🏷️ Basic Information

Make:

BMW

Model:

5-series

Chassis Code:

E28

Model Year:

1981

Production Codes:

Covers all E28 models produced in or around 1981, including variations of sedans and potentially early touring models if applicable to the 1981 production run.

👋 Introduction

Positioning:

The BMW E28 5-series represented BMW's commitment to the executive sedan market, blending sporty driving dynamics with luxury and comfort. It was positioned as a premium offering against competitors like Mercedes-Benz's W123/W124 and Audi's 100.

Competitors:

Key competitors included the Mercedes-Benz W123/W124, Audi 100, Jaguar XJ, and Volvo 240/260 series. The E28 stood out for its superior handling and driver engagement.

Design Philosophy:

The E28 continued the 'Neue Klasse' design language, characterized by its clean lines, Hofmeister kink, and driver-focused cockpit. It offered a balance of aerodynamic efficiency and classic BMW aesthetics.

Performance Focus:

Renowned for its sophisticated suspension and powerful inline-six engines, the E28 offered a dynamic driving experience that set it apart in its class.

📋 Manual Details

Coverage:

Comprehensive A-Z coverage for all repairs and maintenance. Vehicle-specific, not generic.

Page Count:

Unknown (specific page count not provided in product information, but implied to be extensive for A-Z coverage).

Type:

Service and Repair Manual

Language:

English

Format:

Likely printed format, consistent with dealership technician manuals of the era. Potential for digital distribution in modern sales contexts.

📖 Manual Coverage

Engine And Drivetrain:

Detailed procedures for engine repair, overhaul, tuning, cooling system, lubrication system, fuel system (including injection systems for applicable models), exhaust system, and drivetrain components (clutch, gearbox, driveshafts, differentials).

Chassis And Suspension:

Coverage of steering system, front and rear suspension, shock absorbers, springs, bushings, wheel bearings, and alignment specifications.

Brakes:

Complete brake system diagnostics, repair, and overhaul for front and rear brakes (likely disc brakes for most E28 models of this era), including hydraulic systems, parking brake, and any ABS components if present in early models.

Electrical System:

Extensive coverage of the vehicle's electrical system, including wiring diagrams, battery, charging system (alternator), starting system, ignition system, lighting, instrumentation, power accessories, and troubleshooting for electrical faults.

Body And Interior:

Procedures for body panel repair, dent removal, rust repair, glass replacement, door mechanisms, interior trim, upholstery, seats, and climate control system.

Fuel And Emissions:

Details on fuel pumps, fuel pressure regulators, injectors, emissions control systems (e.g., EGR, catalytic converters if fitted), and evaporative emission control systems.

Maintenance:

Routine maintenance, preventative maintenance, oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, and lubrication schedules.

Troubleshooting:

Systematic diagnostic procedures and fault finding for common and uncommon issues across all vehicle systems.

Repair And Overhaul:

Detailed step-by-step instructions for component repair, replacement, and complete overhaul of major mechanical and electrical assemblies.

Specifications And Tolerances:

Precise technical specifications, torque values, clearances, fluid capacities, and operating parameters required for accurate servicing and repair.

Engine Diagnostics:

Detailed diagnostic trees for common engine performance issues, including fuel delivery, ignition timing, air intake, and emissions control.

Suspension And Steering Adjustment:

Procedures for checking and adjusting wheel alignment, replacing suspension components (ball joints, control arms, tie rods), and servicing the power steering system.

Electrical Component Testing:

Methods for testing alternators, starter motors, ignition coils, sensors, relays, and other electrical components using multimeters and specialized test equipment.

Body Repair Techniques:

Guidance on welding, metal fabrication, panel alignment, and installation of new body panels.

Air Conditioning Service:

Procedures for servicing the A/C system, including refrigerant handling (if applicable to the era's refrigerants), component replacement, and leak detection.

Depth:

Dealership-level technical depth, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission rebuilds.

Rebuild Instructions:

Includes complete engine rebuild procedures, with specifications for honing cylinder bores, checking piston ring end gaps, bearing clearances, and valve seat geometry.

Torque Specifications:

Comprehensive list of torque specifications for all critical fasteners, including cylinder head bolts, main bearing caps, and suspension components.

Troubleshooting Charts:

Flowcharts and tables to help diagnose symptoms and pinpoint the root cause of various vehicle malfunctions.

📊 Manual Specifications

File Format:

Likely original print format. Modern reproductions may be PDF or other digital formats.

Print Quality:

Original dealership manuals were typically printed on high-quality, durable paper with clear diagrams and text.

Binding Type:

Likely bound for durability, possibly spiral-bound or hardcover, to withstand frequent use in a workshop environment.

Paper Type:

Sturdy, often glossy or semi-gloss paper for diagrams and photographs.

⚙️ Engine Specifications

Engine Families:

M20 (4-cylinder and 6-cylinder) and M30 (6-cylinder) inline engines. Specific to 1981, common engines would include M20B20 (2.0L), M20B23 (2.3L), and M30B32 (3.2L).

Horsepower Torque Examples:

Example: 520i (M20B20) ~122 hp, 528i (M30B28) ~181 hp, 535i (M30B34) ~215 hp. Specific output varies by engine variant and market. Torque figures also vary significantly.

Fuel Delivery:

Bosch L-Jetronic or Motronic electronic fuel injection for most models. Carburetor systems may be present on base models or in specific markets, though fuel injection was becoming standard.

