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Bmw 5 Series E39 528i Sedan 1997-2002 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Body Style: Sedan Model Variant: 528i Model Years Covered: 1997-2002 Codes Engine Code General: M52B28 👋 Introduction Market Position Segment: Executive Sedan Premium Segment: Yes, positioned in the premium segment of the mid-size luxury sedan market. Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160) Key Features Driving Dynamics: Renowned for its balanced chassis, RWD bias, and engaging driving experience. Build Quality: Exceptional German engineering and build quality typical of BMW. Comfort And Luxury: Spacious interior, high-quality materials, and comfortable ride for a luxury vehicle. Manual Value Proposition: Provides in-depth factory knowledge, enabling owners and technicians to maintain and repair the vehicle to original specifications. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Target Audience: Professional Technicians and DIY Mechanics Page Count Estimated Page Count: Hundreds of Pages (specific count not provided, but implied comprehensive) Manual Type Type: Complete Official Full Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, repair, tuning Transmission: Automatic and Manual: Repair, maintenance, diagnostics, fluid service Drivetrain: Differential, driveshafts, axles: Repair and maintenance Suspension: Front and Rear: Components, diagnostics, alignment, repair Steering: System components, power steering, diagnostics, repair Brakes: Hydraulic system, ABS, pads, rotors, calipers: Diagnosis and repair Electrical System: Wiring diagrams, fuses, relays, battery, charging system, starting system Engine Management: ECU, sensors, fuel injection, ignition system, diagnostics HVAC: Climate control, refrigerant system, blower motor, diagnostics Body And Chassis: Panels, doors, glass, interior trim, structural components Lighting: Headlights, taillights, interior lighting: Diagnostics and repair Exhaust System: Components, mufflers, catalytic converters, diagnostics Fuel System: Tank, pump, lines, injectors, diagnostics Cooling System: Radiator, thermostat, water pump, hoses, diagnostics Safety Systems: Airbags, seatbelts, ABS (as part of braking system) Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tire rotation Preventive Maintenance: Scheduled service tasks, component inspections Troubleshooting: Diagnostic trees, symptom analysis, common fault identification Repair Procedures: Step-by-step instructions for all major component replacements and repairs Disassembly And Assembly: Detailed instructions for taking apart and putting back together vehicle systems Cleaning And Reinstalling: Procedures for cleaning components before reassembly Component Testing: Methods for testing the functionality of individual parts Wiring Diagrams: Comprehensive electrical schematics for all systems Technical Depth Depth: Complete Factory Level Detail Diagnostic Tools: Information applicable to factory diagnostic tools (e.g., DIS, GT1) Special Tools: Identification and usage of specialized tools required for specific repairs 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Zoom Functionality: YES (Zoom IN/OUT) Binding Type Binding: Digital Download (Printable) Paper Type Paper Type: N/A (Digital) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-Cylinder, Naturally Aspirated Engine Code: M52B28TU (for later models within the range) Displacement: 2.8 Liters (2793 cc) Bore X Stroke: 84.0 mm x 81.0 mm Compression Ratio: 10.2:1 Performance Horsepower: 193 hp @ 5500 rpm Torque: 206 lb-ft (280 Nm) @ 3500 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (Bosch Motronic) Fuel Type: Premium Unleaded Gasoline (91 Octane or higher) Cooling System Cooling Capacity: Approx. 8.5 Liters 🔧 Transmission Standard Transmission Type: 5-speed Manual (Getrag 260/6) Optional Transmission Type: 5-speed Automatic (Steptronic) Features Transmission Fluid Type: Dexron III (for Automatic) / GL-4 or GL-5 (for Manual, check specific weight) 📐 Dimensions Exterior Length: 188.5 inches (4788 mm) Width: 70.2 inches (1783 mm) Height: 57.0 inches (1448 mm) Wheelbase: 111.4 inches (2830 mm) Weights Curb Weight: Approx. 3505 lbs (1590 kg) (Manual) / 3593 lbs (1630 kg) (Automatic) Gross Vehicle Weight Rating: Approx. 4586 lbs (2080 kg) Cargo Trunk Volume: 17.1 cubic feet (484 Liters) 🛡️ Safety Features Ratings NHTSA Front Impact: 4 Stars NHTSA Side Impact: 4 Stars (with optional side airbags) Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard Traction Control System (ASC+T - Automatic Stability Control + Traction) Passive Features Airbags: Driver and Front Passenger Airbags (Side airbags optional) Seatbelts: 3-point inertia-reel seatbelts with pretensioners Body Structure: Reinforced safety cage with crumple zones. 💡 Technology Features Infotainment Infotainment System: BMW Professional Radio or optional navigation system (CCC or M-ASK depending on year/options). Audio Features: Optional premium sound systems (e.g., Harman Kardon). Driver Assistance Cruise Control: Standard on most models. Parking Sensors: Optional Park Distance Control (PDC) front and rear. Connectivity Phone Integration: Optional Bluetooth phone integration and BMW Assist telematics (depending on year and options). Comfort Features Climate Control: Automatic climate control (dual-zone) standard on most trims. 🔧 Maintenance Service Intervals Oil Change Interval: Variable Service Interval (Condition Based Service - CBS), typically around 10,000-15,000 miles or 12-24 months. Brake Fluid Flush: Recommended every 2 years. Coolant Replacement: BMW Long-Life Coolant, typically every 4-5 years or 50,000-60,000 miles....
