BMW 528 528i 1997-2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Model Variant: 528 Chassis Code: E39 Generation Generation Designation: E39 Generation Years: 1995-2003 Codes Engine Code Primary: M52B28 👋 Introduction Market Position Segment: Executive Sedan Target Audience: Luxury car buyers seeking performance, comfort, and advanced engineering Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (S160), Jaguar S-Type Key Features Driving Dynamics: Renowned for balanced handling, refined ride quality, and engaging driving experience characteristic of BMW Powertrain Performance: Smooth and potent M52B28 inline-six engine, offering a good balance of power and efficiency for its class Interior Appointments: High-quality materials, driver-focused cockpit, and comfortable seating, epitomizing BMW's luxury ethos 📋 Manual Details Coverage Areas Covered Years: 1997, 1998, 1999, 2000, 2001, 2002 Page Count Page Count: 1002 Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnostics, repair of M52B28 engine components (pistons, crankshaft, camshafts, valves, cylinder head, block) Engine Management And Electronics: DME (Digital Motor Electronics) system, sensors (crankshaft position, camshaft position, MAF, O2), actuators (idle control valve, VANOS), ignition system, fuel injection system diagnostics and repair Transmission Manual: Service and repair procedures for Getrag 5-speed manual transmission, clutch assembly, shift linkage Transmission Automatic: Service and repair procedures for ZF 5HP19FA 5-speed automatic transmission, torque converter, valve body, electronic control unit (EGS) Drivetrain: Rear-wheel drive system, driveshaft, differential (including LSD options), axles, CV joints Suspension And Steering: Front and rear suspension components (struts, shocks, control arms, bushings, anti-roll bars), power steering system, steering rack, tie rods, alignment specifications Brakes: Front and rear brake systems (vented discs), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake calipers, master cylinder, ABS/DSC pump, bleeding procedures, rotor and pad replacement Electrical System: Vehicle electrical system schematics, battery, alternator, starter, lighting system (headlights, taillights, interior), fuse box diagrams, relays, wiring harness repair Body And Chassis: Body panel removal and installation, door mechanisms, hood, trunk, bumpers, structural components, chassis repair HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, blower motor, heater core, A/C compressor, refrigerant system, climate control unit Interior Trim And Comfort: Seat removal, dashboard disassembly, interior trim panel replacement, power windows, power seats, central locking system Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, cabin filter replacement, spark plug replacement, coolant flush, brake fluid flush, differential fluid change Diagnostic Procedures: Troubleshooting guides for common drivability issues, electrical faults, HVAC problems, using diagnostic tools (e.g., OBD-II scanner), interpreting fault codes Repair Procedures: Step-by-step instructions for component replacement, engine rebuild, transmission overhaul, suspension component repair, brake system servicing, electrical component repair Wiring Diagrams: Detailed electrical schematics for all vehicle systems, including engine management, lighting, comfort systems, and power accessories Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine/transmission rebuilds) Diagnostic Capability: Advanced diagnostic procedures for electronic control units (ECUs), sensors, actuators, and communication networks Torque Specifications: Detailed torque specifications for all fasteners and critical assembly points Special Tools: Identification and usage of special tools required for specific repair and diagnostic procedures 📊 Manual Specifications File Format File Format Details: PDF (Portable Document Format), searchable text, bookmarked chapters for easy navigation Print Quality Print Quality Description: High-resolution scans of original factory manual pages, ensuring clarity of text and diagrams Binding Type Binding Type Physical Manual: N/A (Digital PDF format) Paper Type Paper Type Physical Manual: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: M52B28 Engine Type: Inline 6-cylinder, Naturally Aspirated Displacement: 2.8 Liters (2793 cc) Bore X Stroke: 84.0 mm x 84.0 mm Compression Ratio: 10.2:1 Valve Train: DOHC (Double Overhead Camshafts), 24 valves, Double VANOS (Variable Valve Timing) Performance Horsepower: 190 hp @ 5500 rpm (approx.) Torque: 206 lb-ft @ 3950 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-point injection Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Cooling System Coolant Type: BMW Blue Antifreeze/Coolant (G48), 50/50 mixture with distilled water Lubrication Oil Type: Synthetic SAE 5W-30 or 0W-30, meeting BMW LL-01 specification Oil Capacity: Approx. 6.5 liters (6.9 US quarts) with filter 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (Getrag 260/6 or similar) Optional Transmission Type Optional: 5-speed Steptronic Automatic Transmission (ZF 5HP19FA) Features Automatic Transmission Modes: Standard, Sport, Manual (Steptronic) shifting Fluid Specifications Manual Transmission Fluid: GL-4 or GL-5 synthetic gear oil (SAE 75W-90 typically) Automatic Transmission Fluid: BMW ATF LT-71141 or equivalent (e.g., Pentosin ATF1) 📐 Dimensions Exterior Length: 4,819 mm (189.7 in) Width: 1,799 mm (70.8 in) Height: 1,437 mm (56.6 in) Wheelbase: 2,830 mm (111.4 in) Weights Curb Weight: 1,590 - 1,650 kg (3,505 - 3,638 lbs) depending on transmission and equipment Gross Vehicle Weight Rating: Approx. 2,100 kg (4,630 lbs) Cargo Trunk Volume: 460 liters (16.2 cu ft) 🛡️ Safety Features Ratings NHTSA Front Impact: 4-star driver, 5-star passenger...

