BMW 528i 2002 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 2002 Generation Chassis Code: E39 Codes Engine Code: M52TU (common for 528i in this era) 👋 Introduction Market Position Segment: Executive...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Generation

Chassis Code:

Codes

Engine Code:

M52TU (common for 528i in this era)

👋 Introduction

Market Position

Segment:

Executive Sedan, Luxury Mid-size Sedan

Competitive Analysis

Key Competitors:

Mercedes-Benz E-Class (W211), Audi A6 (C5), Lexus GS300, Cadillac CTS.

Key Features

Drivetrain Options:

Rear-wheel drive (RWD) standard, xDrive all-wheel drive (AWD) optional on some E39 variants but not typically on 528i.

Platform Strength:

Renowned for its driving dynamics, balanced chassis, and refined interior.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service, Repair, and Workshop Procedures

Diagnostic Coverage:

Comprehensive diagnostic procedures and troubleshooting for all systems.

Page Count

Estimated Page Count:

Over 1000 pages (typical for comprehensive workshop manuals)

Manual Type

Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, engine management (DME/MS43), emissions control, and all associated components.

Transmission:

Manual (Getrag 420G) and Automatic (ZF 5HP19) transmission service, repair, overhaul, and diagnostics.

Drivetrain:

Driveshafts, CV joints, differential, rear axle, and wheel bearings.

Suspension:

Front and rear suspension systems, struts, shocks, control arms, ball joints, bushings, and alignment procedures.

Brakes:

Brake system components (calipers, rotors, pads), ABS (Anti-lock Braking System), DSC (Dynamic Stability Control), hydraulic lines, and bleeding procedures.

Steering:

Power steering system, steering rack, tie rods, and steering column.

Electrical:

Complete electrical system including battery, alternator, starter, wiring diagrams, fuse box locations, lighting, instruments, comfort electronics, and EWS (Immobilizer).

Body:

Body panels, doors, latches, hinges, windows, mirrors, sunroof, bumpers, and interior trim removal/installation.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant handling, and component replacement.

Safety Restraint:

Airbag system (SRS), seat belts, and related components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin), fluid checks and top-offs, spark plug replacement, belt inspections and replacement.

Major Repairs:

Engine overhaul, cylinder head removal and reinstallation, piston and connecting rod service, crankshaft service, transmission overhaul, differential rebuild.

Diagnostics Troubleshooting:

Step-by-step troubleshooting guides for common faults, diagnostic trouble codes (DTCs) interpretation, and electrical system diagnosis.

Component Replacement:

Detailed instructions for replacing all major and minor components across all vehicle systems.

Special Tools:

Identification and usage of required BMW special tools for specific repair procedures.

Technical Depth

Depth Level:

Comprehensive, from basic fluid changes to complete engine and transmission rebuilds and advanced diagnostics.

Diagnostic Tools Support:

Procedures often refer to BMW-specific diagnostic tools (e.g., GT1, DIS, INPA) for system checks and programming.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Likely searchable text for easy navigation and information retrieval.

Print Quality

Image Resolution:

High resolution for clear diagrams and illustrations.

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-cylinder, naturally aspirated

Engine Displacement:

2.8 Liters (2793 cc)

Engine Code Designation:

M52TU (Technical Update)

Valve Train:

Dual Overhead Camshafts (DOHC), 24 valves, VANOS (Variable Valve Timing) on intake and exhaust.

Performance

Horsepower:

193 hp @ 5500 rpm

Torque:

206 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Engine Management

Bosch Motronic MS43

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission (Getrag 420G)

Optional

Type:

5-Speed Steptronic Automatic Transmission (ZF 5HP19)

Features

Automatic Features:

Driver-selectable modes (Sport, Manual Shift)

Fluid Type

Manual Transmission Fluid:

BMW MTF LT-1 or equivalent GL-4 rated gear oil (specific viscosity may vary, consult manual).

