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BMW 5 Series E39 Service Repair Manual 1997-2002
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Generation Generation Code: E39 Codes Production Years Covered By Manual: 1997-2002 👋 Introduction Market Position Segment: Executive Luxury...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E39
Generation
Generation Code:
E39
Codes
Production Years Covered By Manual:
1997-2002
👋 Introduction
Market Position
Segment:
Executive Luxury Sedan and Wagon (Touring)
Target Audience:
Discerning drivers valuing performance, comfort, and advanced technology.
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type.
Bmw Advantage:
Renowned for 'The Ultimate Driving Machine' ethos, offering superior handling and driver engagement.
Key Features
Design:
Timeless design characterized by BMW's signature kidney grille and Hofmeister kink.
Powertrains:
Smooth inline-six and V8 engines offering a blend of power and refinement.
Chassis Dynamics:
Advanced suspension and steering systems contributing to exceptional ride and handling balance.
Build Quality:
High levels of fit and finish, characteristic of BMW's premium construction.
📋 Manual Details
Coverage Areas
Engine Coverage:
Includes detailed information for M52, M54, and M62 engine families.
Drivetrain Coverage:
Covers rear-wheel drive (RWD) and xDrive (all-wheel drive) systems.
Body And Chassis Coverage:
Comprehensive coverage of exterior body panels, chassis, suspension, steering, and wheels.
Electrical System Coverage:
Detailed diagrams and troubleshooting for all electrical components, including lighting, ECUs, sensors, and comfort systems.
Interior Coverage:
Information on interior trim, seats, airbags, HVAC, and infotainment systems.
Page Count
Estimated Page Count:
> 3000 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, pistons, connecting rods, crankshaft, timing components, oil pump, cooling system.
Engine Management:
Fuel injection, ignition system, electronic control units (ECU), sensors (MAF, O2, crank, cam), emissions control systems (secondary air injection, EVAP).
Transmission Manual:
Manual gearbox overhaul, clutch, flywheel, shift mechanism, gearbox fluid changes.
Transmission Automatic:
Automatic transmission overhaul, torque converter, valve body, transmission fluid and filter changes, electronic transmission control.
Drivetrain Components:
Driveshafts, universal joints, CV joints, differential, axle shafts.
Suspension Front:
Struts, control arms, ball joints, bushings, anti-roll bar.
Suspension Rear:
Multi-link suspension, trailing arms, control arms, shock absorbers, bushings, anti-roll bar.
Steering System:
Power steering pump, steering rack, tie rod ends, steering column, steering angle sensor.
Braking System:
Brake discs, pads, calipers, brake lines, ABS control module, DSC (Dynamic Stability Control), parking brake.
Wheel And Tire System:
Wheel bearing replacement, tire pressure monitoring system (TPMS), wheel specifications.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, oxygen sensors, exhaust hangers.
Cooling System:
Radiator, water pump, thermostat, coolant hoses, expansion tank, fan clutch/electric fan.
HVAC System:
Air conditioning compressor, refrigerant lines, evaporator, heater core, blower motor, climate control module.
Lighting System:
Headlights, taillights, interior lighting, fog lights, Xenon headlights (if equipped).
Body Electrical:
Power windows, power locks, remote keyless entry, door modules, trunk release, sunroof operation.
Safety Systems:
Airbag system components, seat belt pre-tensioners, SRS control module.
Infotainment Audio:
Radio/navigation system, speakers, amplifier, antenna.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, cabin, fuel), fluid checks and top-offs, spark plug replacement, brake fluid flush.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, using diagnostic tools (e.g., OBD-II). Includes DTC (Diagnostic Trouble Code) interpretation.
Engine Repair:
Complete engine overhaul, cylinder head gasket replacement, timing chain/belt replacement, piston ring replacement, valve seal replacement.
Transmission Repair:
Complete transmission overhaul, clutch replacement, torque converter replacement, valve body repair.
