🏷️ Basic Information

Make:

BMW

Model:

525i

Model Code:

E28

Generation Designation:

Second Generation

Engine Code Primary:

M30B25

👋 Introduction

Market Segment:

Executive Sedan / Luxury Mid-size Sedan

Key Competitors:

Mercedes-Benz W123/W124 E-Class, Audi 5000/100, Volvo 740/760, Cadillac Sedan de Ville.

Design Philosophy:

BMW's 'Ultimate Driving Machine' ethos, emphasizing sporty handling, driver engagement, and robust engineering.

Target Audience:

Discerning drivers valuing performance, build quality, and a premium experience.

📋 Manual Details

Covered Years:

1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991

Estimated Page Count:

Approximately 800-1200 pages (typical for comprehensive workshop manuals of this era)

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Complete overhaul, diagnosis, fuel injection (Bosch L-Jetronic/Motronic), ignition system, cooling system, lubrication system, exhaust system.

Transmission:

Manual (Getrag 260) and Automatic (ZF 4HP22) transmission repair, overhaul, diagnostics, fluid specifications, and shift linkage adjustment.

Drivetrain:

Driveshaft, differential, axle shafts, rear axle inspection and repair, lubrication, and troubleshooting.

Suspension:

Front MacPherson struts, rear semi-trailing arms, shock absorbers, springs, bushings, ball joints, wheel bearings, steering linkage, alignment specifications, and troubleshooting.

Brakes:

Front and rear disc brakes (ventilated front), ABS (if equipped), brake fluid specifications, bleeding procedures, caliper and master cylinder overhaul, parking brake adjustment, and troubleshooting.

Steering:

Power steering system diagnosis, fluid specifications, pump and rack repair, tie rod ends, and alignment.

Electrical System:

Complete wiring diagrams, fuse box layout, battery, alternator, starter, lighting system, ignition system, fuel injection control module (ECU), instrument cluster, power windows, locks, mirrors, and troubleshooting using diagnostic codes.

Body And Chassis:

Body panel removal/installation, door mechanisms, window regulators, bumpers, trim, corrosion protection, chassis repair, and jacking points.

Heating And Air Conditioning:

HVAC system diagnosis, refrigerant handling, compressor, evaporator, condenser, blower motor, climate control panel, and troubleshooting.

Interior:

Seat removal, dashboard disassembly, headliner, door panels, and sound insulation.

Maintenance:

Routine maintenance tasks including oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, and belt inspections.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault code interpretation, and symptom-based troubleshooting guides.

Repair:

Step-by-step repair instructions for all major and minor components, including engine rebuilds, transmission overhauls, suspension and brake work, and electrical component replacement.

Diagnostics:

Detailed explanations of diagnostic tools and techniques specific to BMW vehicles of this era, including static and dynamic testing.

Specifications:

Torque specifications, clearances, fluid capacities, and electrical resistance values for accurate repair and maintenance.

Wiring Diagrams:

Comprehensive, high-resolution wiring diagrams for all vehicle systems, crucial for electrical troubleshooting.

Depth Of Coverage:

Comprehensive: Covers basic maintenance to full engine and transmission rebuilds. Suitable for DIY enthusiasts and professional mechanics.

📊 Manual Specifications

Digital File Format:

PDF

Searchable Text:

Yes (typically OCR'd for search functionality)

Printable:

Yes

Image Clarity:

High-resolution scans ensuring clear diagrams and text.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Inline 6-cylinder, SOHC (M30 engine family)

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

Approximately 8.5:1 to 9.0:1 (depending on market and specific model year)

Horsepower:

Approx. 150-170 hp @ 5800-6000 rpm (Varies by year and specific tuning)

Torque:

Approx. 165-180 lb-ft @ 3500-4000 rpm (Varies by year and specific tuning)

Fuel Delivery:

Bosch L-Jetronic or Motronic Electronic Fuel Injection

Fuel Type:

Unleaded gasoline (Octane rating 91+ recommended)

Coolant Type:

Ethylene glycol-based antifreeze (e.g., BMW blue coolant or equivalent G11)

Oil Capacity With Filter:

Approx. 6.5 Quarts (6.2 Liters)

Recommended Oil Viscosity:

10W-40 or 15W-40 (API SG or higher)

🔧 Transmission

Standard Transmission:

