Applicable Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Chassis Code Family:
E39 (5 Series), E60 (5 Series - early production for 2003-2005 models, though manual primarily covers E39 generation for most of the range)
Segment Positioning:
Premium mid-size luxury sedan
Key Competitors:
Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type
Model Strengths:
Driving dynamics, build quality, sophisticated engineering, luxury appointments, powerful engine options
Primary Coverage Focus:
BMW 5 Series Sedan (E39 generation primarily, with potential overlap into early E60 for later years)
Estimated Page Count:
1500-3000+ (typical for comprehensive workshop manuals)
Manual Type:
Workshop Service Repair Manual
Format:
Digital (likely PDF), Printable
Engine Systems:
Engine mechanical (M52TU, M54, M62TU), engine management, cooling, lubrication, fuel injection, emissions control, exhaust systems
Drivetrain Systems:
Manual transmission (Getrag 420G), Automatic transmission (Steptronic GM 5L40-E, ZF 5HP19, ZF 5HP24), driveline, axles, differentials
Chassis Systems:
Suspension (front & rear), steering (hydraulic power steering), brakes (ABS, DSC, brake pad replacement, fluid flush), wheels and tires
Electrical Systems:
Wiring diagrams, battery, charging system, starter, lighting, ignition system, instrumentation, comfort electronics, body control modules (BCM), DME (Digital Motor Electronics), EWS (Electronic Immobilizer System)
Body And Interior:
Body panels, doors, windows, locks, seats, airbags, HVAC (heating, ventilation, air conditioning), interior trim, convertible top (if applicable)
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements (oil, air, cabin), spark plug replacement, brake fluid flush, coolant flush, serpentine belt replacement
Diagnostic Procedures:
Troubleshooting common faults, diagnostic trouble codes (DTCs) interpretation, symptom-based diagnostics
Repair Procedures:
Engine component removal/installation, transmission overhaul, brake caliper replacement, suspension arm replacement, sensor replacement, component testing
Special Tools And Techniques:
Identification and use of BMW specific tools for various repair procedures
Depth Of Coverage:
Comprehensive - from basic routine maintenance to advanced engine, transmission, and electrical system diagnostics and repair
File Format Details:
Searchable PDF, high-resolution images and diagrams, bookmark navigation
Print Quality:
High-resolution, suitable for professional printing (if applicable)
Binding Type:
N/A (for digital format) / Spiral or Perfect Bound (if physical)
Paper Type:
N/A (for digital format)
Engine Variants Covered:
Inline 6-cylinder (M52TU, M54): 2.5L (323i, 325i), 2.8L (328i), 3.0L (330i); V8 (M62TU): 4.4L (540i)
Horsepower Range:
Approximately 170 hp to 290 hp, depending on engine variant
Torque Range:
Approximately 181 lb-ft to 324 lb-ft, depending on engine variant
Fuel Delivery System:
Multi-point fuel injection (MPI) with DME control
Oil Specification:
BMW Longlife-01 (e.g., Castrol Syntec 5W-30 or 5W-40) for most engines; check manual for specific variants.
Standard Transmission:
5-speed manual transmission (e.g., Getrag 420G for larger engines)
Optional Transmission:
5-speed automatic transmission (e.g., GM 5L40-E, ZF 5HP19, ZF 5HP24) with Steptronic function
Automatic Transmission Features:
Steptronic manual shifting mode, adaptive shift programs
Automatic Transmission Fluid:
Specific ATF required (e.g., Dexron III for GM, LT-3/LT-5 for ZF - consult manual for exact fluid and capacity)
Wheelbase:
Approx. 111.4 inches (2830 mm)
Length:
Approx. 188.2 inches (4780 mm)
Width:
Approx. 70.1 inches (1780 mm)
Height:
Approx. 56.7 inches (1440 mm)
Curb Weight Range:
Approx. 3500 - 4000 lbs (1588 - 1814 kg) depending on engine and equipment
NHTSA Front Impact Rating:
Likely 4 or 5 stars for driver/passenger (check specific year tests)
IIHS Crash Test Performance:
Generally good, often 'Good' or 'Acceptable' in frontal and side impact tests for the E39 generation
Active Safety Systems:
Anti-lock Braking System (ABS), Dynamic Stability Control (DSC)
Passive Safety Features:
Front airbags, side-impact airbags, pretensioner seatbelts, reinforced safety cage
Infotainment System:
BMW Professional Radio, optional CD player, optional navigation system (CCC - Car Communication Computer)
Driver Assistance Features:
Park Distance Control (PDC), Cruise Control
Connectivity Features:
Optional Bluetooth phone integration (older systems)
Oil Change Interval:
Variable Service Indicator (VSI) system, typically 10,000-15,000 miles or annually. Consult manual for specific VSI reset procedures.
Spark Plug Replacement:
Approx. 100,000 miles for platinum or iridium plugs (specific type varies by engine)
Brake Fluid Flush:
Typically every 2 years, regardless of mileage
Coolant Flush:
BMW Blue Coolant, interval typically every 2-4 years or per VSI
Power Steering Fluid:
CHF 11S or equivalent Pentosin hydraulic fluid
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)
Common Issues Engine:
Vanos (Variable Valve Timing) solenoids and seals, oil leaks (valve cover gaskets, oil pan gaskets), CCV (Crankcase Ventilation) system failures, cooling system component failures (water pump, thermostat, hoses, expansion tank)
Common Issues Electrical:
Pixelation on instrument cluster display, ABS/DSC module failures, fuel pump failures, alternator issues, headlight leveling system faults
Common Issues Suspension:
Worn control arm bushings, sagging rear springs, strut mount wear
Common Issues Transmission:
Automatic transmission harsh shifting or slipping, manual transmission clutch wear
Brand Philosophy:
'The Ultimate Driving Machine' - focus on performance, handling, and driver engagement
Chassis Generation:
E39 generation (1995-2003 globally, extended to 2003 for many markets, 2004 for some US models). This manual covers the latter half of the E39 lifecycle and potentially very early E60 transition models.
Production Period:
1999-2005 (as defined by manual coverage, primarily 1999-2003 E39)
Car And Driver 10 Best:
The E39 5 Series was a frequent recipient of Car and Driver's 10Best list during its production run.
Jd Power Initial Quality Study:
Generally ranked well for initial quality within its segment.
Emissions Certifications:
EPA and CARB compliant for model years; manual will detail specific emissions components and testing procedures.
