BMW 5 Series 1997-2002 E39 Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Model Years Covered: 1997-2002 Generation Generation Designation: Fourth Generation (E39) Codes Bmw Service Manual Codes: Likely a comprehensive...

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类型: Car

斯库: 374870

标签: 1997 1998 1999 2000 2001 2002 5 Series BMW Car Cars E39

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Years Covered:

1997-2002

Generation

Generation Designation:

Fourth Generation (E39)

Codes

Bmw Service Manual Codes:

Likely a comprehensive service and repair manual, potentially referencing official BMW service bulletin numbers within its content.

👋 Introduction

Market Position

Market Segment:

Executive Sedan / Luxury Mid-size Sedan

Bmw Positioning:

The E39 5 Series was positioned as a premium sports sedan offering a balance of luxury, performance, and advanced technology, competing with the Mercedes-Benz E-Class and Audi A6.

Competitive Analysis

Key Competitors:

Mercedes-Benz W210 E-Class, Audi A6 C5, Lexus GS, Volvo S80.

Key Features

Chassis Design:

Advanced chassis design with extensive use of aluminum components for weight reduction and improved handling.

Handling Dynamics:

Renowned for its 'ultimate driving machine' dynamics, featuring excellent steering feel, chassis balance, and suspension tuning.

Technology Integration:

Early adoption of integrated electronic systems, including CAN bus communication, advanced infotainment, and optional driver aids.

📋 Manual Details

Coverage Areas

Diagnostic Troubleshooting:

Scheduled Maintenance:

Engine Repair:

Transmission Service:

Suspension Steering:

Braking System:

Electrical Systems:

HVAC System:

Body Interior:

Wiring Diagrams:

Page Count

Estimated Page Count:

1000+ (typical for a comprehensive E39 repair manual)

Manual Type

Manual Type:

Complete Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Likely a printed book, but digital formats (PDF) are common for these types of manuals.

📖 Manual Coverage

Systems Covered

Engine Management:

Detailed diagnostics, component testing, and repair procedures for DME (Digital Motor Electronics) systems, including sensors, actuators, and fuel injection.

Transmission Control:

Covers both manual and automatic transmissions (e.g., GM 5L40-E, ZF 5HP19, ZF 5HP24), including shift solenoids, valve bodies, and TCU (Transmission Control Unit) diagnostics.

Suspension Components:

Includes detailed procedures for struts, shocks, control arms, bushings, ball joints, sway bars, and suspension diagnostics.

Steering Systems:

Covers hydraulic power steering systems, steering racks, tie rods, and steering column adjustments.

Brake System Components:

Detailed coverage of ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake fluid service, caliper replacement, rotor machining/replacement, and bleeding procedures.

Climate Control:

Includes diagnosis and repair for HVAC systems, automatic climate control, blower motor, evaporator core, condenser, and refrigerant handling.

Body Electrical:

Covers lighting systems, power windows, central locking, mirrors, seats, door modules, and interior trim removal/installation.

Infotainment Audio:

May include basic troubleshooting for the factory radio, CD changer, and speaker systems.

Instrument Cluster:

Diagnosis and repair of the instrument cluster, including warning lights, gauges, and OBC (On-Board Computer).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin), spark plug replacement, and fluid checks.

Troubleshooting Diagnostics:

Step-by-step diagnostic routines for common and uncommon problems, including symptom identification and fault code interpretation.

Component Replacement:

Detailed instructions for replacing wear items and major components like alternators, starters, water pumps, radiators, and fuel pumps.

Rebuild Procedures:

In-depth procedures for engine internal repairs, transmission overhauls, and differential rebuilds where applicable.

Electrical Repairs:

Detailed wiring diagrams, connector pinouts, and procedures for diagnosing and repairing electrical faults.

Body Panel Removal:

Instructions for removing and reinstalling bumpers, fenders, doors, hoods, and trunk lids.

HVAC System Servicing:

Refrigerant charging, leak detection, component replacement (compressor, expansion valve), and blower motor service.

Safety Systems Service:

Airbag system precautions and replacement procedures, ABS sensor testing, and DSC component diagnosis.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic fluid changes and component replacement to full engine and transmission overhauls, including detailed electrical diagnostics.

Special Tools Required:

Yes, lists and often illustrates special tools required for specific procedures (e.g., timing chain tensioner tools, suspension alignment tools).

Torque Specifications:

Includes detailed torque specifications for all critical fasteners across various systems.

Clearances Tolerances:

Provides critical measurements and tolerances for engine components, brake systems, and suspension parts.

📊 Manual Specifications

File Format

Digital Format:

PDF (if digital) - High resolution, searchable text, printable pages.

Print Quality

Print Quality:

High quality print with clear diagrams and easy-to-read text (if printed).

Binding Type

Binding Type:

Staple-bound, perfect bound, or spiral-bound for durability and ease of use in a workshop environment (if printed).

Paper Type

Paper Type:

Durable, possibly coated paper to withstand grease and oil in a workshop setting (if printed).

