BMW E39 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Model Year: 2002 Generation Generation Name: Fourth Generation Generation Years: 1995-2003 Codes Market Codes: North America, Europe, Global...

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Type: Car

Vendor:

Sku: 369591

Tags: 2002 5 Series BMW Car Cars E39

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Year:

Generation

Generation Name:

Fourth Generation

Generation Years:

1995-2003

Codes

Market Codes:

North America, Europe, Global

👋 Introduction

Market Position

Segment:

Executive Sedan/Wagon

Reputation:

Known for its driving dynamics, build quality, and technological advancements for its era.

Competitive Analysis

Key Competitors:

Mercedes-Benz W210 E-Class, Audi A6 C5, Lexus GS, Jaguar S-Type

Key Features

Design Philosophy:

BMW's 'Ultimate Driving Machine' ethos, balancing luxury with sporty handling.

Interior Appointments:

Driver-centric cockpit, premium materials, available leather and wood trim.

Powertrain Options:

Refined inline-six and V8 engines, known for smoothness and performance.

📋 Manual Details

Coverage Areas

Primary Regions Covered:

North America, Europe (may include specific regional variations)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, assembly, inspection, and repair of all engine variants

Engine Management:

Ignition, fuel injection, emission control systems, sensor diagnostics, DME/ECU operation

Transmission Manual:

Disassembly, assembly, adjustment, and repair of manual gearboxes

Transmission Automatic:

Diagnosis, service, and repair of automatic transmissions (e.g., Steptronic)

Drivetrain:

Driveshafts, differentials, axles, clutch system

Suspension:

Front and rear suspension components, struts, shocks, control arms, bushings, alignment procedures

Steering:

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

Brakes:

ABS, DSC, brake fluid, calipers, rotors, pads, bleeding procedures, parking brake

Electrical System:

Battery, charging system, starter, lighting, fuses, relays, wiring diagrams

Body And Chassis:

Body panels, doors, hood, trunk, bumpers, chassis components, rust prevention

HVAC:

Air conditioning, heating, ventilation system components, climate control

Interior:

Seats, dashboard, trim panels, airbags, seatbelts

Infotainment Audio:

Radio, CD player, navigation system (CCC/M-ASK), speakers

Diagnostics:

Troubleshooting guides, fault codes, diagnostic procedures using ISTA/D (or equivalent diagnostic tools)

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, spark plugs, belts, fluid checks, lubrication

Repair Procedures:

Detailed step-by-step instructions for component removal, disassembly, repair, and reassembly

Troubleshooting:

Systematic diagnostic approaches for identifying and resolving common and uncommon issues

Installation Removal:

Instructions for installing and removing major and minor components

Specifications Tolerances:

Torque specifications, clearances, measurements, and critical tolerances for all components

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Technical Depth

Depth:

Factory-level diagnostic and repair procedures, suitable for professional technicians and experienced DIYers

📊 Manual Specifications

File Format

File Type:

PDF (likely)

Searchability:

Fully searchable text for quick information retrieval

Print Quality

Clarity:

High-resolution images, diagrams, and text for clear understanding

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

M54B30 (3.0L Inline-6)

Displacement:

2979 cc (3.0 Liters)

Bore X Stroke:

84.0 mm x 89.6 mm

Compression Ratio:

10.2:1

Horsepower:

225 hp @ 5900 rpm

Torque:

214 lb-ft @ 3500 rpm

Performance

Engine Variants Available:

2.5L Inline-6 (M54B25), 3.0L Inline-6 (M54B30), 4.4L V8 (M62TU V8)

Engine Type:

Naturally Aspirated, Inline-6 and V8 configurations

Fuel System

Fuel Delivery:

Sequential Multi-Point Fuel Injection (MPI)

Recommended Fuel:

Premium Unleaded Gasoline (91 Octane or higher)

Emission Control:

Dual catalytic converters, secondary air injection, OBD-II compliant

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual (Getrag 420G)

Optional

Optional Transmission:

5-speed Automatic (GM 5L40-E, ZF 5HP19/5HP24)

Features

Automatic Features:

Steptronic manual shifting mode

Manual Gear Ratios 3.0L:

First: 4.23, Second: 2.52, Third: 1.67, Fourth: 1.23, Fifth: 1.00, Reverse: 3.55

📐 Dimensions

Exterior

Length:

