5 Series (E39) Years 1997-2002 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Production Years Covered: 1997-2002 Codes Vin Prefix: WBAP 👋 Introduction Market Position Segment: Executive Sedan/Wagon Target Audience: Owners...

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Type: Car

Vendor:

Sku: 440994

Tags: 1997 1998 1999 2000 2001 2002 5 Series 5 Series (E39) BMW Car Cars

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Production Years Covered:

1997-2002

Codes

Vin Prefix:

👋 Introduction

Market Position

Segment:

Executive Sedan/Wagon

Target Audience:

Owners seeking to perform DIY maintenance and repairs, independent repair shops.

Competitive Analysis

Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160).

Key Features

Dvantages Of Digital:

Cleanliness (no oil on hands), ability to print specific pages, portability.

Completeness:

Designed to be a complete, official full workshop service repair manual.

Accessibility:

Immediately solvable problems via PDF format.

📋 Manual Details

Coverage Areas

All Models Included:

BMW 525i, BMW 528i, BMW 530i, BMW 540i

Body Styles Covered:

Sedan, Sport Wagon

Page Count

Estimated Pages:

Hundreds (PDF format)

Manual Type

Manual Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, timing belt, head gasket, lubrication, cooling, fuel delivery, exhaust systems.

Engine Management:

Engine control unit (ECU), ignition system, emission control systems, sensors, actuators.

Transmission:

Automatic and manual transmission servicing, repair, and overhaul. Fluid change procedures.

Drivetrain:

Front axle, rear axle, driveshafts, CV joints, differentials.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment.

Steering:

Power steering system, steering rack, tie rods, steering column.

Brakes:

Hydraulic system, brake discs, brake pads, calipers, ABS system, parking brake.

Electrical System:

Full electrical system diagnostics, troubleshooting, wiring diagrams, battery, alternator, starter motor, lighting, accessories.

Body And Chassis:

Body panels, doors, windows, convertible top mechanisms (if applicable), underbody protection, chassis components.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system servicing, refrigerant handling, component replacement.

Interior Trim:

Dashboard, seats, door panels, headliner removal and installation.

Procedures Included

Basic Maintenance:

Oil changes, filter replacements (air, oil, fuel, cabin), tire pressure checks, fluid level checks.

Scheduled Maintenance:

Detailed schedules for routine servicing based on mileage and time.

Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues.

Repair Procedures:

Detailed, numbered instructions for all repairable components.

Component Replacement:

Instructions for replacing major and minor components.

Overhaul Procedures:

Comprehensive procedures for complete engine and transmission overhauls.

Electrical Diagnostics:

Diagnosis of electrical faults using wiring diagrams and test procedures.

Diagnostic Codes:

Interpretation and troubleshooting of On-Board Diagnostic (OBD-II) trouble codes.

Technical Depth

Depth Of Information:

High - Covers everything from basic maintenance to complex engine rebuilds and electrical diagnostics.

Detail Level:

Detailed substeps, notes, cautions, and warnings for critical information.

Illustrations:

Detailed illustrations, drawings, and photos for each procedure.

Wiring Diagrams:

Integrated and detailed wiring diagrams for ease of electrical troubleshooting.

Torque Specifications:

Included for all critical fasteners and components.

Special Tools:

Identification and usage of special tools required for specific repairs.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, enabling quick information retrieval.

Print Quality

Printability:

High quality, allowing for printing of specific sections as needed.

Binding Type

Binding:

Digital (PDF) - no physical binding.

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

525I Engine:

M54B25: 2.5L Inline-6 (24 valves)

528I Engine:

M52TU B28: 2.8L Inline-6 (24 valves)

530I Engine:

M54B30: 3.0L Inline-6 (24 valves)

540I Engine:

M62TU B44: 4.4L V8 (32 valves)

Performance

525I Horsepower:

189 hp @ 6000 rpm

528I Horsepower:

193 hp @ 5300 rpm

530I Horsepower:

225 hp @ 5900 rpm

540I Horsepower:

282 hp @ 5400 rpm

525I Torque:

191 lb-ft @ 3500 rpm

528I Torque:

206 lb-ft @ 3950 rpm

530I Torque:

214 lb-ft @ 3500 rpm

540I Torque:

324 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery Type:

Electronic Fuel Injection (EFI)

Engine Management System:

Bosch Motronic DME (Digital Engine Electronics)

🔧 Transmission

Standard

525I Transmission:

5-speed manual Getrag S5D 250G

528I Transmission:

5-speed manual Getrag S5D 250G

530I Transmission:

5-speed manual Getrag S5D 250G

540I Transmission:

6-speed manual ZF S6-37ZH

Optional

525I Optional Transmission:

5-speed automatic Steptronic GM A5S 325Z

528I Optional Transmission:

5-speed automatic Steptronic GM A5S 325Z

530I Optional Transmission:

5-speed automatic Steptronic GM A5S 325Z

540I Optional Transmission:

5-speed automatic Steptronic GM 5L440E

Features

Steptronic:

Allows manual shifting of automatic transmission.

