BMW 528 528i 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 2002 Chassis Code: E39 Codes Engine Code Primary: M52TU (M52B28TU) Chassis Variant: Sedan 👋 Introduction Market Position Segment: Executive Sedan Segment...

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类型: Car

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标签: 2002 528 528i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Chassis Code:

Codes

Engine Code Primary:

M52TU (M52B28TU)

Chassis Variant:

Sedan

👋 Introduction

Market Position

Segment:

Executive Sedan

Segment Details:

Mid-size luxury sedan

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class (W211), Audi A6 (C5), Lexus GS (JZS160), Jaguar S-Type

Key Features

Model Positioning:

Represents the entry-level luxury sedan offering in BMW's 5 Series lineup for the 2002 model year.

Driver Focus:

Known for its 'Ultimate Driving Machine' ethos, offering precise handling and a driver-centric cockpit.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Downloadable PDF

Completeness:

Complete Official Factory Documentation

Page Count Estimate:

Hundreds of pages (estimated 1000+)

Manual Type

Manual Purpose:

Repair, Service, Maintenance, Diagnostics, Overhaul

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine management (DME), VANOS

Transmission:

Manual (Getrag 420G) and Automatic (Steptronic GM A5S 360R/A5S 390R) transmission repair, overhaul, diagnostics, fluid specifications, and relearn procedures

Drivetrain:

Driveshaft, differential, axles, wheel bearings

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications

Steering:

Power steering system, steering rack, tie rods, steering column, pump

Brakes:

Front and rear brake systems (vented discs), ABS, DSC, brake fluid specifications, bleeding procedures, component replacement

Electrical:

Complete electrical system, wiring diagrams, battery, alternator, starter, fuses, relays, lighting, power accessories, diagnostic connector (OBD-II)

Body:

Body panels, doors, hood, trunk, bumpers, glass, sunroof, interior trim, sound deadening

Climate Control:

HVAC system, A/C system components, blower motor, heater core, refrigerant specifications, climate control unit diagnostics

Safety Systems:

Airbags, seatbelt pre-tensioners, SRS system diagnostics

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, brake pad/rotor replacement

Troubleshooting:

Diagnostic flowcharts, common symptoms, fault code interpretation, specific component troubleshooting

Repair:

Detailed step-by-step repair procedures for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement, brake caliper service

Diagnostics:

Engine performance diagnostics, electrical system diagnostics, ABS/DSC system troubleshooting, HVAC system fault finding

Specifications:

Torque specifications for all fasteners, clearances, fluid capacities, electrical component resistance values

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine/transmission rebuilds and advanced diagnostics)

Detail Level:

Factory-level detail, including diagrams, illustrations, and schematics

📊 Manual Specifications

File Format

File Format:

Searchable:

Print Quality:

High-resolution, suitable for professional printing

Print Quality

Printable:

Yes, individual pages or entire document

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-cylinder, DOHC, 24 valves

Displacement:

2.8 Liters (2793 cc)

Bore X Stroke:

84.0 mm x 83.6 mm

Compression Ratio:

10.2:1

Valvetrain:

Double VANOS (Variable Valve Timing)

Performance

Horsepower:

193 hp @ 5500 rpm

Torque:

206 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Sequential Fuel Injection (SFI)

Fuel Type Recommended:

Premium Unleaded (91 Octane or higher)

Engine Management System:

BMW Digital Motor Electronics (DME) MS43

🔧 Transmission

Standard

Transmission Type:

5-speed manual (Getrag 420G)

Optional

Transmission Type:

5-speed automatic with Steptronic (GM A5S 360R/A5S 390R)

Features

Automatic Features:

Steptronic manual shifting mode

Fluid Specs

Automatic Transmission Fluid:

BMW ATF LT 71141 (or equivalent Dexron III H)

Manual Transmission Fluid:

BMW MTF LT-2 (or equivalent SAE 75W-90 synthetic)

📐 Dimensions

Exterior

Length:

188.3 inches (4783 mm)

Width:

71.1 inches (1806 mm)

Height:

57.4 inches (1458 mm)

Wheelbase:

111.4 inches (2830 mm)

Weights

Curb Weight Manual:

3571 lbs (1620 kg)

Curb Weight Automatic:

3627 lbs (1645 kg)

Gross Vehicle Weight Rating:

4564 lbs (2070 kg)

Cargo

Trunk Volume:

16.1 cu ft (456 L)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not rated (vehicle pre-dates more comprehensive standardized ratings)

IIHS Crashworthiness:

Good (for comparable vehicles of the era)

Active Features

Traction Control:

Automatic Stability Control (ASC) / Automatic Stability Control + Traction (ASC+T)

Braking System:

Anti-lock Braking System (ABS), Dynamic Stability Control (DSC)

Passive Features

Airbags:

Frontal airbags for driver and passenger, side-impact airbags (optional on some trims, standard on others)

Seatbelts:

3-point inertia-reel seatbelts with front belt pretensioners

Chassis Design:

Integrated safety cell with crumple zones

💡 Technology Features

Infotainment

Audio System:

BMW Professional Radio or optional CD player with up to 10 speakers. Optional Logic 7 audio system.

Navigation:

Optional BMW Professional Navigation System with a CRT screen.

Driver Assistance

Stability Control:

DSC (Dynamic Stability Control) with ABS and Traction Control

Cruise Control:

Standard electronic cruise control

Connectivity

Diagnostic Port:

OBD-II (16-pin connector) located under the dashboard for engine and emission diagnostics.

Bmw Assist:

Optional BMW Assist telematics system with emergency call functionality.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable (based on oil condition sensor, typically 7,500-15,000 miles or 12-24 months, refer to manual for exact conditions)

Engine Oil Filter Replacement:

Replace with each oil change

Air Filter Replacement:

Every 30,000 miles or as needed based on inspection

Cabin Air Filter Replacement:

Every 15,000 miles or annually

Spark Plug Replacement:

Platinum: 100,000 miles; Long-life (e.g., NGK BKR6EQUP): 60,000 miles

Coolant Flush:

Every 2 years or 30,000 miles

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil Capacity:

6.5 US quarts (6.2 Liters) with filter, for M52TU engine

Engine Oil Viscosity:

BMW High Performance Synthetic Engine Oil SAE 5W-30 or 5W-40

Coolant Type:

BMW Blue Antifreeze/Coolant (G48)

Brake Fluid Type:

DOT 4

Known Issues

Cooling System:

Plastic coolant expansion tank and radiator frequently develop cracks and leaks. Water pump failure is also common.

Oil Leaks:

Valve cover gasket, oil pan gasket, and front crankshaft seal are common sources of oil leaks.

Vanos:

Vanos solenoids can fail, leading to rough idle, loss of power, and poor fuel economy. The sealing rings within the Vanos unit can also degrade.

Suspension:

Worn control arm bushings, ball joints, and rear subframe bushings are frequent issues leading to clunking noises and poor handling.

Electrical Failures:

CCFL angel eye rings (if equipped), door lock actuators, window regulators, and ABS wheel speed sensors are common electrical failures.

Ignition System:

Coil-on-plug ignition systems can fail, leading to misfires and check engine lights.

📚 Vehicle History

Brand Heritage

Brand Identity:

BMW (Bayerische Motoren Werke AG) is renowned for producing performance-oriented luxury vehicles with a strong emphasis on driving dynamics and engineering.

Model Evolution

E39 Generation:

The E39 5 Series, produced from 1995 to 2003, is considered a benchmark in its class for its handling, build quality, and technological advancements for its time.

528I Positioning E39:

The 528i was a popular mid-range model in the E39 lineup, bridging the gap between the 525i and the more powerful 530i and V8 models.

Production

Production Period:

1996-2000 (for the M52TU engine variant)

Manufacturing Locations:

Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E39 5 Series chassis was a frequent recipient of Car and Driver's 10Best awards during its production run, including the 2002 model year.

Ward S Auto:

Various E39 models received accolades for their powertrain and design from WardsAuto.

Ratings

Consumer Reports:

Generally rated well for reliability and performance for its era, though certain common issues are noted.