4871 mm (191.8 in)

Width:

1798 mm (70.8 in)

Height:

1439 mm (56.7 in)

Wheelbase:

2830 mm (111.4 in)

Front Track:

1510 mm (59.4 in)

Rear Track:

1524 mm (60.0 in)

Cargo

Trunk Volume:

520 liters (18.4 cu ft)

Weights

Curb Weight Est 3.0L:

1565 kg (3450 lbs)

Gvw Est 3.0L:

2100 kg (4630 lbs)

Wheel Bolt Pattern:

5x120

Center Bore:

72.5 mm

🛡️ Safety Features

Ratings

NHTSA Front Driver Side:

NHTSA Front Passenger Side:

IIHS Side Impact:

Acceptable (for models with side airbags)

Active Features

Traction Control:

Automatic Stability Control (ASC) or Dynamic Stability Control (DSC)

Antilock Brakes:

Standard Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and front passenger airbags, optional side airbags, optional head airbags

Seatbelts:

Three-point inertia-reel seatbelts with pre-tensioners and force limiters

Body Structure:

Reinforced safety cell with crumple zones

💡 Technology Features

Infotainment

Infotainment System:

BMW Professional Radio, optional Business or Professional CD/Navigation systems

Navigation System:

Optional on-board navigation computer (CCC or M-ASK)

Audio System:

Standard 6-speaker system, optional Hi-Fi or Harman Kardon premium audio

Driver Assistance

Parking Assist:

Optional Rear Park Distance Control (PDC)

Cruise Control:

Standard cruise control system

Connectivity

Bluetooth:

Optional Bluetooth hands-free interface

Auxiliary Input:

Optional auxiliary audio input

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable (Condition Based Service - CBS system), typically 10,000-15,000 miles or annually

Air Filter Replacement:

Every 30,000 miles or as needed

Cabin Filter Replacement:

Every 15,000 miles or annually

Spark Plug Replacement M54:

Every 100,000 miles (typically Bosch or NGK Platinum/Iridium)

Coolant Flush Interval:

Every 2-4 years or 30,000-50,000 miles

Fluid Specifications

Engine Oil Spec:

BMW Longlife-01 (LL-01) or LL-01 FE, typically SAE 0W-40 or 5W-30 synthetic

Engine Oil Capacity 3.0L:

6.5 liters (6.9 US quarts)

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) or equivalent

Brake Fluid Spec:

DOT 4 (BMW recommends DOT 4 PLUS)

Transmission Fluid Auto:

BMW ATF LT-71141 or Dexron III (for older units), consult manual for specific transmission

Power Steering Fluid Spec:

Pentosin CHF 11S or equivalent hydraulic fluid

Known Issues

Common Failure Oil Vanos:

Failure of VANOS solenoids and seals leading to rough idle and reduced performance

Common Failure Cooling System:

Plastic coolant expansion tank and water pump failure (e.g., plastic impeller)

Common Failure Suspension:

Worn control arm bushings, ball joints, and front sway bar links

Common Failure Eebox:

Water ingress into the Engine Control Unit (ECU) due to faulty drain channels (common on pre-facelift models)

Common Failure Headliner:

Sagging headliner fabric

Common Failure ABS Asc Sensor:

Failure of ABS/ASC wheel speed sensors

📚 Vehicle History

Brand Heritage

Brand Focus:

BMW is renowned for its engineering prowess, performance-oriented vehicles, and luxury segment presence.

Model Evolution

E39 Introduction:

Introduced in 1995 as a replacement for the E34 5 Series, the E39 marked a significant leap in design, technology, and refinement.

E39 Facelift:

Received a significant facelift for the 2001 model year, introducing updated headlights (angel eyes), taillights, bumpers, and interior enhancements.

E39 Performance Variant:

The E39 M5, equipped with a 4.9L S62 V8 engine, is a highly sought-after performance variant of this generation.

Production

Production Years E39:

1995-2003

Manufacturing Locations:

Dingolfing, Germany; Rosslyn, South Africa; Graz, Austria (Magna Steyr)

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

Named to Car and Driver's 10 Best list multiple times during its production run.

Overall Reception:

Critically acclaimed for its blend of performance, comfort, and technology, establishing a benchmark in the executive sedan class.