Brand Perception:
Luxury, Performance, Engineering
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type
Vehicle Focus:
Balanced ride and handling, refined interior, powerful engine options, advanced (for its time) technology
Manual Value Proposition:
Provides OEM-level diagnostic and repair information, empowering owners and technicians to maintain and restore the E39 to factory standards.
Primary Coverage:
Mechanical, Electrical, Body, and Diagnosis
Target Audience:
Professional Mechanics and DIY Enthusiasts
Type:
Factory Service Manual / Repair Manual
Powertrain:
Engine Mechanical, Fuel System, Ignition System, Emission Control, Engine Management, Cooling System, Lubrication System, Exhaust System
Drivetrain:
Transmission (Manual & Automatic), Clutch, Driveshafts, Differential, Axles
Chassis:
Suspension (Front & Rear), Steering System, Braking System (ABS, DSC), Wheels & Tires
Electrical:
Battery, Charging System, Starting System, Lighting, Instrumentation, Audio System, Climate Control, Power Accessories (Windows, Locks, Seats)
Body And Interior:
Body Panels, Doors, Bumpers, Glass, Upholstery, Trim, Security System
Diagnostics:
Diagnostic Trouble Codes (DTCs), On-Board Diagnostics (OBD-II), System Schematics, Troubleshooting Flowcharts
Maintenance:
Scheduled Maintenance Intervals, Fluid Checks & Changes, Filter Replacements, Spark Plug Replacement, Belt Inspection & Replacement
Repair:
Engine Overhaul, Transmission Rebuild, Brake Component Replacement, Suspension Component Replacement, Electrical Component Repair/Replacement, Body Panel Repair
Disassembly Assembly:
Detailed step-by-step instructions for removing and reinstalling all major components and sub-assemblies
Troubleshooting:
Systematic diagnosis of common and uncommon faults with guided steps to identify root causes
Specifications Data:
Torque values, clearances, fluid capacities, electrical specifications, diagnostic data
Depth:
Comprehensive (from basic fluid checks to full engine and transmission overhauls, including electronic diagnostics)
Searchability:
Fully searchable PDF with hyperlinked table of contents
Quality:
High-resolution, clear diagrams and text
Printability:
Printable pages for easy workshop use
Binding:
Not Applicable (Digital Format)
Paper Type:
Not Applicable (Digital Format)
Engine Families Covered:
M52TU (Inline-6) and M62TU (V8)
Common Variants Covered:
523i (2.5L), 525i (2.5L - M54 on later E39s, but M52TU predecessor), 528i (2.8L), 530i (3.0L - M54 on later E39s, but M52TU predecessor), 540i (4.4L V8)
528I Performance:
Approx. 193 hp @ 5300 rpm, 206 lb-ft @ 3950 rpm
540I Performance:
Approx. 290 hp @ 5400 rpm, 324 lb-ft @ 3600 rpm
Injection Type:
Electronic Fuel Injection (EFI) - Bosch Motronic
Fuel Type:
Premium Unleaded Gasoline (91+ Octane Recommended)
Inline 6 Std:
5-speed Manual (Getrag 260/6 or ZF S5-31)
V8 Std:
5-speed Automatic (ZF 5HP24)
Inline 6 Opt:
5-speed Automatic (ZF 5HP19)
V8 Opt:
6-speed Manual (Getrag 420G - rare option, primarily on 540i Sport)
Automatic Features:
Steptronic (manual shifting mode)
Length:
Approx. 190.6 inches (4842 mm)
Width:
Approx. 71.1 inches (1806 mm)
Height:
Approx. 57.0 inches (1448 mm)
Curb Weight 528I:
Approx. 3571 lbs (1620 kg)
Curb Weight 540I:
Approx. 3858 lbs (1750 kg)
NHTSA Front Impact:
4/5 Stars (as of its era)
IIHS Side Impact:
Good (as of its era)
ABS:
Standard Anti-lock Braking System
Asc:
Optional/Standard Automatic Stability Control (ASC+T on some models)
Dsc:
Dynamic Stability Control (available on later models or as an option)
Airbags:
Frontal airbags, Side airbags (optional/standard)
Seatbelts:
Pretensioning seatbelts with force limiters
Head Unit:
BMW Business CD, BMW Professional CD RDS, BMW Navigation Professional (with MK III or MK IV drives)
Audio Options:
Harman Kardon sound system (optional)
Parking Sensors:
Park Distance Control (PDC) available on some models.
Phone Integration:
BMW Assist/TeleAid system (early cellular integration), optional Bluetooth phone preparation.
Oil Change Interval:
BMW Condition Based Service (CBS) system dictates intervals, typically 10,000-15,000 miles or annually. Manual will provide detailed CBS reset procedures.
Coolant Change:
BMW recommends every 2 years or 30,000 miles (refer to manual for specific variant)
Spark Plugs:
Approx. 100,000 miles for long-life plugs (e.g., NGK BKR6EQUP for M52TU/M54, NGK BKR5EKN for M62TU)
Engine Oil 5W-30:
BMW Longlife-01 (LL-01) approved synthetic oil, e.g., Castrol Syntec 5W-30, Mobil 1 5W-30
Coolant:
BMW Blue Antifreeze/Coolant (G48 formulation) mixed 50/50 with distilled water
Transmission Fluid Auto:
ZF Lifeguardfluid 5 (LF-01), e.g., Pentosin ATF1 or genuine ZF fluid
Transmission Fluid Manual:
MTF LT-2 (e.g., Castrol SMX-S or equivalent)
Brake Fluid:
DOT 4 BMW Premium Brake Fluid
Cooling System:
Plastic expansion tank cracking, water pump failure, thermostat housing leaks.
Vanos:
VANOS (Variable Valve Timing) system seals can degrade, leading to rough idle and low-end torque loss.
Suspension:
Front control arm bushings and rear shock mounts are common wear items.
Electrical:
Pixelation on the instrument cluster LCD (often requires refurbishing), ABS/DSC sensor failures, alternator failures.
Oil Leaks:
Valve cover gasket leaks, oil pan gasket leaks, O-ring seals.
Bmw Philosophy:
'The Ultimate Driving Machine' - focus on performance, engineering, and driver engagement.
E39 Introduction:
Launched in 1995 as a replacement for the E34 5 Series. Known for its sophisticated chassis, improved aerodynamics, and luxurious yet driver-focused interior.
E39 Facelift:
Significant facelift (LCI) occurred in September 2000, introducing updated headlights, taillights, bumpers, and interior enhancements, as well as new engine options (e.g., M54). This manual specifically covers the pre-LCI 2000 model year.
Manufacturing Locations:
Dingolfing, Germany; Rosslyn, South Africa; Magna Steyr, Austria
