BMW 5 Series Service Repair Manual 1997-2003

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Codes Chassis Codes: E39 Generation Generation Identifier: Fourth Generation (E39) Model Years Covered By Manual: 1997, 1998, 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Vehicle Segment: Executive/Luxury Sedan and Wagon Target Audience: Professionals, families, enthusiasts valuing performance, luxury, and advanced engineering Competitive Analysis Primary Competitors: Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type Key Features Bmw Philosophy: 'Ultimate Driving Machine' focus on dynamic handling, driver engagement, and refined powertrains E39 Strengths: Excellent chassis dynamics, powerful inline-six and V8 engines, high-quality interior, robust construction Manual Value Proposition: Empowers owners and technicians with the detailed knowledge required to maintain and repair the sophisticated E39 platform 📋 Manual Details Coverage Areas Regions Covered: Global (primarily North America and Europe, with adaptable specifications) Page Count Estimated Page Count: 1500+ Manual Type Type: Comprehensive Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing components, valve train Engine Management: Fuel injection (DME/EDC), ignition system, emissions control (VANOS, catalytic converters), ECU diagnostics, sensor and actuator testing Transmission Manual: Clutch, gearbox internal components, shifting mechanisms, removal and installation Transmission Automatic: Torque converter, valve body, planetary gear sets, hydraulic systems, electronic control, removal and installation Drivetrain: Driveshafts, universal joints, differential, axle shafts, wheel bearings Suspension: Front and rear suspension components (struts, shocks, control arms, bushings, springs), alignment specifications Steering: Power steering system, steering rack, tie rods, steering column, troubleshooting Brakes Hydraulic: Brake system components (master cylinder, calipers, wheel cylinders, brake lines), bleeding procedures Brakes ABS Dsc: ABS/DSC control module, wheel speed sensors, hydraulic modulator, diagnostic procedures Electrical Power: Battery, alternator, starter motor, charging system troubleshooting Electrical Lighting: Headlights, taillights, interior lights, fog lights, bulb replacement, wiring diagrams Electrical Accessories:...

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Sku: 583800

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Tags: 5 Series BMW

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Codes

Chassis Codes:

Generation

Generation Identifier:

Fourth Generation (E39)

Model Years Covered By Manual:

1997, 1998, 1999, 2000, 2001, 2002, 2003

👋 Introduction

Market Position

Vehicle Segment:

Executive/Luxury Sedan and Wagon

Target Audience:

Professionals, families, enthusiasts valuing performance, luxury, and advanced engineering

Competitive Analysis

Primary Competitors:

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

Key Features

Bmw Philosophy:

'Ultimate Driving Machine' focus on dynamic handling, driver engagement, and refined powertrains

E39 Strengths:

Excellent chassis dynamics, powerful inline-six and V8 engines, high-quality interior, robust construction

Manual Value Proposition:

Empowers owners and technicians with the detailed knowledge required to maintain and repair the sophisticated E39 platform

📋 Manual Details

Coverage Areas

Regions Covered:

Global (primarily North America and Europe, with adaptable specifications)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Comprehensive Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing components, valve train

Engine Management:

Fuel injection (DME/EDC), ignition system, emissions control (VANOS, catalytic converters), ECU diagnostics, sensor and actuator testing

Transmission Manual:

Clutch, gearbox internal components, shifting mechanisms, removal and installation

Transmission Automatic:

Torque converter, valve body, planetary gear sets, hydraulic systems, electronic control, removal and installation

Drivetrain:

Driveshafts, universal joints, differential, axle shafts, wheel bearings

Suspension:

Front and rear suspension components (struts, shocks, control arms, bushings, springs), alignment specifications

Steering:

Power steering system, steering rack, tie rods, steering column, troubleshooting

Brakes Hydraulic:

Brake system components (master cylinder, calipers, wheel cylinders, brake lines), bleeding procedures

Brakes ABS Dsc:

ABS/DSC control module, wheel speed sensors, hydraulic modulator, diagnostic procedures

Electrical Power:

