Market Positioning:
The E39 generation BMW 5 Series (1997-2002) represented the pinnacle of executive luxury and driving dynamics for its era, targeting discerning buyers who valued performance, comfort, and advanced engineering. This manual serves DIY enthusiasts and professional mechanics alike looking to maintain or repair these sophisticated vehicles.
Competitive Analogs:
Competed directly with vehicles like the Mercedes-Benz E-Class (W210), Audi A6 (C5), and Lexus GS. The E39 was praised for its superior handling and driver engagement compared to many rivals.
Manual Key Features:
Instant download in PDF format, PC & Mac compatible, detailed step-by-step instructions, exploded views, diagrams, illustrations, and comprehensive specifications for all covered models and years.
Coverage Area Summary:
Comprehensive coverage for all BMW E39 5 Series models from 1997-2002, including 525i, 528i, 530i, and 540i variants.
Page Count Estimate:
Extensive, likely exceeding 2000 pages based on typical workshop manual depth for this era and range of models.
Manual Type:
Workshop Service Repair Manual
Format:
PDF (Portable Document Format)
File Delivery:
Instant digital download, providing immediate access to repair information.
Systems Covered List:
Engine (all variants), Transmission (automatic and manual), Drivetrain, Suspension, Steering, Brakes, Fuel System, Cooling System, Exhaust System, Electrical System (including complex wiring diagrams), Bodywork, Interior Trim, HVAC, SRS (Airbag) System, ABS/ASC System, On-Board Diagnostics (OBD).
Chassis Systems Covered:
Complete coverage of suspension components (struts, shocks, control arms, bushings), steering rack and pump, wheel bearings, and brake systems (pads, rotors, calipers, ABS module, hydraulic lines).
Engine Management Systems:
Detailed coverage of DME (Digital Motor Electronics) and EGS (Electronic Gearbox Control) modules, including sensor inputs, outputs, and operating parameters.
Procedures Included List:
Routine maintenance (oil changes, filter replacements, inspections), Component removal and installation, Engine overhaul, Transmission servicing and repair, Brake system diagnostics and repair, Suspension component replacement, Steering system service, Electrical troubleshooting, HVAC system repair, Body panel repair and adjustment, Diagnostic procedures, Tune-up specifications, Wheel alignment data, Torque specifications for all fasteners.
Bodywork Procedures:
Repair and replacement of body panels, door mechanisms, window systems, lighting, bumpers, and interior trim components. Includes information on corrosion protection and seam sealing.
Troubleshooting Guides:
Extensive troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs), and electrical schematic tracing.
Technical Depth:
In-depth technical information covering everything from basic maintenance to complex diagnostic procedures and complete engine/transmission rebuilds. Includes detailed exploded views, diagrams, and step-by-step instructions for accuracy.
Diagnostic Procedures:
Detailed procedures for using OBD-II scanners and BMW's proprietary diagnostic tools (like DIS or GT1), including reading fault codes, live data stream analysis, and component activation tests.
Wiring Diagrams:
Comprehensive and detailed wiring diagrams for all electrical systems, essential for diagnosing electrical faults.
File Format Details:
Digital PDF file, compatible with PC and Mac operating systems (Windows 95/98/2000/NT/XP/Vista/7/8 and macOS). Searchable text for quick information retrieval.
Searchability:
Yes, the PDF format allows for full-text searching to quickly locate specific procedures or information.
Print Quality Description:
High-resolution digital format suitable for printing individual pages or the entire manual. Clear illustrations and diagrams.
Binding Type:
N/A (Digital Download - no physical binding)
Paper Type:
N/A (Digital Download - no physical paper)
Engine Options:
BMW M52/M54 inline-six engines (2.5L, 2.8L, 3.0L displacement) and M62 V8 engine (4.4L displacement).
525I Performance Typical:
Approx. 189 hp @ 5900 rpm, 181 lb-ft torque @ 3950 rpm (for 2.5L M54B25).
530I Performance Typical:
Approx. 225 hp @ 5900 rpm, 214 lb-ft torque @ 3500 rpm (for 3.0L M54B30).
540I Performance Typical:
Approx. 282 hp @ 5400 rpm, 324 lb-ft torque @ 3600 rpm (for 4.4L M62TU V8).