Getrag 260 5-speed manual

Optional Transmission:

ZF 4HP22 4-speed automatic

Manual Gear Ratios:

Typical ratios: 1st 4.07, 2nd 2.25, 3rd 1.42, 4th 1.00, 5th 0.81; Final Drive 3.25 or 3.73

Automatic Transmission Fluid:

Dexron III or Mercon equivalent (ZF Lifeguardfluid 5)

Clutch Type:

Hydraulically actuated single dry plate

📐 Dimensions

Length:

Approx. 4,700 mm (185.0 in)

Width:

Approx. 1,720 mm (67.7 in)

Height:

Approx. 1,400 mm (55.1 in)

Wheelbase:

Approx. 2,795 mm (110.0 in)

Wheel Bolt Pattern:

5 x 120 mm

Wheel Offset:

ET 18 to ET 22

Curb Weight:

Approx. 1,450 - 1,550 kg (3,200 - 3,417 lbs)

Gross Vehicle Weight Rating:

Approx. 2,000 kg (4,400 lbs)

Towing Capacity:

Consult manual for specific rating, typically around 3,500 lbs / 1,500 kg

🛡️ Safety Features

Crash Test Ratings:

NHTSA ratings for this era were not as standardized as today. However, the E28 chassis was known for its robust safety cell.

ABS:

Optional Anti-lock Braking System (ABS) available on later models.

Seatbelts:

Three-point inertia-reel seatbelts, front and rear.

Headrests:

Front and rear adjustable headrests.

Crumple Zones:

Designed crumple zones front and rear for energy absorption.

Steering Column:

Collapsible steering column.

💡 Technology Features

Audio System:

Typically an AM/FM stereo radio with cassette player. Upgraded Hi-Fi systems were optional.

Dashboard Controls:

Analog gauges for speed, tachometer, fuel, and engine temperature. Mechanical controls for HVAC and radio.

Cruise Control:

Optional electronic cruise control.

ABS:

As mentioned, optional ABS significantly enhanced braking safety.

Original Connectivity:

Limited to radio and cassette. No digital connectivity features.

🔧 Maintenance

Oil And Filter Change:

Every 7,500-10,000 miles or 12 months, whichever comes first (manual recommendation may vary).

Transmission Fluid Change:

Manual: Every 50,000-60,000 miles. Automatic: Every 30,000-50,000 miles (highly recommended).

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles.

Spark Plug Replacement:

Every 30,000-60,000 miles (depending on plug type, typically copper or platinum).

Brake Fluid:

DOT 3 or DOT 4 (high-temperature glycol-based)

Power Steering Fluid:

ATF Dexron II or III equivalent (check specific manual for exact type)

Common Problems:

Cooling system leaks (hoses, radiator, water pump), fuel pump failure, idle control valve issues, electrical component corrosion (especially grounds), window regulator failure, rust (wheel arches, rockers, door bottoms).

Engine Mounts:

Engine mounts degrade over time, leading to vibration and harshness.

Fuel Line Cracks:

Rubber fuel lines can degrade and crack, posing a fire risk.

Injector Seals:

Leaking injector seals can cause rough idling and fuel smell.

📚 Vehicle History

Bmw Legacy:

BMW has a long-standing reputation for building driver-focused, high-performance luxury vehicles.

E28 Development:

The E28 was an evolution of the E12 5 Series, featuring updated styling, improved aerodynamics, and enhanced technology. It was BMW's second generation of the 5 Series sedan.

E28 Introduction Year:

Introduced in 1981 (in Europe), North American introduction was for the 1982 model year.

E28 Facelift:

Received a facelift in 1984/1985, which included updated front and rear fascias, larger US-spec bumpers, and revised interior trim.

Production Period:

1981-1988 (E28 chassis)

Manufacturing Locations:

Germany (Dingolfing plant primarily)

Sales Figures Global:

Total E28 production was over 720,000 units worldwide.

🏆 Awards & Recognition

Editorial Reviews:

Consistently praised by automotive journalists for its driving dynamics, build quality, and luxury appointments, often winning comparison tests against rivals.

Industry Awards:

While specific awards for this model year are hard to pinpoint without detailed historical archives, the 5 Series platform as a whole received numerous accolades during its production run, solidifying BMW's reputation in the luxury segment.