Cooling Type:

Pressurized liquid cooling system with a fan, radiator, water pump, and thermostat.

Ignition Type:

Electronic ignition systems, often with distributor and coil. Early Motronic systems integrated ignition and fuel control.

Engine Displacements:

Common displacements include 2.0L (M20B20), 2.3L (M20B23), 2.7L (M20B27 - introduced later), 2.8L (M30B28), 3.2L (M30B32), and 3.5L (M30B34).

🔧 Transmission

Standard Transmission:

Typically a 4-speed or 5-speed manual transmission (Getrag units common).

Optional Transmission:

ZF 3-speed or 4-speed automatic transmission.

Clutch Type:

Single dry plate clutch, hydraulically actuated.

Gear Ratios:

Specific gear ratios vary by engine and transmission type. The manual will detail these for each model variant.

📐 Dimensions

Length:

Approx. 4,730 mm (186.2 in) for sedan variants. Specific dimensions might vary slightly by model year and market.

Width:

Approx. 1,700 mm (66.9 in).

Height:

Approx. 1,415 mm (55.7 in).

Curb Weight:

Varies by engine and equipment, typically ranging from 1,300 kg to 1,500 kg (2,866 lbs to 3,307 lbs).

Gross Vehicle Weight Rating:

Available in the manual, essential for payload calculations.

Wheelbase:

Approx. 2,795 mm (110.0 in).

Passenger Capacity:

Seats five occupants.

🛡️ Safety Features

Crash Test Data:

Official crash test data from the early 1980s is less standardized than today. The E28 was known for its robust build quality and safety cell structure for its era.

Braking System:

Standard disc brakes on all wheels for most models. Some performance variants might have larger or vented discs. ABS was not standard on 1981 models, but might have been an option on higher-end variants or introduced later in the E28 lifecycle.

Seatbelts:

Standard front and rear seatbelts. Shoulder belts were common for front occupants.

Body Structure:

Reinforced passenger cell and crumple zones designed for the safety standards of the time.

💡 Technology Features

Audio System:

Factory-fitted radios, often AM/FM with cassette player. Some models may have offered premium audio options from brands like Blaupunkt or Becker.

Cruise Control:

Optional cruise control system available on many models.

Exterior Features:

Manual window cranks were common, though power windows were an option. Power mirrors were also an option. Early E28s might have had manual door locks, with central locking becoming more prevalent.

Climate Control:

Manual HVAC systems with adjustable fan speed and temperature. Optional air conditioning was widely available.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, depending on driving conditions. Consult manual for exact specifications.

Spark Plug Replacement:

Intervals vary by plug type but often around 20,000 - 30,000 miles (32,000 - 48,000 km). The manual will specify recommended types and intervals.

Timing Belt Chain:

M20 engines use a timing belt, typically requiring replacement every 40,000 - 60,000 miles (64,000 - 96,000 km). M30 engines use a timing chain, which is generally maintenance-free unless issues arise.

Engine Oil Type:

Viscosity grades like 10W-40 or 20W-50 were common. The manual will specify the correct API service classification and viscosity for different climates and engine variants (e.g., BMW High Performance Synthetic).

Coolant Type:

A mixture of distilled water and ethylene glycol-based antifreeze (typically a 50/50 mix). The manual will specify BMW-approved antifreeze.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid. The manual will specify the exact DOT rating and the importance of using fresh, sealed fluid.

Transmission Fluid Type Manual:

GL-4 or GL-5 gear oil for manual transmissions. Specific viscosity grades (e.g., 75W-90) will be detailed.

Transmission Fluid Type Automatic:

Dexron II or equivalent automatic transmission fluid. Manual will specify exact type and capacity.

Power Steering Fluid:

Specific power steering fluid type recommended by BMW for the era. The manual will detail this.

Common Problems:

Rust (wheel arches, rocker panels, sills), cooling system issues (cracked coolant expansion tanks, failing water pumps), fuel distributor problems in early injected models, differential seal leaks, and aged rubber bushings in suspension and subframes.

Electrical Gremlins:

Due to age, wiring insulation degradation, connector corrosion, and failing relays or vacuum hose leaks are common causes of electrical issues.

Engine Oil Capacity:

Typically 4.5 to 6.0 liters (4.7 to 6.3 US quarts) depending on engine size. Manual will provide exact figures.

Coolant Capacity:

Approx. 8.0 to 10.0 liters (8.5 to 10.5 US quarts). Manual will provide precise capacity.

📚 Vehicle History

Bmw Legacy:

BMW has a long history of producing driver-focused sedans, and the 5-series lineage, starting with the E12, established BMW as a leader in the premium sports sedan segment.

E28 Development:

The E28 was the second generation of the 5-series, succeeding the E12. It introduced significant improvements in aerodynamics, chassis dynamics, and available technology, while retaining the core BMW driving DNA.

Production Years:

The E28 generation was produced from 1981 to 1987, with the 1981 model representing the initial introduction of this platform.

Manufacturing Locations:

Primarily manufactured in Germany (Dingolfing plant).

🏆 Awards & Recognition

Contemporary Reviews:

The E28 was widely praised by automotive journalists for its driving dynamics, build quality, and sophisticated engineering. It solidified BMW's reputation for creating the 'ultimate driving machine'.

Reliability Reputation:

Generally considered reliable when properly maintained, though specific components like the fuel injection system and cooling system require attention as they age.