Market Position:
The E39 5 Series represented BMW's mid-size luxury sedan and wagon offering, known for its superior driving dynamics, refined interiors, and advanced technology for its era, competing against rivals like the Mercedes-Benz E-Class and Audi A6.
Competitive Analysis:
The E39 was lauded for its balanced chassis, powerful inline-six and V8 engines, and driver-focused cockpit. This workshop manual provides the necessary depth to maintain and repair these sophisticated vehicles, ensuring their performance characteristics are preserved.
Key Features:
Digital format for convenient access and printing, detailed illustrations, numbered step-by-step instructions, troubleshooting guides, and comprehensive coverage of all major vehicle systems.
Coverage Areas:
North America, Europe, and Global markets where E39 was sold
Page Count:
Hundreds of pages (exact count not specified, but implied to be extensive)
Manual Type:
Workshop Manual / Service Manual / Repair Manual
Systems Covered:
Engine mechanical, Engine management, Fuel system, Ignition system, Cooling system, Exhaust system, Clutch, Transmission (manual and automatic), Driveline, Suspension (front and rear), Steering system, Brakes (ABS, DSC), Body (interior and exterior), Electrical system (lighting, accessories, power features), HVAC system, SRS (airbag) system, Diagnostic procedures
Bodywork Interior:
Trim removal and installation, seat adjustment mechanisms, dashboard components, door panel removal, headliner servicing.
Bodywork Exterior:
Fender removal, bumper cover installation, headlight and taillight replacement, door hinge adjustment, trunk lid and hood alignment.
Procedures Included:
Scheduled maintenance, Routine checks, Lubrication, Oil changes, Filter replacements (air, oil, fuel, cabin), Spark plug replacement, Belt replacement, Brake pad and rotor replacement, Suspension component repair (shocks, struts, bushings), Steering system repair, Engine diagnostics and repair, Transmission servicing and repair, Electrical troubleshooting, Wiring diagram interpretation, Body panel repair and replacement, Climate control system servicing, Drivetrain component repair, Exhaust system repair, Diagnostic trouble code (DTC) interpretation and resolution, Complete engine overhaul, Timing belt/chain replacement (where applicable by engine variant), Head gasket replacement
Head Gasket Replacement:
Detailed step-by-step instructions for removing cylinder heads, replacing head gaskets, and reassembling the engine, including torque specifications and crucial alignment procedures.
Timing Chain Maintenance:
Includes procedures for inspecting and replacing timing chain guides and tensioners on applicable engines, a critical maintenance item for long-term engine health.
Technical Depth:
Comprehensive, ranging from basic owner maintenance tasks to complex mechanical and electrical system repairs, suitable for DIY enthusiasts and professional mechanics.
Engine Variants Covered:
Inline-6 (2.5L, 2.8L) and V8 (4.4L, 4.6L M-tuned for 540i variants)
525I Engine Power:
Approx. 189 hp @ 5900 rpm (M52TU B25)
528I Engine Power:
Approx. 190 hp @ 5300 rpm (M52TU B28)
530I Engine Power:
Approx. 225 hp @ 5900 rpm (M54 B30)
540I Engine Power:
Approx. 282 hp @ 5400 rpm (M62 B44TU)
530I Engine Torque:
Approx. 225 lb-ft @ 3500 rpm (M54 B30)
540I Engine Torque:
Approx. 324 lb-ft @ 3600 rpm (M62 B44TU)
Fuel System Type:
Electronic Fuel Injection (EFI) with Bosch Motronic engine management
Timing Chain Intervals:
No scheduled replacement (designed for the life of the engine with proper maintenance), but inspection and potential tensioner/guide replacement is covered.
Spark Plug Replacement Interval:
Approximately 100,000 miles (or as specified in the manual, varies by engine)
Standard Transmission Offered:
5-speed Manual Transmission (Getrag 280/370)
Optional Transmission Offered:
5-speed Automatic Transmission (GM 5L40-E for 6-cyl, ZF 5HP30/5HP24 for V8)
Transmission Fluid Type:
BMW ATF Dexron III/VI (for GM 5L40-E), ZF Lifeguardfluid 5 (for ZF 5HP series) - manual specifies exact BMW part numbers
Automatic Transmission Fluid Change Interval:
BMW initially recommended 'lifetime' fluid, but later revised to recommend fluid and filter changes approximately every 60,000 miles for optimal longevity. Manual details the procedure.
