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BMW 5 Series E39 528i Sport Wagon 1997-2002 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Body Style: Sport Wagon Engine Variant: 528i Generation Generation Code: E39 Codes Production Years Covered: 1997-2002 👋 Introduction Market Position Vehicle Segment: Executive Mid-size Station Wagon Bmw Positioning: Represents BMW's commitment to offering sporty, luxurious, and practical vehicles with a focus on driving dynamics. Competitive Analysis Key Competitors: Mercedes-Benz E-Class Estate, Audi A6 Avant, Volvo V70. Key Features Driving Dynamics: Renowned for BMW's signature handling, precise steering, and balanced chassis. Practicality: Combines executive car comfort and performance with the versatility of a wagon body style for cargo and passenger transport. Build Quality: High standards of German engineering and materials. 📋 Manual Details Coverage Areas Vehicle Coverage: BMW 5 Series (E39) 528i Sport Wagon 1997-2002 Page Count Estimated Page Count: Extensive (typical for comprehensive service manuals covering multiple years and systems) Manual Type Manual Type: Service Repair Manual Language Language: English Format File Format: PDF Delivery Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Full coverage including M52/M52TU engine diagnostics, repair, overhaul, timing, cooling, lubrication, fuel delivery, ignition, emissions control. Transmission: Coverage for both manual (Getrag) and automatic (ZF 5HP series) transmissions, including diagnostics, fluid changes, repair, and overhaul procedures. Drivetrain: Detailed information on rear-wheel drive system, driveshafts, differentials, CV joints, and wheel bearings. Suspension: Comprehensive coverage of front and rear suspension components, including struts, shock absorbers, control arms, bushings, anti-roll bars, and steering system. Brakes: In-depth coverage of hydraulic brake system, including ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake calipers, rotors, pads, lines, and bleeding procedures. Electrical System: Extensive coverage of automotive electrical systems, including battery, charging system, starter motor, lighting, fuses, relays, wiring diagrams, ECU (Engine Control Unit), and body control modules. Body And Chassis: Detailed procedures for body panel repair, door mechanisms, glass replacement, interior trim removal, and structural components. HVAC: Coverage of climate control system, including AC compressor, refrigerant, heater core, blower motor, and control modules. Safety Systems: Information on airbags, seatbelts, and associated control modules. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt inspection/replacement. Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation, diagnostic tool usage (e.g., OBD-II). Repair: Step-by-step repair procedures for all major vehicle systems, including component removal, installation, and adjustment. Rebuilds: Detailed instructions for complete engine and transmission overhauls. Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle systems. Technical Depth Scope: From basic DIY maintenance to advanced engine and transmission rebuilds, suitable for both novice and professional mechanics. 📊 Manual Specifications File Format File Type: PDF Print Quality Printable: Full Printable Zoom Capability: YES Binding Type Binding Type: Digital Download (no physical binding) Paper Type Paper Type: N/A (Digital) Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: Compatible with All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: M52B28 (for 1997-1998) / M52TU B28 (for 1999-2000) Engine Type: Inline-6 Cylinder, DOHC, 24 Valves Displacement: 2.8 Liters (2793 cc) Performance Horsepower: 190-193 hp @ 5500-5800 rpm (depending on year and specific engine variant) Torque: 200-206 lb-ft @ 3950-4250 rpm (depending on year and specific engine variant) Fuel System Fuel Delivery: Multi-point Fuel Injection (Bosch Motronic) Fuel Type: Premium Unleaded Gasoline (91+ Octane) Cooling System Coolant Type: BMW Blue Antifreeze (G48 ethylene glycol based) or equivalent Coolant Capacity: Approximately 9.5 Liters (10.0 US quarts) Lubrication System Oil Type: BMW Longlife-01 (LL-01) or BMW Longlife-98 (LL-98) compliant synthetic oil, typically SAE 5W-30 or 5W-40 Oil Capacity: Approximately 6.5 Liters (6.9 US quarts) with filter change Ignition System Spark Plugs: Typically Bosch FGR7DQP+ or equivalent (check specific VIN for exact part number) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (Getrag Type G280) Optional Transmission Type Optional: 5-speed Automatic Transmission (ZF 5HP19Z or 5HP19FLA) Features Automatic Features: Steptronic manual shifting mode Fluid Specifications Automatic Transmission Fluid: ZF Lifeguardfluid 5 (or equivalent LT 71141 specification fluid) Fluid Capacity Automatic Transmission Fluid Capacity: Approximately 9 Liters (9.5 US quarts) for complete fill; ~4.5 Liters for change with filter. 📐 Dimensions Exterior Length: Approx. 4,871 mm (191.8 inches) Width: Approx. 1,799 mm (70.8 inches) Height: Approx. 1,437 mm (56.6 inches) Wheelbase: Approx. 2,830 mm (111.4 inches) Cargo Cargo Volume: Approx. 465 Liters (16.4 cubic feet) with rear seats up, expandable to over 1500 Liters with seats folded. Weights Curb Weight: Approx. 1,650 - 1,750 kg (3,638 - 3,858 lbs) depending on transmission and equipment. Gross Vehicle Weight Rating: Approx. 2,150 kg (4,740 lbs) Wheels And Tires Wheel Bolt Pattern: 5x120 mm Standard Wheel Size: 16 or 17 inches (depending on Sport Wagon package) Standard Tire Sizes: 205/55 R16, 225/55 R16, or 235/45 R17 🛡️ Safety Features Ratings NHTSA Front Impact Rating: Generally good for its era, though specific ratings may vary by model year and...
