Engine Mechanical:
Engine assembly, disassembly, overhaul, valve train, cooling system, lubrication system, timing components
Engine Management:
Fuel injection, ignition system, emissions control, DME (Digital Motor Electronics) diagnostics and troubleshooting
Transmission Manual:
Service, repair, and overhaul of manual transmissions
Transmission Automatic:
Service, repair, and overhaul of Steptronic automatic transmissions (e.g., GM 5L40-E, ZF 5HP19)
Drivetrain:
Clutch, driveshafts, differential, axles, wheel bearings
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications
Steering:
Steering system components, power steering, steering rack, tie rods, steering angle sensor
Brakes:
Brake system components (discs, pads, calipers, lines), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), parking brake
Electrical System:
Battery, charging system, starter motor, lighting, power windows, central locking, mirrors
Body And Chassis:
Body panels, doors, hood, trunk lid, bumpers, interior trim, sunroof, chassis components
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant, components
Body Electronics:
Instrument cluster, OBC (On-Board Computer), SRS (Supplemental Restraint System - Airbags), door modules, seat modules
Infotainment:
Radio, navigation system (e.g., Business CD, Professional CD, M-ASK, MKIII/MKIV Navigation), speaker systems
Maintenance Tasks:
Oil change, filter replacement (oil, air, cabin, fuel), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change
Repair Procedures:
Engine rebuild, transmission repair, brake caliper replacement, suspension component replacement, starter/alternator replacement
Diagnostic Procedures:
Troubleshooting guides for common issues, diagnostic trouble codes (DTCs), component testing methods
Electrical Diagnostics:
Wiring diagrams for all systems, connector pinouts, voltage drop testing, continuity testing
Calibration Procedures:
Steering angle sensor calibration, ABS/DSC sensor calibration (where applicable)
Troubleshooting Guides:
Step-by-step guides for diagnosing and resolving common and uncommon problems
Depth:
Comprehensive from basic maintenance to full engine and transmission overhauls
Diagnostic Detail:
Includes detailed diagnostic fault codes (DTCs) and their meanings, along with specific troubleshooting trees
Component Replacement:
Detailed instructions for removal and installation of all major and minor components
Torque Specifications:
All critical torque specifications for fasteners and assemblies
Wiring Diagrams:
Complete, high-resolution wiring schematics for all electrical systems
Engine Variants Covered:
M52/M54 Inline-6 (2.5L, 2.8L, 3.0L), M62 V8 (4.4L), S62 V8 (4.9L - M5)
2.5L I6 (M52/M54):
Displacement: 2494cc, Power: 170 hp @ 5500 rpm, Torque: 181 lb-ft @ 3950 rpm (M52B25)
2.8L I6 (M52/M54):
Displacement: 2793cc, Power: 193 hp @ 5500 rpm, Torque: 206 lb-ft @ 3800 rpm (M52B28)
3.0L I6 (M54):
Displacement: 2979cc, Power: 225 hp @ 5900 rpm, Torque: 214 lb-ft @ 3500 rpm (M54B30)
4.4L V8 (M62):
Displacement: 4398cc, Power: 282 hp @ 5400 rpm, Torque: 317 lb-ft @ 3600 rpm (M62B44)
4.9L V8 (S62 - M5):
Displacement: 4941cc, Power: 400 hp @ 6600 rpm, Torque: 369 lb-ft @ 4700 rpm
Acceleration 0 60 Mph Typical:
6.5-8.5 seconds (depending on engine and transmission)
Injection Type:
Electronic Multi-Point Fuel Injection (MPI) with VANOS (Variable Valve Timing)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)
Oil Type:
BMW High Performance Synthetic Engine Oil (e.g., BMW Longlife-01 or LL-04 specifications)
Oil Capacity Typical:
6.5 - 7.5 liters (depending on engine)
Oil Change Interval:
Typically every 7,500 - 15,000 miles or 12-24 months, depending on driving conditions and oil used (BMW Condition Based Service - CBS)
Air Filter Replacement:
Every 30,000 miles or as indicated by CBS
Cabin Filter Replacement:
Every 15,000 - 30,000 miles or annually
Spark Plug Replacement:
Typically every 60,000 - 100,000 miles depending on plug type and engine
Brake Fluid Flush:
Every 2 years regardless of mileage
Power Steering Fluid:
Pentosin CHF 11S or Pentosin CHF 202 (check specific model/year requirements)
Coolant Capacity:
Approx. 8.0 - 9.5 liters (depending on engine)
Common Wear Items:
VANOS solenoids and seals, oil separator (CCV) system, cooling system components (water pump, thermostat, hoses), ignition coils, ABS wheel speed sensors, front suspension bushings and control arms
E39 Specific Issues:
Pixelated LCD display in instrument cluster, sagging headliner, rear shock mount failure, vacuum leaks
Brand Focus:
BMW is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, handling, and engineering excellence.
E39 Introduction:
The E39 5 Series debuted in 1995 for the 1996 model year and was produced until 2003. The 1997-2001 models represent the early to mid-production phase of this generation.
E39 Facelift:
A significant facelift occurred for the 2001 model year, introducing revised headlights, taillights, bumpers, and engine updates (e.g., M54 engines replacing M52TU). This manual covers pre-facelift and early facelift models.
Manufacturing Locations:
Germany (Dingolfing), Austria (Graz - Magna Steyr for some models)
