BMW 528i 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 2002 Product Name: BMW 528i 2002 Full Service Repair Manual 👋 Introduction Market Position Segment: Executive Sedan Competitive Analysis Competitors 2002:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Product Name:

BMW 528i 2002 Full Service Repair Manual

👋 Introduction

Market Position

Segment:

Executive Sedan

Competitive Analysis

Competitors 2002:

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

Key Features

Chassis:

E39 Platform

Driving Dynamics:

Renowned for balanced handling, rear-wheel drive bias, and driver-focused cockpit

Luxury Appointments:

Premium interior materials, advanced comfort features for its era

📋 Manual Details

Coverage Areas

General Coverage:

Repair, maintenance, rebuilding, refurbishing, restoration, diagnostics

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, based on description)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, component testing, fuel injection, ignition system, cooling system, lubrication system, exhaust system

Transmission:

Automatic and Manual Transmission diagnosis, repair, overhaul, fluid specifications, and procedures

Drivetrain:

Front Wheel Drive, Rear Wheel Drive, axle shafts, differentials, driveshafts, CV joints

Suspension:

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

Steering:

Power steering system diagnosis, repair, rack and pinion, steering column, steering wheel

Brakes:

Brake system diagnosis, repair, ABS (Anti-lock Braking System), brake pads, rotors, calipers, brake lines, hydraulic system

Electrical System:

Wiring diagrams, starter, alternator, battery, fuses, relays, lighting, ignition, power windows, power locks, body control modules (BCM)

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis, repair, refrigerant handling, blower motor, climate control panel

Body And Interior:

Body panel repair, door mechanisms, seat mechanisms, dashboard, trim components, glass replacement

Diagnostic Troubleshooting:

Troubleshooting guides, fault codes, diagnostic procedures using scan tools (e.g., BMW DIS or ISTA)

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups

Repair:

Component replacement, sub-assembly repair, major overhauls

Rebuilding:

Engine rebuilding, transmission rebuilding, component restoration

Diagnostics:

Step-by-step diagnostic procedures, circuit testing, component testing

Technical Depth

Depth:

Comprehensive (covers basic maintenance to complete engine/transmission rebuilds and advanced diagnostics)

📊 Manual Specifications

File Format

Digital Format:

PDF (Searchable, Printable, Bookmarked)

Print Quality

Image Resolution:

High-resolution images and diagrams

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M54B30

Engine Type:

Inline 6-Cylinder, DOHC, 24 Valves

Displacement:

2979 cc (3.0 Liters)

Performance

Horsepower:

225 hp @ 6100 rpm

Torque:

214 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (Bosch Motronic ME 7.2)

Fuel Type:

Premium Unleaded Gasoline (91 Octane Recommended)

Engine Management

Bosch Motronic ME 7.2

Emission Controls:

Secondary Air Injection System, EGR (California models), Catalytic Converter

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Getrag S5D 320Z)

Optional

Type:

5-speed Steptronic Automatic Transmission (GM 5L40-E)

Features

Steptronic:

Allows manual gear selection via shift lever or steering wheel buttons

Fluid Specifications

Automatic Transmission Fluid:

Dexron III/VI compatible (e.g., ZF LifeguardFluid 5)

Manual Transmission Fluid:

BMW recommended synthetic gear oil (e.g., Castrol SAF-XJ 75W-140 or equivalent)

📐 Dimensions

Exterior

Length:

188.5 inches (4788 mm)

Width:

70.2 inches (1783 mm)

Height:

56.5 inches (1435 mm)

Wheelbase:

111.4 inches (2830 mm)

Weights

Curb Weight:

Approximately 3500-3700 lbs (1588-1678 kg)

Gross Vehicle Weight Rating:

Approximately 4500 lbs (2041 kg)

Cargo

Trunk Capacity:

13.7 cubic feet (388 liters)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

4-star driver, 4-star passenger

IIHS Side Impact:

Active Features

Standard Anti-lock Braking System

Standard Automatic Stability Control

Optional Dynamic Stability Control (traction and stability enhancement)

Passive Features

Airbags:

Frontal airbags, front side-impact airbags

Seatbelts:

3-point inertia-reel seat belts with pretensioners

Head Restraints:

Active front head restraints (reduce whiplash injuries)

💡 Technology Features

Infotainment

Navigation System:

Optional BMW Professional Navigation System with CD-ROM based maps

Audio System:

Optional Harman Kardon premium sound system, CD player, Cassette deck

Driver Assistance

Cruise Control:

Standard electronic cruise control

Parking Sensors:

Optional rear Park Distance Control (PDC)

Connectivity

Telematics:

Optional Tele Aid (emergency assistance service)

Comfort Features

Climate Control:

Standard automatic climate control with dual-zone temperature control

Seats:

Optional power adjustable front seats with memory function, heated seats

🔧 Maintenance

Service Intervals

Oil Change:

BMW Condition Based Service (CBS) or approximately every 7,500-10,000 miles / 12 months, whichever comes first (check CBS indicator)

Engine Air Filter:

Inspect every 30,000 miles, replace as needed (or per CBS)

Cabin Air Filter:

Replace every 30,000 miles or annually (or per CBS)

Spark Plugs:

Replace every 100,000 miles (long-life iridium type)

Fluid Specifications

Engine Oil:

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

Coolant:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) diluted 50/50 with distilled water

Brake Fluid:

DOT 4, low viscosity (BMW High Performance DOT 4 or equivalent)

Power Steering Fluid:

Pentosin CHF 11S or equivalent hydraulic fluid

Known Issues

Cooling System:

Plastic coolant expansion tank can become brittle and crack, leading to leaks. Water pump and thermostat housing are common failure points.

Oil Leaks:

Valve cover gasket, oil pan gasket, and oil filter housing gasket can leak due to age and heat.

Rear Main Seal:

Can develop leaks over time, often requiring transmission removal to replace.

Suspension Bushings:

Control arm bushings and sway bar bushings wear out, causing steering looseness and noise.

Window Regulators:

Plastic components within the window regulator assembly can fail, causing windows to drop.

Ccv System:

Crankcase Ventilation (CCV) system can clog, leading to increased oil consumption and potential vacuum leaks.

ABS Wheel Speed Sensors:

Can fail intermittently, triggering ABS and/or DSC warning lights.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure, engineering excellence, luxury performance

Model Evolution

E39 Generation:

Fourth generation of the BMW 5 Series (1995-2003), known for significant improvements in chassis dynamics and build quality over its predecessor (E34)

Production

Model Years:

1997-2003 (for E39 528i)

Manufacturing Locations:

Dingolfing, Germany

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E39 5 Series (including the 528i) was a perennial recipient of Car and Driver's 10Best list during its production run for its outstanding driving dynamics and overall execution.

Consumer Reports Ratings:

Generally rated well for reliability and performance by publications like Consumer Reports, though some specific components required attention over time.