BMW 5 Series (E39) Years 1997-2002 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Generation Generation Name: Fourth Generation Generation Years: 1995-2003 (Europe), 1997-2003 (North America) Codes Covered Years: 1997, 1998, 1999,...

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类型: Car

斯库: 372701

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

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Generation

Generation Name:

Fourth Generation

Generation Years:

1995-2003 (Europe), 1997-2003 (North America)

Codes

Covered Years:

1997, 1998, 1999, 2000, 2001, 2002

👋 Introduction

Market Position

Segment:

Executive Sedan and Wagon

Target Audience:

Owners seeking to perform maintenance and repairs, DIY enthusiasts, professional mechanics.

Competitive Analysis

Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160).

Key Features

Manual Value Proposition:

Comprehensive, detailed, digital for ease of use and printing specific sections.

Ease Of Use:

Numbered instructions, bold figure numbers, numbered table of contents for quick information retrieval.

Visual Aids:

Detailed illustrations, drawings, photos, and enlarged inset views for clarity.

Delivery Method:

Instant Download

📋 Manual Details

Coverage Areas

Models Covered:

525i, 528i, 530i, 540i

Body Styles Covered:

Sedan, Sport Wagon (Touring)

Page Count

Estimated Page Count:

Hundreds (as specified in product description)

Manual Type

Type:

Service and Repair Manual (Workshop Manual)

Language

Language:

English

Format

File Format:

Adobe Acrobat Document (.pdf)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, maintenance, diagnostics, including timing belt and head gasket replacement (for applicable engines).

Transmission:

Repair and service procedures for both manual and automatic transmissions.

Drivetrain:

Differential, drive shafts, axles, and related components.

Suspension:

Front and rear suspension components, including shock absorbers, struts, control arms, bushings, and alignment.

Steering:

Power steering system, steering rack, tie rods, and related components.

Brakes:

Disc brake systems (front and rear), including pad replacement, rotor service, caliper repair, brake fluid bleeding, and ABS system diagnostics.

Electrical System:

Comprehensive coverage of the vehicle's electrical system, including battery, alternator, starter, lighting, power windows, central locking, and diagnostic procedures.

Engine Management:

Fuel injection system, ignition system, emissions control, and ECU diagnostics.

Cooling System:

Radiator, water pump, thermostat, hoses, and coolant specifications.

Fuel System:

Fuel pump, fuel filter, fuel injectors, and fuel tank service.

Exhaust System:

Catalytic converter, mufflers, exhaust pipes, and oxygen sensors.

HVAC System:

Air conditioning and heating system components, refrigerant, and service procedures.

Body And Chassis:

Body panel removal and installation, door mechanisms, interior trim, glass, and chassis components.

Body Electrical:

Wiper system, horn, interior lighting, and control modules.

Safety Systems:

Airbag system diagnostics and service, seat belt mechanisms.

Procedures Included

Maintenance:

Oil changes, filter replacements (air, oil, fuel, cabin), spark plug replacement, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid).

Troubleshooting:

Diagnostic procedures for common and uncommon issues, electrical system troubleshooting, fault code interpretation.

Repair:

Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, and electrical component replacement.

Installation:

Procedures for installing replacement parts and components.

Diagnostics:

Detailed diagnostic charts, wiring diagrams, and procedures for identifying and resolving problems.

Technical Depth

Depth:

Comprehensive, from basic owner maintenance to advanced engine and transmission overhauls. Suitable for DIY enthusiasts and professional mechanics.

Detail Level:

Detailed substeps, notes, cautions, and warnings for critical information.

📊 Manual Specifications

File Format

File Type:

Searchable:

Implied by PDF format and digital delivery, allowing for text search.

Print Quality

Printability:

Full Printable

Zoom Capability:

Zoom IN/OUT YES

Binding Type

Binding:

Digital Download (No physical binding)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine 525I:

M54B25 (2.5L inline-6), VANOS, Double VANOS

Engine 528I:

M52TUB28 (2.8L inline-6), VANOS

Engine 530I:

M54B30 (3.0L inline-6), VANOS, Double VANOS

Engine 540I:

M62B44 (4.4L V8), VANOS (early), Double VANOS (later models, from 1998/1999)

Performance

Horsepower 525I:

189 hp @ 6000 rpm (M54B25)

Torque 525I:

245 Nm (181 lb-ft) @ 3500 rpm (M54B25)

Horsepower 528I:

190 hp @ 5500 rpm (M52TUB28)

Torque 528I:

280 Nm (207 lb-ft) @ 3950 rpm (M52TUB28)

Horsepower 530I:

225 hp @ 5900 rpm (M54B30)

Torque 530I:

300 Nm (221 lb-ft) @ 3500 rpm (M54B30)

Horsepower 540I:

282 hp @ 5400 rpm (M62B44 - 1997-1998), 290 hp @ 5400 rpm (M62TU B44 - 1999-2003)

Torque 540I:

440 Nm (325 lb-ft) @ 3600 rpm (M62B44), 440 Nm (325 lb-ft) @ 3600 rpm (M62TU B44)

Fuel System

Fuel Injection:

Electronic Fuel Injection (EFI), Bosch Motronic management.

