BMW 5 Series E39 Service Repair Manual 1997-2002

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Model Years Covered: 1997-2002 Codes Engine Codes Covered: M52B20, M52B25, M52B28, M54B22, M54B25, M54B30, M62B44, M62B44TU, M62B46, S62B50 👋 Introduction Market Position Segment: Mid-size luxury sedan and wagon. Target Audience: Discerning buyers seeking performance, luxury, and advanced engineering; owners looking for DIY maintenance and repair capabilities. Competitive Analysis Key Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Volvo S80. Key Features Driver Focus: Renowned for its 'Ultimate Driving Machine' ethos, precise handling, and driver-centric cockpit. Luxury Appointments: High-quality interior materials, comfortable ride, advanced (for its era) technology and safety features. Powertrain Options: Wide range of inline-six and V8 engines, including high-performance M models. 📋 Manual Details Coverage Areas Geographical Coverage: Primarily North America, Europe, and international markets for the E39 generation. Trim Level Coverage: All E39 trims including base, Sport, Luxury, M Sport, and specific model variants (e.g., 525i, 530i, 540i, M5). Page Count Estimated Page Count: Hundreds of pages (exact count varies by specific edition, typically 1000+ pages for comprehensive versions). Manual Type Type: Comprehensive Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, block assembly, pistons, rings, crankshaft, camshafts, valve train, timing systems, lubrication system, cooling system, fuel injection, emissions control. Engine Management: Engine Control Unit (ECU) diagnostics, sensor functions (MAP, MAF, O2, Crankshaft, Camshaft), ignition system, emission systems (EVAP, EGR), DME (Digital Motor Electronics) troubleshooting. Transmission Manual: Manual gearbox (Getrag 226/260 variants) removal, disassembly, assembly, clutch system, shifter mechanism. Transmission Automatic: Automatic transmission (GM 5L40-E, ZF 5HP19, ZF 5HP24, ZF 5HP30 variants) overhaul, valve body diagnostics, torque converter, electronic control systems. Drivetrain: Driveshafts, CV joints, differential, rear axle, wheel bearings, ABS wheel speed sensors. Suspension: Front and rear suspension components (struts, shocks, control arms, sway bars, bushings), steering system (rack and pinion, power steering pump, hydraulic lines), wheel alignment specifications. Brakes: Brake system hydraulics, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), DSC sensors, brake fluid specifications, rotor and pad replacement, caliper overhaul, parking brake. Electrical System: 12V battery system, charging system (alternator), starter motor, lighting (headlights, taillights, interior), fuses and relays, wiring diagrams for all circuits. Body And Interior: Body panel removal and installation, door mechanisms, glass replacement, interior trim, seats, dashboard, sunroof, convertible top (if applicable), sound deadening. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant R134a, compressor, condenser, evaporator, climate control module, cabin air filter replacement. Infotainment And Electronics: Radio/navigation system (Business, Professional, MK series navigation), instrument cluster, power windows, central locking, keyless entry, cruise control, onboard computer (OBC). Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, cabin filter replacement, spark plug replacement, coolant flush, brake fluid flush, drive belt inspection and replacement. Diagnostic Troubleshooting: Step-by-step diagnostic procedures for common and uncommon faults, OBD-II (On-Board Diagnostics) code interpretation and clearing, circuit testing. Repair And Rebuild: Detailed instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly for all major vehicle systems. Bodywork And Collision: Panel replacement, bumper repair, dent removal techniques, glass replacement procedures. Electrical Component Replacement: Replacement of starters, alternators, sensors, ECUs, light bulbs, switches, and relays. Special Tool Requirements: Identification and usage instructions for specialized BMW tools required for certain procedures. Technical Depth Depth Of Information: Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, including detailed diagnostic flowcharts and wiring diagrams. Diagnostic Capabilities: Advanced diagnostic procedures, including sensor data analysis, actuator testing, and ECU relearning procedures. Component Identification: Detailed diagrams and exploded views for identifying and locating all parts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text (depending on original source quality). Print Quality Image Resolution: High-resolution images and diagrams for clarity. Layout: Organized into logical sections with clear headings and subheadings, often mirroring factory manual structure. Binding Type Digital Format: N/A (Digital PDF) Paper Type Digital Format: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Variant Examples: 3.0L Inline-6 (M54B30), 4.4L V8 (M62B44TU), 4.9L V8 (S62B50 - M5). Engine Type: Inline 4-stroke gasoline, DOHC, Valvetronic (later models), VANOS (Variable Valve Timing). Performance Horsepower Range: 189 hp (525i) to 414 hp (M5). Torque Range: 206 lb-ft (525i) to 380 lb-ft (M5). Fuel System Fuel Delivery: Multi-point fuel injection (Bosch Motronic ECU). Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended). Emission Controls Catalytic Converter: Standard, two-stage catalytic converters. 🔧 Transmission Standard Transmission Type: 5-speed Manual (Getrag). Optional Transmission Type: 5-speed Automatic (GM Steptronic, ZF Steptronic). Features Steptronic Functionality: Allows manual gear selection via shifter or steering wheel buttons (on select models). Fluid Specifications Automatic Transmission Fluid: ATF LT 71141 (for ZF transmissions), Dexron III/VI (for GM transmissions). Manual Transmission Fluid: SAE 75W-90 API GL-4 or GL-5 gear oil (e.g., BMW P/N 83 22 9 407 771). 📐 Dimensions Exterior Length: Approx. 190.2 inches...