Battery, alternator, starter motor, charging system troubleshooting

Electrical Lighting:

Headlights, taillights, interior lights, fog lights, bulb replacement, wiring diagrams

Electrical Accessories:

Power windows, door locks, mirrors, sunroof, wipers, horn, seat adjustment

Body Exterior:

Body panels, doors, hood, trunk, bumpers, glass replacement, seals

Body Interior:

Dashboard, upholstery, trim panels, headliner, carpet replacement

Climate Control:

HVAC system, blower motor, evaporator, condenser, refrigerant handling, heater core

Safety Restraint:

Airbag system, seatbelts, SRS module diagnostics

Infotainment:

Radio, CD player, navigation system (CCC/M-ASK), speaker replacement

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting guides, electrical symptom analysis

Procedures Included

Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, transmission fluid service, differential fluid change

Repair:

Component replacement (alternator, starter, water pump, fuel pump, mass air flow sensor), radiator replacement, exhaust system repair, suspension component replacement, brake pad/rotor replacement, CV axle replacement, door lock actuator replacement

Diagnostics:

OBD-II scanning and interpretation, live data analysis, component testing with multimeter, electrical circuit tracing, vacuum leak testing, fuel pressure testing

Rebuilds:

Engine rebuild procedures (complete disassembly, inspection, reassembly), transmission rebuild procedures (automatic and manual)

Installation:

Accessory installation (e.g., trailer hitch), aftermarket part installation guidance, component installation

Technical Depth

Depth Level:

Expert/Professional Level (suitable for DIY enthusiasts and professional technicians)

Diagnostic Tools Required:

Basic hand tools, torque wrench, multimeter, OBD-II scanner (BMW specific recommended), pressure gauges, diagnostic software (e.g., ISTA/D - not included in manual)

Wiring Diagrams Coverage:

Detailed, system-specific wiring diagrams for all major electrical systems

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Searchability:

Full text search enabled for quick information retrieval

Print Quality

Resolution:

High-resolution images and diagrams suitable for printing

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Common Engines Covered:

M52/M54 Inline-6 (2.5L, 2.8L, 3.0L), S62 V8 (4.9L M5)

Engine Code Example I6:

M54B30 (3.0L)

Engine Code Example V8:

S62B50 (4.9L M5)

Performance

I6 Horsepower Range:

189 hp to 228 hp

I6 Torque Range:

232 Nm to 300 Nm

V8 Horsepower M5:

394 hp @ 6600 rpm

V8 Torque M5:

500 Nm @ 3800 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) with Bosch Motronic or Siemens DME engine management

Fuel Type:

Premium Unleaded Gasoline (91 RON or higher)

Engine Internals

Valvetrain:

Dual Overhead Camshafts (DOHC), 4 valves per cylinder, Double VANOS (Variable Valve Timing)

🔧 Transmission

Standard

Standard Transmission I6:

5-speed Manual (Getrag 260/6)

Standard Transmission V8 M5:

6-speed Manual (Getrag 420G)

Optional

Optional Transmission I6:

5-speed Automatic (GM A5S360R/A5S390R or ZF 5HP19)

Optional Transmission V8:

5-speed Automatic (ZF 5HP30) for 540i

Features

Transmission Fluid Spec Auto:

Dexron III/VI or equivalent (BMW P/N 83 22 0 024 249 or 83 22 0 026 973)

Transmission Fluid Spec Manual:

SAE 75W-90 Synthetic Gear Oil (BMW P/N 83 22 0 309 031 or equivalent)

Clutch Type:

Dry single-plate (manual transmission)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2830 mm (111.4 in)

Length:

Approx. 4767 mm (187.7 in)

Width:

Approx. 1798 mm (70.8 in)

Height:

Approx. 1435 mm (56.5 in)

Cargo

Trunk Capacity:

Approx. 460 liters (16.2 cu ft)

Weights

Curb Weight Range:

Approx. 1570 kg (3461 lbs) to 1780 kg (3924 lbs)

Gvw Range:

