparable models of the era) Active Features...

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Description

🏷️ Basic Information

Identification

Make:

Model:

5-series

Chassis Code:

Model Year:

Applicable Model Years Within Generation:

1996-2003

Codes

Internal Bmw Project Code:

👋 Introduction

Market Position

Vehicle Market Segment:

Executive/Luxury Sedan and Wagon

Competitive Analysis

Key Competitors E39 Era:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type, Volvo S80

Key Features

E39 Generation Highlights:

Exceptional driving dynamics (often lauded as a driver's car), refined interior, advanced engineering, available V8 engines, robust construction

Manual Value Proposition

Manual Benefit:

Provides factory-level diagnostic and repair information, enabling accurate and efficient maintenance and repair, saving time and money compared to dealership service.

Manual Authenticity

Manual Origin:

Exact same manual used by dealership technicians

📋 Manual Details

Coverage Areas

Coverage Scope:

All models and all repairs A-Z

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (Likely PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, fuel injection, ignition, lubrication, cooling, exhaust, emissions control, engine management (DME), timing systems

Transmission Systems:

Manual and automatic transmissions, clutch, driveshafts, differentials, CV joints

Braking Systems:

Front and rear brakes, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid, parking brake

Suspension Steering:

Front and rear suspension (MacPherson strut, multi-link), steering systems (rack and pinion), power steering

Electrical Electronics:

Battery, charging system, starter, lighting, instruments, body electronics module (BE/GM), comfort modules, diagnostic systems (OBD-II), wiring diagrams

HVAC Systems:

Heating, ventilation, and air conditioning (HVAC), climate control, refrigerant systems

Body Chassis:

Body construction, panels, doors, windows, interior trim, bumpers, chassis components, corrosion protection

Safety Systems:

Airbags, seatbelt systems, passive safety features

Procedures Included

Maintenance Procedures:

Scheduled maintenance (oil changes, filter replacements, inspections), fluid level checks and top-offs, belt replacement, spark plug replacement

Repair Procedures:

Engine component repair/replacement (e.g., head gasket, pistons), transmission overhaul, brake caliper/rotor replacement, suspension arm/bush replacement, electrical component diagnosis and repair, HVAC component repair

Troubleshooting:

Diagnostic fault codes (DTCs), symptom-based troubleshooting guides, electrical circuit testing, fuel system diagnostics

Diagnostics:

OBD-II diagnostics, BMW-specific diagnostic procedures, sensor testing, actuator testing

Technical Depth

Depth Of Information:

Comprehensive, from basic maintenance to complete overhaul and advanced diagnostics

Data Specificity:

Vehicle-specific technical data, torque specifications, clearances, timing settings, electrical schematics

Tool Requirements:

Special tools and equipment required for specific repairs

📊 Manual Specifications

File Format

Digital File Type:

Print Quality

Resolution And Clarity:

High resolution for clear diagrams and text

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

Searchability

Text Searchability:

Fully searchable text for quick information retrieval

⚙️ Engine Specifications

Primary Engine Options 2003 Model Year

Engine Variant 1 Code:

M54B25

Engine Variant 1 Displacement:

2.5 Liters (2494 cc)

Engine Variant 1 Configuration:

Inline 6-cylinder (I6), DOHC, 24 valves

Engine Variant 1 Horsepower:

189 hp @ 6000 rpm

Engine Variant 1 Torque:

236 Nm (174 lb-ft) @ 3500 rpm

Engine Variant 2 Code:

M54B30

Engine Variant 2 Displacement:

3.0 Liters (2979 cc)

Engine Variant 2 Configuration:

Inline 6-cylinder (I6), DOHC, 24 valves

Engine Variant 2 Horsepower:

225 hp @ 6000 rpm

Engine Variant 2 Torque:

289 Nm (213 lb-ft) @ 3500 rpm

Engine Variant 3 Code:

M62TU V8 (for 540i)

Engine Variant 3 Displacement:

4.4 Liters (4398 cc)

Engine Variant 3 Configuration:

V8, DOHC, 32 valves, VANOS

Engine Variant 3 Horsepower:

290 hp @ 5400 rpm

Engine Variant 3 Torque:

440 Nm (325 lb-ft) @ 3600 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Bosch Motronic ME7.x)

Technical Features

Engine Management:

Digital Motor Electronics (DME) with diagnostic capabilities

Valve Control:

Double VANOS (Variable Valve Timing) on M54 and M62TU engines

🔧 Transmission

Standard Transmission

525I 530I Standard:

5-speed manual transmission (Getrag GS5-39DZ)

Optional Transmission

525I 530I Optional:

5-speed automatic transmission (ZF 5HP19)

540I Optional:

5-speed automatic transmission (ZF 5HP24)

