Target Audience:
Professional automotive technicians, experienced DIYers, and BMW enthusiasts seeking to perform maintenance, diagnostics, and repairs on their E39 5 Series.
Value Proposition:
Provides factory-level technical data and procedures, essential for accurate and effective repairs, saving on dealership service costs.
Detail Level:
Offers unparalleled detail on specific E39 models, including variations in engine and drivetrain options.
Diagnostic Focus:
Emphasis on understanding BMW's electronic control units and diagnostic protocols of the era.
Engine:
Complete engine mechanical and electrical diagnostics, overhaul, and repair for inline-6 (M52, M54) and V8 (M62, S62) engines. Includes timing chain, VANOS, cooling system, lubrication, fuel injection, ignition, and emissions.
Transmission:
Manual and Automatic Transmission (GM 5L40-E, ZF 5HP19, ZF 5HP24, ZF S5-31) repair, overhaul, fluid specifications, and electronic control diagnostics.
Drivetrain:
Driveshaft, differential, axles, and wheel bearings, including lubrication and repair procedures.
Suspension:
Front and rear suspension components, steering system (rack and pinion), wheel alignment specifications, and component replacement.
Brakes:
Hydraulic brake system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake rotor/pad replacement, fluid specifications, bleeding procedures, and component diagnostics.
Electrical:
Complete wiring diagrams, fuse box locations, diagnostic trouble codes (DTCs), DME (Digital Motor Electronics), EWS (Electronic Immobilizer System), body control modules (BCM), lighting, instrument cluster, climate control, SRS (Supplemental Restraint System), and audio systems.
Bodywork:
Body panel removal and installation, door mechanisms, window regulators, sunroof, bumpers, and cosmetic trim. Includes chassis and frame repair overview.
HVAC:
Climate control system diagnosis, repair, refrigerant handling, blower motor, evaporator, condenser, and heater core replacement.
Maintenance:
Scheduled maintenance tasks, oil and filter changes, spark plug replacement, air filter replacement, cabin filter replacement, brake fluid flush, coolant replacement, transmission fluid service.
Troubleshooting:
Systematic diagnostic procedures for common drivability issues, electrical faults, and mechanical problems. Includes symptom-based troubleshooting charts.
Repair:
Detailed step-by-step repair instructions for virtually all components and systems, from minor adjustments to complete component overhauls.
Installation:
Procedures for installing replacement parts and aftermarket accessories where applicable.
Diagnostics:
Extensive diagnostic procedures, including use of BMW-specific diagnostic tools (e.g., DISplus, ISTA/D - though this manual predates ISTA/D, it covers the foundational systems). Includes sensor data interpretation and fault code analysis.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including in-depth electrical system troubleshooting and module diagnostics.
Print Quality:
High-resolution print suitable for professional mechanics and DIY enthusiasts. Clear diagrams and illustrations.
Paper Type:
Durable, high-quality paper stock designed for shop environments. Often bound with protective covers.
Binding Type:
Professional binding (e.g., perfect binding, spiral binding) allowing for easy page turning and lay-flat viewing.
Digital Format Availability:
Often available as PDF, but this product listing specifies 'Print'.
Specific Models Covered:
Covers all E39 sedan (4-door) and touring (wagon) models produced between 1997 and 2002, including 525i, 528i, 530i, 540i, and M5 variants.
Engine Variants:
2.5L Inline-6 (M52TU, M54B25), 2.8L Inline-6 (M52TU), 3.0L Inline-6 (M54B30), 4.4L V8 (M62), 4.0L V8 (M62), 4.9L V8 (S62 - M5)
Horsepower Range:
Approx. 170 hp (2.5L) to 400 hp (M5)
Torque Range:
Approx. 180 lb-ft (2.5L) to 368 lb-ft (M5)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch Motronic or Siemens DME control.
ECU Types:
MS41, MS42, MS43 (inline-6), ME7.2 (V8)
Standard Transmission:
5-Speed Manual (Getrag S5D 250G, ZF S5-31)
Optional Transmission:
5-Speed Automatic (GM 5L40-E, ZF 5HP19, ZF 5HP24)
Automatic Features:
Steptronic (manual shifting mode on select automatics)
Manual Fluid:
GL-4 or GL-5 gear oil, specific viscosity recommended by BMW (e.g., 75W-90).
Automatic Fluid Gm:
Dexron III or equivalent
Automatic Fluid Zf:
ZF Lifeguardfluid 5 (or equivalent ATF with specific specifications)
NHTSA Ratings:
Generally performed well in crash tests for its era. Specific ratings may vary by year and test protocol.
Active Safety:
ABS, ASC+T (Automatic Stability Control and Traction), DSC (Dynamic Stability Control) on later models.
Passive Safety:
Front airbags, side-impact airbags, available head-protection system (HPS), three-point seatbelts with pre-tensioners.
Chassis Construction:
Reinforced chassis and safety cell construction.
Infotainment System:
BMW Professional Radio, optional CD player, optional navigation system (MK II, MK III), optional TV tuner, optional DSP (Digital Sound Processing) audio.
Driver Assistance Features:
Cruise control, Park Distance Control (PDC) on later models.
Connectivity Features:
Optional CD changer, optional cellular phone integration (e.g., BMW Assist).
Climate Control Type:
Manual or fully automatic dual-zone climate control.
Oil Change Interval:
Typically 7,500 - 15,000 miles or 12-24 months, depending on driving conditions and oil type (BMW Condition Based Service system can vary this).
Major Service Intervals:
Spark plugs usually around 100,000 miles. Coolant typically every 2-4 years. Drive belts and tensioners inspected regularly and replaced as needed.
Engine Oil Spec:
BMW Longlife-01 (LL-01) or LL-04 approved synthetic oil, typically 0W-40 or 5W-40/5W-30 depending on climate and engine. Manual specifies exact grades.
Coolant Spec:
BMW Blue Antifreeze/Coolant (G48) mixed 50/50 with distilled water.
Brake Fluid Spec:
DOT 4 (BMW recommends DOT 4+ or equivalent).
Power Steering Fluid:
Pentosin CHF 11S or equivalent hydraulic fluid.
Common E39 Issues:
Coolant expansion tank cracking, oil filter housing gasket leaks, VANOS solenoid failure, ignition coil failure, rear subframe mounts, window regulator failures, blower motor resistor failure, ABS/DSC sensor issues, headlight condensation, PIE (Plastic Intake Manifold) cracking (on some M54 engines).
Bmw Legacy:
BMW has a long-standing reputation for performance, luxury, and engineering excellence in the premium automotive segment.
E39 Introduction:
The E39 generation of the 5 Series was introduced in 1995 (Europe) and 1996 (North America), replacing the E34. It was produced until 2003.
E39 Facelift:
Received a significant facelift in 2000, introducing updated engines (M54 series), revised styling (headlights, taillights, bumpers), and new technology features.
Production Period:
1995/1996 – 2003
Manufacturing Locations:
Mainly Dingolfing, Germany, with some assembly in other locations globally.