Approx. 2070 kg (4564 lbs) to 2250 kg (4960 lbs)

Tires Wheels

Wheel Bolt Pattern:

5x120 mm

Common Tire Sizes:

205/65R15, 225/55R16, 235/45R17, 235/40R18 (M5)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

4/5 Stars (Driver/Passenger)

IIHS Side Impact:

Acceptable

Active Features

Stability Control:

Dynamic Stability Control (DSC) standard on most models

Traction Control:

Automatic Stability Control and Traction (ASC+T) or Dynamic Traction Control (DTC)

Anti-lock Braking System (ABS) standard

Passive Features

Airbags:

Frontal airbags, side-impact airbags, optional head protection airbags

Seatbelts:

3-point inertia-reel seatbelts with pre-tensioners

Chassis Safety:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Nav System Options:

Optional M-ASK (Monochrome Advanced Car Information System) or CCC (Car Communication Computer) Navigation systems.

Audio Systems:

Various BMW Professional CD/Radio systems, Harman Kardon premium audio option.

Driver Assistance

Cruise Control:

Standard cruise control, optional Active Cruise Control (ACC) on some models.

Parking Assistance:

Optional Park Distance Control (PDC) front and rear.

Connectivity

Bluetooth Integration:

Optional Bluetooth mobile phone preparation available on later models.

Telematics:

Optional Tele Aid emergency call system (precursor to ConnectedDrive).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable Service Interval Indicator (VSI) system, typically 7,500-15,000 miles (12,000-24,000 km) based on driving conditions. Recommended maximum of 1 year.

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as indicated by VSI.

Spark Plug Replacement I6:

NGK BKR6EQUP platinum plugs: 100,000 miles (160,000 km)

Coolant Flush:

Every 2-3 years or 30,000 miles (48,000 km)

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil Spec:

SAE 5W-30 Synthetic (BMW LL-01 approved or equivalent) - e.g., Castrol Syntec 5W-30

Engine Oil Capacity I6:

Approx. 6.5 liters (6.9 US quarts)

Engine Oil Capacity V8:

Approx. 7.5 liters (7.9 US quarts)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based), 50/50 mix with distilled water

Known Issues

Common E39 Issues Cooling:

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

Common E39 Issues Vanos:

VANOS (Variable Valve Timing) solenoids and seals can degrade, leading to rough idle or loss of power.

Common E39 Issues Suspension:

Front lower control arm bushings (lollipops) wear out, leading to steering looseness. Rear subframe bushings can also fail.

Common E39 Issues Electrical:

CCM (Check Control Module) issues, pixelated instrument cluster displays, ABS/DSC sensor failures, alternator regulator failure.

Common E39 Issues Oil Leaks:

Valve cover gasket leaks, oil pan gasket leaks, oil filter housing gasket leaks.

Common E39 Issues Oil Pan Drain Plug:

Stripped oil pan drain plug threads are a common, albeit avoidable, issue.

📚 Vehicle History

Brand Heritage

Bmw Motorsport:

BMW's legacy in performance engineering and motorsport influences the 5 Series, especially the M5 variants.

Model Evolution

E39 Introduction:

Introduced in 1995 (Europe) and 1996 (North America), replacing the E34 generation.

E39 Facelift:

Significant facelift in 2000 introduced updated styling, M54 engines, and improved features.

E39 Variants:

Available as sedan (E39) and wagon (E39 Touring), with specific models like 525i, 530i, 540i, and the high-performance M5.

Production

Production Years:

1995-2003

Manufacturing Locations:

Dingolfing, Germany and various assembly plants worldwide.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

BMW 5 Series consistently received Car and Driver's 10Best awards in numerous years during this generation.

Ward Auto 10 Best Engines:

BMW's inline-6 engines (M52/M54) were frequently recognized in Ward's 10 Best Engines lists.

Ratings

Consumer Reports Reliability:

Generally rated good to excellent for reliability in its class, though specific common issues are noted.

Certifications

Emisiones Compliance:

Met EPA and CARB emissions standards for its respective model years.