Transmission Features

Automatic Transmission Features:

Steptronic (manual shifting mode)

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-2 (or equivalent specification)

Automatic Transmission Fluid 5Hp19:

Dexron III

Automatic Transmission Fluid 5Hp24:

Dexron III

📐 Dimensions

Exterior Sedan

Length Sedan:

4770 mm (187.8 in)

Width Sedan:

1799 mm (70.8 in)

Height Sedan:

1436 mm (56.5 in)

Wheelbase Sedan:

2830 mm (111.4 in)

Exterior Wagon

Length Wagon:

4795 mm (188.8 in)

Width Wagon:

1799 mm (70.8 in)

Height Wagon:

1454 mm (57.2 in)

Wheelbase Wagon:

2830 mm (111.4 in)

Weights

Curb Weight 525I Manual:

Approx. 1550 kg (3417 lbs)

Curb Weight 530I Automatic:

Approx. 1580 kg (3483 lbs)

Curb Weight 540I Automatic:

Approx. 1680 kg (3704 lbs)

Gvw Gross Vehicle Weight Rating:

Varies by model, consult manual for specific figure

Cargo

Trunk Volume Sedan:

Approx. 520 liters (18.4 cu ft)

Cargo Volume Wagon:

Approx. 460-1550 liters (16.2-54.7 cu ft) with rear seats folded

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

Good (for comparable models of the era)

IIHS Side Impact Rating:

Good (for comparable models of the era)

Active Features

Active Safety Systems:

ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), ASC+T (Automatic Stability Control + Traction)

Passive Features

Passive Safety Features:

Front airbags, side airbags, optional head airbags (Side Impact Protection System - SIPS), pre-tensioned seatbelts

💡 Technology Features

Infotainment

Infotainment System Options:

BMW Professional Radio, optional Business or Professional Navigation Systems, optional CD changer, optional Harman Kardon sound system.

Driver Assistance

Driver Assistance Features:

Cruise control, Park Distance Control (PDC) optional.

Connectivity

Connectivity Features:

Optional integrated cellular phone preparation (often with Bluetooth in later E39s, though less common in early 2003 models).

Diagnostics Interface

Diagnostic Port:

OBD-II connector located under the dashboard (for emissions and some powertrain diagnostics), BMW's proprietary 20-pin diagnostic connector often found in the engine bay or under the dash (for comprehensive BMW-specific diagnostics).

🔧 Maintenance

Service Intervals Typical

Oil Change Interval:

Variable Service Indicator (VSI) system, typically 10,000-15,000 miles or 12-24 months, depending on driving conditions.

Air Filter Replacement:

Every 30,000 miles or as indicated by VSI.

Cabin Filter Replacement:

Every 15,000-30,000 miles or annually.

Spark Plug Replacement:

Approx. 100,000 miles (depending on spark plug type - Long Life)

Fluid Specifications

Engine Oil Specification:

BMW Longlife-01 (LL-01) or LL-98; SAE 0W-40 or 5W-30 (depending on climate and specific engine)

Coolant Specification:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)

Brake Fluid Specification:

DOT 4

Known Issues

Common E39 Issues 1:

Oil pan gasket leaks, valve cover gasket leaks, CCV (Crankcase Ventilation) system failures, cooling system component degradation (hoses, water pump, expansion tank), ABS/DSC wheel speed sensor failures, VANOS seal ring wear, rear subframe mounting point cracks (especially on earlier models), window regulator failures.

Common E39 Issues 2:

Ignition coil failures, mass airflow sensor (MAF) issues, power steering hose leaks, squeaky suspension bushings, pixilation on the instrument cluster display.

Technical Tips

Maintenance Importance:

Regular maintenance is crucial for the longevity and performance of these sophisticated vehicles. The manual provides exact procedures to ensure correct execution.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure, performance, luxury, engineering innovation

Model Evolution

E39 Introduction Year:

E39 Generation Key Updates:

Significant chassis revisions, improved aerodynamics, more powerful engines, introduction of CAN bus electronics, introduction of Steptronic transmission, updated styling (facelift in 2000/2001)

Production

E39 Production Years:

1995-2003

E39 Manufacturing Locations:

Germany (Dingolfing), Austria (Graz), South Africa

Model Variant Highlights

E39 M5 Mention:

While this manual focuses on standard models, the E39 platform also hosted the highly acclaimed E39 M5 (S62 engine), representing the pinnacle of performance for this generation.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E39 5-series was frequently featured on Car and Driver's 10Best lists during its production run, particularly for its driving dynamics and engineering.

Ratings

Automotive Journalism Reputation:

Consistently praised by automotive journalists for its blend of luxury, performance, and handling, often considered one of the best sedans of its era.