BMW 528i 1997-2002 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: BMW Model: 528i Model Code: E39 Chassis Code: E39 Generation Generation Name: Fourth Generation Generation Years: 1995-2003 Codes Engine Code Primary: M52B28 Vin Engine Character: M 👋 Introduction Market Position Segment: Executive Sedan / Mid-size Luxury Car Target Audience: Discerning car owners seeking premium performance, comfort, and advanced engineering, including DIY enthusiasts and professional mechanics. Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS300, Jaguar S-Type. Competitive Advantage: Renowned driving dynamics ('The Ultimate Driving Machine'), refined inline-six engines, sophisticated chassis, and premium interior quality. Key Features Driving Dynamics: Excellent handling, responsive steering, balanced chassis, contributing to its sporty feel. Engine Smoothness: The M52B28 inline-six engine is celebrated for its inherent smoothness and refined operation. Build Quality: High standards of German engineering and assembly, leading to durable construction. Interior Comfort: Luxurious materials, ergonomic design, comfortable seating for long journeys. 📋 Manual Details Coverage Areas Years Covered: 1997, 1998, 1999, 2000, 2001, 2002 Model Variants Covered: 528i (Sedan & Touring, where applicable) Page Count Estimated Page Count: 2000+ Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive engine repair, diagnostics, overhaul, timing, lubrication, cooling, fuel injection, ignition, emissions control. Transmission: Manual and Automatic transmission repair, diagnostics, fluid changes, rebuild procedures, torque converter, clutch. Drivetrain: Driveshaft, differential, axles, wheel bearings, CV joints. Suspension: Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications. Steering: Power steering system, steering rack, tie rods, steering column, diagnostic and repair procedures. Brakes: Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pads, rotors, calipers, fluid specifications, bleeding procedures, parking brake. Electrical System: Complete wiring diagrams, fuse box locations, relay functions, starter, alternator, battery, lighting, power windows, mirrors, central locking, ignition switch. Bodywork And Chassis: Body panel removal and installation, door mechanisms, interior trim, bumpers, underbody, rust repair considerations. Heating Ventilation Air Conditioning: HVAC system diagnosis, AC compressor, refrigerant, blower motor, climate control unit, heater core. Comfort Systems: Seats (power adjustment, heating), sunroof, interior lighting. Procedures Included Maintenance: Routine scheduled maintenance (oil changes, filter replacements, spark plugs, belts), inspection points, lubrication. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting, error code interpretation (where applicable via OBDI/OBDII). Repair: Step-by-step repair instructions for all major components and systems, including component removal, installation, and adjustment. Diagnostics: Engine performance diagnostics, electrical system diagnostics, module testing, sensor testing. Rebuilding: Complete engine and transmission rebuilding procedures with specifications and tolerances. Special Tools: Identification and use of specialized BMW tools required for specific repair procedures. Technical Depth Depth: Comprehensive, from basic fluid checks and filter changes to complete engine and transmission overhauls, advanced electrical diagnostics, and body repairs. 📊 Manual Specifications File Format Quality: High-resolution digital PDF, often searchable and bookmarked for easy navigation. Printable: Yes, individual pages or sections can be printed. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline 6-Cylinder Displacement: 2793 cc (2.8 Liters) Bore X Stroke: 84.0 mm x 81.0 mm Compression Ratio: 10.2:1 Valve Train: DOHC (Double Overhead Camshaft), 24 valves (4 per cylinder) Engine Management: Bosch Motronic M5.2 (or M5.2.1 later) Performance Horsepower Hp: 190 hp @ 5500 rpm Torque Lb-Ft: 206 lb-ft @ 3950 rpm Redline: 6500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-point injection. Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Fuel Tank Capacity: 70 Liters (18.5 US Gallons) 🔧 Transmission Standard Type: 5-speed Manual Transmission (Getrag 260/5) Optional Type: 5-speed Automatic Transmission (ZF 5HP18 or 5HP19) Features Automatic Features: Steptronic manual shift mode (on later models). Fluid Specifications Automatic Transmission Fluid: BMW ATF LT-3 (or equivalent like Mobil ATF LT 71141, Pentosin ATF1) Manual Transmission Fluid: BMW Manual Transmission Fluid MTF LT-2 (or equivalent GL-4 rated gear oil) 📐 Dimensions Exterior Length: 4,774 mm (188.0 in) Width: 1,790 mm (70.5 in) Height: 1,436 mm (56.5 in) Wheelbase: 2,830 mm (111.4 in) Front Track: 1,511 mm (59.5 in) Rear Track: 1,525 mm (60.0 in) Interior Front Headroom: Approx. 980 mm (38.6 in) Rear Headroom: Approx. 950 mm (37.4 in) Cargo Trunk Volume: Approx. 520 Liters (18.4 cu ft) Weights Curb Weight: 1,540 - 1,630 kg (3,395 - 3,594 lbs) depending on transmission and options. Gross Vehicle Weight Rating: Approx. 2,100 kg (4,630 lbs) Wheels And Tires Wheel Size Standard: 16 x 7.0 inches Tire Size Standard: 225/55R16 Wheel Bolt Pattern: 5 x 120 mm Offset: ET 20 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver/Passenger) IIHS Side Impact: Acceptable Active Features ABS: Standard Anti-lock Braking System Dsc: Optional Dynamic Stability Control (DSC III) Traction Control: Optional Traction Control System (ASC+T) Passive Features Airbags: Driver and front passenger airbags, optional side airbags. Seatbelts: Three-point inertia-reel seat belts...

