BMW 528i 1999 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 1999 Codes Chassis Code: E39 Generation Generation: Fourth Generation (E39) 👋 Introduction Market Position Positioning: Premium mid-size sedan, offering a blend...

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Art.-Nr: 398992

Stichworte: 1999 528i BMW Car Cars Misc

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Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Generation

Generation:

Fourth Generation (E39)

👋 Introduction

Market Position

Positioning:

Premium mid-size sedan, offering a blend of luxury, performance, and advanced engineering.

Competitive Analysis

Competitors:

Competed directly with the Mercedes-Benz E-Class, Audi A6, Lexus GS, and Cadillac Seville of the era.

Key Features

Design:

Praised for its sophisticated and timeless design, embodying BMW's characteristic ' Hofmeister kink' and balanced proportions.

Driving Dynamics:

Renowned for its excellent handling, precise steering, and comfortable ride, characteristic of BMW's 'Ultimate Driving Machine' philosophy.

Engine Performance:

The inline-six engine provided smooth power delivery and a refined driving experience.

Interior Quality:

High-quality materials, ergonomic driver-focused cockpit, and comfortable seating.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, based on typical offerings)

Page Count

Page Count:

Estimated 1000+ pages (typical for a comprehensive workshop manual)

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive coverage of the M52B28 engine, including diagnostics, disassembly, assembly, and component testing.

Engine Management:

Detailed information on the Siemens MS 42 engine management system, including sensor locations, operation, diagnostic trouble codes (DTCs), and troubleshooting procedures.

Transmission:

Service and repair procedures for both the Getrag 5-speed manual transmission (S5D 320Z) and the ZF 5HP19FA 5-speed automatic transmission, including fluid capacities and change intervals.

Drivetrain:

Repair and maintenance of the rear-wheel-drive system, including driveshafts, universal joints, and differential components.

Suspension:

Detailed procedures for front and rear suspension components, including struts, shock absorbers, control arms, bushings, and alignment specifications.

Brakes:

Comprehensive brake system coverage, including hydraulic systems, ABS (Anti-lock Braking System) component testing and repair, rotor and pad replacement, and bleeding procedures.

Steering:

Service and repair of the power steering system, including the steering rack, pump, hoses, and fluid specifications.

Electrical System:

Extensive coverage of the vehicle's electrical system, including wiring diagrams, fuse box layouts, component testing, battery, charging system, and starter motor.

Lighting:

Headlight, taillight, interior lighting, and exterior lighting system diagnostics and repair.

Climate Control:

Service and repair of the HVAC (Heating, Ventilation, and Air Conditioning) system, including refrigerant handling (with appropriate warnings), component replacement, and troubleshooting.

Body And Trim:

Procedures for body panel removal and installation, interior trim components, bumpers, and door mechanisms.

Body Electrical:

Coverage of power windows, central locking, mirrors, and other body-related electrical systems.

Fuel System:

Repair and maintenance of the fuel pump, injectors, fuel filter, and fuel tank.

Exhaust System:

Information on exhaust components, catalytic converter, and muffler replacement.

Cooling System:

Radiator, water pump, thermostat, hoses, and coolant specifications.

Safety Systems:

Information on airbag systems, seat belts, and their associated sensors and control modules.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules, including oil changes, filter replacements, spark plug intervals, and fluid checks.

Troubleshooting:

Comprehensive diagnostic procedures for common and uncommon issues, often presented with symptom-based troubleshooting trees.

Repair Procedures:

Step-by-step instructions for virtually every repair task, from simple component replacement to major overhauls.

Component Replacement:

Specific instructions for replacing parts such as alternators, starters, water pumps, ignition coils, and sensors.

Diagnostics:

Guidance on using diagnostic tools and interpreting diagnostic trouble codes (DTCs) for various electronic control units (ECUs).

Rebuilding Procedures:

Instructions for complete engine and transmission rebuilds, including torque specifications and clearances.

Electrical Diagnostics:

Detailed steps for diagnosing electrical faults using multimeters and understanding wiring diagrams.

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment.

Technical Depth

Depth:

Expert-level detail, suitable for professional mechanics and serious DIY enthusiasts.