Fluid Specifications

Automatic Transmission Fluid:

BMW LT-2 or equivalent (e.g., Dexron III H) - Manual will specify exact type and quantity.

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent - Manual will specify exact type and quantity.

📐 Dimensions

Exterior

Wheelbase:

Approximately 111.4 inches (2830 mm)

Length:

Approximately 188.8 inches (4800 mm)

Width:

Approximately 70.2 inches (1783 mm)

Height:

Approximately 57.0 inches (1448 mm)

Weights

Curb Weight Min:

Approximately 3571 lbs (1620 kg) for 525i

Curb Weight Max:

Approximately 4057 lbs (1840 kg) for 540i Sedan

🛡️ Safety Features

Ratings

NHTSA Ratings:

Generally high safety ratings for its era, though specific year ratings may vary.

Active Features

Standard Anti-lock Braking System (ABS)

Optional/Standard Automatic Stability Control (ASC+T on some models)

Traction Control:

Standard on most models, advanced on later versions.

Passive Features

Airbags:

Frontal airbags for driver and passenger, optional side airbags.

Seatbelts:

Three-point seatbelts with pretensioners.

Chassis Design:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Infotainment System:

BMW Business CD, Professional RDS CD, or optional Navigation systems with CD changer capabilities.

Display:

Central LCD screen in the dashboard for climate control, radio, navigation, and vehicle information.

Driver Assistance

Parking Assistance:

Optional Park Distance Control (PDC) sensors (front and rear).

Connectivity

Phone Integration:

Optional Bluetooth phone preparation with a cradle in the center console or armrest.

Convenience Features

Cruise Control:

Standard cruise control system.

Rain Sensing Wipers:

Optional rain-sensing automatic wipers.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 to 15,000 miles (12,000 to 24,000 km) or annually, based on BMW's Condition Based Service (CBS) system or specific model recommendations. Manual will provide precise guidance.

Air Filter Replacement:

Approximately every 30,000 miles (48,000 km), or as indicated by the CBS.

Spark Plug Replacement:

Around 60,000 miles (96,000 km) for standard plugs, potentially longer for iridium or platinum types. V8 engines may have different intervals.

Fluid Specifications

Engine Oil Specification:

BMW Longlife-01 (LL-01) synthetic oil, typically 5W-30 or 0W-30. Manual will specify exact type and viscosity based on engine.

Coolant Specification:

BMW Blue Antifreeze/Coolant (G48) or equivalent (ethylene glycol-based, silicate-inhibited). Mixture of 50/50 with distilled water.

Brake Fluid Specification:

DOT 4 (e.g., BMW High Performance DOT 4). Replace every 2 years.

Known Issues

Cooling System Weaknesses:

Plastic coolant expansion tanks can become brittle and leak; water pumps and thermostat housings are common failure points.

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and oil filter housing gaskets are prone to leaks over time.

Suspension Wear:

Control arm bushings and rear shock mounts can wear out, leading to noise and poor handling.

Vibration Issues:

Driveshaft flex disc (guibo) and center support bearing can fail, causing vibrations, especially under acceleration.

Electrical Quirks:

ABS/DSC warning lights, pixelated displays (from dead pixels on the instrument cluster), and headlight leveling issues are not uncommon.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

The 'Ultimate Driving Machine' ethos, emphasizing performance, luxury, and engineering.

Model Evolution

E39 Generation:

The E39 generation (1995-2003) was the fourth generation of the 5 Series, succeeding the E34 and preceding the E60.

Key Advancements:

Significant improvements in chassis dynamics, ride comfort, and technology compared to its predecessor.

Production

Production Period:

1995-2003 globally; 1997-2002 for models covered by this manual.

🏆 Awards & Recognition

Recognitions

Automotive Journalism Awards:

Consistently praised by automotive journalists for its driving dynamics, build quality, and refined interior. Often ranked among the best in its class.