528I Performance Typical:
Approx. 193 hp @ 5300 rpm, 206 lb-ft torque @ 3950 rpm (for 2.8L M52B28).
Fuel System Type:
Electronic Fuel Injection (EFI) with Bosch Motronic engine management (specific version varies by engine and year).
Ignition System:
Distributorless ignition system (DIS) with coil-on-plug for inline-6, or coil-on-plug for V8 engines.
Standard Transmission Type:
5-speed manual transmission (Getrag 260/6 for some early models, later ZF models).
Optional Transmission Type:
5-speed Steptronic automatic transmission (GM 5L40-E for inline-6, ZF 5HP24 for V8).
Transmission Features:
Steptronic feature allows manual gear selection. Rear-wheel drive standard, xDrive (all-wheel drive) available on some later models (though not explicitly covered by all E39 manuals, this manual likely focuses on RWD).
Exterior Dimensions Typical Sedan:
Length: ~188.0 inches, Width: ~71.0 inches, Height: ~57.0 inches.
Interior Dimensions Typical Passenger Volume:
Around 100 cubic feet, offering ample space for five occupants.
Cargo Dimensions Typical Trunk Volume:
Approximately 15-16 cubic feet, depending on sedan or touring variant.
Curb Weight Typical Range:
Approximately 3500-4000 lbs, depending on engine and equipment.
Safety Ratings Typical:
Generally good safety ratings for its time, with front and side airbags, ABS, and traction control.
Active Safety Features:
Anti-lock Braking System (ABS), Automatic Stability Control (ASC) or Automatic Stability Control + Traction (ASC+T), Dynamic Stability Control (DSC) available on later models.
Passive Safety Features:
Front airbags, front side-impact airbags, front and rear head protection system (HPS) airbags (on some models), crumple zones, reinforced safety cage.
Infotainment Systems:
BMW Business or Professional CD radios, optional navigation systems (MKIII or MKIV), cassette player, integrated phone systems (early cellular technology).
Driver Assistance Features:
Cruise control, parking sensors (Park Distance Control - PDC), rain-sensing wipers (on some models), automatic climate control, self-leveling headlights (on some models).
Connectivity Options:
Early telematics systems, optional CD changer integration, potential for aftermarket Bluetooth or aux input installations.
Typical Oil Change Interval:
Variable Service Interval (VSI) system based on driving conditions, typically around 7,500-15,000 miles or 12-24 months. Manual specifies checking oil level regularly between changes.
Brake Fluid Flush Interval:
Every 2 years (regardless of mileage) to maintain optimal braking performance and prevent corrosion.
Engine Oil Specification:
BMW Longlife-01 (LL-01) or LL-04 approved synthetic oil, typically SAE 0W-40 or 5W-30 depending on climate and specific engine. (Refer to manual for precise recommendation).
Coolant Specification:
BMW Blue Antifreeze/Coolant (G48 formulation), typically a 50/50 mix with distilled water.
Transmission Fluid Automatic Spec:
Dexron III or equivalent for GM 5L40-E; ATF LT 71141 or equivalent for ZF 5HP24. (Crucial to use the correct fluid; manual specifies exact type).
Brake Fluid Specification:
DOT 4 High Performance Brake Fluid.
Power Steering Fluid Specification:
Pentosin CHF 11S or BMW Power Steering Fluid (specifically for hydraulic systems with active steering components).
Common E39 Issues List:
Cooling system failures (plastic components like expansion tank and radiator), VANOS seal wear, oil separator (CCV) failure leading to oil leaks and rough running, oil pan gasket leaks, ABS/ASC sensor issues, window regulator failures, front suspension bushings wear, fuel pump failures, pixilation on the LCD instrument cluster display.
Brand Heritage Context:
BMW's heritage is rooted in aircraft engine manufacturing, transitioning to motorcycles and then automobiles. Known for producing 'The Ultimate Driving Machine' with a focus on performance, engineering, and driver engagement.
E39 Generation Evolution:
The E39 generation (1995-2003) replaced the E34 and was succeeded by the E60. It introduced significant advancements in chassis design, electronics, and engine technology, featuring a more aerodynamic and refined body style.
Production Years:
1995-2003 globally, with the models covered by this manual specifically from 1997-2002.
Manufacturing Locations:
Primarily Germany (Dingolfing plant), with some assembly also occurring in other BMW facilities worldwide.
