🏷️ Basic Information

Make:

BMW

Model:

E39

Generation:

E39

Chassis Code:

E39

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, and BMW E39 owners seeking detailed technical information for maintenance and repair.

Value Proposition:

Provides factory-level repair information, enabling cost savings and empowering owners to maintain their vehicles effectively.

Uniqueness:

Offers comprehensive coverage, detailed step-by-step instructions, and technical diagrams equivalent to dealership workshop manuals.

Accessibility:

Digital PDF format allows for easy access and printing of specific sections as needed.

📋 Manual Details

Systems Covered:

General Information, Engine, Injection/Ignition System, Clutch, Gearbox, Suspension System, Wheels, Braking System, Control Driving Instructions, Air Temperature Control System, Electrical System, Bodywork, Exploded Views & Diagrams

Estimated Page Count:

Varies by specific model year and engine, but expected to be extensive, likely exceeding 1000 pages for a complete workshop manual compilation.

Type:

Service and Repair Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair procedures for all engine variants offered in the E39 chassis, including cylinder head, block, pistons, crankshaft, camshafts, timing systems, lubrication system, and cooling system.

Fuel System:

Fuel injection system (including DME/ECU functions), fuel pumps, injectors, fuel lines, fuel pressure regulation, and evaporative emission control systems.

Clutch:

Clutch assembly, hydraulic clutch system, master and slave cylinders, and adjustment procedures.

Transmission Manual:

Manual gearbox internal components, clutch operation, shift linkage, and removal/installation procedures.

Transmission Automatic:

Automatic transmission overhaul, valve body diagnosis, electronic control unit (EGS) functions, fluid changes, and torque converter service.

Drivetrain:

Driveshafts, CV joints, differential, wheel bearings, and rear axle assembly.

Suspension:

Front and rear suspension components, control arms, ball joints, bushings, shock absorbers, struts, springs, anti-roll bars, and alignment specifications.

Wheels:

Wheel bearing replacement, wheel bolt torque specifications, and tire pressure monitoring system (TPMS) if applicable.

Braking System:

Brake pad and rotor replacement, brake caliper service, brake fluid bleeding and replacement, ABS system diagnosis and repair, DSC (Dynamic Stability Control) system.

Steering:

Power steering system, steering rack, tie rods, steering column, and steering angle sensor.

Bodywork:

Exterior panel removal and installation, door mechanisms, hood, trunk, bumpers, interior trim, and basic body repair guidance.

Electrical System:

Complete wiring diagrams, fuse box locations and functions, relay assignments, component testing, starter, alternator, battery, lighting systems (headlights, taillights, interior), power windows, mirrors, central locking.

Climate Control:

HVAC system diagnosis, blower motor, climate control module, refrigerant system, heater core, evaporator, and AC compressor.

Comfort Systems:

Seats, power seat adjustments, sunroof operation, and interior electronics.

Ignition System:

Spark plugs, ignition coils, ignition module, crankshaft and camshaft position sensors, and ignition timing procedures.

Routine Maintenance:

Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, coolant flushes, brake fluid replacement.

Troubleshooting:

Diagnostic fault codes (DTCs), symptom-based troubleshooting guides, and logic trees for identifying issues.

Repair Procedures:

Step-by-step instructions for component replacement, adjustment, and overhaul across all major vehicle systems.

Diagnostic Procedures:

Guidance on using diagnostic tools (e.g., BMW DIS/ISTA), reading live data, and performing actuator tests.

Exploding Views:

Detailed exploded view diagrams are provided for all major components and systems, aiding in identification and reassembly.

Engine Rebuild:

Includes instructions for complete engine disassembly, inspection of internal components, machining specifications, and reassembly for engine overhaul.

Depth:

Comprehensive, covering everything from basic fluid checks and filter replacements to complete engine and transmission rebuilds. Includes detailed diagnostic information and electrical schematics.

Torque Settings:

Comprehensive torque specifications for all fasteners, critical for proper assembly and preventing damage.

Fluid Capacities:

Precise fluid capacities for engine oil, coolant, transmission fluid, brake fluid, power steering fluid, and differential fluid for all variants.

Electrical Diagrams:

Complete, detailed electrical schematics for all vehicle systems, essential for diagnosing and repairing electrical faults.

📊 Manual Specifications

File Type:

PDF

Printability:

All pages are printable, allowing users to create physical copies for workshop use.

Binding:

Not applicable (digital format)

Paper Quality:

Not applicable (digital format)

Text Search:

Likely contains searchable text for quick information retrieval.

⚙️ Engine Specifications

Engine Options:

The E39 chassis offered a range of inline-4, inline-6, and V8 gasoline engines, including M50, M52, M54, and S62 (M5) variants, as well as diesel engines (M47, M57). The manual would cover specific engines based on the user's E39 configuration.

Typical Performance Ranges:

Horsepower and torque figures vary significantly by engine: e.g., 2.5L inline-6 (approx. 170-190 hp), 3.0L inline-6 (approx. 225-231 hp), 4.4L V8 (approx. 282-290 hp), 4.9L V8 (M5 - approx. 400 hp). The manual will provide exact specifications.

