2003 BMW M5 E39 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: M5 Chassis Code: E39 Model Year: 2003 Generation E Series Generation: E39 (Fifth Generation) Codes Engine Code Primary: S62 👋 Introduction Market Position...

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Type: Car

Vendor:

Sku: 455015

Tags: 2003 5 Series BMW Car Cars M5 E39

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Model Year:

Generation

E Series Generation:

E39 (Fifth Generation)

Codes

Engine Code Primary:

👋 Introduction

Market Position

Vehicle Class:

High-performance luxury sedan

Target Audience:

Enthusiasts, owners seeking to perform their own maintenance and repairs, independent repair shops specializing in BMW.

Competitive Analysis

Competitors Era:

Mercedes-Benz E-Class AMG, Audi S6, Porsche Panamera (later models), Jaguar XJ-R

Key Features

Manual Advantage 1:

Vehicle-Specific (Not Generic)

Manual Advantage 2:

Technician-Level Detail

Manual Advantage 3:

Comprehensive Electrical Schematics

Manual Advantage 4:

Digital Format (Printable, Scalable, Portable)

Value Proposition:

Empowers owners to maintain and repair their M5 E39 with the same factory-level information used by BMW technicians, saving time and money.

📋 Manual Details

Coverage Areas

Model Variants Covered:

All M5 E39 variants

Repair Scope:

A-Z (All Repairs)

Page Count

Estimated Page Count:

Extensive (Exact count not specified, but implies comprehensive factory documentation)

Manual Type

Manual Classification:

Factory Authorized Service and Repair Manual

Usage Type:

Dealership Technician Level

Language

Language:

English

Format

Digital Format:

File Distribution:

Speed Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Intake/Exhaust, Cooling, Lubrication, Ignition, Starting, Charging, Automatic Transmission, Manual Transmission, Transfer Case, Drive Shaft, Differential, Axles

Chassis And Suspension:

Suspension, Steering, Power Steering, Brakes (Control, Standard, Parking), Wheels, Tires

Body And Interior:

Body & Chassis, Exterior & Interior Trim, Doors, Hood, Windows, Mirrors, Seat Belts, Air Conditioning, Supplemental Restraint System (SRS), Seats, Instrument Panel, Door Locks

Electrical And Electronics:

Electrical System, Wiring Schematics, Engine Control System, Cruise Control, Engine Immobilizer, Wiper & Washer, Horn, Meter, Audio/Visual Systems, Multiplex/CAN Communication

Procedures Included

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements, inspections

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation

Repair Procedures:

Step-by-step instructions for component removal, installation, adjustment, and rebuilding

Calibration And Adjustment:

Specific calibration procedures for electronic systems and mechanical components

Technical Depth

Depth Of Coverage:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including complex electronic diagnostics.

Diagnostic Tools Reference:

Implied reference to BMW's diagnostic tools (e.g., DIS, ISTA) and procedures for using them.

Wiring Diagrams:

Complete, detailed wiring schematics for all vehicle systems.

Illustrations And Diagrams:

High-quality illustrations and exploded view diagrams for component identification and assembly.

📊 Manual Specifications

File Format

Document Format:

Software Requirements:

Adobe PDF Reader, Winzip (both free online)

Operating System Compatibility:

Windows (Vista 32/64, XP, ME, 98, NT, 2000), MAC

Print Quality

Printability:

Fully Printable (individual pages or full manual)

Image Scalability:

Scalable Images (allows for enlarged printing of diagrams)

Binding Type

Binding:

N/A (Digital format, no physical binding)

Paper Type

Paper Quality:

N/A (Digital format, print on demand)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated V8

Displacement:

4.9 Liters (4941 cc)

Bore X Stroke:

94.0 mm x 89.0 mm

Compression Ratio:

11.0:1

Performance

Horsepower:

400 hp @ 6600 rpm (DIN)

Torque:

368 lb-ft (500 Nm) @ 3800 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Multi-point)

Fuel Type:

Premium Unleaded Gasoline (91-98 RON)

Engine Features

Valvetrain:

Dual Overhead Camshafts (DOHC), 4 Valves per Cylinder, VANOS (Variable Valve Timing)

Engine Management:

Bosch Motronic ME 7.2

🔧 Transmission

Standard

Transmission Type:

