BMW 528i 1997-2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Model Code: E39 Production Years: 1997-2002 Generation Generation Name: Fifth Generation E39 Codes Engine Code Primary: M52B28 👋 Introduction Market Position Market...

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类型: Car

斯库: 372921

标签: 1997 1998 1999 2000 2001 2002 528i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Code:

Production Years:

1997-2002

Generation

Generation Name:

Fifth Generation E39

Codes

Engine Code Primary:

M52B28

👋 Introduction

Market Position

Market Segment:

Executive Mid-Size Sedan

Target Audience:

Luxury car buyers seeking performance, comfort, and advanced engineering.

Competitive Analysis

Primary Competitors:

Mercedes-Benz E-Class (W210), Audi A6 (C5), Lexus GS Series, Jaguar S-Type.

Key Selling Points:

Engaging driving dynamics, superior build quality, sophisticated technology, powerful inline-six engine.

Key Features

Chassis Platform:

E39 platform, known for excellent chassis rigidity and handling balance.

Engine Layout:

Front engine, rear-wheel drive (optional xDrive on later models, but not typically for 528i).

Design Philosophy:

Understated elegance, driver-focused cockpit, robust construction.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive Workshop Repair and Service

Covered Models:

BMW 528i (E39 Chassis)

Covered Years:

1997, 1998, 1999, 2000, 2001, 2002

Page Count

Estimated Page Count:

Over 1500

Manual Type

Manual Type:

Workshop Repair and Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, cooling, lubrication, fuel delivery, ignition, emissions control, engine management (DME), performance tuning (limited).

Transmission:

Manual and Automatic transmission repair, diagnosis, fluid specifications, shift control, clutches, torque converters.

Drivetrain:

Driveshafts, universal joints, differential, axles, CV joints, lubrication.

Suspension:

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

Steering:

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

Brakes:

Front and rear brake systems (disc), ABS, DSC, brake pads, rotors, calipers, brake lines, bleeding procedures, hydraulic system.

Electrical:

12V electrical system, battery, alternator, starter motor, lighting, fuses, relays, wiring diagrams, diagnostic connectors (OBD-II), ECU functions.

Climate Control:

HVAC system, A/C refrigerant, compressor, evaporator, heater core, blower motor, climate control module, diagnosis and repair.

Body And Interior:

Body panels, doors, windows, locks, seats, dashboard, trim, interior components, body repair procedures, rust prevention.

Chassis And Frame:

Chassis design, structural integrity, unibody construction, jacking points, towing information.

Wheels And Tires:

Wheel specifications, tire sizes, inflation pressures, lug nut torque, rotation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, air filter replacement, cabin air filter replacement.

Troubleshooting:

Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, diagnostic trouble codes (DTCs).

Repair And Rebuild:

Step-by-step instructions for component removal, installation, and rebuilding for major systems.

Diagnostics:

Using diagnostic tools, interpreting live data, pinpoint testing of electrical circuits.

Specifications And Tolerances:

Precise measurements, clearances, torque values, and alignment angles for all components.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, including component locations and wire colors.

Software And Coding:

Limited discussion on ECU updates or coding procedures, primarily focused on diagnosis.

Technical Depth

Depth Level:

Expert/Professional Level

Detail Level:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts.

Rebuild Instructions:

Detailed procedures for engine and transmission rebuilds.

Diagnostic Trees:

Includes systematic diagnostic flowcharts for fault finding.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable

Print Quality

Print Readability:

High-resolution images and text for clear printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-Cylinder, DOHC, 24 Valves

Engine Displacement:

2.8 Liters (2793 cc)

Bore X Stroke:

84.0 mm x 83.6 mm

Compression Ratio:

10.2:1

Engine Code Specific:

M52TUB28 (later models feature VANOS improvements)

Performance

Horsepower Est:

193 hp @ 5500 rpm

Torque Est:

206 lb-ft @ 3950 rpm

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Premium Unleaded (91 Octane or higher recommended)

Fuel Pump Type:

In-tank electric fuel pump

Engine Management

Engine Control Unit:

Siemens MS41.0 or MS42.0 (depending on year)

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil-in-Plug (CIP)

Variable Valve Timing:

Double VANOS (Variable Valve Timing)

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Getrag 260/5

Optional

Optional Transmission Type:

5-Speed Automatic Steptronic (GM 5L40-E)

Features

Transmission Fluid Spec Manual:

BMW MTF-LT-1 or equivalent (e.g., Red Line D4 ATF can be used in some cases, consult manual for specifics)

Transmission Fluid Spec Automatic:

Dexron III or Dexron VI (GM recommends Dexron VI for newer models but Dexron III is common for this era; manual will specify)

Clutch Type:

Hydraulically actuated single dry plate clutch (Manual)

📐 Dimensions

Exterior

Length:

188.2 inches (4780 mm)

Width:

71.5 inches (1816 mm)

Height:

56.7 inches (1440 mm)

Wheelbase:

111.4 inches (2830 mm)

Interior

Front Headroom:

38.8 inches (985 mm)

Rear Headroom:

37.5 inches (952 mm)

Front Legroom:

41.5 inches (1054 mm)

Rear Legroom:

35.8 inches (909 mm)

Cargo

Trunk Volume:

15.2 cu ft (430 L)

Weights

Curb Weight Est Manual:

3571 lbs (1620 kg)

Curb Weight Est Automatic:

3616 lbs (1640 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4600 lbs (2087 kg)

Towing Capacity:

Not Recommended for towing without specific BMW accessory kit and manual consultation.