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Sku: 274197

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Tags: 1997 1998 1999 2000 2001 2002 5 Series E39 BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Years Covered:

1997-2002

Codes

Engine Codes Covered:

M52B20, M52B25, M52B28, M54B22, M54B25, M54B30, M62B44, M62B44TU, M62B46, S62B50

👋 Introduction

Market Position

Segment:

Mid-size luxury sedan and wagon.

Target Audience:

Discerning buyers seeking performance, luxury, and advanced engineering; owners looking for DIY maintenance and repair capabilities.

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Volvo S80.

Key Features

Driver Focus:

Renowned for its 'Ultimate Driving Machine' ethos, precise handling, and driver-centric cockpit.

Luxury Appointments:

High-quality interior materials, comfortable ride, advanced (for its era) technology and safety features.

Powertrain Options:

Wide range of inline-six and V8 engines, including high-performance M models.

📋 Manual Details

Coverage Areas

Geographical Coverage:

Primarily North America, Europe, and international markets for the E39 generation.

Trim Level Coverage:

All E39 trims including base, Sport, Luxury, M Sport, and specific model variants (e.g., 525i, 530i, 540i, M5).

Page Count

Estimated Page Count:

Hundreds of pages (exact count varies by specific edition, typically 1000+ pages for comprehensive versions).

Manual Type

Type:

Comprehensive Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block assembly, pistons, rings, crankshaft, camshafts, valve train, timing systems, lubrication system, cooling system, fuel injection, emissions control.

Engine Management:

Engine Control Unit (ECU) diagnostics, sensor functions (MAP, MAF, O2, Crankshaft, Camshaft), ignition system, emission systems (EVAP, EGR), DME (Digital Motor Electronics) troubleshooting.

Transmission Manual:

Manual gearbox (Getrag 226/260 variants) removal, disassembly, assembly, clutch system, shifter mechanism.

Transmission Automatic:

Automatic transmission (GM 5L40-E, ZF 5HP19, ZF 5HP24, ZF 5HP30 variants) overhaul, valve body diagnostics, torque converter, electronic control systems.

Drivetrain:

Driveshafts, CV joints, differential, rear axle, wheel bearings, ABS wheel speed sensors.

Suspension:

Front and rear suspension components (struts, shocks, control arms, sway bars, bushings), steering system (rack and pinion, power steering pump, hydraulic lines), wheel alignment specifications.

Brakes:

Brake system hydraulics, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), DSC sensors, brake fluid specifications, rotor and pad replacement, caliper overhaul, parking brake.

Electrical System:

12V battery system, charging system (alternator), starter motor, lighting (headlights, taillights, interior), fuses and relays, wiring diagrams for all circuits.

Body And Interior:

Body panel removal and installation, door mechanisms, glass replacement, interior trim, seats, dashboard, sunroof, convertible top (if applicable), sound deadening.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant R134a, compressor, condenser, evaporator, climate control module, cabin air filter replacement.

Infotainment And Electronics:

Radio/navigation system (Business, Professional, MK series navigation), instrument cluster, power windows, central locking, keyless entry, cruise control, onboard computer (OBC).

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, cabin filter replacement, spark plug replacement, coolant flush, brake fluid flush, drive belt inspection and replacement.

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon faults, OBD-II (On-Board Diagnostics) code interpretation and clearing, circuit testing.

Repair And Rebuild:

Detailed instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly for all major vehicle systems.

Bodywork And Collision:

Panel replacement, bumper repair, dent removal techniques, glass replacement procedures.

Electrical Component Replacement:

Replacement of starters, alternators, sensors, ECUs, light bulbs, switches, and relays.

Special Tool Requirements:

Identification and usage instructions for specialized BMW tools required for certain procedures.

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, including detailed diagnostic flowcharts and wiring diagrams.

Diagnostic Capabilities:

Advanced diagnostic procedures, including sensor data analysis, actuator testing, and ECU relearning procedures.

Component Identification:

Detailed diagrams and exploded views for identifying and locating all parts.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text (depending on original source quality).

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Layout:

Organized into logical sections with clear headings and subheadings, often mirroring factory manual structure.

Binding Type

Digital Format:

N/A (Digital PDF)

Paper Type

Digital Format:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Variant Examples:

3.0L Inline-6 (M54B30), 4.4L V8 (M62B44TU), 4.9L V8 (S62B50 - M5).

Engine Type:

Inline 4-stroke gasoline, DOHC, Valvetronic (later models), VANOS (Variable Valve Timing).

Performance

Horsepower Range:

189 hp (525i) to 414 hp (M5).

