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BMW 5 Series (E39) 528i Sedan 1997-2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E39 Variant: 528i Sedan Model Years Covered: 1997-2002 👋 Introduction Market Position Positioning: The E39 5 Series represented BMW's...
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BMW 5 Series (E39) 528i Sedan 1997-2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E39
Variant:
528i Sedan
Model Years Covered:
1997-2002
👋 Introduction
Market Position
Positioning:
The E39 5 Series represented BMW's mid-size luxury sedan offering, positioned as a premium vehicle known for its driving dynamics, build quality, and sophisticated engineering.
Competitive Analysis
Competitors:
Competed against the Mercedes-Benz E-Class, Audi A6, Lexus GS, and Jaguar S-Type during its production run.
Key Features
Strengths:
Renowned for its balanced chassis, powerful inline-six engines, driver-focused interior, and advanced technology for its era.
📋 Manual Details
Coverage Areas
Coverage Scope:
Full Service and Repair
Page Count
Estimated Page Count:
Comprehensive (specific count not provided, implies extensive detail)
Manual Type
Type:
Professional Workshop Manual / Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, tuning, cooling system, lubrication system, fuel injection, ignition system, emission control systems
Transmission:
Manual and Automatic transmission service, repair, overhaul, fluid specifications
Drivetrain:
Front axle, rear axle, drive shafts, differential, wheel bearings
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, control arms, steering gear, power steering system, wheel alignment specifications
Brakes:
Brake system diagnosis, repair, maintenance of front and rear brakes (discs, pads, calipers, lines, master cylinder), ABS system components
Electrical Electronic:
Complete wiring diagrams, battery, alternator, starter, lighting systems, instrument cluster, power windows, locks, mirrors, HVAC controls, ECU diagnosis and repair
Bodywork:
Body panel removal and installation, doors, hood, trunk, bumpers, interior trim, glass replacement
HVAC:
Air conditioning system service, refrigerant, compressor, blower motor, climate control panel diagnosis and repair
Exhaust System:
Catalytic converter, mufflers, exhaust manifolds, oxygen sensors.
Wheels Tires:
Wheel specifications, tire pressure recommendations, lug bolt torque specifications.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides
Repair:
Step-by-step repair procedures for all major components and systems, including complete disassembly and reassembly instructions
Diagnostics:
Detailed diagnostic strategies, use of diagnostic tools, interpretation of sensor data
Body Electrical:
Operation and repair of lighting systems (headlights, taillights, interior), power accessories (windows, locks, mirrors, seats), wipers, horn, central locking, remote keyless entry.
Chassis Control:
Diagnosis and repair of ABS, ASC+T systems, including wheel speed sensors, ABS control module, and hydraulic unit.
Component Replacement:
Detailed instructions for replacing components such as radiators, alternators, starters, fuel pumps, brake calipers, control arms, mass airflow sensors, etc.
Torque Specifications:
Comprehensive torque specifications for all critical fasteners throughout the vehicle.
Technical Depth
Depth:
Comprehensive, covering basic DIY maintenance to advanced mechanical and electrical repairs, including engine rebuilds and complex system diagnostics
Diagnostic Tools:
Information implicitly supports the use of BMW's proprietary diagnostic systems (e.g., GT1/TIS) and generic OBD-II scanners.
Manual Type
Clarity And Usability:
Designed for ease of use with clear text, high-quality diagrams, exploded views, and step-by-step instructions, suitable for both novice DIYers and professional mechanics.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Fully Printable
Viewing Features
Zoom Capability:
Zoom IN/OUT enabled
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility
Operating Systems:
Compatible with All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
M52B28 (often referred to by its displacement)
Engine Type:
Naturally Aspirated Inline-6 Cylinder
Displacement:
2.8 Liters (2793 cc)
Bore X Stroke:
84.0 mm x 83.6 mm
Compression Ratio:
10.2:1
Horsepower:
193 hp @ 5500 rpm (SAE Net)
Torque:
206 lb-ft (279 Nm) @ 3950 rpm (SAE Net)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic M5.2 or M5.4)
Fuel Type:
Premium Unleaded Gasoline (91 AKI or higher recommended)
Cooling System
Cooling Type:
Liquid-cooled, pressurized system with engine-driven fan and electric auxiliary fan
Lubrication System
Oil Type:
BMW Longlife-98 (LL-98) specification 5W-40 or 5W-30 synthetic oil
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with individual ignition coils (coil-on-plug for later models)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (Getrag 260/6 or ZF S5-31)
Optional
Transmission Type:
5-speed Automatic Transmission (ZF 5HP18 or 5HP19)
Features
Automatic Features:
Steptronic manual shift mode (on some models)
Fluid Specifications
Automatic Transmission Fluid:
BMW ATF LT-2 or LT-3 (Dexron III compatible, but genuine BMW fluid recommended)
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 synthetic gear oil
📐 Dimensions
Exterior
Length:
188.2 inches (4780 mm)
Width:
70.2 inches (1783 mm)
Height:
57.1 inches (1450 mm)
Wheelbase:
111.4 inches (2830 mm)
Weights
Curb Weight:
Approximately 3500-3700 lbs (1588-1678 kg) depending on transmission and options
Gross Vehicle Weight Rating:
Varies by model, typically around 4600 lbs (2087 kg)
Cargo
Trunk Volume:
16.1 cubic feet (456 Liters)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4/5 stars (for comparable models/years)
NHTSA Front Impact Passenger:
4/5 stars (for comparable models/years)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Automatic Stability Control (ASC+T) on most models
Passive Features
Airbags:
Standard front airbags, optional side airbags
Seatbelts:
3-point inertia-reel seat belts with pre-tensioners
💡 Technology Features
Infotainment
Head Unit:
BMW Professional Radio/Cassette or optional CD player, integrated navigation system (MKII or MKIII) on some models.
Audio System:
Standard 6-speaker system, optional Harman Kardon premium sound system.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Assistance:
Optional rear parking sensors (Park Distance Control - PDC).
Connectivity
Onboard Computer:
Standard On-Board Computer providing fuel consumption, range, average speed, and check control messages.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles (16,000-24,000 km) or annually, using synthetic oil. Check Condition Based Service (CBS) system on newer models within this range.
Spark Plug Replacement:
Approximately 60,000 miles (96,000 km) for standard plugs; iridium plugs can last longer.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Coolant Flush:
Every 2-3 years or as recommended by the manual.
Fluid Specifications
Engine Oil Capacity:
Approximately 6.5 quarts (6.2 liters) with filter change for the 2.8L engine.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based)
Power Steering Fluid:
BMW Power Steering Fluid or Pentosin CHF 11S (check specific requirements)
Known Issues
Common Problems:
Vibration damper (harmonic balancer) failure, cooling system leaks (plastic expansion tank, hoses), VANOS system issues, oil leaks from valve cover gasket and oil pan gasket, ABS/ASC sensor failures, window regulator failures, headlight condensation.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's 'Ultimate Driving Machine' philosophy emphasizing performance, luxury, and advanced engineering.
Model Evolution
E39 Generation:
The E39 generation, introduced in 1995 for the 1996 model year (in Europe) and 1997 (in North America), represented a significant redesign over its E34 predecessor. It offered improved aerodynamics, chassis dynamics, and advanced electronic features.
Production
Production Years Global:
1995-2003
Manufacturing Locations:
Primarily Dingolfing, Germany; also assembled in other locations including South Africa and Egypt.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E39 5 Series (including various engine variants) was a frequent recipient of Car and Driver's '10Best' awards during its production years, lauded for its driving dynamics and overall excellence.
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