Automatic Transmission Fluid:

ZF Lifeguardfluid 5 (or equivalent Esso JWS 3309/Mobil ATF 3309)

📐 Dimensions

Exterior

Length:

190.2 inches (4831 mm)

Width:

71.5 inches (1816 mm)

Height:

57.4 inches (1458 mm)

Wheelbase:

115.4 inches (2931 mm)

Weights

Curb Weight:

Approx. 3600-3700 lbs (1633-1678 kg), varies by option

Gross Vehicle Weight Rating:

Consult vehicle's VIN plate or owner's manual

Cargo

Trunk Volume:

18.0 cubic feet (510 L)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash:

5-star (driver and passenger) - Model Year 2002

IIHS Front Offset Crash:

Active Features

Stability Control:

Dynamic Stability Control (DSC) standard

Braking Assistance:

Anti-lock Braking System (ABS) standard

Passive Features

Airbags:

Frontal airbags (driver/passenger), side-impact airbags (front), optional side-impact airbags (rear).

Seat Belts:

3-point inertia-reel seat belts with pretensioners and force limiters

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD or Professional CD/RDS radio. Optional navigation system (MK III/IV).

Display:

Central Information Display (CID) in the dashboard, potentially with trip computer and navigation prompts.

Driver Assistance

Cruise Control:

Standard cruise control functionality.

Parking Assistance:

Optional rear park distance control (PDC).

Connectivity

Phone Integration:

Optional Bluetooth or older cellular phone integration (via base plate).

Lighting

Headlights:

Halogen projector headlights standard, optional Xenon HID headlights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 to 10,000 miles or 12 months, depending on driving conditions and oil quality. Condition Based Service (CBS) system may indicate based on usage.

Air Filter Replacement:

Every 30,000 miles or as needed, inspect at each oil service.

Cabin Air Filter Replacement:

Every 15,000-30,000 miles or annually, depending on conditions.

Spark Plug Replacement:

Platinum spark plugs: ~100,000 miles. If applicable, inspect at 60,000 miles.

Coolant Flush:

Typically every 2-4 years or 30,000-50,000 miles (BMW blue coolant is long-life).

Fluid Specifications

Engine Oil:

SAE 0W-30 or 5W-30 Synthetic, meeting BMW LL-01 specification.

Engine Oil Capacity:

6.5 US quarts (6.2 Liters) with filter change

Coolant:

BMW Blue Antifreeze/Coolant (G48) mixed with distilled water 50/50.

Brake Fluid:

DOT 4, preferably low viscosity (LV) if specified for ABS/DSC systems.

Known Issues

Cooling System:

Plastic coolant expansion tanks can become brittle and crack; water pumps and thermostat housings also prone to failure over time.

Oil Leaks:

Valve cover gasket, oil pan gasket, and oil filter housing gasket are common leak points.

Suspension Wear:

Control arm bushings, tie rod ends, and ball joints are common wear items leading to steering looseness and uneven tire wear.

ABS Asc Wheel Speed Sensors:

Wheel speed sensors can fail, triggering ABS/ASC warning lights.

Ccv System:

Crankcase Ventilation (CCV) system can clog, leading to oil consumption and potential seal failures.

Pixel Display Failure:

Instrument cluster LCD display (MID/OBC) can lose pixels.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure, focus on performance, handling, and driver engagement.

Model Evolution

E39 Introduction:

The E39 generation of the 5 Series was introduced in 1995 (for model year 1996) and ran until 2003.

528I Positioning:

The 528i represented the mid-range inline-six engine option for the E39, offering a blend of performance and efficiency.

Production

Manufacturing Location:

Mainly Dingolfing, Germany, and also Spartanburg, South Carolina, USA for some markets.

🏆 Awards & Recognition

Recognitions

Car And Driver Best:

Car and Driver 10Best Cars list multiple times for the E39 generation.

Automobile Magazine All Stars:

Automobile Magazine All-Stars award for the E39 generation.

Certifications

Safety Certification:

Consistently high safety ratings from IIHS and NHTSA for its era.