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BMW 5 Series E39 Workshop Repair Manual 1997-2002

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Years Covered: 1997-2002 👋 Introduction Market Position Target Audience: Professional automotive technicians, DIY enthusiasts, BMW owners seeking in-depth...
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BMW 5 Series E39 Workshop Repair Manual 1997-2002
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E39
Years Covered:
1997-2002
👋 Introduction
Market Position
Target Audience:
Professional automotive technicians, DIY enthusiasts, BMW owners seeking in-depth maintenance and repair knowledge
Competitive Analysis
Value Proposition:
Provides the same detailed, factory-level information as official BMW dealer service manuals at a fraction of the cost.
Key Features
Diagrams Illustrations:
Numerous step-by-step diagrams and detailed illustrations for complex procedures
Accuracy Completeness:
Guaranteed accuracy and completeness of information derived from official BMW documentation.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service & Repair Manual
Language:
English
Format:
Downloadable Digital Format (likely PDF)
Page Count
Estimated Page Count:
Extensive (typically 2000+ pages for full workshop manuals)
Format
File Format Quality:
High-resolution, searchable PDF for easy navigation and printing
📖 Manual Coverage
Systems Covered
Powertrain:
Engine overhaul, fuel system, cooling system, exhaust system, ignition system, engine management (DME/ECU diagnostics)
Drivetrain:
Transmission (manual & automatic), clutch, driveshafts, differential, axles
Chassis Suspension Steering:
Front & rear suspension components, steering system, wheel alignment specifications
Brakes:
Brake system diagnosis, repair, ABS/DSC system troubleshooting, brake component replacement
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting systems, fuses, relays, diagnostic connectors (OBD-II)
Body And Interior:
Body panel repair, interior trim removal/installation, doors, windows, seats, HVAC system
Procedures Included
Preventive Maintenance:
Scheduled service intervals, oil changes, filter replacements, fluid checks and top-offs
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon faults, fault code interpretation
Repair Rebuild:
Detailed procedures for component removal, repair, and reassembly, including major overhauls
Specifications Tolerances:
Torque specifications, clearances, measurements, and tolerances for all components
Technical Depth
Depth Level:
Comprehensive (equivalent to official dealer workshop manuals)
Diagnostic Capabilities:
Advanced diagnostic procedures, including use of specialized tools and software (e.g., INPA, ISTA)
📊 Manual Specifications
File Format
Searchability:
Full text search enabled
Print Quality
Printability:
Printable pages, with clear diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Variants Covered:
Covers a wide range of E39 engines including M52/M54 (Inline-6 petrol), M62 (V8 petrol), and M47/M57 (Diesel variants)
Performance
Typical Horsepower Range:
150 hp (2.0L 4-cyl diesel) to 400 hp (M5 V8)
Typical Torque Range:
205 Nm (2.0L 4-cyl diesel) to 500 Nm (M5 V8)
Fuel System
Fuel Delivery:
Bosch Motronic or Siemens DME engine management systems, fuel injection (MPI/GDI), common rail for diesel variants.
Engine Management
ECU Details:
Detailed information on DME (Digital Motor Electronics) functions, sensor inputs, and actuator outputs.
🔧 Transmission
Standard
Manual Transmission Options:
Getrag 5-speed and 6-speed manual transmissions
Optional
Automatic Transmission Options:
ZF 5HP18, 5HP19, 5HP24, 5HP30 automatic transmissions
Features
Transmission Control:
Information on EGS (Electronic Gearbox Control) modules for automatic transmissions, including adaptive learning.
Fluid Specifications
Automatic Transmission Fluid:
Dexron III/VI, LT71141, or specific ZF fluid depending on transmission model. Refer to manual for exact specifications.
📐 Dimensions
Exterior
Wheelbase:
Approximately 2830 mm (111.4 in)
Length:
Approximately 4770 mm (187.8 in)
Width:
Approximately 1800 mm (70.9 in)
Height:
Approximately 1435 mm (56.5 in)
Weights
Curb Weight:
Varies by model and engine, typically 1500-1800 kg (3300-4000 lbs)
Gross Vehicle Weight Rating:
Varies, typically 2000-2300 kg (4400-5000 lbs)
Cargo
Trunk Volume:
Approximately 520 liters (18.4 cu ft)
🛡️ Safety Features
Ratings
NHTSA Safety Rating:
Generally good for its era, though specific NHTSA ratings for early E39 models can be hard to find. Often achieved 4-star frontal impact ratings.
Active Features
Traction Control:
ASC+T (Automatic Stability Control and Traction) or DSC (Dynamic Stability Control) depending on model year and options.
Antilock Brakes:
Standard ABS system
Passive Features
Airbags:
Frontal airbags for driver and passenger, optional side airbags.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners and force limiters.
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD RDS, optional Navigation systems (MKII/MKIII).
Audio System:
Standard 6-speaker system, optional Hi-Fi or Top Hi-Fi systems with amplifiers and subwoofers.
Driver Assistance
Cruise Control:
Standard cruise control functionality.
Parking Sensors:
Optional Park Distance Control (PDC) system.
Connectivity
Bluetooth Integration:
Optional Bluetooth phone preparation available on later models.
Telematics:
Optional TeleService functionality for remote vehicle diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
BMW Condition Based Service (CBS) system typically indicated intervals around 15,000-25,000 km (9,000-15,000 miles) or annually, whichever came first. Manual provides specific guidance.
Spark Plug Replacement:
Approximately 100,000 km (60,000 miles) for standard plugs, longer for iridium plugs. Manual will specify exact intervals per engine.
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) or LL-04 approved synthetic oil, typically 0W-30, 0W-40, 5W-30, or 5W-40 depending on engine and climate. Manual specifies exact viscosity and capacity.
Coolant:
BMW Blue Antifreeze/Coolant (G48) or equivalent, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 Low Viscosity (LV) or DOT 4 Plus. Replace every 2 years.
Known Issues
Common Wear Items:
VANOS unit seals, oil pan gaskets, valve cover gaskets, cooling system components (thermostat, water pump, expansion tank), control arm bushings, sway bar links, intake manifold gaskets (M52TU/M54).
Electrical Gremlins:
LCM (Light Control Module) issues, ABS/DSC sensor failures, pixelated instrument cluster displays (LCD separation).
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for producing premium, performance-oriented luxury sedans with advanced engineering.
Model Evolution
E39 Positioning:
The E39 replaced the E34 and was known for its refined ride, sophisticated handling, and technological advancements, setting a new benchmark for its class.
Production
Production Period:
1995-2003 (with sedan production ending 2003 and Touring (wagon) ending 2004)
Key Facelifts:
Facelifted in 2000, with updated headlights, taillights, bumpers, and interior electronics. Some engine variants also saw updates.
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Car and Driver magazine named the BMW 5 Series to its annual '10Best' list multiple times during its production run.
Ward'S Auto World:
Likely received accolades from automotive publications for its design, engineering, and performance during its era.
Certifications
Iso Certification:
Manufactured in facilities adhering to stringent automotive quality standards.
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