BMW 528i 2001 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 2001 Codes Chassis Code: E39 Engine Code Family: M52TU 👋 Introduction Market Position Segment: Executive/Luxury Mid-size Sedan Target Audience: Owners seeking...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code Family:

M52TU

👋 Introduction

Market Position

Segment:

Executive/Luxury Mid-size Sedan

Target Audience:

Owners seeking in-depth DIY repair and maintenance knowledge

Competitive Analysis

Competitors 2001:

Mercedes-Benz E-Class, Audi A6, Lexus GS, Jaguar S-Type

Key Features Vehicle

Driving Dynamics:

Renowned BMW 'Ultimate Driving Machine' handling and ride comfort

Powertrain:

Smooth and powerful M52TU inline-6 engine

Interior Appointments:

High-quality materials, driver-focused cockpit

📋 Manual Details

Coverage Areas

Manual Type:

Full Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

M52TU 2.8L Inline-6 (DOHC, 24 valves)

Engine Management:

DME MS43, VANOS system operation and repair

Transmission Manual:

Getrag 6-speed manual transmission

Transmission Automatic:

GM 5L40-E 5-speed automatic transmission

Drivetrain:

Rear-wheel drive, differential, driveshafts, CV joints

Suspension:

Front strut/control arm, rear multi-link, springs, dampers, bushings

Steering:

Hydraulic power steering system, steering rack, pump

Brakes:

Front and rear disc brakes, ABS, DSC (Dynamic Stability Control), EBD

Electrical System:

12V battery, alternator, starter motor, fuses, relays, wiring diagrams

Lighting:

Headlights, taillights, interior lighting, bulb replacement

HVAC:

Air conditioning, heater core, blower motor, climate control system

Interior:

Seats, dashboard, door panels, trim components

Bodywork:

Exterior panels, bumpers, doors, hood, trunk, glass, seals

Fuel System:

Fuel pump, injectors, fuel filter, fuel tank

Cooling System:

Radiator, thermostat, water pump, coolant hoses, expansion tank

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks, spark plug replacement, belt replacement

Diagnostics:

Troubleshooting common faults, using diagnostic scan tools (generic and BMW specific)

Repair:

Engine rebuild, transmission overhaul, brake caliper replacement, suspension component replacement

Rebuild:

Detailed procedures for major component overhauls

Refurbish:

Cosmetic and mechanical restoration guidance

Restoration:

Comprehensive guidance for bringing a vehicle back to original specifications

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Diagnostic Coverage:

Detailed fault code explanations and diagnostic flowcharts

Torque Specifications:

Specific torque values for all critical fasteners

Electrical Diagrams:

High-quality, detailed wiring diagrams for all vehicle systems

📊 Manual Specifications

File Format

File Type:

Searchable:

Yes (text-searchable)

Printable:

Print Quality

Resolution:

High-resolution (suitable for digital viewing and printing)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-6 Cylinder

Displacement:

2.8 Liters (2793 cc)

Bore X Stroke:

84.0 mm x 90.0 mm

Compression Ratio:

10.2:1

Valvetrain:

Double Overhead Camshafts (DOHC), 4 valves per cylinder, 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 multi-point injection

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Cooling System

Coolant Capacity:

Approx. 8.5 Liters (8.9 US Quarts)

Lubrication

Oil Capacity:

Approx. 6.5 Liters (6.8 US Quarts) with filter

Recommended Oil Viscosity:

SAE 5W-30 Synthetic (BMW LL-01 approved)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual (Getrag S5D 250G)

Optional

Transmission Type:

5-speed Automatic (GM 5L40-E)

Features

Automatic Modes:

Steptronic manual shift control

Fluid Specifications

Manual Transmission Fluid:

SAE 75W-90 Synthetic Gear Oil (BMW MTF LT-2)

Automatic Transmission Fluid:

Dexron III/Mercon (BMW P/N 83 22 0 024 359 or equivalent)

📐 Dimensions

Exterior

Length:

188.2 inches (4780 mm)

Width:

71.1 inches (1806 mm)

Height:

57.1 inches (1450 mm)

Wheelbase:

113.4 inches (2881 mm)

Front Track:

60.1 inches (1527 mm)

Rear Track:

59.6 inches (1514 mm)

Weights

Curb Weight:

Approximately 3571 lbs (1620 kg) for manual transmission

Gross Vehicle Weight Rating:

Approximately 4500 lbs (2041 kg)

Towing Capacity:

Not specified/intended for towing

Cargo

Trunk Volume:

14.1 cubic feet (399 liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4 stars (driver and passenger)

NHTSA Side Impact:

4 stars (front and rear passengers)

Active Features

Stability Control:

Standard Dynamic Stability Control (DSC)

Traction Control:

Standard Automatic Stability Control (ASC+T) on some models

Brake Assist:

Standard Electronic Brake-force Distribution (EBD)

Passive Features

Airbags:

Front airbags, optional side-impact airbags

Seatbelts:

3-point inertia-reel seatbelts with pretensioners and force limiters

Chassis Design:

High-strength steel body structure

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD or Professional RDS radio, optional navigation system (Mk III/Mk IV)

Speaker System:

Standard 10-speaker system, optional Harman Kardon premium audio

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC)

Cruise Control:

Standard electronic cruise control

Connectivity

Cellular Integration:

Optional Bluetooth preparation and cellular phone integration

🔧 Maintenance

Service Intervals

Oil Change Interval:

BMW Condition Based Service (CBS) system, typically 7,500-15,000 miles or annually, whichever comes first

Engine Air Filter:

Every 30,000 miles or as indicated by CBS

Cabin Air Filter:

Every 15,000 miles or annually

Spark Plugs:

Every 100,000 miles (platinum/iridium type)

Coolant Flush:

Every 2-4 years or 30,000-60,000 miles

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Power Steering Fluid:

ATF Dexron III/Mercon (BMW P/N 81 22 9 407 764 or equivalent)

Brake Fluid:

DOT 4 (BMW P/N 81 22 9 407 741 or equivalent)

Known Issues

Cooling System:

Plastic coolant expansion tank and radiator can become brittle and crack; water pump plastic impeller prone to failure

Suspension:

Front control arm bushings, sway bar links, and rear subframe bushings are common wear items

Electrical:

ABS/DSC sensor failures, VANOS solenoid issues, ignition coil failures

Oil Leaks:

Valve cover gasket, oil pan gasket, and rear main seal can leak over time

Interior:

Pixelated instrument cluster display (LCD dead pixels), headliner sagging

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Engineering excellence, driving pleasure, performance

Model Evolution

E39 Generation:

Fourth generation 5 Series (1996-2003), known for refined chassis and improved build quality over E34

E39 Facelift:

Refreshed in 2000 (model year 2001), featuring updated headlights, taillights, bumpers, and interior trim

Production

Production Years:

1997-2003 (E39 generation)

Manufacturing Locations:

Germany (Dingolfing plant)

🏆 Awards & Recognition

Recognitions

Car And Driver Best:

Car and Driver 10 Best list multiple times during its production run

Auto Motor Sport Awards:

Frequently awarded 'Best in Class' in its segment by European automotive publications

Certifications

Safety Certifications:

Achieved high safety ratings from IIHS and NHTSA for its era