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Bmw 5 Series E39 528i Sedan 1997-2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E39
Body Style:
Sedan
Model Variant:
528i
Model Years Covered:
1997-2002
Codes
Engine Code General:
M52B28
👋 Introduction
Market Position
Segment:
Executive Sedan
Premium Segment:
Yes, positioned in the premium segment of the mid-size luxury sedan market.
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS (JZS160)
Key Features
Driving Dynamics:
Renowned for its balanced chassis, RWD bias, and engaging driving experience.
Build Quality:
Exceptional German engineering and build quality typical of BMW.
Comfort And Luxury:
Spacious interior, high-quality materials, and comfortable ride for a luxury vehicle.
Manual Value Proposition:
Provides in-depth factory knowledge, enabling owners and technicians to maintain and repair the vehicle to original specifications.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Target Audience:
Professional Technicians and DIY Mechanics
Page Count
Estimated Page Count:
Hundreds of Pages (specific count not provided, but implied comprehensive)
Manual Type
Type:
Complete Official Full Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnostics, repair, tuning
Transmission:
Automatic and Manual: Repair, maintenance, diagnostics, fluid service
Drivetrain:
Differential, driveshafts, axles: Repair and maintenance
Suspension:
Front and Rear: Components, diagnostics, alignment, repair
Steering:
System components, power steering, diagnostics, repair
Brakes:
Hydraulic system, ABS, pads, rotors, calipers: Diagnosis and repair
Electrical System:
Wiring diagrams, fuses, relays, battery, charging system, starting system
Engine Management:
ECU, sensors, fuel injection, ignition system, diagnostics
HVAC:
Climate control, refrigerant system, blower motor, diagnostics
Body And Chassis:
Panels, doors, glass, interior trim, structural components
Lighting:
Headlights, taillights, interior lighting: Diagnostics and repair
Exhaust System:
Components, mufflers, catalytic converters, diagnostics
Fuel System:
Tank, pump, lines, injectors, diagnostics
Cooling System:
Radiator, thermostat, water pump, hoses, diagnostics
Safety Systems:
Airbags, seatbelts, ABS (as part of braking system)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotation
Preventive Maintenance:
Scheduled service tasks, component inspections
Troubleshooting:
Diagnostic trees, symptom analysis, common fault identification
Repair Procedures:
Step-by-step instructions for all major component replacements and repairs
Disassembly And Assembly:
Detailed instructions for taking apart and putting back together vehicle systems
Cleaning And Reinstalling:
Procedures for cleaning components before reassembly
Component Testing:
Methods for testing the functionality of individual parts
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Technical Depth
Depth:
Complete Factory Level Detail
Diagnostic Tools:
Information applicable to factory diagnostic tools (e.g., DIS, GT1)
Special Tools:
Identification and usage of specialized tools required for specific repairs
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality:
YES (Zoom IN/OUT)
Binding Type
Binding:
Digital Download (Printable)
Paper Type
Paper Type:
N/A (Digital)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-Cylinder, Naturally Aspirated
Engine Code:
M52B28TU (for later models within the range)
Displacement:
2.8 Liters (2793 cc)
Bore X Stroke:
84.0 mm x 81.0 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
193 hp @ 5500 rpm
Torque:
206 lb-ft (280 Nm) @ 3500 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (Bosch Motronic)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher)
Cooling System
Cooling Capacity:
Approx. 8.5 Liters
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (Getrag 260/6)
Optional
Transmission Type:
5-speed Automatic (Steptronic)
Features
Transmission Fluid Type:
Dexron III (for Automatic) / GL-4 or GL-5 (for Manual, check specific weight)
📐 Dimensions
Exterior
Length:
188.5 inches (4788 mm)
Width:
70.2 inches (1783 mm)
Height:
57.0 inches (1448 mm)
Wheelbase:
111.4 inches (2830 mm)
Weights
Curb Weight:
Approx. 3505 lbs (1590 kg) (Manual) / 3593 lbs (1630 kg) (Automatic)
Gross Vehicle Weight Rating:
Approx. 4586 lbs (2080 kg)
Cargo
Trunk Volume:
17.1 cubic feet (484 Liters)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars
NHTSA Side Impact:
4 Stars (with optional side airbags)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard Traction Control System (ASC+T - Automatic Stability Control + Traction)
Passive Features
Airbags:
Driver and Front Passenger Airbags (Side airbags optional)
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Body Structure:
Reinforced safety cage with crumple zones.
