1997-2002 BMW 5 Series E39 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Product Name: 1997-2002 BMW 5 Series E39 Workshop Service Repair Manual Generation Production Years: 1995-2003 (E39) Codes Manual...

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类型: Car

斯库: 299513

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

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Product Name:

1997-2002 BMW 5 Series E39 Workshop Service Repair Manual

Generation

Production Years:

1995-2003 (E39)

Codes

Manual Coverage Years:

1997-2002

👋 Introduction

Market Position

Target Audience:

BMW E39 owners, independent repair shops, automotive enthusiasts.

Competitive Analysis

Value Proposition:

Enables DIY repairs, reduces reliance on expensive dealership services, provides in-depth technical understanding.

Key Features

Accessibility:

Searchable PDF format for quick information retrieval.

Support:

Email support available for inquiries.

📋 Manual Details

Coverage Areas

Body Styles:

• Sedan

• Sport Wagon

Engine Variants Covered:

• 525i

• 528i

• 530i

• 540i

Page Count

Estimated Page Count:

Extensive (specific number not provided, but implied comprehensive)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Compatibility:

Windows / Macintosh

📖 Manual Coverage

Systems Covered

Major Systems:

• General Maintenance

• Engine

• Transmission

• Suspension

• Steering

• Brakes

• Body

• Body Equipment

• Electrical System

• Equipment and Accessories

Procedures Included

Repair Procedures:

Detailed repair instructions for all covered systems.

Maintenance Procedures:

Comprehensive general maintenance procedures.

Troubleshooting Guidance:

Implied through workshop service manual nature.

Technical Depth

Depth Of Coverage:

Advanced diagnostics, repair, and overhaul procedures.

Searchability:

Quickly searchable PDF format.

📊 Manual Specifications

File Format

Type:

Digital (PDF)

Print Quality

Quality:

Assumed high-quality digital reproduction, suitable for printing.

Binding Type

Type:

N/A (Digital Format)

Paper Type

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine 525I

Engine Code:

M50/M52/M54 (depending on exact year and region)

Configuration:

Inline-6 Cylinder

Displacement:

2.5 Liters (2494 cc)

Primary Engine 528I

Engine Code:

M52/M54 (depending on exact year and region)

Configuration:

Inline-6 Cylinder

Displacement:

2.8 Liters (2793 cc)

Primary Engine 530I

Engine Code:

M54 (introduced later in E39 production)

Configuration:

Inline-6 Cylinder

Displacement:

3.0 Liters (2979 cc)

Primary Engine 540I

Engine Code:

M62 / M62TU (TU = Technical Update)

Configuration:

V8 Cylinder

Displacement:

4.4 Liters (4398 cc)

Performance

Power Output Range:

Approx. 190 hp (525i) to 290 hp (540i, M62TU)

Torque Output Range:

Approx. 205 lb-ft (525i) to 324 lb-ft (540i, M62TU)

Fuel System

Type:

Sequential Multi-Port Fuel Injection (MPFI) on all variants.

Engine Maintenance

Spark Plugs:

Specific part numbers and torque specifications will be detailed in the manual.

Timing Belt Chain:

Inline-6 engines use timing chains; V8 engines use timing chains. Service intervals and checks are covered.

🔧 Transmission

Standard

Type:

5-speed Manual (Getrag 260/S5D 250G for 6-cyl, Getrag 420G for V8)

Optional

Type:

5-speed Automatic (ZF 5HP18, 5HP19, 5HP24, 5HP30 depending on engine)

Features

Manual Shift Patterns:

Detailed shift patterns and procedures will be included.

Automatic Transmission Control:

Information on Steptronic functionality (if equipped) and electronic control units.

Fluid Specifications

Automatic Transmission Fluid:

Specific ZF fluid types (e.g., ZF LifeguardFluid 5) will be detailed.

Manual Transmission Fluid:

Specific gear oil specifications (e.g., Pentosin, Castrol) will be detailed.

📐 Dimensions

Exterior

Wheelbase:

Approximately 111.4 inches (2830 mm)

Length:

Approximately 188.4 inches (4786 mm)

Width:

Approximately 70.2 inches (1783 mm)

Height:

Approximately 56.5 inches (1435 mm)

Cargo

Trunk Volume:

Sedan: approx. 17.7 cu ft (500 L); Wagon: Varies with seats up/down

Weights

Curb Weight Range:

Approximately 3500 lbs (525i) to 4000 lbs (540i)

🛡️ Safety Features

Ratings

NHTSA Ratings:

Refer to specific model year and configuration; generally performed well for its era.

Active Features

Braking System:

Four-wheel disc brakes with ABS. Later models may feature Dynamic Stability Control (DSC).

Traction Control:

Available on many models (ASC+T or DSC).

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags optional on many models.

Body Structure:

Reinforced chassis and crumple zones.

💡 Technology Features

Infotainment

Navigation System:

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

Audio System:

Various BMW Business and Professional CD/Radio units. Harman Kardon upgrade available on some models.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Connectivity

Phone Integration:

Optional BMW integrated cellular phone system (often analogue or early digital).

🔧 Maintenance

Service Intervals

Oil Change:

Variable Service Interval (VSI) system or typically 7,500-10,000 miles, depending on driving conditions and oil type. Manual will specify exact intervals and indicators.

Air Filter:

Check/replace every 15,000-30,000 miles or as per VSI system.

Cabin Filter:

Replace annually or as needed.

Brake Fluid:

Flush and replace every 2 years.

Fluid Specifications

Engine Oil:

BMW Longlife-01 (LL-01) or equivalent synthetic oil, viscosity typically 5W-30 or 5W-40 (refer to manual for specific engine requirements).

Coolant:

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

Known Issues

Common E39 Issues:

• Cooling system component failures (water pump, thermostat, hoses, expansion tank)

• Vanoseal leaks (M52/M54 engines)

• ABS/DSC wheel speed sensor failures

• Ignition coil failures

• Sway bar links and bushings wear

• Headliner sagging

• Pixelfehler (display pixel failure) in instrument cluster and radio

• Oil separator system (CCV) clogging (M54 engines)

• Eccentric shaft sensor failure (N62 V8, later model specific but relevant context)

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Performance, luxury, and engineering excellence.

Model Evolution

E39 Introduction:

Launched in 1995 (for the 1996 model year in Europe, 1997 in North America), succeeded the E34.

Midcycle Refresh:

Facelift in 2000, featuring updated headlights, taillights, bumpers, and interior refinements, along with introduction of M54 engines.

Production

Manufacturing Locations:

Primary production in Dingolfing, Germany. CKD assembly in other locations.

Production End:

E39 production ended in 2003, succeeded by the E60 5 Series.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

BMW 5 Series (various E39 configurations) frequently appeared on Car and Driver's 10Best lists during its production run.

Ratings

Reliability Reputation:

Generally considered reliable when properly maintained, though specific components can be costly to repair if neglected.