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Tipo: Car

Fabricante:

Sku: 418057

Coleções: ALL BMW

Disponibilidade: Em estoque

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

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Model:

Model Variant:

Chassis Code:

Generation

Generation Designation:

Generation Years:

1995-2003

Codes

Engine Code Primary:

M52B28

👋 Introduction

Market Position

Segment:

Executive Sedan

Target Audience:

Luxury car buyers seeking performance, comfort, and advanced engineering

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (S160), Jaguar S-Type

Key Features

Driving Dynamics:

Renowned for balanced handling, refined ride quality, and engaging driving experience characteristic of BMW

Powertrain Performance:

Smooth and potent M52B28 inline-six engine, offering a good balance of power and efficiency for its class

Interior Appointments:

High-quality materials, driver-focused cockpit, and comfortable seating, epitomizing BMW's luxury ethos

📋 Manual Details

Coverage Areas

Covered Years:

1997, 1998, 1999, 2000, 2001, 2002

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, diagnostics, repair of M52B28 engine components (pistons, crankshaft, camshafts, valves, cylinder head, block)

Engine Management And Electronics:

DME (Digital Motor Electronics) system, sensors (crankshaft position, camshaft position, MAF, O2), actuators (idle control valve, VANOS), ignition system, fuel injection system diagnostics and repair

Transmission Manual:

Service and repair procedures for Getrag 5-speed manual transmission, clutch assembly, shift linkage

Transmission Automatic:

Service and repair procedures for ZF 5HP19FA 5-speed automatic transmission, torque converter, valve body, electronic control unit (EGS)

Drivetrain:

Rear-wheel drive system, driveshaft, differential (including LSD options), axles, CV joints

Suspension And Steering:

Front and rear suspension components (struts, shocks, control arms, bushings, anti-roll bars), power steering system, steering rack, tie rods, alignment specifications

Brakes:

Front and rear brake systems (vented discs), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), brake calipers, master cylinder, ABS/DSC pump, bleeding procedures, rotor and pad replacement

Electrical System:

Vehicle electrical system schematics, battery, alternator, starter, lighting system (headlights, taillights, interior), fuse box diagrams, relays, wiring harness repair

Body And Chassis:

Body panel removal and installation, door mechanisms, hood, trunk, bumpers, structural components, chassis repair

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, blower motor, heater core, A/C compressor, refrigerant system, climate control unit

Interior Trim And Comfort:

Seat removal, dashboard disassembly, interior trim panel replacement, power windows, power seats, central locking system

Procedures Included

Routine Maintenance:

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

Diagnostic Procedures:

Troubleshooting guides for common drivability issues, electrical faults, HVAC problems, using diagnostic tools (e.g., OBD-II scanner), interpreting fault codes

Repair Procedures:

Step-by-step instructions for component replacement, engine rebuild, transmission overhaul, suspension component repair, brake system servicing, electrical component repair

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, including engine management, lighting, comfort systems, and power accessories

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

Diagnostic Capability:

Advanced diagnostic procedures for electronic control units (ECUs), sensors, actuators, and communication networks

Torque Specifications:

Detailed torque specifications for all fasteners and critical assembly points

Special Tools:

Identification and usage of special tools required for specific repair and diagnostic procedures

📊 Manual Specifications

File Format

File Format Details:

PDF (Portable Document Format), searchable text, bookmarked chapters for easy navigation

Print Quality

Print Quality Description:

High-resolution scans of original factory manual pages, ensuring clarity of text and diagrams

Binding Type

Binding Type Physical Manual:

N/A (Digital PDF format)

Paper Type

Paper Type Physical Manual:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M52B28

Engine Type:

Inline 6-cylinder, Naturally Aspirated

Displacement:

2.8 Liters (2793 cc)

Bore X Stroke:

84.0 mm x 84.0 mm

Compression Ratio:

10.2:1

Valve Train:

DOHC (Double Overhead Camshafts), 24 valves, Double VANOS (Variable Valve Timing)

Performance

Horsepower:

190 hp @ 5500 rpm (approx.)

