🏷️ Basic Information Identification Make: BMW Model: 528i Year: 2002 Product Name: BMW 528i 2002 Full Service Repair Manual 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Competitors 2002: Mercedes-Benz E-Class (W211), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type, Cadillac CTS Key Features Chassis: E39 Platform Driving Dynamics: Renowned for balanced handling, rear-wheel drive bias, and driver-focused cockpit Luxury Appointments: Premium interior materials, advanced comfort features for its era 📋 Manual Details Coverage Areas General Coverage: Repair, maintenance, rebuilding, refurbishing, restoration, diagnostics Page Count Estimated Page Count: 1500+ Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (likely PDF, based on description) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, component testing, fuel injection, ignition system, cooling system, lubrication system, exhaust system Transmission: Automatic and Manual Transmission diagnosis, repair, overhaul, fluid specifications, and procedures Drivetrain: Front Wheel Drive, Rear Wheel Drive, axle shafts, differentials, driveshafts, CV joints Suspension: Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications Steering: Power steering system diagnosis, repair, rack and pinion, steering column, steering wheel Brakes: Brake system diagnosis, repair, ABS (Anti-lock Braking System), brake pads, rotors, calipers, brake lines, hydraulic system Electrical System: Wiring diagrams, starter, alternator, battery, fuses, relays, lighting, ignition, power windows, power locks, body control modules (BCM) HVAC: Heating, Ventilation, and Air Conditioning system diagnosis, repair, refrigerant handling, blower motor, climate control panel Body And Interior: Body panel repair, door mechanisms, seat mechanisms, dashboard, trim components, glass replacement Diagnostic Troubleshooting: Troubleshooting guides, fault codes, diagnostic procedures using scan tools (e.g., BMW DIS or ISTA) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups Repair: Component replacement, sub-assembly repair, major overhauls Rebuilding: Engine rebuilding, transmission rebuilding, component restoration Diagnostics: Step-by-step diagnostic procedures, circuit testing, component testing Technical Depth Depth: Comprehensive (covers basic maintenance to complete engine/transmission rebuilds and advanced diagnostics) 📊 Manual Specifications File Format Digital Format: PDF (Searchable, Printable, Bookmarked) Print Quality Image Resolution: High-resolution images and diagrams Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: M54B30 Engine Type: Inline 6-Cylinder, DOHC, 24 Valves Displacement: 2979 cc (3.0 Liters) Performance Horsepower: 225 hp @ 6100 rpm Torque: 214 lb-ft @ 3500 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (Bosch Motronic ME 7.2) Fuel Type: Premium Unleaded Gasoline (91 Octane Recommended) Engine Management ECU: Bosch Motronic ME 7.2 Emission Controls: Secondary Air Injection System, EGR (California models), Catalytic Converter 🔧 Transmission Standard Type: 5-speed Manual Transmission (Getrag S5D 320Z) Optional Type: 5-speed Steptronic Automatic Transmission (GM 5L40-E) Features Steptronic: Allows manual gear selection via shift lever or steering wheel buttons Fluid Specifications Automatic Transmission Fluid: Dexron III/VI compatible (e.g., ZF LifeguardFluid 5) Manual Transmission Fluid: BMW recommended synthetic gear oil (e.g., Castrol SAF-XJ 75W-140 or equivalent) 📐 Dimensions Exterior Length: 188.5 inches (4788 mm) Width: 70.2 inches (1783 mm) Height: 56.5 inches (1435 mm) Wheelbase: 111.4 inches (2830 mm) Weights Curb Weight: Approximately 3500-3700 lbs (1588-1678 kg) Gross Vehicle Weight Rating: Approximately 4500 lbs (2041 kg) Cargo Trunk Capacity: 13.7 cubic feet (388 liters) 🛡️ Safety Features Ratings NHTSA Frontal Impact: 4-star driver, 4-star passenger IIHS Side Impact: Good Active Features ABS: Standard Anti-lock Braking System Asc: Standard Automatic Stability Control Dsc: Optional Dynamic Stability Control (traction and stability enhancement) Passive Features Airbags: Frontal airbags, front side-impact airbags Seatbelts: 3-point inertia-reel seat belts with pretensioners Head Restraints: Active front head restraints (reduce whiplash injuries) 💡 Technology Features Infotainment Navigation System: Optional BMW Professional Navigation System with CD-ROM based maps Audio System: Optional Harman Kardon premium sound system, CD player, Cassette deck Driver Assistance Cruise Control: Standard electronic cruise control Parking Sensors: Optional rear Park Distance Control (PDC) Connectivity Telematics: Optional Tele Aid (emergency assistance service) Comfort Features Climate Control: Standard automatic climate control with dual-zone temperature control Seats: Optional power adjustable front seats with memory function, heated seats 🔧 Maintenance Service Intervals Oil Change: BMW Condition Based Service (CBS) or approximately every 7,500-10,000 miles / 12 months, whichever comes first (check CBS indicator) Engine Air Filter: Inspect every 30,000 miles, replace as needed (or per CBS) Cabin Air Filter: Replace every 30,000 miles or annually (or per CBS) Spark Plugs: Replace every 100,000 miles (long-life iridium type) Fluid Specifications Engine Oil: SAE 5W-30 Synthetic (BMW Longlife-01 approved) Coolant: BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) diluted 50/50 with distilled water Brake Fluid: DOT 4, low viscosity (BMW High Performance DOT 4 or equivalent) Power Steering Fluid: Pentosin CHF 11S or equivalent hydraulic fluid Known Issues Cooling System: Plastic coolant expansion tank can become brittle and crack, leading to leaks. Water pump and thermostat housing are common failure points. Oil Leaks: Valve cover gasket, oil pan gasket, and oil filter housing gasket can leak due to age...