Torque Range:

206 lb-ft (525i) to 380 lb-ft (M5).

Fuel System

Fuel Delivery:

Multi-point fuel injection (Bosch Motronic ECU).

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended).

Emission Controls

Catalytic Converter:

Standard, two-stage catalytic converters.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual (Getrag).

Optional

Transmission Type:

5-speed Automatic (GM Steptronic, ZF Steptronic).

Features

Steptronic Functionality:

Allows manual gear selection via shifter or steering wheel buttons (on select models).

Fluid Specifications

Automatic Transmission Fluid:

ATF LT 71141 (for ZF transmissions), Dexron III/VI (for GM transmissions).

Manual Transmission Fluid:

SAE 75W-90 API GL-4 or GL-5 gear oil (e.g., BMW P/N 83 22 9 407 771).

📐 Dimensions

Exterior

Length:

Approx. 190.2 inches (4831 mm).

Width:

Approx. 71.5 inches (1816 mm).

Height:

Approx. 57.0 inches (1448 mm).

Wheelbase:

Approx. 111.4 inches (2830 mm).

Interior

Front Headroom:

Approx. 38.5 inches (978 mm).

Rear Legroom:

Approx. 37.2 inches (945 mm).

Cargo

Trunk Volume:

Approx. 15.1 cu ft (428 L).

Weights

Curb Weight:

Approx. 3500-4000 lbs (1588-1814 kg) depending on engine and trim.

🛡️ Safety Features

Ratings

NHTSA Crash Test Ratings:

Generally Good ratings in frontal and side impacts for its era (specific ratings may vary by year/testing methodology).

Active Features

Active Safety Systems:

ABS, DSC (Dynamic Stability Control), ASC+T (Automatic Stability Control + Traction).

Passive Features

Passive Safety Features:

Front and side airbags, front seatbelt pre-tensioners, crumple zones, reinforced safety cell.

Lighting

Headlight Technology:

Halogen standard, Xenon HID optional (with auto-leveling).

💡 Technology Features

Infotainment

Navigation System:

BMW Professional Navigation system with CD-ROM based maps (MK-IV navigation computer).

Audio System:

BMW Business CD, BMW Professional CD, optional Harman Kardon sound system.

Driver Assistance

Cruise Control:

Standard cruise control, active cruise control (ACC) available on select models.

Parking Assistance:

Optional rear parking sensors (Park Distance Control - PDC).

Connectivity

Telephony:

Optional integrated Bluetooth or cellular phone preparation.

Comfort Features

Climate Control:

Automatic dual-zone climate control with cabin air filtration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-15,000 miles (12,000-24,000 km) or annually, as indicated by the Condition Based Service (CBS) system or manufacturer recommendation.

Spark Plug Replacement:

Every 60,000 miles (100,000 km) for standard plugs; 100,000 miles (160,000 km) for long-life iridium plugs.

Coolant Flush:

Every 2-4 years or 30,000-50,000 miles (48,000-80,000 km).

Fluid Specifications

Engine Oil Specification:

BMW Longlife-01 (LL-01) or LL-04 approved synthetic oil, typically 5W-30 or 5W-40 depending on engine and climate. Check manual for precise grade.

Coolant Specification:

BMW Blue Antifreeze/Coolant (G48 or equivalent ethylene glycol based with silicate inhibitors) mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 4 Low Viscosity (LV) or DOT 4 Plus (BMW P/N 81 22 9 407 688 or equivalent).

Known Issues

Cooling System:

Plastic coolant expansion tank failure (cracking), thermostat housing leaks, water pump failure.

Suspension And Steering:

Front control arm bushings (bushings or complete arms), tie rod ends, subframe bushings, power steering hose leaks.

Electrical System:

ABS/DSC module failure, window regulator failure, VANOS solenoid issues, ignition coil failure, alternator failure.

Engine Specific Issues:

M54 CCV (Crankcase Ventilation) system clogging, oil pan gasket leaks, valve cover gasket leaks, M62TU timing chain tensioner guides wear.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Emphasis on engineering excellence, driving dynamics, and premium quality.

Model Evolution

E39 Generation:

Introduced in 1995 (as 1996 model in Europe), replaced the E34. Known for significant improvements in chassis dynamics, technology, and refinement.

Mid-Cycle Refresh:

Facelift introduced in 2000 (for 2001 model year) featured revised front and rear styling (headlights, taillights, kidney grille), updated interior trim, and new engine options (M54 series).

Production

Production Years:

1995-2003 (Sedan), 1996-2004 (Touring/Wagon).

Manufacturing Locations:

Germany (Dingolfing), Austria, Thailand, Russia, Egypt, Indonesia, South Africa, and India.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Consistently recognized by Car and Driver magazine as one of the '10Best' cars multiple times during its production run for its blend of performance, luxury, and value.

Ratings

Automotive Journalism Accolades:

Praised by automotive critics for its sophisticated chassis, responsive engines, and comfortable ride, solidifying its position as a benchmark in the luxury sedan segment.