Wheelbase Sedan:
111.4 inches (2830 mm)
Length Sedan:
188.7 inches (4793 mm)
Width Sedan:
70.2 inches (1783 mm)
Height Sedan:
56.6 inches (1438 mm)
Wheelbase Wagon:
111.4 inches (2830 mm)
Curb Weight 528I:
Approximately 3571 lbs (1620 kg)
Curb Weight 540I:
Approximately 3858 lbs (1750 kg)
Gross Vehicle Weight Rating:
Varies by model, detailed in manual
Cargo Volume Sedan:
Approx. 15.0 cubic feet
Cargo Volume Wagon:
Approx. 21.8 cubic feet (rear seats up) / 59.3 cubic feet (rear seats folded)
NHTSA Front Impact Rating:
5-Star (for the period)
Active Safety Features:
ABS (Anti-lock Braking System), ASC+T (Automatic Stability Control and Traction Control), DSC (Dynamic Stability Control - later models)
Passive Safety Features:
Front airbags, Side airbags (optional or standard depending on trim/year), Seatbelt pre-tensioners, Crumple zones, Reinforced chassis
Recall Information Coverage:
Manual likely references common safety-related issues that may have been subject to recalls or technical service bulletins (TSBs), such as airbag sensor issues or fuel pump concerns.
Infotainment Systems Covered:
Details on the BMW Professional Radio, Navigation systems (MK III, MK IV), CD changers, and premium audio systems (e.g., Harman Kardon).
Driver Assistance Features:
Parking sensors (Park Distance Control - PDC), cruise control, and optional automatic climate control.
Connectivity Features:
Details on BMW's early phone integration systems (e.g., BMW Assist) and external audio inputs (where applicable).
Electrical Diagnostics Coverage:
Comprehensive wiring diagrams for all major systems, diagnostic procedures for common electrical faults, and information on modules like the DME (Digital Motor Electronics), ABS control unit, and body control modules.
Oil Change Interval:
Variable Service Interval Indicator (VSI) system typically recommends oil changes between 7,500 and 15,000 miles or annually, depending on driving conditions. Manual details VSI reset procedures.
Brake Fluid Change Interval:
Recommended every 2 years, regardless of mileage, to maintain braking performance and prevent corrosion.
Engine Oil Specification:
BMW Longlife-98 (LL-98) or Longlife-01 (LL-01) synthetic oil, typically SAE 5W-30 or 5W-40 depending on climate. Manual will specify exact BMW approval numbers.
Coolant Specification:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) mixed 50/50 with distilled water.
Power Steering Fluid:
Pentosin CHF 11S or an approved equivalent.
Clutch Fluid Type:
DOT 4 (for manual transmission models)
Common Issues Covered:
Vanous problems such as cooling system leaks (radiator, hoses, expansion tank), oil leaks (valve cover gasket, oil pan gasket, oil filter housing), CCV system failures, ABS/DSC sensor issues, window regulator failures, fuel pump failures, pixilation on the instrument cluster LCD, and worn suspension bushings.
Ccv System Maintenance:
Details on inspecting and replacing the Crankcase Ventilation (CCV) system, a common failure point leading to oil consumption and engine issues.
Cooling System Maintenance:
Procedures for replacing the water pump (often plastic impeller failure), thermostat, radiator, and hoses, which are common wear items.
Brand Heritage:
BMW (Bayerische Motoren Werke AG) has a long-standing reputation for building performance-oriented luxury vehicles, with a focus on driving pleasure ('The Ultimate Driving Machine').
Model Evolution:
The E39 succeeded the E34 and was a significant evolution, featuring a stiffer chassis, improved aerodynamics, and a wider range of advanced features. It was succeeded by the E60 generation.
Production Period:
1995-2003 (E39 platform worldwide, with 1997-2002 being the specific focus of this manual).
Production Locations:
Primary assembly in Dingolfing, Germany.
Car And Driver 10 Best:
The E39 5 Series was frequently named to Car and Driver's '10Best' list during its production years, acknowledging its benchmark status in the luxury sport sedan segment.
Ward S 10 Best Engines:
Several of the E39's engines, particularly the inline-six variants, were recognized by Ward's '10Best Engines' for their smoothness, power delivery, and efficiency.
