🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E39

Model Years:

1997, 1998, 1999, 2000, 2001, 2002

Market Segment:

Executive Car / Luxury Car

👋 Introduction

Market Segment:

The E39 5 Series represented BMW's benchmark in the mid-size luxury sedan and wagon segment, competing with models like the Mercedes-Benz E-Class and Audi A6.

E39 Strengths:

Renowned for its superior driving dynamics, refined interior, robust build quality, and advanced (for its time) technology.

Driving Dynamics:

Exceptional handling, balanced chassis, responsive steering, and powerful engine options.

Build Quality:

High-quality materials, solid construction, and long-term durability were hallmarks of the E39 generation.

Value For Money:

Provides comprehensive technical data enabling owners to perform maintenance and repairs, significantly reducing dealership costs.

Diy Support:

Empowers DIY mechanics with the detailed knowledge required to maintain and repair their E39 effectively.

📋 Manual Details

General Data Maintenance:

True

Engine:

True

Transmission:

True

Suspension Steering Brakes:

True

Body:

True

Body Equipment:

True

Electrical System:

True

Equipment Accessories:

True

Electrical Wiring Diagrams:

True

Estimated Page Count:

Extensive (typically 2000+ pages for factory-level detail)

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

File Format:

PDF

Compatibility:

All Windows and Mac Operating Systems

Printability:

All pages printable

Software Requirements:

Adobe PDF Reader, WinZip (for download)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing, lubrication system, cooling system, fuel system (injection, pumps, injectors), exhaust system.

Engine Management:

Engine control unit (ECU) diagnosis, sensor identification and testing (MAF, O2, Crankshaft Position, Camshaft Position, Throttle Position), ignition system, emissions control systems.

Transmission Manual:

Clutch operation, gearbox overhaul, shift mechanism, gear ratios, lubrication.

Transmission Automatic:

Automatic transmission (e.g., GM 5L40-E, ZF 5HP series) diagnosis, overhaul, control modules, torque converter, fluid specifications and cooling.

Drivetrain:

Driveshaft, differential, axle shafts, wheel bearings.

Suspension:

Front and rear suspension components (struts, shocks, control arms, bushings, springs), alignment specifications, ride height.

Steering:

Power steering system (pump, rack and pinion, hoses), steering column, steering angle sensor (if applicable).

Brakes:

Brake system components (discs, pads, calipers, master cylinder, ABS/DSC module), hydraulic system bleeding, parking brake.

Body Structure:

Body panel removal and installation, structural components, door mechanisms, hood and trunk operation, glass replacement.

Body Equipment:

Seats, interior trim, headliner, climate control system (HVAC components, blower motor, evaporator, condenser), sunroof operation, power windows, central locking.

Electrical System Basic:

Battery, alternator, starter motor, fuses, relays, lighting systems (headlights, taillights, interior lights), horn.

Electrical System Complex:

Body Control Module (BCM), Instrument Cluster, infotainment system (radio, navigation), comfort features (heated seats, memory seats), cruise control, diagnostic connectors (OBD-II).

Accessories:

Wiper system, rear defroster, power mirrors, keyless entry, alarm system.

Safety Systems:

Airbag system (SRS module, sensors, airbag modules), seatbelt pre-tensioners.

Preventative Maintenance:

Scheduled maintenance items, fluid changes, filter replacements, inspections.

Diagnosis Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation, wiring harness testing.

Repair Overhaul:

Detailed instructions for disassembly, repair, and reassembly of all major vehicle components.

Component Replacement:

Guidance on replacing specific parts like spark plugs, brake pads, water pump, alternator, fuel pump, etc.

Adjustment Calibration:

Procedures for adjusting door latches, parking brake, throttle body, etc.

Electrical Component Testing:

Testing procedures for sensors, actuators, control modules, using multimeters and oscilloscopes.

Wiring Diagram Interpretation:

Detailed explanation and usage of comprehensive electrical wiring diagrams.

Depth:

Factory-level detail, covering everything from basic maintenance to complete engine and transmission rebuilds.

Documentation Style:

Step-by-step instructions with hundreds of photos and illustrations.

Audience:

Suitable for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

PDF Quality:

High-resolution, ensuring clarity of illustrations and text.

Searchability:

Likely text-searchable PDF for quick information retrieval.

Printability Notes:

Designed for clear printing, allowing users to create physical copies of specific sections or the entire manual.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine 525I:

M54B25 (2.5L Inline-6), 189 hp @ 6000 rpm, 232 Nm (171 lb-ft) @ 3500 rpm (later models might use M52TU).

Engine 528I:

M52TUB28 (2.8L Inline-6), 190 hp @ 5300 rpm, 270 Nm (199 lb-ft) @ 3950 rpm.

Engine 530I:

M54B30 (3.0L Inline-6), 225 hp @ 5900 rpm, 289 Nm (214 lb-ft) @ 3500 rpm.