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BMW 5 Series E39 528i Sport Wagon 1997-2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E39
Body Style:
Sport Wagon
Engine Variant:
528i
Generation
Generation Code:
E39
Codes
Production Years Covered:
1997-2002
👋 Introduction
Market Position
Vehicle Segment:
Executive Mid-size Station Wagon
Bmw Positioning:
Represents BMW's commitment to offering sporty, luxurious, and practical vehicles with a focus on driving dynamics.
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class Estate, Audi A6 Avant, Volvo V70.
Key Features
Driving Dynamics:
Renowned for BMW's signature handling, precise steering, and balanced chassis.
Practicality:
Combines executive car comfort and performance with the versatility of a wagon body style for cargo and passenger transport.
Build Quality:
High standards of German engineering and materials.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
BMW 5 Series (E39) 528i Sport Wagon 1997-2002
Page Count
Estimated Page Count:
Extensive (typical for comprehensive service manuals covering multiple years and systems)
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Delivery
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Full coverage including M52/M52TU engine diagnostics, repair, overhaul, timing, cooling, lubrication, fuel delivery, ignition, emissions control.
Transmission:
Coverage for both manual (Getrag) and automatic (ZF 5HP series) transmissions, including diagnostics, fluid changes, repair, and overhaul procedures.
Drivetrain:
Detailed information on rear-wheel drive system, driveshafts, differentials, CV joints, and wheel bearings.
Suspension:
Comprehensive coverage of front and rear suspension components, including struts, shock absorbers, control arms, bushings, anti-roll bars, and steering system.
Brakes:
In-depth coverage of hydraulic brake system, including ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake calipers, rotors, pads, lines, and bleeding procedures.
Electrical System:
Extensive coverage of automotive electrical systems, including battery, charging system, starter motor, lighting, fuses, relays, wiring diagrams, ECU (Engine Control Unit), and body control modules.
Body And Chassis:
Detailed procedures for body panel repair, door mechanisms, glass replacement, interior trim removal, and structural components.
HVAC:
Coverage of climate control system, including AC compressor, refrigerant, heater core, blower motor, and control modules.
Safety Systems:
Information on airbags, seatbelts, and associated control modules.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt inspection/replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation, diagnostic tool usage (e.g., OBD-II).
Repair:
Step-by-step repair procedures for all major vehicle systems, including component removal, installation, and adjustment.
Rebuilds:
Detailed instructions for complete engine and transmission overhauls.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems.
Technical Depth
Scope:
From basic DIY maintenance to advanced engine and transmission rebuilds, suitable for both novice and professional mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printable:
Full Printable
Zoom Capability:
YES
Binding Type
Binding Type:
Digital Download (no physical binding)
Paper Type
Paper Type:
N/A (Digital)
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility
Operating Systems:
Compatible with All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
M52B28 (for 1997-1998) / M52TU B28 (for 1999-2000)
Engine Type:
Inline-6 Cylinder, DOHC, 24 Valves
Displacement:
2.8 Liters (2793 cc)
Performance
Horsepower:
190-193 hp @ 5500-5800 rpm (depending on year and specific engine variant)
Torque:
200-206 lb-ft @ 3950-4250 rpm (depending on year and specific engine variant)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (Bosch Motronic)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Cooling System
Coolant Type:
BMW Blue Antifreeze (G48 ethylene glycol based) or equivalent
Coolant Capacity:
Approximately 9.5 Liters (10.0 US quarts)
Lubrication System
Oil Type:
BMW Longlife-01 (LL-01) or BMW Longlife-98 (LL-98) compliant synthetic oil, typically SAE 5W-30 or 5W-40
Oil Capacity:
Approximately 6.5 Liters (6.9 US quarts) with filter change
Ignition System
Spark Plugs:
Typically Bosch FGR7DQP+ or equivalent (check specific VIN for exact part number)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (Getrag Type G280)
Optional
Transmission Type Optional:
5-speed Automatic Transmission (ZF 5HP19Z or 5HP19FLA)
Features
Automatic Features:
Steptronic manual shifting mode
Fluid Specifications
Automatic Transmission Fluid:
ZF Lifeguardfluid 5 (or equivalent LT 71141 specification fluid)
Fluid Capacity
Automatic Transmission Fluid Capacity:
Approximately 9 Liters (9.5 US quarts) for complete fill; ~4.5 Liters for change with filter.