Suspension And Steering Repair:
Replacement of control arms, ball joints, tie rod ends, steering rack overhaul, wheel bearing replacement, shock/strut replacement.
Brake System Repair:
Brake pad and rotor replacement, brake caliper overhaul, brake line bleeding and replacement, ABS/DSC module troubleshooting.
Electrical System Repair:
Wiring harness repair, sensor replacement, ECU troubleshooting and replacement, module programming procedures (where applicable).
Body And Trim Repair:
Body panel alignment and replacement, interior trim panel removal and installation, door mechanism repair, window regulator replacement.
HVAC System Repair:
Refrigerant system service, compressor replacement, evaporator/heater core replacement, blower motor replacement.
Diagnostic Tree Flowcharts:
Flowcharts and decision trees for diagnosing specific symptoms.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
Diagnostic Capability:
Includes detailed diagnostic procedures and fault code interpretation, essential for modern vehicle repair.
Torque Specifications:
Precise torque values for all fasteners across all systems, critical for proper assembly.
Clearances And Tolerances:
Specifications for engine component clearances, valve lash adjustments, and other critical tolerances.
Wiring Diagrams:
Extensive and detailed electrical wiring diagrams for all vehicle systems.
Component Identification:
Clear identification and location of all major components and sensors.
📊 Manual Specifications
File Format
Type:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for hands-on use in the workshop.
Print Quality
Image Resolution:
High-resolution images, diagrams, and illustrations for clarity.
Binding Type
Type:
N/A (Digital download)
Paper Type
Type:
N/A (Digital download)
⚙️ Engine Specifications
Primary Engine
Engine Code Example 1:
M54B25 (2.5L Inline-6)
Engine Code Example 2:
M54B30 (3.0L Inline-6)
Engine Code Example 3:
M62TU B44 (4.4L V8)
Engine Code Example 4:
S62B50 (5.0L V8 - M5)
Performance
Power Output Example 1:
M54B25: 184 hp @ 6000 rpm
Torque Output Example 1:
M54B25: 175 lb-ft @ 3500 rpm
Power Output Example 2:
M54B30: 225 hp @ 6000 rpm
Torque Output Example 2:
M54B30: 214 lb-ft @ 3500 rpm
Power Output Example 3:
M62TU B44: 282 hp @ 5400 rpm
Torque Output Example 3:
M62TU B44: 324 lb-ft @ 3600 rpm
Power Output Example 4:
S62B50 (M5): 394 hp @ 6600 rpm
Torque Output Example 4:
S62B50 (M5): 368 lb-ft @ 4800 rpm
Fuel System
Injection Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Requirement:
Premium Unleaded Gasoline (91+ octane)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual (Getrag S5D 250G for 6-cylinder, optional on some V8s)
Optional
Transmission Type Optional 1:
5-Speed Steptronic Automatic (GM A5S 325Z for 6-cylinder)
Transmission Type Optional 2:
5-Speed Steptronic Automatic (GM 5L40-E for V8, M62TU)
Transmission Type Optional 3:
6-Speed Manual (Getrag 420G for M5, S62 engine)
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) standard; xDrive (All-Wheel Drive) available on select models (e.g., 525iX, 530iX in some markets).
Steptronic Functionality:
Allows manual selection of gears via selector lever or steering wheel buttons (on some models).
📐 Dimensions
Exterior
Length:
Approx. 4,800-4,880 mm (Sedan); 4,870 mm (Touring)
Width:
Approx. 1,760-1,800 mm
Height:
Approx. 1,440-1,470 mm (Sedan); 1,470-1,480 mm (Touring)
Interior
Wheelbase:
Approx. 2,830 mm
Cargo
Trunk Volume:
Approx. 520 liters (Sedan); Approx. 460 liters (Touring, seats up)
Weights
Curb Weight:
Approx. 1,500-1,750 kg (depending on engine and options)
🛡️ Safety Features
Ratings
Eunceap Rating:
Likely 4 or 5 stars for its era (Euro NCAP was developing during this period).