Injection Type:

Electronic Fuel Injection (EFI), with specific systems like Bosch Motronic or Siemens DME, depending on the engine and model year.

Oil Viscosity Recommendations:

Commonly recommended viscosities include 0W-40, 5W-30, and 5W-40 synthetic oils, with specific recommendations varying by engine and climate. Refer to the manual for exact BMW LL-01 or LL-04 specifications.

Coolant Type:

BMW Blue antifreeze or equivalent (G48), typically a 50/50 mixture with distilled water.

Timing Drive:

Varies by engine: some use a timing chain with VANOS (Variable Valve Timing), others may have a timing belt (less common on E39). The manual will detail the specific system and service intervals for the timing chain tensioners and guides.

🔧 Transmission

Manual Transmission:

Commonly available with Getrag 5-speed and 6-speed manual transmissions, depending on engine and model year.

Automatic Transmission:

Available with ZF 5-speed automatic transmissions (e.g., 5HP18, 5HP19, 5HP24, 5HP30) and later Steptronic (manual shifting mode) versions.

Automatic Transmission Features:

Sport and Steptronic modes for enhanced driving experience.

Automatic Transmission Fluid:

Specific ZF Lifeguard fluids or equivalent approved by BMW are typically required. The manual will specify the exact fluid type (e.g., ATF LT3, LT5).

📐 Dimensions

Body Styles:

Sedan (4-door) and Touring (wagon/estate 5-door).

Curb Weight Range:

Approximately 1500 kg to over 1800 kg, depending on body style, engine, and equipment.

Bolt Pattern:

5x120 mm

Offset Range:

Typically ET15 to ET20 for 17-inch and larger wheels, with variations based on specific wheel size and design. Manual will provide exact specifications.

🛡️ Safety Features

Crash Test Ratings:

The E39 generally received good safety ratings for its era. Specific ratings from organizations like NHTSA or IIHS would vary by model year and testing methodology. The manual may contain some safety system overview.

Active Safety:

Anti-lock Braking System (ABS), Dynamic Stability Control (DSC), Traction Control System (ASC+T) on some models.

Passive Safety:

Front airbags, side airbags, seatbelt pretensioners, and reinforced body structure.

💡 Technology Features

Audio System:

BMW Business CD, BMW Professional CD, or optional Navigation systems with CD playback, radio, and potentially cassette players. Harman Kardon audio upgrade was also available.

Navigation:

Optional Professional Navigation system with CRT or later LCD screen, often utilizing CD-ROM based maps.

Cruise Control:

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

Phone Integration:

Optional Bluetooth phone preparation or integrated phone systems.

Headlight Options:

Halogen headlights, with optional Xenon (HID) headlights for improved illumination.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 to 15,000 miles (12,000 to 24,000 km) or annually, depending on driving conditions and oil used. The vehicle's onboard computer (service indicator) will prompt for service. The manual will provide detailed guidance.

Brake Fluid Interval:

Recommended every 2 years, regardless of mileage.

Coolant Interval:

BMW Longlife coolant typically has a long service life, often up to 5 years or 100,000 miles, but the manual will specify based on the specific coolant and vehicle condition.

Power Steering Fluid:

BMW approved hydraulic fluid (e.g., Pentosin CHF 11S or equivalent). The manual will provide the exact specification.

Brake Fluid Spec:

DOT 4 low viscosity brake fluid.

Common E39 Problems:

Cooling system issues (plastic expansion tank, water pump, hoses), VANOS system wear, oil leaks (valve cover gasket, oil pan gasket), ABS/DSC sensor failures, VANOS solenoid failures, check engine light illumination due to various sensors, rear shock mount failure, EWS immobilizer issues.

Cooling System Maintenance:

Regular inspection and replacement of cooling system components is crucial to prevent overheating and severe engine damage. The manual will detail the procedure.

Spark Plug Type:

Specific iridium or platinum spark plugs recommended by BMW, with replacement intervals typically around 100,000 miles, but the manual will provide the exact part numbers and intervals.

📚 Vehicle History

Bmw Legacy:

The E39 continued BMW's tradition of producing well-engineered, driver-focused luxury sedans and wagons with a strong emphasis on performance and handling.

E39 Lifecycle:

Produced from 1995 to 2003 (sedan) and 1996 to 2004 (Touring). It succeeded the E34 and was succeeded by the E60. It featured significant advancements in technology, comfort, and safety compared to its predecessor.

Production Locations:

Primarily manufactured in Dingolfing, Germany, with some assembly potentially in other locations or contract manufacturers.

M5 Variant:

The E39 M5, equipped with the S62 4.9L V8 engine, is a highly sought-after performance variant of the E39.

🏆 Awards & Recognition

Car And Driver 10Best:

The E39 5 Series, including the 528i and 540i, was frequently listed on Car and Driver's '10Best' lists during its production run, highlighting its exemplary driving dynamics and overall quality.

Consumer Reports Ratings:

Generally received good ratings from consumer organizations for reliability and performance, though specific ratings varied by model year and engine choice.