💡 Technology Features
Infotainment
Infotainment System:
BMW Professional Radio or optional navigation system (CCC or M-ASK depending on year/options).
Audio Features:
Optional premium sound systems (e.g., Harman Kardon).
Driver Assistance
Cruise Control:
Standard on most models.
Parking Sensors:
Optional Park Distance Control (PDC) front and rear.
Connectivity
Phone Integration:
Optional Bluetooth phone integration and BMW Assist telematics (depending on year and options).
Comfort Features
Climate Control:
Automatic climate control (dual-zone) standard on most trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable Service Interval (Condition Based Service - CBS), typically around 10,000-15,000 miles or 12-24 months.
Brake Fluid Flush:
Recommended every 2 years.
Coolant Replacement:
BMW Long-Life Coolant, typically every 4-5 years or 50,000-60,000 miles.
Spark Plug Replacement:
Around 60,000-100,000 miles, depending on spark plug type (standard vs. long-life).
Fluid Specifications
Engine Oil Spec:
BMW Long-Life Oil (e.g., BMW LL-01 for synthetic, or specific viscosity like 5W-30 or 10W-40 as per owner's manual/engine condition).
Engine Oil Capacity:
Approx. 6.5 Liters (with filter).
Coolant Type:
BMW Blue or Green Long-Life Coolant (ethylene glycol based, silicate-free).
Known Issues
Cooling System Failures:
Common failures include plastic expansion tanks cracking, water pump impeller failure, and thermostat housing leaks.
Oil Pan Gasket Leaks:
Oil pan gasket and valve cover gasket leaks are frequent due to age and material degradation.
ABS/Dsc Module Failures:
The ABS/DSC control module can fail, often due to cracked solder joints on the circuit board.
Vanos System Issues:
Degradation of the O-rings in the VANOS (Variable Valve Timing) system can lead to rough idling and loss of low-end torque.
Pixel Display Failure:
The instrument cluster LCD display (pixelated) can fail, rendering vital information unreadable.
Rear Shock Mounts:
Rear shock absorber mounts can wear out, causing clunking noises over bumps.
Window Regulator Failure:
Window regulators are a common failure point, leading to windows not operating.
Maintenance Tips
Importance Of Maintenance:
Adhering to the service intervals and using high-quality parts is crucial for longevity and performance of the E39.
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, luxury, and engineering.
Model Evolution
E39 Introduction:
The E39 generation of the 5 Series was introduced in 1995 (as a 1996 model in North America), replacing the E34.
E39 Facelift:
Received a significant facelift in 2000 (for the 2001 model year) with updated headlights (angel eyes), taillights, and minor interior/exterior styling changes.
Production
Production Period:
1995–2003 (with the 528i model primarily within the 1997-2002 timeframe).
Manufacturing Locations:
Primarily Dingolfing, Germany.
🏆 Awards & Recognition
Recognitions
Car And Driver Awards:
Consistently featured on Car and Driver's '10Best' lists during its production years.
Industry Accolades:
Widely praised for its driving dynamics, chassis balance, and luxury appointments.
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