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Type: Car

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Sku: 401511

Collections: ALL BMW

Availability: In stock

Tags: 1997 1998 1999 2000 2001 2002 528i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Code:

Chassis Code:

Generation

Generation Name:

Fourth Generation

Generation Years:

1995-2003

Codes

Engine Code Primary:

M52B28

Vin Engine Character:

👋 Introduction

Market Position

Segment:

Executive Sedan / Mid-size Luxury Car

Target Audience:

Discerning car owners seeking premium performance, comfort, and advanced engineering, including DIY enthusiasts and professional mechanics.

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS300, Jaguar S-Type.

Competitive Advantage:

Renowned driving dynamics ('The Ultimate Driving Machine'), refined inline-six engines, sophisticated chassis, and premium interior quality.

Key Features

Driving Dynamics:

Excellent handling, responsive steering, balanced chassis, contributing to its sporty feel.

Engine Smoothness:

The M52B28 inline-six engine is celebrated for its inherent smoothness and refined operation.

Build Quality:

High standards of German engineering and assembly, leading to durable construction.

Interior Comfort:

Luxurious materials, ergonomic design, comfortable seating for long journeys.

📋 Manual Details

Coverage Areas

Years Covered:

1997, 1998, 1999, 2000, 2001, 2002

Model Variants Covered:

528i (Sedan & Touring, where applicable)

Page Count

Estimated Page Count:

2000+

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine repair, diagnostics, overhaul, timing, lubrication, cooling, fuel injection, ignition, emissions control.

Transmission:

Manual and Automatic transmission repair, diagnostics, fluid changes, rebuild procedures, torque converter, clutch.

Drivetrain:

Driveshaft, differential, axles, wheel bearings, CV joints.

Suspension:

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

Steering:

Power steering system, steering rack, tie rods, steering column, diagnostic and repair procedures.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake pads, rotors, calipers, fluid specifications, bleeding procedures, parking brake.

Electrical System:

Complete wiring diagrams, fuse box locations, relay functions, starter, alternator, battery, lighting, power windows, mirrors, central locking, ignition switch.

Bodywork And Chassis:

Body panel removal and installation, door mechanisms, interior trim, bumpers, underbody, rust repair considerations.

Heating Ventilation Air Conditioning:

HVAC system diagnosis, AC compressor, refrigerant, blower motor, climate control unit, heater core.

Comfort Systems:

Seats (power adjustment, heating), sunroof, interior lighting.

Procedures Included

Maintenance:

Routine scheduled maintenance (oil changes, filter replacements, spark plugs, belts), inspection points, lubrication.

Troubleshooting:

Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting, error code interpretation (where applicable via OBDI/OBDII).

Repair:

Step-by-step repair instructions for all major components and systems, including component removal, installation, and adjustment.

Diagnostics:

Engine performance diagnostics, electrical system diagnostics, module testing, sensor testing.

Rebuilding:

Complete engine and transmission rebuilding procedures with specifications and tolerances.

Special Tools:

Identification and use of specialized BMW tools required for specific repair procedures.

Technical Depth

Depth:

Comprehensive, from basic fluid checks and filter changes to complete engine and transmission overhauls, advanced electrical diagnostics, and body repairs.

📊 Manual Specifications

File Format

Quality:

High-resolution digital PDF, often searchable and bookmarked for easy navigation.

Printable:

Yes, individual pages or sections can be printed.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Displacement:

2793 cc (2.8 Liters)

Bore X Stroke:

84.0 mm x 81.0 mm

Compression Ratio:

10.2:1

Valve Train:

DOHC (Double Overhead Camshaft), 24 valves (4 per cylinder)

Engine Management:

Bosch Motronic M5.2 (or M5.2.1 later)

Performance

Horsepower Hp:

190 hp @ 5500 rpm

Torque Lb-Ft:

206 lb-ft @ 3950 rpm

Redline:

6500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection.

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Fuel Tank Capacity:

70 Liters (18.5 US Gallons)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Getrag 260/5)

Optional

Type:

5-speed Automatic Transmission (ZF 5HP18 or 5HP19)

Features

Automatic Features:

Steptronic manual shift mode (on later models).