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

🔧 Transmission

Standard

Transmission Standard:

5-speed Manual (Getrag 280 for 6-cyl, ZF S6-37 for 8-cyl)

Optional

Transmission Optional:

5-speed Automatic (ZF 5HP19 for 6-cyl, ZF 5HP24 for 8-cyl)

Features

Automatic Features:

Steptronic manual shift mode (on most models).

📐 Dimensions

Exterior

Wheelbase:

2830 mm (111.4 in)

Length Sedan:

4770 mm (187.8 in)

Length Wagon:

4865 mm (191.5 in)

Width:

1799 mm (70.8 in)

Height Sedan:

1436 mm (56.5 in)

Height Wagon:

1470 mm (57.9 in)

Cargo

Trunk Volume Sedan:

520 L (18.4 cu ft)

Cargo Volume Wagon Seats Up:

465 L (16.4 cu ft)

Cargo Volume Wagon Seats Down:

1525 L (53.8 cu ft)

Weights

Curb Weight 525I Auto:

approx. 1590 kg (3505 lbs)

Curb Weight 540I Auto:

approx. 1760 kg (3880 lbs)

🛡️ Safety Features

Ratings

NHTSA Front Driver:

5-star (for models equipped with optional side airbags)

NHTSA Front Passenger:

5-star (for models equipped with optional side airbags)

Active Features

Stability Control:

Dynamic Stability Control (DSC) standard on most models.

Traction Control:

Automatic Stability Control and Traction (ASC+T) standard on most models.

Brakes:

Anti-lock Braking System (ABS) standard.

Passive Features

Airbags:

Front airbags, optional front side airbags, optional head protection system (HPS).

Seatbelts:

3-point inertia-reel seatbelts with pretensioners and force limiters.

💡 Technology Features

Infotainment

Navigation System:

Optional BMW Professional Navigation System (Mk III/Mk IV).

Audio System:

Optional Hi-Fi or Top Hi-Fi sound systems from Harman Kardon.

Climate Control:

Automatic climate control with dual-zone temperature settings.

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Cruise Control:

Standard cruise control.

Connectivity

Phone Integration:

Optional Bluetooth hands-free preparation and cradle.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil used (refer to manual for specifics).

Brake Fluid Change:

Recommended every 2 years.

Coolant Change:

Typically every 2-4 years or 30,000-50,000 miles.

Transmission Fluid Change:

Recommended at intervals such as 60,000 miles for automatic transmissions, though BMW often listed as 'lifetime' fluid (manual service is prudent).

Fluid Specifications

Engine Oil Type:

Synthetic engine oil meeting BMW LL-01 specifications (e.g., 0W-30, 5W-30, 5W-40).

Coolant Type:

BMW Blue Antifreeze (G48) or equivalent ethylene glycol-based coolant with corrosion inhibitors.

Brake Fluid Type:

DOT 4 or DOT 4 LV (Low Viscosity) brake fluid.

Power Steering Fluid:

Pentosin CHF 11S or BMW approved equivalent.

Known Issues

Common E39 Issues Cooling:

Plastic coolant expansion tanks prone to cracking, thermostat housing leaks, water pump failure.

Common E39 Issues Suspension:

Control arm bushings, sway bar links, front strut mounts wear out.

Common E39 Issues Electrical:

CCFL angel eye headlights dimming/flickering, OBC 'check control' system faults, ABS/DSC sensor issues.

Common E39 Issues Engine:

PCV (Positive Crankcase Ventilation) system clogs (causing oil leaks/sludge), VANOS solenoids/seals, oil pan gasket leaks (especially on M62 V8).

Common E39 Issues Transmission:

Automatic transmission valve body issues, driveshaft flex disc wear.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Ultimate Driving Machine, focus on performance, luxury, and engineering.

Model Evolution

E39 Introduction:

Introduced in 1995 (Europe) and 1996 (North America) as the successor to the E34 5 Series.

E39 Facelift:

Significant facelift (LCI) for the 2001 model year, introducing updated styling, engines (M54 series), and technology.

Performance Variants:

M5 (E39) with S62 4.9L V8 engine, not covered in this specific manual.

Production

Production Period:

1995-2003

Manufacturing Plants:

Dingolfing, Germany; Austria; Brazil; Egypt; Russia; Thailand; Ukraine; Vietnam.

🏆 Awards & Recognition

Recognitions

Car And Driver Best List:

Car and Driver '10Best' list multiple times during its production run.

Ward S Auto World Engine And Powertrain:

Some E39 engines, particularly the M54 inline-six, were recognized for their engineering.