⚙️ Engine Specifications

Primary Engine

Engine Options:

M52TU (Inline-6), M62TU (V8), S62 (V8 - for M5 model).

Engine Codes Examples:

M52TUB25 (2.5L), M52TUB28 (2.8L), M62TUB44 (4.4L), M62TUB35 (3.5L), S62B50 (5.0L).

Performance

Horsepower Range:

189 hp (2.5L) to 400 hp (M5 5.0L).

Torque Range:

245 Nm (2.5L) to 500 Nm (M5 5.0L).

Fuel System

Fuel Delivery:

Sequential multi-point fuel injection (MFI), Electronic throttle control (ETC) on later models and V8s.

Fuel Type:

Premium Unleaded Gasoline (91+ Octane).

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual (Getrag 280/5 for most models).

Optional

Optional Transmission:

5-speed Automatic (GM 5L40-E, ZF 5HP19, ZF 5HP24 - depending on engine).

Features

Automatic Features:

Steptronic (manual shifting mode) on most automatic transmissions.

Fluid Specs

Automatic Transmission Fluid:

BMW ATF LT-3 (e.g., Pentosin ATF1 or equivalent recommended by manufacturer). Specifics vary by transmission type.

Manual Transmission Fluid:

API GL-4/GL-5 or manufacturer-specific gear oil (e.g., BMW Manual Transmission Fluid MTF LT-2). Specifics vary by transmission.

📐 Dimensions

Exterior

Wheelbase:

111.4 inches (2830 mm)

Overall Length:

188.0 inches (4775 mm)

Overall Width:

71.0 inches (1803 mm)

Overall Height:

57.5 inches (1461 mm)

Weights

Curb Weight Range:

Approx. 3500 - 4000 lbs (1588 - 1814 kg), varying by engine and options.

Wheel Bolt Pattern:

5x120 mm

Center Bore:

72.5 mm

Cargo

Trunk Volume:

Approx. 15.0 cubic feet (425 liters)

🛡️ Safety Features

Ratings

NHTSA Ratings:

Generally received good ratings for its era, with some models achieving 4 or 5 stars in frontal impact tests. Specific ratings may vary by year and testing protocol.

Active Features

Standard Anti-lock Braking System (ABS).

Optional Dynamic Stability Control (DSC) / Traction Control.

Passive Features

Airbags:

Frontal airbags for driver and passenger, optional side-impact airbags.

Body Structure:

Reinforced passenger cell, crumple zones.

💡 Technology Features

Infotainment

Navigation System:

Optional BMW Professional Navigation system with CD-ROM based maps.

Audio System:

Factory Harman Kardon audio system available on higher trims, with CD player and optional CD changer.

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC).

Headlights:

Optional Xenon headlights with automatic leveling.

Connectivity

Cellular Integration:

Optional BMW Assist with Tele Aid functionality (emergency services, vehicle location).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, depending on driving conditions and oil used. BMW's Condition Based Service (CBS) system would monitor this.

Spark Plug Replacement:

Around 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (e.g., platinum or iridium).

Coolant Flush:

Recommended every 2-4 years or 30,000-50,000 miles (48,000-80,000 km).

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil Type:

BMW Longlife-01 (LL-01) or LL-98 approved synthetic oil, typically 5W-30 or 5W-40, depending on engine and climate.

Coolant Type:

BMW Blue Antifreeze (G48 ethylene glycol based).

Power Steering Fluid:

CHF 11S hydraulic fluid (Pentosin).

Known Issues

Cooling System:

Common issues include thermostat housing leaks, water pump failure, and radiator cracks. The plastic coolant expansion tank can also become brittle.

Vanos:

Variable Valve Timing (VANOS) system can develop leaks in seals, leading to rough idle and power loss. This is particularly true for the Double VANOS on M52TU engines.

Oil Pan Gasket:

Oil pan gasket leaks are common due to age and heat.

Window Regulators:

Plastic components in window regulators can break, causing windows to fall into the door.

Suspension Bushings:

Control arm bushings, thrust arm bushings, and subframe bushings can wear out, leading to sloppy handling and noise.

ABS Wheel Speed Sensors:

These sensors are prone to failure, triggering ABS and DSC warning lights.

Mass Air Flow Sensor:

Can become dirty or fail, leading to poor engine performance and check engine lights.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's heritage is rooted in engineering excellence, performance, and driver-focused vehicles, epitomized by the 'Ultimate Driving Machine' slogan.

Model Evolution

Predecessor:

E34 5 Series.

Successor:

E60 5 Series.

Production

Production Period:

1995-2003 (E39 chassis globally).

Manufacturing Locations:

Primary production in Dingolfing, Germany; also assembled in various international locations.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E39 5 Series was a frequent recipient of Car and Driver's '10Best' lists, lauded for its driving dynamics and overall excellence.

Motor Trend Car Of The Year:

While not winning the overall award, it was consistently a strong contender and highly rated by MotorTrend.