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1997 2002 BMW 5 Series E39 Complete Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Year Range Covered: 1997-2002 Generation Generation Name: Fourth Generation (E39) Codes E Code: E39 👋 Introduction Market Position...
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Type: Car
Vendor:
Sku: 370481
1997 2002 BMW 5 Series E39 Complete Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E39
Year Range Covered:
1997-2002
Generation
Generation Name:
Fourth Generation (E39)
Codes
E Code:
E39
👋 Introduction
Market Position
Segment:
Executive Sedan
Brand Perception:
Represents a significant step up in luxury, performance, and technology for BMW, solidifying its position in the premium segment.
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (S160), Volvo S80.
Key Features
Safety Cage:
All-steel body construction acting as an occupant safety cage, enhanced by computer-aided engineering for optimized rigidity without excessive weight.
Engineering Advancements:
Leverages computer-aided engineering for structural rigidity, hinting at advanced manufacturing and design for its era.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Workshop Service Repair Manual
Language:
English
Format:
PDF
Availability:
Instant Download
Compatibility:
All Versions of Windows & Mac
Printable:
Yes
Software Requirements:
Adobe PDF Reader & WinZip
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul procedures, component testing, specifications, and diagnostic information for all E39 engine variants.
Engine Management And Electronics:
Diagnosis and repair of DME (Digital Motor Electronics), sensor testing, fuel injection systems, ignition systems, and emissions control.
Transmission Manual:
Repair, overhaul, and adjustment procedures for manual transmissions, including clutch system service.
Transmission Automatic:
Detailed diagnostic and repair procedures for automatic transmissions, including valve body service, torque converter replacement, and transmission control modules (TCM).
Drivetrain And Axles:
Service and repair of drive shafts, universal joints, differential, and half-shafts.
Suspension:
Front and rear suspension component replacement, alignment procedures, shock absorber and strut service, control arm and bushing replacement.
Steering:
Power steering system diagnosis and repair, steering rack and pump service, steering column adjustment.
Brakes:
Front and rear brake component replacement (pads, rotors, calipers), ABS system diagnosis and repair, brake fluid service, parking brake adjustment.
Electrical System:
Comprehensive wiring diagrams, component location, troubleshooting of charging system, starting system, lighting, and accessory circuits.
Body And Chassis:
Body panel repair, door mechanism service, window regulator replacement, interior trim removal, and chassis reinforcement details.
Heating Ventilation Air Conditioning HVAC:
Diagnosis and repair of AC system components, climate control modules, blower motor, and heater core replacement.
Restraint Systems:
Airbag system diagnosis, SRS module service, seat belt repair.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common and complex issues, fault code interpretation.
Procedures Included
Routine Maintenance:
Oil change intervals, filter replacement, spark plug replacement, coolant service, brake fluid flush.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls.
Component Replacement:
Detailed instructions for replacing all major and minor components across all vehicle systems.
Diagnostic Procedures:
Systematic diagnostic approaches for identifying and resolving faults using both basic tools and advanced diagnostic equipment.
Wiring Diagrams:
Complete, high-resolution electrical schematics for all vehicle circuits.
Technical Depth
Depth:
Factory-level detail, suitable for professional technicians and advanced DIY mechanics.
Diagnostics:
Advanced diagnostic strategies and troubleshooting trees for complex electronic and mechanical issues.
Rebuild Procedures:
Comprehensive instructions for rebuilding major components like engines and transmissions.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Implied by PDF format, though specific searchability depends on the OCR quality of the original document.
Print Quality
Quality:
High quality, suitable for clear printing.
Binding Type
Type:
Digital (Instant Download)
Paper Type
Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Variants:
Includes coverage for various inline-6 and V8 gasoline engines, and potentially diesel variants common in the E39 chassis.
Common Engines:
M52/M54 (2.5L, 2.8L, 3.0L inline-6), M62/S62 (4.4L, 4.9L V8, including M5 variant).
Performance
Power Output:
Ranges from approximately 170 hp (520i) to over 400 hp (M5).
Torque Output:
Varies significantly by engine, with higher torque figures for larger displacement and performance variants.
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) with advanced electronic control units (ECU/DME).
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended).
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (Getrag or ZF).
Optional
Type:
5-speed Steptronic Automatic Transmission (ZF 5HP series).
Features
Steptronic:
Allows manual selection of gears via the gear selector or steering wheel buttons (on some models).
📐 Dimensions
Exterior
Body Styles:
4-door Sedan.
Wheelbase:
Approximately 113.4 inches (2880 mm).
Weights
Curb Weight:
Ranges from approximately 3500 lbs to over 4000 lbs depending on engine and options.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Good (for its era, tested with different standards than today).
IIHS Side Impact:
Good (for its era).
Active Features
ABS:
Standard Anti-lock Braking System.
Asc:
Optional Automatic Stability Control (ASC+T on later models).
Passive Features
Airbags:
Frontal airbags for driver and passenger, optional side airbags.
Seatbelts:
Pre-tensioning front seatbelts with force limiters.
💡 Technology Features
Infotainment
System Overview:
Features BMW's Professional Radio system, optional CD changer, and optional navigation system (MKIII/MKIV).
Display:
Central LCD display for radio, navigation, and vehicle status information. Later models may have integrated LCM (Light Control Module) for lighting and convenience functions.
Driver Assistance
Cruise Control:
Standard cruise control. Adaptive Cruise Control (ACC) was available on some later models.
Parking Sensors:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Cellular:
Optional integrated car phone or Bluetooth preparation in later production years.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 7,500 to 10,000 miles or 12-15,000 km, or as indicated by the Condition Based Service (CBS) system.
Brake Fluid:
Recommended every 2 years, regardless of mileage.
Coolant:
BMW long-life coolant typically requires flushing and replacement every 4 years or 60,000 miles.
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or BMW Longlife-98 (LL-98) compliant synthetic oil, typically 5W-30 or 0W-40.
Transmission Fluid Manual:
Specific GL-4 or GL-5 gear oil, depending on transmission type. Consult manual for exact spec (e.g., ATF Dexron III for some automatic transmissions).
Brake Fluid Type:
DOT 4 Low Viscosity (LV) or DOT 4 PLUS.
Known Issues
Cooling System:
Plastic coolant expansion tanks can become brittle and crack, leading to leaks. Water pump failure is also common.
Suspension Components:
Wear of control arm bushings (e.g., front lower control arm bushings), sway bar links, and tie rod ends is common due to age and mileage.
Oil Leaks:
Valve cover gasket, oil pan gasket, and front/rear main seals can develop leaks over time.
Electrical Gremlins:
Can be prone to various electrical issues, including ABS/DSC module failures, window regulator failures, and sensor issues. Battery drain can also be a problem.
Vanos System:
Variable Valve Timing (Vanos) system can develop issues, leading to rough idle or loss of power (e.g., solenoid failure, o-ring degradation).
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW is renowned for its 'Ultimate Driving Machine' slogan, emphasizing performance, handling, and driver engagement.
Model Evolution
Predecessor:
BMW E34 5 Series.
Successor:
BMW E60 5 Series.
Production
Production Years:
1995–2003 (though market availability often extends into 2004).
Manufacturing Locations:
Germany (Dingolfing).
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E39 5 Series was a consistent recipient of Car and Driver's 10Best awards, highlighting its excellent blend of performance, luxury, and handling.
Motor Trend Car Of The Year:
While not a winner, it was a strong contender in its class, often praised in comparison tests.
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