Target Audience:
Owners seeking to perform DIY maintenance and repairs, independent repair shops.
Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C4/C5), Lexus GS300 (JZS160).
Vehicle Features:
Renowned for its balanced chassis, sophisticated engineering, comfortable ride, and a potent inline-6 engine.
Manual Value Proposition:
Provides essential technical knowledge for maintaining and repairing the sophisticated E39 platform, saving on labor costs and ensuring proper upkeep.
Engine Mechanical:
Complete overhaul procedures for M52B28, including cylinder head, block, crankshaft, pistons, connecting rods, timing components, cooling system, lubrication system.
Engine Management:
EFI system diagnostics, fuel injection, ignition system, DME (Digital Motor Electronics) control unit, sensor testing and replacement, emissions control systems.
Transmission Manual:
Overhaul and repair of the 5-speed Getrag manual gearbox, clutch system, shift linkage.
Transmission Automatic:
Service and repair of the 4-speed Steptronic automatic transmission, including valve body, torque converter, electronic controls.
Suspension:
Front and rear suspension systems (MacPherson strut front, multi-link rear), shock absorbers, springs, control arms, bushings, steering system.
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System) components, brake fluid, hydraulic lines, parking brake.
Electrical System:
12V electrical system, battery, alternator, starter motor, wiring diagrams for all circuits, fuses, relays, lighting systems.
Body And Chassis:
Body panel removal and installation, interior trim, doors, hood, trunk, chassis components, corrosion protection.
HVAC:
Heating, Ventilation, and Air Conditioning system service, refrigerant, compressor, blower motor, climate control unit.
Diagnostic Troubleshooting:
Extensive troubleshooting guides, fault code interpretation (OBD-II), diagnostic procedures for all major systems.
Maintenance Routine:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, coolant flushes, brake fluid changes, power steering fluid changes.
Component Replacement:
Detailed step-by-step instructions for replacing major components like alternators, starters, water pumps, fuel pumps, sensors, engine mounts, transmission mounts, driveshafts, CV joints.
Rebuild Procedures:
Complete engine and transmission rebuild procedures with torque specifications and clearances.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, testing circuits, component testing.
Suspension Alignment:
Alignment specifications and procedures.
Tire Wheel Service:
Tire mounting and balancing, wheel installation.
Body Repair:
Minor body panel repair, door and lock adjustments.
Depth:
Comprehensive; covers everything from routine maintenance and fluid changes to complete engine and transmission overhauls, complex electrical diagnostics, and structural repairs.
Configuration:
2.8L Inline 6-Cylinder, DOHC, 24 Valves
Bore X Stroke:
84 mm x 83.6 mm
Compression Ratio:
10.2:1
Horsepower:
190 hp @ 5500 RPM
Torque:
207 lb-ft @ 3950 RPM
Injection:
Bosch Motronic M5.2 Sequential Multi-Point Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Coolant Capacity:
Approx. 9.5 Liters (10.0 US Quarts)
Oil Capacity:
Approx. 6.5 Liters (6.9 US Quarts) with filter change
Recommended Oil Viscosity:
SAE 5W-30 or 5W-40 Synthetic
Oil Change:
Every 7,500-10,000 miles or 12 months using synthetic oil, or as indicated by the Condition Based Service (CBS) system (which became more prevalent in later E39 models).
Air Filter:
Inspect every 15,000 miles, replace every 30,000 miles or as needed.
Cabin Filter:
Replace every 15,000 miles or annually.
Spark Plugs:
Replace every 60,000 miles (depending on plug type, e.g., long-life iridium).
Coolant Flush:
Every 30,000 miles or 2 years.
Brake Fluid Flush:
Every 2 years.
Engine Oil:
SAE 5W-30 or 5W-40 Synthetic, BMW Longlife-98 specification.
Coolant:
BMW Blue Antifreeze/Coolant (G48) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Power Steering Fluid:
Pentosin CHF 11S or equivalent.
Common Problems:
Cooling system components (water pump, thermostat, hoses, expansion tank), VANOS (Variable Valve Timing) system issues (whirring noise, loss of power), PCV system clogs, oil leaks (valve cover gaskets, oil pan gaskets), ABS/ASC sensor failures, window regulator failures, sagging headliner.
Bmw Philosophy:
Focus on 'The Ultimate Driving Machine', combining performance, luxury, and engineering.
E39 Introduction:
The E39 generation of the 5 Series debuted in 1995 (in Europe) and 1996 (in North America), succeeding the E34. The 528i replaced the 525i from the previous generation.
E39 Characteristics:
Known for its improved chassis dynamics, enhanced safety, and more luxurious interior compared to its predecessor.
Production Period:
1995-2003 (E39 generation), 1997-2000 (528i model)
Manufacturing Plants:
Dingolfing, Germany; Rosslyn, South Africa; Magna Steyr, Austria.
