🏷️ Basic Information

Make:

BMW

Model:

Sedan

Production Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005

Chassis Codes Covered:

E60 (for 2004-2005 models, though manual likely covers earlier 5 Series generations as well)

👋 Introduction

Target Audience:

BMW owners seeking to perform their own maintenance and repairs, independent repair shops, and automotive technicians.

Value Proposition:

Provides detailed, manufacturer-level information at a fraction of the cost of dealership service, enabling significant cost savings for owners.

Comprehensiveness:

Covers virtually every aspect of vehicle service and repair, offering a complete resource for DIY or professional use.

Detail Level:

Extensive technical specifications, torque values, wiring diagrams, and procedural steps.

📋 Manual Details

Vehicle Models Covered:

BMW 5 Series Sedan (specific internal codes like E39 for earlier years and potential introduction of E60 for later years within this range, requiring clarification based on the actual manual's scope).

Estimated Pages:

Likely 1500+ pages (typical for comprehensive full service repair manuals of this era).

Type:

Full Service Repair Manual

Language:

English

Format:

Digital (PDF likely, given the description)

📖 Manual Coverage

Engine:

Detailed diagnostics, repair procedures, component testing, specifications for various gasoline engines (e.g., M54B22, M54B25, M54B30, M62TU V8).

Transmission:

Manual and automatic transmission overhaul, diagnostics, fluid specifications, torque converter service, clutch replacement (manual).

Drivetrain:

Front axle, rear axle, driveshaft, differential, CV joints, wheel bearings, drive shafts.

Suspension:

Front and rear suspension systems, shock absorbers, struts, control arms, ball joints, bushings, springs, steering linkage, wheel alignment.

Brakes:

Brake system diagnostics, front and rear brake pad and rotor replacement, caliper service, brake fluid flush and bleeding, ABS/DSC system components and troubleshooting.

Steering:

Power steering system, steering rack, steering column, steering wheel removal/installation, alignment.

Electrical System:

Complete wiring diagrams, component location, fuse box layouts, battery and charging system, starter, alternator, ignition system, lighting (headlights, taillights, interior), power accessories (windows, locks, mirrors).

Engine Management And Emissions:

ECU diagnosis, sensor testing (MAF, O2, Crankshaft Position, Camshaft Position), fuel injection system, ignition timing, emission control systems (catalytic converter, EVAP).

Heating And Air Conditioning:

HVAC system diagnosis, refrigerant handling, blower motor, evaporator, condenser, compressor, climate control module.

Body And Interior:

Body panel removal and installation, door mechanisms, interior trim, dashboard removal, seats, airbags system.

Chassis And Frame:

Frame integrity checks, structural components, rust prevention.

Maintenance:

Routine maintenance: oil change, filter replacement (oil, air, fuel, cabin), spark plug replacement, fluid checks and top-offs, tire rotation, brake inspections.

Repair:

Engine rebuild, transmission overhaul, suspension component replacement, brake caliper rebuilding, electrical component repair, body panel repair and replacement.

Diagnostics:

Step-by-step troubleshooting guides, fault code interpretation (OBD-II), common problem diagnosis, electrical circuit tracing.

Installation:

Component installation: alternators, starters, water pumps, fuel pumps, sensors, body panels, interior components, audio systems.

Troubleshooting:

Systematic approach to identifying and resolving malfunctions across all vehicle systems.

Depth:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic fluid changes to complete engine and transmission rebuilds.

Diagnostic Tools:

References to necessary diagnostic tools, scan tools, and specialized equipment for accurate troubleshooting and repair.

📊 Manual Specifications

Quality:

High-resolution, searchable text with clear diagrams and illustrations.

Illustrations:

Detailed line drawings, exploded views, and some photographic representations.

Binding:

N/A (if digital PDF)

Paper Quality:

N/A (if digital PDF)

⚙️ Engine Specifications

Engine Options Covered:

Likely includes inline-6 engines (M54 series: 2.5L, 3.0L) and potentially V8 engines (M62TU 4.4L) for the 5 Series (E39 and early E60).

Horsepower Torque Ranges:

Approx. 184-255 hp and 230-300 lb-ft torque depending on engine variant and year.

Fuel Delivery:

Electronic Fuel Injection (EFI), multi-point injection (MPI).

ECU Type:

Siemens MS43, MS45, DMEs, Siemens MSS70 for V8.

Coolant Type:

BMW Blue Antifreeze (G48 ethylene glycol based) or equivalent.

Oil Type:

BMW Longlife-01 (LL-01) approved synthetic oils, typically 5W-30 or 5W-40.

🔧 Transmission

Transmission Type Standard:

5-speed manual (e.g., Getrag 260/6, Getrag 420G) for certain trims and years.

Transmission Type Optional:

5-speed automatic (e.g., ZF 5HP19) and later 6-speed automatic (e.g., ZF 6HP19) for higher performance models and newer years.

Transmission Fluid Specs:

Automatic transmission fluid (ATF) specific to the ZF transmission model (e.g., ZF LifeguardFluid8 for 6HP).

📐 Dimensions

Wheelbase:

Approximately 113.4 inches (E39 chassis).

Length:

Approximately 190.2 inches (E39 chassis).

Curb Weight:

Approx. 3400-3800 lbs depending on engine and configuration.

🛡️ Safety Features

NHTSA Frontal Crash Test:

Likely received 5-star ratings for frontal and side impact from NHTSA (for E39 generation).

ABS:

Standard Anti-lock Braking System (ABS) and Dynamic Stability Control (DSC).

Airbags:

Frontal airbags, side-impact airbags, and curtain airbags (optional on some models).

💡 Technology Features

Head Unit Features:

BMW Business CD, BMW Professional CD, navigation systems (MKIII, MKIV), and early iDrive systems on later E60 models.

Cruise Control:

Standard cruise control, active cruise control (optional on some models).

Phone Integration:

Bluetooth integration (optional, with cradle or TCU module), hands-free calling.

Headlight Types:

Halogen reflector headlights, Xenon/HID headlights with adaptive features (optional).

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles or 12-15,000 km, or based on vehicle condition monitoring system (CBS).

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Spark Plug Replacement:

Every 60,000-100,000 miles depending on spark plug type (e.g., Long Life Platinum/Iridium).

Power Steering Fluid:

Pentosin CHF 11S or BMW Hydraulic Fluid.

Coolant Capacity:

Approximately 8.0 - 9.5 liters depending on engine.

Common Problems:

Oil pan gasket leaks, valve cover gasket leaks, CCV system issues (crankcase ventilation), cooling system leaks (water pump, thermostat, hoses), ABS/DSC sensor failures, fuel pump issues, VANOS system (variable valve timing) solenoid/seals, suspension bushings and control arms wear.

📚 Vehicle History

Bmw Philosophy:

Focus on 'Ultimate Driving Machine,' blending performance, luxury, and engineering.

E39 Generation:

The E39 5 Series (1995-2003) was a highly acclaimed generation known for its ride quality, handling, and build quality. This manual covers the later years of this generation.

E60 Introduction:

The E60 5 Series began production in 2003 for the 2004 model year, marking a significant design and technology shift. The manual may also encompass early E60 models.

Manufacturing Locations:

Primarily Dingolfing, Germany, and some assembly in other global locations.

🏆 Awards & Recognition

Car And Driver 10Best:

The E39 5 Series was frequently recognized on Car and Driver's '10Best' list during its production run.