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...

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Type: Car

Vendor:

Sku: 396213

Tags: 1997 1998 1999 2000 2001 2002 5 Series 5 Series E39 528i Sedan BMW Car Cars

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Body Style:

Sedan

Model Variant:

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:

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

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.