Positioning:
The BMW 5 Series (E28) in 1981 represented BMW's executive sedan offering, blending performance, luxury, and engineering prowess. The 528i was a key model, positioned as a powerful yet refined option in the premium segment, competing with vehicles from Mercedes-Benz, Audi, and other luxury manufacturers.
Competitors:
Mercedes-Benz W123 (280E), Audi 5000 (CD).
Vehicle Attributes:
Renowned M30 inline-six engine, sophisticated independent suspension, driver-focused ergonomics, high build quality, and engaging driving dynamics.
Purpose:
This workshop manual is essential for BMW enthusiasts and mechanics seeking to maintain, diagnose, and repair their 1981 BMW 528i. It provides the official technical data and procedures necessary for keeping this classic vehicle in optimal condition.
Powertrain:
Engine mechanical (M30B28), fuel injection (Bosch L-Jetronic), ignition system, cooling system, exhaust system, transmission (manual and automatic), driveline.
Chassis:
Suspension (front MacPherson struts, rear semi-trailing arms), steering system (power steering), braking system (front ventilated discs, rear discs), wheels and tires.
Electrical:
12-volt electrical system, battery, charging system (alternator), starting system, lighting system, instrumentation, wiring diagrams, fuses and relays, power accessories.
Body And Interior:
Body structure, exterior panels, doors, windows, locks, interior trim, seats, climate control (HVAC), heating and ventilation, body hardware.
Climate Control:
Operation, maintenance, and troubleshooting of the HVAC system, including blower motor, heater core, and A/C (if equipped).
Instrumentation:
Functionality and troubleshooting of the dashboard gauges, warning lights, and indicator systems.
Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and top-offs, belt inspections and tensioning, brake pad replacement, tune-up procedures.
Repair And Overhaul:
Engine disassembly, reassembly, cylinder head service, piston and connecting rod service, crankshaft service, transmission overhaul, brake caliper and rotor replacement, suspension component replacement.
Diagnostics And Troubleshooting:
Step-by-step troubleshooting guides for common issues, diagnostic procedures for engine performance, electrical faults, and mechanical problems, using diagnostic tools.
Emission Controls:
Details on emission control systems, troubleshooting, and component testing relevant to the era.
Body Repair:
Procedures for body panel alignment, rust repair considerations, and attachment methods for exterior trim.
Diagnostic Flowcharts:
Detailed flowcharts for diagnosing electrical and mechanical issues.
Depth:
Comprehensive; covers routine maintenance to full engine and transmission rebuilds, including detailed torque specifications, clearances, and diagnostic flowcharts.
Specifications:
Includes detailed torque specifications, measurement tolerances, valve clearances, timing marks, and component identification.
Engine Type:
Naturally Aspirated Inline-6
Displacement:
2788 cc (2.8 Liters)
Horsepower Ps:
184 PS (135 kW) at 5800 rpm (approx.)
Torque Lb Ft:
181 lb-ft (245 Nm) at 4200 rpm (approx.)
Fuel Delivery:
Bosch L-Jetronic Fuel Injection
Fuel Type:
Premium Unleaded Gasoline
Ignition Type:
Electronic Ignition (Distributor-based)
Cooling Type:
Water-Cooled
Coolant Type:
Ethylene Glycol-based antifreeze
Crash Test Data:
NHTSA and IIHS data from this era is limited and not directly comparable to modern standards. However, BMWs of this period were known for robust body structures.
Brakes:
Power-assisted disc brakes (front ventilated, rear solid).
Steering:
Servotronic power steering (variable assist).
Seatbelts:
Three-point inertia-reel seatbelts with front pretensioners.
Body Structure:
Reinforced passenger safety cell, crumple zones.
Oil Change:
Every 5,000-7,500 miles or 6-12 months (depending on driving conditions).
Transmission Fluid Service:
Automatic: Inspect every 30,000 miles, change fluid/filter as needed (often debated, manual often recommends life-of-unit but service is recommended). Manual: Change fluid every 50,000-100,000 miles.
Spark Plugs:
Replace every 30,000 miles (Bosch W8 AC or equivalent).
Timing Belt Chain:
M30 engines use a timing chain, requiring no scheduled replacement but inspection for tension and wear.
Engine Oil:
API SG or higher, SAE 20W-50 or 10W-40 (check owner's manual for specific ambient temperature recommendations).
Coolant:
BMW Blue Antifreeze or equivalent, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4.
Engine Common Problems:
Valve stem seals (oil consumption), fuel distributor leaks (Bosch K-Jetronic if fitted to later models, but 528i is L-Jet), vacuum leaks, coolant leaks from hose connections or radiator.
Electrical Common Problems:
Corroded grounds, aging wiring harness insulation, failing starter solenoids, intermittent headlight issues.
Chassis Common Problems:
Worn suspension bushings (control arms, trailing arms), aging rubber components, seized brake calipers.
Bmw Philosophy:
BMW's long-standing reputation for building driver-oriented sedans with potent engines and superior handling.
E28 Introduction:
The E28 platform succeeded the E12 5 Series, introducing more angular styling, improved aerodynamics, and updated mechanicals. The 528i was a significant iteration within the E28 lineup.
Production Years:
E28 Series: 1981-1988. 528i specific production: 1981-1987 (varying by market).
Manufacturing Locations:
Germany (primarily Dingolfing)