Torque:

206 lb-ft @ 3950 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Cooling System

Coolant Type:

BMW Blue Antifreeze/Coolant (G48), 50/50 mixture with distilled water

Lubrication

Oil Type:

Synthetic SAE 5W-30 or 0W-30, meeting BMW LL-01 specification

Oil Capacity:

Approx. 6.5 liters (6.9 US quarts) with filter

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission (Getrag 260/6 or similar)

Optional

Transmission Type Optional:

5-speed Steptronic Automatic Transmission (ZF 5HP19FA)

Features

Automatic Transmission Modes:

Standard, Sport, Manual (Steptronic) shifting

Fluid Specifications

Manual Transmission Fluid:

GL-4 or GL-5 synthetic gear oil (SAE 75W-90 typically)

Automatic Transmission Fluid:

BMW ATF LT-71141 or equivalent (e.g., Pentosin ATF1)

📐 Dimensions

Exterior

Length:

4,819 mm (189.7 in)

Width:

1,799 mm (70.8 in)

Height:

1,437 mm (56.6 in)

Wheelbase:

2,830 mm (111.4 in)

Weights

Curb Weight:

1,590 - 1,650 kg (3,505 - 3,638 lbs) depending on transmission and equipment

Gross Vehicle Weight Rating:

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

Cargo

Trunk Volume:

460 liters (16.2 cu ft)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star driver, 5-star passenger (1999 model year)

IIHS Side Impact:

Good (2001 model year)

Active Features

Traction Control:

ASR (Anti-Slip Regulation) standard on most models

Stability Control:

Optional DSC (Dynamic Stability Control) available on later models

Standard Anti-lock Braking System (ABS)

Passive Features

Airbags:

Front dual-stage airbags, optional side-impact airbags

Seatbelts:

3-point seatbelts with pretensioners for all occupants

💡 Technology Features

Infotainment

Radio And Audio:

BMW Business or Professional CD/RDS radio systems, optional premium Hi-Fi sound systems

Navigation:

Optional M-ASK or M-ASK II (Multi-Audio System Controller) navigation systems

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC) front and rear

Cruise Control:

Standard cruise control system

Connectivity

Telematics:

Optional BMW Assist telematics system

Lighting

Headlights:

Halogen projector headlights standard, optional Xenon (HID) headlights with auto-leveling and washers

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, using synthetic oil

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions

Cabin Air Filter Replacement:

Every 15,000 - 20,000 miles (24,000 - 32,000 km)

Spark Plug Replacement:

Typically every 60,000 - 100,000 miles (96,000 - 160,000 km) for platinum or iridium plugs

Coolant Flush And Replacement:

Every 2-3 years or 30,000 - 50,000 miles (48,000 - 80,000 km)

Brake Fluid Flush:

Every 2 years, regardless of mileage

Fluid Specifications

Power Steering Fluid:

BMW Power Steering Fluid (Pentosin CHF 11S or equivalent)

Brake Fluid:

DOT 4 (low viscosity) brake fluid

Known Issues

Common Issue 1:

VANOS (Variable Valve Timing) solenoid and seal leaks, leading to rough idle or power loss

Common Issue 2:

Coolant expansion tank and hoses degradation, leading to leaks and potential overheating

Common Issue 3:

Oil pan gasket and valve cover gasket leaks due to age and material breakdown

Common Issue 4:

ABS/DSC wheel speed sensor failure, triggering warning lights and disabling ABS/DSC functions

Common Issue 5:

Ignition coil failure, leading to misfires and rough running

Common Issue 6:

Headlight leveling system failure (auto-leveling Xenons)

Common Issue 7:

Fuel pump and fuel pressure regulator issues

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Bayerische Motoren Werke AG (BMW) known for its 'Ultimate Driving Machine' slogan, emphasizing performance, engineering, and driver engagement

Model Evolution

E39 Introduction:

The E39 generation of the 5 Series was introduced in 1995 (as a 1996 model) in Europe and 1996 (as a 1997 model) in North America, replacing the E34 generation. The 528i variant replaced the 525i from the previous generation.

E39 Facelift:

A significant facelift occurred in 2000 (for the 2001 model year), introducing revised headlights (angel eyes), taillights, bumpers, and interior updates. The 528i was replaced by the 530i (with the M54B30 engine) in most markets post-facelift, though some 528i production may have continued into early 2001.

Production

Production Period For 528I:

1997-2000 (primarily, with some 2001 models potentially existing)

Manufacturing Locations:

Dingolfing, Germany; Rosslyn, South Africa; Graz, Austria (contract manufacturing)

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E39 5 Series frequently appeared on Car and Driver's '10Best' list during its production years, recognized for its blend of luxury, performance, and handling.

Motor Trend Car Of The Year:

While not winning the top award, the E39 5 Series was a strong contender and praised by MotorTrend for its engineering and driving dynamics.