Fluid Specifications

Automatic Transmission Fluid:

BMW ATF LT-3 (or equivalent like Mobil ATF LT 71141, Pentosin ATF1)

Manual Transmission Fluid:

BMW Manual Transmission Fluid MTF LT-2 (or equivalent GL-4 rated gear oil)

📐 Dimensions

Exterior

Length:

4,774 mm (188.0 in)

Width:

1,790 mm (70.5 in)

Height:

1,436 mm (56.5 in)

Wheelbase:

2,830 mm (111.4 in)

Front Track:

1,511 mm (59.5 in)

Rear Track:

1,525 mm (60.0 in)

Interior

Front Headroom:

Approx. 980 mm (38.6 in)

Rear Headroom:

Approx. 950 mm (37.4 in)

Cargo

Trunk Volume:

Approx. 520 Liters (18.4 cu ft)

Weights

Curb Weight:

1,540 - 1,630 kg (3,395 - 3,594 lbs) depending on transmission and options.

Gross Vehicle Weight Rating:

Approx. 2,100 kg (4,630 lbs)

Wheels And Tires

Wheel Size Standard:

16 x 7.0 inches

Tire Size Standard:

225/55R16

Wheel Bolt Pattern:

5 x 120 mm

Offset:

ET 20

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4/5 Stars (Driver/Passenger)

IIHS Side Impact:

Acceptable

Active Features

Standard Anti-lock Braking System

Optional Dynamic Stability Control (DSC III)

Traction Control:

Optional Traction Control System (ASC+T)

Passive Features

Airbags:

Driver and front passenger airbags, optional side airbags.

Seatbelts:

Three-point inertia-reel seat belts with pretensioners and force limiters.

Chassis Safety:

Reinforced safety cage, crumple zones, side-impact protection beams.

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD or Professional CD/RDS radio with cassette player. Optional navigation system (CCC).

Audio System:

Standard 6-speaker system; optional premium Hi-Fi system with amplifier and more speakers.

Display:

Central information display (CID) in the dashboard for vehicle status, warnings, and navigation (if equipped).

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Assistance:

Optional rear parking sensors (Park Distance Control - PDC).

Connectivity

Phone Integration:

Optional Bluetooth hands-free preparation with cradle.

🔧 Maintenance

Service Intervals

Oil Change:

Every 10,000-15,000 miles (15,000-25,000 km) or annually, depending on driving conditions and oil type. BMW Condition Based Service (CBS) may adjust this.

Air Filter Replacement:

Every 30,000-45,000 miles (50,000-75,000 km)

Cabin Filter Replacement:

Every 15,000-20,000 miles (25,000-30,000 km)

Spark Plug Replacement:

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

Coolant Flush:

Every 4-5 years or 60,000 miles (100,000 km)

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil Type:

SAE 0W-40 or 5W-30 Synthetic Engine Oil meeting BMW Longlife-01 (LL-01) specification.

Engine Oil Capacity:

6.5 Liters (6.9 US Quarts) with filter change.

Coolant:

BMW Blue or Green Antifreeze/Coolant (ethylene glycol based) mixed 50/50 with distilled water.

Power Steering Fluid:

ATF Dexron III or Pentosin CHF 11S (check specific VIN for correct type).

Known Issues

Cooling System:

Plastic expansion tanks can become brittle and crack, leading to coolant leaks. Water pump and thermostat failures are also common.

Vibration Dampener:

The rubber element in the harmonic balancer (crankshaft pulley) can degrade, causing vibrations and potential belt system failure.

Oil Pan Gasket:

Oil pan gasket leaks are common due to age and material degradation.

ABS Wheel Speed Sensors:

Front ABS wheel speed sensors are prone to failure, triggering ABS and/or DSC warning lights.

Ccv System:

The Crankcase Ventilation (CCV) system can become clogged, leading to increased crankcase pressure, oil leaks, and rough running.

Pixel Display Failure:

The Instrument Cluster (IC) LCD display often suffers from dead pixels or complete failure.

Door Lock Actuators:

Central locking actuators can fail, preventing doors from locking or unlocking properly.

Headlight Leveling:

Headlight leveling sensors and motors can fail, causing improper headlight aim.

📚 Vehicle History

Brand Heritage

Brand Identity:

Bayerische Motoren Werke AG (BMW), a German automobile, motorcycle, and engine manufacturer, renowned for performance, luxury, and driving pleasure.

Model Evolution

E39 Introduction:

The E39 generation replaced the E34 and was produced from 1995 (for the 1996 model year) through 2003.

528I Positioning:

The 528i was a core model within the E39 lineup, offering a balance of performance and efficiency from its 2.8-liter inline-six.

Facelift:

The E39 received a significant facelift in 2000 (for the 2001 model year), introducing updated headlights (angel eyes), taillights, bumpers, and interior trim.

Production

Production Locations:

Germany (Dingolfing plant)

Production Years For 528I:

1996-2000 (replaced by 530i in 2001 for US market, but 528i continued in other markets).

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E39 5 Series, including variants like the 528i, was a frequent recipient of Car and Driver's 10Best list for its class.

Popular Mechanics:

Often cited for its engineering and driving dynamics by automotive publications.

Ratings

Reliability Perception:

While generally well-regarded for engineering, specific maintenance can be costly compared to some Japanese or American rivals. However, when properly maintained, these vehicles can be quite reliable.