Engine 540I:

M62B44 (4.4L V8), 282 hp @ 5400 rpm, 440 Nm (325 lb-ft) @ 3600 rpm (later models M62TU with 290 hp).

Engine Construction:

Inline-6 (2.5L, 2.8L, 3.0L) and V8 (4.4L), all-aluminum block and head construction.

Fuel Injection:

Multi-point fuel injection (MPFI) with advanced engine management.

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Spark Plugs 540I:

Typically NGK BKR6EQUP (or equivalent), 8 required.

Oil Capacity 528I 530I:

Approx. 6.9 US quarts (6.5 liters) with filter.

Oil Capacity 540I:

Approx. 7.9 US quarts (7.5 liters) with filter.

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 or equivalent), 50/50 mix with distilled water.

🔧 Transmission

Standard Transmission 525I 528I 530I:

5-speed Getrag manual (e.g., S5D 250G).

Standard Transmission 540I:

6-speed ZF manual (e.g., ZF S6-370).

Optional Transmission 525I 528I:

5-speed automatic (GM 5L40-E).

Optional Transmission 530I:

5-speed automatic (GM 5L40-E).

Optional Transmission 540I:

5-speed automatic (ZF 5HP30).

Automatic Transmission Features:

Steptronic (manual shifting capability), adaptive shift programs.

Automatic Transmission Fluid Type:

Dexron III (or BMW approved equivalent).

Manual Transmission Fluid Type:

MTF LT-2 or equivalent (e.g., Red Line D4 ATF).

📐 Dimensions

Sedan Length:

Approx. 188.0 inches (4778 mm)

Wagon Length:

Approx. 190.1 inches (4828 mm)

Wheelbase:

Approx. 111.4 inches (2830 mm)

Curb Weight 525I:

Approx. 3500-3700 lbs (1588-1678 kg)

Curb Weight 540I:

Approx. 3800-4000 lbs (1724-1814 kg)

🛡️ Safety Features

NHTSA Front Impact:

5-Star (for driver and passenger in many tests).

ABS:

Standard Anti-lock Braking System (ABS) across all models.

Traction Control:

Standard Automatic Stability Control (ASC+T) or Dynamic Stability Control (DSC).

Airbags:

Front airbags, optional side airbags.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Radio System:

BMW Business CD or Professional CD/RDS radios, often with cassette player. Optional navigation system (CCC).

Speaker System:

Standard 6 or 8 speaker system; optional premium HiFi system with amplifier.

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

Optional Park Distance Control (PDC) sensors.

Phone Integration:

Optional Bluetooth preparation and cellular phone integration.

🔧 Maintenance

Oil Change Interval:

BMW Condition Based Service (CBS) system or typically every 7,500-10,000 miles (12,000-16,000 km) or annually, whichever comes first. Manual provides detailed guidance on when specific services are due.

Engine Air Filter:

Typically replaced every 30,000 miles (48,000 km) or as per CBS. Manual details inspection and replacement.

Cabin Air Filter:

Typically replaced every 15,000 miles (24,000 km) or annually. Manual shows location and replacement procedure.

Brake Fluid Flush:

Recommended every 2 years, regardless of mileage. Manual details the bleeding procedure.

Power Steering Fluid:

BMW CHF 11S (or Pentosin equivalent).

Brake Fluid:

DOT 4.

Cooling System:

Plastic expansion tank cracks, thermostat housing leaks, water pump failure (especially electric ones on later models). Manual provides replacement instructions.

Vibration Damping:

Lower control arm bushings (front), rear subframe bushings, driveshaft flex disc (guibo) wear. Manual outlines inspection and replacement.

Oil Leaks:

Valve cover gasket, oil pan gasket, oil filter housing gasket. Manual details removal and installation procedures.

Electrical:

ABS/DSC sensor failures, headlight leveling module issues, door lock actuator failures. Manual's wiring diagrams are crucial for troubleshooting.

📚 Vehicle History

Bmw Philosophy:

BMW's long-standing reputation for 'The Ultimate Driving Machine', emphasizing performance, luxury, and advanced engineering.

E39 Introduction:

The E39 was introduced in 1995 for the 1996 model year in Europe and later for the 1997 model year in North America, replacing the E34 generation.

E39 Facelift:

Received a significant facelift in 2000 (for the 2001 model year), introducing updated headlights (angel eyes), taillights, bumpers, and interior refinements, along with the M54 engine for 6-cylinder models.

Production Years:

1995-2003 (globally)

Manufacturing Locations:

Primarily Dingolfing, Germany.

🏆 Awards & Recognition

Car And Driver 10 Best:

The E39 5 Series was frequently featured on Car and Driver's 10Best lists during its production run, lauded for its blend of luxury and performance.

Motor Trend Car Of The Year:

While not a winner, it was a strong contender and well-regarded by automotive journalists.

Overall Reputation:

Considered one of the finest driving sedans of its era, known for its robust engineering and driver engagement.