Applicable Variants:
520i, 523i, 525i, 535i, 540i, 520d, 525d, 530d
Generation:
Fourth Generation (E39)
Generation Production Years:
1995-2004 (sedan), 1997-2004 (touring)
Market Segment:
Executive sedan, luxury sports sedan
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type
Bmw E39 Strengths:
Driving dynamics, build quality, sophisticated engineering, potent engine options, premium interior
Manual Benefit:
Enables owners to perform maintenance and repairs themselves, saving significant costs compared to dealership services and providing a deeper understanding of vehicle systems.
Engine Systems:
Engine mechanical, cooling, lubrication, fuel injection, ignition, exhaust, emissions
Transmission Systems:
Manual transmission, automatic transmission (including Steptronic), clutch, driveshafts, differential
Braking Systems:
Hydraulic system, ABS, DSC, brake pads, rotors, lines, parking brake
Suspension Steering:
Front suspension, rear suspension, steering rack, power steering, wheel alignment
Electrical Systems:
Battery, charging system, starter, lighting, ignition, body electronics (EWS, LCM, GM, DME), instrument cluster, SRS (airbags)
Climate Control:
HVAC system, A/C compressor, heater core, blower motor, climate control unit
Body And Interior:
Body panels, doors, windows, locks, seats, trim, sunroof, convertible top (if applicable)
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement
Diagnostic Troubleshooting:
Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Electrical Repairs:
Wiring diagrams, component testing, circuit diagnosis
Engine Repairs:
Head gasket replacement, timing chain service, piston and ring replacement, valve adjustments
Transmission Repairs:
Clutch replacement, automatic transmission service, torque converter replacement
Technical Depth:
Comprehensive (suitable for professional technicians and advanced DIYers)
File Format Details:
Searchable PDF, allows for easy printing of specific sections or the entire document
Print Quality Recommendation:
High-resolution graphics and clear text for easy reproduction
Binding Type If Printed:
Coil-bound or comb-bound recommended for lay-flat usability in a workshop environment
Paper Type Recommendation:
Durable paper stock, preferably laminated for key pages exposed to grease and fluids
Engine Options 2002:
M54B22 (2.2L I6), M54B25 (2.5L I6), M54B30 (3.0L I6), M62B35TU (3.5L V8), M62B44TU (4.4L V8), M57D25 (2.5L I6 Diesel), M57D30 (3.0L I6 Diesel)
540I Engine Power:
Approx. 290 hp @ 5400 rpm (M62B44TU)
540I Engine Torque:
Approx. 324 lb-ft @ 3600 rpm (M62B44TU)
525I Engine Power:
Approx. 184 hp @ 6000 rpm (M54B25)
530D Engine Power:
Approx. 193 hp @ 4000 rpm (M57D30)
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic ME 7.2 for gasoline, EDC15 for diesel)
Fuel Type:
Premium Unleaded Gasoline (91+ octane), Diesel for diesel models
Standard Transmission Gasoline:
5-speed Manual (Getrag 420G on higher output models, ZF S5-31J on lower output models)
Standard Transmission Diesel:
5-speed Manual
Optional Transmission Gasoline:
5-speed Steptronic Automatic (GM A5S360R/A5S325Z/GA6HP26Z depending on engine)
Optional Transmission Diesel:
5-speed Automatic
Transmission Features:
Steptronic manual shifting mode on automatic transmissions, limited-slip differential available on some performance models.
Wheelbase:
Approx. 115.4 inches (2930 mm)
Length:
Approx. 191.1 inches (4855 mm)
Width:
Approx. 71.5 inches (1816 mm)
Height:
Approx. 57.0 inches (1448 mm)
Curb Weight 520I:
Approx. 3400-3500 lbs (1540-1590 kg)
Curb Weight 540I:
Approx. 3800-3950 lbs (1725-1790 kg)
Gross Vehicle Weight Rating Gvwr:
Varies by model, typically 4600-5000 lbs
NHTSA Frontal Crash Rating:
5-star (for models tested)
Active Safety Systems:
Anti-lock Braking System (ABS), Dynamic Stability Control (DSC), Traction Control (ASC+T)
Passive Safety Features:
Front airbags, side-impact airbags, front and rear head protection system (HPS), front seatbelt pretensioners
Chassis Safety Design:
Reinforced passenger cell, crumple zones
Infotainment System:
BMW Professional Radio, optional Business CD, optional Navigation system (CCC or M-ASK).
Features Available:
CD player, cassette player, optional TV tuner, optional 6-disc CD changer, Bluetooth integration (via aftermarket or specific modules).
Driver Assistance Features:
Park Distance Control (PDC), Cruise Control, Rain-sensing wipers, Auto-dimming rearview mirror.
Connectivity Options:
BMW Assist telematics system (subscription-based, likely defunct for 2002 models), pre-wiring for mobile phones.
Oil Change Interval:
Typically 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil quality (via Condition Based Service - CBS system).
Brake Fluid Flush Interval:
Every 2 years
Coolant Flush Interval:
BMW Long-Life Coolant typically lasts 3-5 years or 50,000-75,000 miles; consult manual for specific type.
Engine Oil Specification:
SAE 0W-40 or 5W-30 Synthetic, meeting BMW Longlife-01 (LL-01) specification for gasoline engines; consult manual for diesel specifications (e.g., LL-04).
Transmission Fluid Automatic:
Dexron III/VI or equivalent for GM transmissions; ATF LT-2 or equivalent for ZF transmissions. Lifelong fluid is often claimed, but a change is recommended around 100,000 miles.
Power Steering Fluid:
Pentosin CHF 11S or ZF Lenkgetriebeflüssigkeit (LSK)
Common E39 Issues Gasoline:
VANOS seal wear, coolant expansion tank cracking, water pump failure, PCV system issues (vacuum leaks), oil pan gasket leaks, ABS/DSC sensor failures, ignition coil failure, starter motor issues, window regulator failure.
Common E39 Issues Diesel:
Glow plug issues, injector seal leaks, turbocharger problems, EGR valve clogging, DPF issues (if equipped with early DPF).
Air Filter Part Number Example:
Mann-Filter C 25 217 / 1 (for M54 engines)
Cabin Air Filter Part Number Example:
Mann-Filter CU 25 001 (Activated Carbon)
Bmw Philosophy:
Ultimate Driving Machine, focus on performance, luxury, and engineering excellence.
E39 Development Focus:
Designed to be the most advanced and dynamically capable 5 Series to date, with significant improvements in chassis stiffness, aerodynamics, and technology over the E34.
E39 Production Locations:
Dingolfing, Germany; Rosslyn, South Africa; Magna Steyr, Austria
E39 Total Production:
Approx. 1.5 million units worldwide
