🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E39

Generation Designation:

Fourth Generation

Internal Project Code:

E39

👋 Introduction

Segment:

Executive Sedan/Wagon

Target Audience:

Discerning buyers valuing luxury, performance, and engineering.

Key Competitors:

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

Vehicle Attributes:

Renowned for driving dynamics, sophisticated engineering, upscale interiors, and a range of powerful inline-six and V8 engines.

📋 Manual Details

Primary Coverage:

Service, Repair, Maintenance, Troubleshooting

Specific Systems:

Engine, Transmission, Drivetrain, Suspension, Brakes, Steering, Electrical, Bodywork, HVAC, Fuel System, Exhaust System, Interior/Exterior Trim

Estimated Page Count:

Extensive (typical factory service manuals for this era are 2000+ pages)

Type:

Factory Service Manual / Workshop Manual

Language:

English

File Format:

PDF

Compatibility:

Windows (95/98/ME/XP/Vista/7), Linux, macOS

📖 Manual Coverage

Engine:

Detailed diagnostics, repair procedures, component identification for M52/M54 (6-cylinder) and M62 (V8) engines, including timing, valve adjustments, cooling system, lubrication, fuel injection, ignition, emission controls.

Transmission:

Service and repair for both automatic (e.g., GM 5L40-E, ZF 5HP series) and manual transmissions, including fluid changes, seal replacement, clutch service (manual), and internal component repair.

Drivetrain:

Front and rear suspension geometry, component replacement (control arms, ball joints, shock absorbers, struts), wheel alignment specifications, differential service (fluid changes, seal replacement), driveshaft and CV joint maintenance.

Brakes:

Hydraulic system diagnostics, brake pad and rotor replacement, caliper service, ABS/DSC system troubleshooting, parking brake adjustment and repair.

Electrical:

Comprehensive wiring diagrams, component location, fuse and relay identification, diagnostic procedures for ECU, body control module (BCM), lighting, power accessories, instrument cluster, and infotainment systems.

Exhaust:

Component identification, replacement procedures for catalytic converters, mufflers, exhaust pipes, and oxygen sensors. Emissions system diagnostics.

Interior Trim:

Removal and installation procedures for door panels, dashboard components, center console, headliner, and seat upholstery.

Exterior Trim:

Removal and installation of bumpers, grilles, headlights, taillights, mirrors, and body side moldings.

Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, differential fluid change, transmission fluid change, cabin air filter replacement.

Repair:

Engine component rebuilds (e.g., head gasket, VANOS), transmission overhaul, suspension component replacement, brake system overhauls, starter and alternator replacement, radiator and water pump replacement.

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, fault code interpretation (OBD-II), electrical system fault finding, mechanical component testing.

Clutch Service:

Replacement of clutch disc, pressure plate, release bearing, and pilot bearing for manual transmission models. Flywheel inspection and resurfacing/replacement.

Propeller Shaft:

Inspection and replacement of universal joints, center support bearing, and balancing.

Depth:

Comprehensive from routine maintenance to complete engine and transmission rebuilds, including detailed torque specifications, diagnostic procedures, and component testing methods.

Special Tools:

Identification and usage of specialized BMW tools required for specific repair procedures (e.g., VANOS tools, engine timing tools).

Engine Management:

Detailed explanation of DME (Digital Motor Electronics) functions, sensor inputs (MAF, MAP, O2, Crank/Cam position), actuator outputs (injectors, ignition coils, VANOS solenoids), and diagnostic procedures.

Chassis Electronics:

Coverage of ABS, DSC, EBD, and early traction control systems, including sensor diagnostics, hydraulic unit troubleshooting, and module communication.

📊 Manual Specifications

Quality:

High-resolution PDF, designed for clear viewing and printing of diagrams and text.

Searchability:

Likely text-searchable PDF, allowing quick navigation to specific topics.

Print Capability:

Printable pages for on-the-go reference.

Binding:

Not Applicable (Digital Download)

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

525I:

3.0L M54B30 I6 (later models) or 2.5L M52TU B25 I6 (earlier models)

528I:

2.8L M52TU B28 I6

530I:

3.0L M54B30 I6

540I:

4.4L M62TU V8

530I Hp:

225 hp @ 5900 rpm

530I Torque:

214 lb-ft @ 3500 rpm

540I Hp:

290 hp @ 5400 rpm

540I Torque:

324 lb-ft @ 3600 rpm

Injection Type:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded (91 octane or higher recommended)

🔧 Transmission

525I 528I 530I:

5-speed manual transmission (Getrag 420G) or 5-speed Steptronic automatic transmission.