Detail Level:

Includes detailed torque specifications, clearances, diagnostic flowcharts, and component-specific testing procedures.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchable:

Yes (typically, if professionally scanned/generated)

Printable:

Print Quality

Image Resolution:

High-resolution (crucial for clarity of diagrams and schematics)

Diagram Clarity:

Excellent, with clear line drawings and schematics.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M52B28

Engine Type:

DOHC Inline-6 Cylinder

Displacement:

2.8 Liters (2793 cc)

Bore X Stroke:

84 mm x 81 mm

Compression Ratio:

10.2:1

Performance

Horsepower:

193 hp @ 5300 rpm

Torque:

206 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (Bosch Motronic 5.2.1 or Siemens MS 42)

Recommended Fuel:

Premium Unleaded (91 octane or higher)

Engine Management

ECU Type:

Siemens MS 42 (or Bosch Motronic 5.2.1 on earlier models)

🔧 Transmission

Standard

Transmission Type:

Getrag 5-speed Manual Transmission (S5D 320Z)

Optional

Transmission Type:

ZF 5HP19FA 5-speed Automatic Transmission

Features

Manual Gear Ratios:

Refer to manual for specific ratios; typically geared for a balance of performance and economy.

Automatic Features:

Steptronic manual shift mode (on most models)

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-1 or equivalent (e.g., Red Line MTL)

Automatic Transmission Fluid:

BMW ATF LT-3 or ZF LifeguardFluid 5 (or equivalent)

📐 Dimensions

Exterior

Length:

188.3 inches (4783 mm)

Width:

70.2 inches (1783 mm)

Height:

57.0 inches (1448 mm)

Wheelbase:

111.4 inches (2830 mm)

Weights

Curb Weight:

Approx. 3550 - 3700 lbs (1610 - 1680 kg), depending on transmission and options.

Cargo

Trunk Capacity:

17.7 cu ft (501 L)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not explicitly rated by NHTSA for this specific model year and configuration, but generally considered safe for its era.

IIHS Crash Test:

Not readily available for this specific model year from IIHS.

Active Features

Standard Anti-lock Braking System (ABS).

Traction Control:

Standard Automatic Stability Control (ASC) or Automatic Stability Control + Traction (ASC+T).

Passive Features

Airbags:

Driver and front passenger airbags. Optional side airbags.

Seat Belts:

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

Body Structure:

Reinforced safety cell with front and rear crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory BMW Business or Professional CD/radio systems. Cassette player common.

Navigation:

Optional BMW Business or Professional navigation system (CRT screen).

Driver Assistance

Cruise Control:

Standard cruise control system.

Parking Sensors:

Optional rear Park Distance Control (PDC).

Connectivity

Onboard Computer:

Standard check control system and on-board computer for vehicle status and basic information.

Convenience

Remote Keyless Entry:

Standard.

Power Features:

Power windows, power mirrors, power locks, power adjustable seats (with memory on some models).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 - 10,000 miles (or as indicated by the vehicle's condition-based service system), using the correct oil specification.

Spark Plug Replacement:

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

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles.

Fluid Specifications

Engine Oil Type:

BMW Longlife-98 (LL-98) specification, typically a 5W-30 or 5W-40 synthetic oil. Refer to manual for exact specification.

Engine Oil Capacity:

6.5 liters (6.9 US quarts) with filter.

Coolant Type:

BMW Blue Antifreeze (G48 or equivalent G11 specification) mixed with distilled water (50/50).

Brake Fluid:

DOT 4

Known Issues

Cooling System:

Plastic coolant expansion tanks and radiator end tanks can become brittle and crack; water pump impellers can degrade.

Valve Cover Gasket:

Oil leaks from the valve cover gasket are common due to aging rubber.

Oil Pan Gasket:

Oil pan gasket leaks can also occur over time.

ABS Wheel Speed Sensors:

ABS sensor failures can lead to ABS and traction control warning lights.

Fuel Pump:

Fuel pump can fail over time, leading to starting issues or loss of power.

Mass Airflow Sensor:

MAF sensor can become dirty or fail, affecting engine performance and fuel economy.

Window Regulators:

Power window regulators can fail.

Heater Control Valve:

Heater control valve (or O-rings) can leak.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW AG, a German company with a long history of producing high-performance and luxury vehicles, known for its engineering prowess and driving dynamics.

Model Evolution

E39 Introduction:

The E39 5 Series replaced the E34 generation and was produced from 1995 to 2003. The 528i was a core model within this generation.

E39 Platform:

The E39 chassis was a significant step forward in terms of chassis design, suspension technology (featuring aluminum suspension components for reduced unsprung weight), and technology integration.

Production

Manufacturing Locations:

Primarily manufactured in Dingolfing, Germany.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E39 generation of the 5 Series was a frequent recipient of Car and Driver's 10 Best lists in its earlier years.

Auto Express Reviews:

Generally received positive reviews from automotive publications for its driving dynamics and build quality.

Certifications

Build Quality:

Recognized for high build quality and material selection typical of BMW.