Segment:
Executive Mid-size Sedan/Wagon
Brand Philosophy:
Ultimate Driving Machine, focus on performance, luxury, and advanced engineering.
Competitors:
Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS300/LS400, Jaguar S-Type.
Unique Selling Points:
Inline-6 engine smoothness, sophisticated chassis tuning, excellent handling for its class, premium interior materials, wagon practicality.
Engine:
Full mechanical, electrical, and troubleshooting for the M52TU inline-6 engine.
Transmission:
Automatic (GM 5L40-E) and manual (ZF S5-36/37) transmission overhaul, diagnostics, and fluid service.
Drivetrain:
Rear-wheel drive (RWD) and xDrive (if applicable for the specific year/market, though E39 528i is typically RWD), driveshaft, differential, and axles.
Suspension:
Front and rear suspension components, struts, shocks, bushings, springs, and alignment procedures.
Brakes:
ABS, DSC (Dynamic Stability Control), EBD (Electronic Brakeforce Distribution), brake calipers, rotors, pads, hydraulic lines, and bleeding procedures.
Steering:
Power steering system, steering rack, tie rods, and steering column.
Electrical:
Complete wiring diagrams, ECU functions, body electronics, lighting, ignition, charging system, and starter.
Comfort Systems:
HVAC (Heating, Ventilation, and Air Conditioning), climate control, power windows, seats, locks, sunroof, and interior trim.
Body And Chassis:
Body panel removal and installation, door mechanisms, tailgate, chassis structure, and corrosion protection.
Diagnostic Tools:
Information on using BMW's diagnostic tools (e.g., GT1, DIS) and common OBD-II troubleshooting.
Maintenance:
Oil changes, filter replacements, spark plug changes, coolant flushes, brake fluid changes, and belt replacements.
Troubleshooting:
System-specific diagnostic flowcharts, symptom-based troubleshooting guides, and fault code interpretation.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems.
Overhaul:
Detailed procedures for engine and transmission rebuilds.
Diagnostics:
Electrical system diagnostics, sensor testing, actuator testing, and ECU diagnosis.
Calibration:
Procedures for recalibrating sensors and control modules after replacement (e.g., steering angle sensor).
Alignment:
Front and rear wheel alignment specifications and procedures.
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical schematics and diagnostic trees.
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Displacement:
2.8 Liters (2793 cc)
Bore X Stroke:
84.0 mm x 90.0 mm
Compression Ratio:
10.2:1
Horsepower:
193 hp @ 5500 rpm
Torque:
206 lb-ft (280 Nm) @ 3800 rpm
Fuel Delivery:
Multi-point Fuel Injection (MPI) with Siemens DMEs.
Fuel Type:
Premium Unleaded (91 Octane Recommended)
ECU:
Siemens MS42.0 (for manual transmission) or MS43.0 (for automatic transmission).
Type:
Double Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing) on intake camshaft.
Type:
5-Speed Manual Transmission (ZF S5-36/37)
Type:
5-Speed Automatic Transmission (GM 5L40-E)
Automatic Modes:
Standard Drive (D), Sport (S), and Manual Sequential Shift (Steptronic).
Manual Transmission Fluid:
BMW MTF LT-1 or equivalent API GL-4 SAE 75W-90 synthetic gear oil.
Automatic Transmission Fluid:
Dexron III or Dexron VI compatible ATF.
Length:
4,942 mm (194.6 in)
Width:
1,801 mm (70.9 in)
Height:
1,457 mm (57.4 in)
Wheelbase:
2,830 mm (111.4 in)
Front Track:
1,511 mm (59.5 in)
Rear Track:
1,525 mm (60.0 in)
Seating Capacity:
5 Passengers
Cargo Volume Seats Up:
550 Liters (19.4 cu ft)
Cargo Volume Seats Down:
1,640 Liters (57.9 cu ft)
Curb Weight:
1,650 - 1,750 kg (3,638 - 3,858 lbs)
Gross Vehicle Weight Rating:
Approx. 2,150 kg (4,740 lbs)
Towing Capacity:
2,000 kg (4,400 lbs) (with factory tow hitch)
NHTSA Front Impact:
4-Star Driver, 4-Star Passenger (for Sedan, wagon typically similar).
IIHS Side Impact:
Good (for applicable year sedans, wagon might vary).
ABS:
Standard Anti-lock Braking System.
Traction Control:
Standard ASC+T (Automatic Stability Control + Traction) or optional DSC (Dynamic Stability Control).
Stability Control:
Dynamic Stability Control (DSC) became more prevalent in later years.
Airbags:
Driver and front passenger airbags, optional side-impact airbags.
Seatbelts:
3-point inertia-reel seat belts with pre-tensioners and force limiters for front seats.
Head Restraints:
Active head restraints for front seats.
Radio Options:
BMW Business CD/RDS, BMW Professional CD/RDS, optional CD changer.
Navigation:
Optional BMW Professional navigation system with CRT screen and CD-ROM maps.
Cruise Control:
Standard electronic cruise control.
Parking Sensors:
Optional rear parking sensors (Park Distance Control - PDC).
Onboard Computer:
BMW On-Board Computer (OBC) with fuel economy, range, and trip computer functions.
Phone Integration:
Optional BMW Bluetooth preparation or cellular phone cradle integration.
Oil Change Interval:
BMW Condition Based Service (CBS) recommendations, typically every 10,000-15,000 miles or annually, using synthetic oil.
Spark Plug Replacement:
Approximately 60,000 miles (refer to manual for specific plug type and gap).
Coolant Flush:
Every 2-3 years or as indicated by CBS. Use BMW Blue Antifreeze (G48).
Engine Oil Type:
Synthetic SAE 5W-30 or 5W-40 meeting BMW Longlife-01 (LL-01) or LL-98 specifications.
Engine Oil Capacity:
7.0 Liters (7.4 US Quarts) with filter change.
Power Steering Fluid:
ATF Dexron III or CHF 11S (check specific vehicle build).
Common Issues Engine:
Oil filter housing gasket leaks, CCV (Crankcase Ventilation) system clogging leading to vacuum leaks, VANOS solenoid failure, vacuum hose degradation.
Common Issues Cooling:
Plastic coolant expansion tank cracking, water pump bearing failure, thermostat housing leaks, radiator leaks.
Common Issues Suspension:
Control arm bushings (bushings) failure, front sway bar links wear, rear subframe bushings deterioration.
Common Issues Electrical:
ABS/ASC wheel speed sensor failure, fuel pump failure, alternator failure, headlight leveling sensor issues, window regulator failure.
Common Issues Transmission:
Automatic transmission torque converter lock-up issues, transmission control module (TCM) failure, clutch master/slave cylinder leaks (manual).
Heritage Focus:
BMW's long history of producing well-engineered, driver-focused vehicles, particularly known for inline-6 engines and advanced chassis design.
E39 Introduction:
Introduced in 1995 (as a 1996 model) for sedan, wagon followed in 1997. The E39 replaced the E34 generation.
E39 Facelift:
Facelift (LCI) occurred in 2000, introducing updated styling, new engines (including M54), and improved electronics. This manual covers pre-facelift and early facelift models.
E39 Variants:
Included 520i, 523i, 525i, 528i, 530i, 535i, 540i, and the high-performance M5 (E39).
Production Period:
1997-2002 for the 528i Sport Wagon.
Manufacturing Locations:
Primarily Dingolfing, Germany.