Active Features
Traction Control:
ASC+T (Automatic Stability Control + Traction) standard or optional.
Stability Control:
DSC (Dynamic Stability Control) available on later models and higher trims.
Braking Assist:
ABS (Anti-lock Braking System) standard, likely with Brake Assist.
Passive Features
Airbags Front:
Driver and front passenger airbags standard.
Airbags Side:
Front side-impact airbags optional or standard on higher trims.
Airbags Head:
Head protection system (side curtain airbags) optional on later models.
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners and force limiters for front seats.
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD or Professional CD radios, optional navigation systems (MK III/IV).
Audio System:
Standard 6-speaker system, optional Harman Kardon or Logic7 premium audio.
Driver Assistance
Parking Assist:
Park Distance Control (PDC) sensors (front and rear) available.
Cruise Control:
Standard cruise control system.
Connectivity
Bluetooth:
Optional Bluetooth hands-free system (car phone preparation).
Key System:
Remote keyless entry and immobilizer system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 miles or 12 months, using BMW Longlife-01 (LL-01) approved synthetic oil.
Air Filter Replacement:
Every 30,000 miles or as needed based on driving conditions.
Cabin Air Filter Replacement:
Every 15,000 miles or annually.
Spark Plug Replacement:
Platinum or Iridium plugs: typically 60,000-100,000 miles (refer to specific engine type).
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Coolant Flush:
Typically every 2-4 years or 30,000-50,000 miles (using BMW Blue Coolant).
Fluid Specifications
Engine Oil:
BMW Longlife-01 (LL-01) specification 5W-30 or 5W-40 synthetic oil.
Transmission Fluid Auto:
BMW ATF LT-71141 (or equivalent Dexron III based fluid, verify specific transmission).
Transmission Fluid Manual:
BMW MTF LT-1 or MTF LT-2 (Manual Transmission Fluid).
Coolant:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based).
Brake Fluid:
DOT 4.
Power Steering Fluid:
Pentosin CHF 11S or equivalent hydraulic fluid.
Known Issues
Cooling System Common:
Plastic cooling system components (expansion tank, radiator, water pump housing) can become brittle and crack over time, leading to coolant leaks.
Vibration Harmonic Balancer:
Rubber element in the harmonic balancer can degrade, causing engine vibrations and potential failure.
Oil Leaks:
Valve cover gaskets, oil pan gaskets, and oil filter housing gaskets are common sources of oil leaks.
Suspension Wear:
Front control arm bushings, sway bar links, and rear multi-link bushings are prone to wear, leading to clunking noises and poor handling.
Window Regulators:
Plastic components in power window regulators can fail, causing windows to drop.
ABS Wheel Speed Sensors:
Front ABS wheel speed sensors are prone to failure, leading to ABS and DSC warning lights.
Ccv System M54:
Crankcase Ventilation (CCV) system can clog, leading to increased oil consumption and potential vacuum leaks.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's long-standing reputation for performance, engineering, and luxury motoring dating back to the early 20th century.
Model Evolution
E39 Predecessor:
Succeeded the E34 5 Series.
E39 Successor:
Succeeded by the E60 5 Series.
Platform Development:
Shared engineering principles with the E38 7 Series and E53 X5.
Production
Production Start:
1995 (model year 1996 in some markets)
Production End:
2003 (model year 2003 in some markets, with E60 phasing in).
Manufacturing Locations:
Primary manufacturing in Dingolfing, Germany; assembly also occurred in other global locations.
Sales Figures:
One of BMW's most successful generations, with over 1.4 million units sold globally.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Consistently recognized by Car and Driver magazine in its annual '10Best' list during its production run.
Motor Trend Car Of The Year:
Competed strongly for Car of the Year awards in its segment.
Ratings
Reliability Perception:
Generally considered reliable when properly maintained, though certain components require proactive attention.
Certifications
Bmw Quality Standards:
Built to stringent BMW quality and engineering standards.