6-speed Manual Transmission

Manual Transmission Model:

Getrag 420G

Optional

Optional Transmission:

None (Exclusively manual for E39 M5)

Features

Clutch Type:

Hydraulically operated, single dry plate

Final Drive Ratio:

3.15:1 (Standard)

📐 Dimensions

Exterior

Length:

191.1 inches (4854 mm)

Width:

71.0 inches (1803 mm)

Height:

56.7 inches (1440 mm)

Wheelbase:

111.4 inches (2830 mm)

Weights

Curb Weight:

Approx. 3,800 - 3,900 lbs (1724 - 1769 kg)

Gross Vehicle Weight Rating:

Approx. 4,790 lbs (2173 kg)

Cargo

Trunk Capacity:

14.1 cu ft (400 liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (for E39 platform generally)

NHTSA Front Impact Passenger:

5-Star (for E39 platform generally)

Active Features

Braking System:

Four-wheel disc brakes with ABS, Dynamic Stability Control (DSC), Electronic Brake-force Distribution (EBD)

Traction Control:

Automatic Stability Control and Traction (ASC+T)

Passive Features

Airbags:

Frontal airbags (driver & passenger), Side airbags (front door mounted), Head Protection System (HPS)

Seat Belts:

Three-point inertia-reel seat belts with pretensioners and force limiters

Chassis Construction:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Navigation System:

Optional BMW Professional Navigation System with CD-ROM based maps.

Audio System:

BMW Business or Professional CD radios, optional Harman Kardon sound system.

Driver Assistance

Cruise Control:

Standard cruise control system.

Parking Assistance:

Optional rear park distance control (PDC).

Connectivity

Telematics:

Optional Tele Aid or BMW Assist telematics system (functionality may be limited due to network obsolescence).

Climate Control

Climate Control System:

Dual-zone automatic climate control.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 - 10,000 miles or annually, depending on driving conditions (refer to manual for specific guidance).

Brake Fluid Flush Interval:

Every 2 years

Coolant Flush Interval:

Every 2-3 years or as per BMW specifications

Spark Plug Replacement:

Typically around 60,000 miles (refer to manual for specific plug type and interval)

Fluid Specifications

Engine Oil Type And Viscosity:

BMW Longlife-01 approved synthetic oil, typically SAE 0W-40 or 5W-30 (check manual for precise BMW LL-01 specification).

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol-based)

Brake Fluid Type:

DOT 4 (BMW Super-DOT 4 recommended)

Transmission Fluid Type:

MTF LT-2 (Manual Transmission Fluid) - specific BMW fluid is crucial.

Known Issues

Rod Bearings:

Potential for wear on rod bearings due to high-performance use; requires proactive inspection and potential replacement.

Rear Main Seal Leaks:

Common leak point, especially with age and mileage.

S62 Throttle Bodies:

Individual throttle bodies can become sticky or develop vacuum leaks, affecting performance and idle quality.

Cooling System:

Plastic expansion tanks can become brittle and crack; water pump and thermostat are also wear items.

Vanos System:

Seals within the VANOS system can degrade, leading to a loss of low-RPM torque and potential rattles.

📚 Vehicle History

Brand Heritage

Bmw M Division:

BMW M GmbH (Motorsport) division, renowned for creating high-performance versions of BMW's standard road cars.

Model Evolution

E39 M5 Introduction:

Introduced in 1998 (as a 1999 model in Europe, 2000 in North America), the E39 M5 represented the pinnacle of the 5 Series performance for its generation.

E39 M5 Engine Development:

The S62 engine was a development of the M62 V8, heavily modified by BMW M with individual throttle bodies, a unique crank, and upgraded internals for enhanced performance.

Production

Production Years:

1998-2003

Production Location:

Dingolfing, Germany

Total Production Numbers:

Approximately 20,484 units worldwide

🏆 Awards & Recognition

Recognitions

Car And Driver Award:

Car and Driver's 10Best list multiple times (for the E39 generation generally, with M5 variants being highly acclaimed).

Motor Trend Award:

Highly praised by automotive journalists for its performance and handling.

Certifications

Manual Quality Certification:

Factory authorized and produced for dealership use, indicating adherence to BMW's internal technical documentation standards.