540I:

5-speed Steptronic automatic transmission (GM 5L40-E).

540I Manual Option:

A rare 6-speed manual transmission (Getrag 420G) was available on some 540i models, particularly early ones.

Steptronic:

Allows manual shifting of automatic transmission via selector lever or steering wheel buttons.

📐 Dimensions

Wheelbase:

115.4 inches (2931 mm)

Length:

190.6 inches (4841 mm)

Width:

71.5 inches (1816 mm)

Height:

57.0 inches (1448 mm)

Curb Weight Range:

Approx. 3,500 - 4,000 lbs (1588 - 1814 kg) depending on engine and configuration.

🛡️ Safety Features

NHTSA Front Impact:

5-star (for driver and front passenger in most model years).

IIHS Frontal Offset:

Good (Insurance Institute for Highway Safety).

Traction Control:

Automatic Stability Control (ASC+T) standard on most models, Dynamic Stability Control (DSC) available/standard on later models.

Braking System:

Anti-lock Braking System (ABS) standard, Electronic Brake-force Distribution (EBD).

Airbags:

Frontal airbags for driver and passenger, side-impact airbags (optional or standard depending on trim/year), optional head protection airbags.

💡 Technology Features

Head Unit:

BMW Professional RDS, Business CD/Cassette, or optional Navigation system (MKII/MKIII).

Audio System:

Optional Harman Kardon premium sound system.

Cruise Control:

Standard cruise control, adaptive cruise control (optional on some later models).

Parking Assistance:

Optional rear park distance control (PDC).

Cellular Integration:

Optional BMW Assist telematics system with integrated cellular phone functionality.

🔧 Maintenance

Oil Change Interval:

Variable Service Interval (VSI) system based on driving conditions, typically recommended every 7,500-15,000 miles or 12-24 months. Consult manual for specific vehicle condition.

Coolant Replacement:

Initial fill typically lasts longer, but often recommended around 30,000-60,000 miles or every 2-4 years.

Spark Plug Replacement:

Depending on plug type (standard vs. long-life), intervals can range from 30,000 to 100,000 miles.

Engine Oil:

BMW Longlife-01 (LL-01) or BMW Longlife-98 (LL-98) synthetic oil, viscosity typically 0W-40 or 5W-40. Consult owner's manual for exact specification and capacity (approx. 6.5-8.5 quarts).

Coolant:

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

Transmission Fluid Auto:

Specific ATF fluid like Dexron III or IV (or BMW approved equivalent). Transmission fluid and filter replacement interval typically 50,000-100,000 miles, though some sources suggest earlier for longevity.

Differential Fluid:

Hypoid gear oil (e.g., GL-5), viscosity typically 75W-90 or 80W-90. Capacity approx. 1.2-1.5 liters.

Cooling System:

Plastic coolant expansion tank and hoses prone to cracking/leaking. Water pump impeller can fail. Thermostat housing leaks.

Engine Components:

VANOS (Variable Valve Timing) solenoids and seals can fail, leading to rough idle and power loss. Oil pan gasket leaks. CCV (Crankcase Ventilation) system can clog.

Suspension:

Front lower control arm bushings and ball joints wear out, causing steering looseness and tire wear. Rear subframe bushings can degrade.

Electrical:

Ignition coil failures (especially pre-facelift). Window regulator failures. Heater control valve leaks. LCM (Light Control Module) issues. ABS/DSC sensor failures.

Interior:

Pixelation on the instrument cluster display (LCD segments failing).

📚 Vehicle History

Bmw Philosophy:

BMW's long-standing reputation for engineering excellence, performance ('The Ultimate Driving Machine'), and luxury.

E39 Introduction:

Launched in 1995 (as a 1996 model in Europe, later in North America), the E39 was a significant advancement over the E34, introducing more sophisticated electronics, improved chassis dynamics, and a broader range of engines.

Facelift Lci:

Significant facelift (LCI - Life Cycle Impulse) occurred for the 2001 model year, introducing revised headlights (angel eyes), taillights, bumpers, interior trim updates, and the new M54 engines across the range.

Production Period:

1995 - 2003 (Sedan), 1997 - 2004 (Wagon).

Manufacturing Locations:

Mainly Dingolfing, Germany, with some assembly in other global locations.

🏆 Awards & Recognition

Car And Driver 5 Best Cars:

Car and Driver recognized the 5 Series (E39) on its annual '10Best Cars' list multiple times during its production run, highlighting its balance of luxury, performance, and handling.

Motor Trend Car Of The Year:

While not a 'Car of the Year' winner during this period, the 5 Series consistently received high marks and comparisons in competitive reviews.