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (for period models)

NHTSA Front Impact Passenger:

5-Star (for period models)

IIHS Front Offset Crash Test:

Good (for period models, specific year ratings may vary)

Active Features

Standard Anti-lock Braking System

Optional Dynamic Stability Control

Traction Control:

Standard Traction Control (often linked to DSC)

Passive Features

Airbags Front:

Dual Front Supplemental Restraint System (SRS) Airbags

Airbags Side:

Optional Side Impact Airbags (door mounted or seat mounted)

Seatbelts:

3-point inertia-reel seat belts with pretensioners

Body Structure:

High-strength steel safety cage

💡 Technology Features

Infotainment

Head Unit:

BMW Business CD or Professional CD/RDS radios, optional Professional navigation system (MK series).

Speaker System:

Standard 6-speaker system, optional Harman Kardon premium audio.

Display:

Central multi-function display (MFD) in the instrument cluster and dashboard for vehicle status and navigation.

Driver Assistance

Parking Sensors:

Optional Park Distance Control (PDC) front and rear.

Cruise Control:

Standard cruise control.

Rain Sensing Wipers:

Optional rain sensor for automatic wiper activation.

Connectivity

Phone Integration:

Optional Bluetooth preparation with integrated hands-free system.

Diagnostic Port:

OBD-II compliant diagnostic connector for engine and system diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 to 10,000 miles or annually, depending on driving conditions and oil used (consult manual for specific recommendations).

Spark Plug Replacement:

100,000 miles for iridium spark plugs (if fitted), otherwise consult manual for earlier intervals for standard plugs.

Air Filter Replacement:

Every 30,000 miles or as needed based on conditions.

Cabin Air Filter Replacement:

Every 15,000 to 30,000 miles or annually.

Coolant Flush:

Every 2-4 years or 30,000-60,000 miles (BMW Longlife-01 coolant recommended).

Fluid Specifications

Engine Oil Specification:

BMW LL-01 or LL-04 approved synthetic oil, typically 5W-30 or 5W-40 viscosity.

Engine Oil Capacity:

6.5 US quarts (6.2 liters) with filter change.

Coolant Specification:

BMW Longlife-01 Coolant (or equivalent G48/G11 type) mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 4, or BMW DOT 4 HP (High Performance)

Power Steering Fluid:

Pentosin CHF 11S or BMW approved equivalent.

Known Issues

Cooling System:

Plastic coolant expansion tanks prone to cracking, water pump failure (especially plastic impeller versions), radiator leaks.

Oil Leaks:

Valve cover gasket, oil pan gasket, oil filter housing gasket are common leak points due to age and material degradation.

Suspension Components:

Front control arm bushings (RTABs) and ball joints wear out, leading to steering wander and clunking noises.

Electrical Issues:

ABS/DSC sensor failures, VANOS solenoid issues, headlight leveling sensor problems, sometimes EWS (immobilizer) faults.

Fuel System:

Fuel pump failure, clogged fuel injectors.

Exhaust System:

Catalytic converter failure, muffler corrosion.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW AG, a German company renowned for producing high-performance luxury vehicles with a focus on driving dynamics and engineering excellence.

Model Evolution

E39 Introduction:

The E39 generation 5 Series was introduced in 1995 (as a 1997 model in North America) and replaced the E34. It represented a significant evolution in design, technology, and chassis dynamics.

E39 Facelift:

The E39 received a significant facelift in 2000, including updated headlights (angel eyes), taillights, bumpers, and engine enhancements (e.g., introduction of the M54 engine in later 525i/530i).

528I Positioning:

The 528i served as a popular mid-range model within the E39 lineup, offering a balance of performance and luxury without the higher cost of the V8-powered 540i.

Production

Production Location:

Dingolfing, Germany and Rosslyn, South Africa

Production Years E39 Globally:

1995-2004

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The E39 5 Series generation was frequently recognized on Car and Driver's 10Best lists during its production run, lauded for its handling and overall refinement.

Motor Trend Car Of The Year:

While not a direct winner for the 528i specifically, the E39 platform was highly regarded by automotive press.

Ratings

Consumer Reports Ratings:

Consistently rated well for predicted reliability in its early years, though later model years saw some decline in predicted reliability due to complex electronics and age-related wear.

Certifications

Emisiones Compliance:

Meets EPA and CARB emissions standards for its respective model years.