📐 Dimensions
Exterior
Length:
Approx. 4,871 mm (191.8 inches)
Width:
Approx. 1,799 mm (70.8 inches)
Height:
Approx. 1,437 mm (56.6 inches)
Wheelbase:
Approx. 2,830 mm (111.4 inches)
Cargo
Cargo Volume:
Approx. 465 Liters (16.4 cubic feet) with rear seats up, expandable to over 1500 Liters with seats folded.
Weights
Curb Weight:
Approx. 1,650 - 1,750 kg (3,638 - 3,858 lbs) depending on transmission and equipment.
Gross Vehicle Weight Rating:
Approx. 2,150 kg (4,740 lbs)
Wheels And Tires
Wheel Bolt Pattern:
5x120 mm
Standard Wheel Size:
16 or 17 inches (depending on Sport Wagon package)
Standard Tire Sizes:
205/55 R16, 225/55 R16, or 235/45 R17
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Generally good for its era, though specific ratings may vary by model year and testing methodology.
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard ASC+T (Automatic Stability Control and Traction) or optional DSC (Dynamic Stability Control).
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags.
Seatbelts:
Pretensioning front seatbelts.
Chassis Structure:
Reinforced safety cage structure.
💡 Technology Features
Infotainment
Radio System:
BMW Business or Professional CD/Radio systems, often with cassette player.
Navigation:
Optional MKII or MKIII navigation system with CD-ROM map data.
Audio System:
Standard 10-speaker system, optional Harman Kardon sound system.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Sensors:
Optional rear Park Distance Control (PDC).
Connectivity
Phone Integration:
Optional BMW On-Board Hands-Free System with Bluetooth or cellular cradle.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or annually, depending on oil type and driving conditions (consult manual for specific BMW LL-01 recommendations).
Coolant Change Interval:
Initial change at 4 years/50,000 miles, then every 2 years/30,000 miles thereafter.
Spark Plug Replacement:
Typically around 100,000 miles for iridium or platinum plugs.
Transmission Fluid Change Interval:
BMW's 'lifetime' fill recommendation for automatics is often debated; recommended change interval for ZF automatics is typically 50,000-80,000 miles for longevity.
Fluid Specifications
Power Steering Fluid:
Pentosin CHF 11S or equivalent hydraulic fluid (check specific BMW recommendation).
Brake Fluid:
DOT 4 Low Viscosity (LV) or DOT 4 Plus.
Known Issues
Cooling System Failures:
Plastic cooling system components (expansion tank, water pump, thermostat housing) are prone to cracking/failure due to age and heat.
Vanos System:
M52TU engines can experience VANOS solenoid failure or piston ring wear, leading to rough idle and reduced performance.
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing gasket are common sources of oil leaks.
Suspension Wear:
Control arm bushings, ball joints, and tie rod ends can wear out, causing steering looseness and noise.
ABS/Dsc Sensors:
Wheel speed sensors can fail, triggering ABS and DSC warning lights.
Climate Control Modules:
Pixelation or failure of the climate control display and buttons can occur.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's enduring legacy of building 'The Ultimate Driving Machine'.
Model Evolution
E39 Introduction:
The E39 5 Series was introduced in 1995 (as a 1996 model year in the US) and represented a significant evolution in design, technology, and refinement over its E34 predecessor.
Wagon Variant:
The wagon variant (Touring) was introduced later in the E39 lifecycle, offering a more practical alternative for families and those needing extra cargo space.
Production
Production Period:
1997-2002 for the 528i Sport Wagon
Manufacturing Location:
Primarily Dingolfing, Germany
🏆 Awards & Recognition
Recognitions
Car And Driver 5 Series:
The E39 5 Series generation frequently appeared on Car and Driver's '10Best' lists for its class.
Bmw Engineering Acclaim:
The E39 chassis is widely regarded as one of BMW's finest designs for its balance of comfort, handling, and build quality.
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