🏷️ Basic Information

Make:

BMW

Models Covered:

5 Series, 6 Series

Chassis Codes Covered:

E12, E24, E28, E34

Model Variants Covered:

518, 520i, 524d, 525i, 528i, 530i, 533i, 535i, M535i, M5 (E28), 525e, 528e, 535i (E34), M5 (E34), 630CS, 633CSi, 635CSi, M635CSi

E Code E12 Years:

1972-1981

E Code E24 Years:

1976-1989

E Code E28 Years:

1979-1987

E Code E34 Years:

1987-1995

👋 Introduction

Target Audience:

Enthusiasts and owners of BMW E12, E24, E28, and E34 models undertaking restoration or extensive maintenance.

Niche Appeal:

Highly regarded classic BMW coupes and sedans with a dedicated following, making restoration manuals essential.

Competitor Manuals:

While official BMW workshop manuals exist, this specialized guide offers a focused approach to restoration, often with practical tips not found in OEM documents.

Practical Advice:

Emphasis on practical, hands-on techniques and advice from an experienced restorer.

Model Cross Referencing:

Covers a broad range of models and generations within the 5 and 6 Series, providing cross-applicability where relevant.

Restoration Philosophy:

Guides owners through the entire restoration process, from sourcing parts to final detailing.

📋 Manual Details

Restoration Focus:

Comprehensive restoration of mechanical, electrical, and bodywork components.

Acquisition Advice:

Guidance on selecting and purchasing suitable donor vehicles.

Engine Restoration:

Detailed procedures for engine overhaul, tuning, and repair for various engine families.

Bodywork And Chassis:

Includes rust repair, panel replacement, corrosion prevention, suspension, and steering system restoration.

Electrical System:

Troubleshooting and repair of wiring harnesses, lighting, instrumentation, and auxiliary systems.

Interior Restoration:

Advice on upholstery, dashboard, trim, and sound deadening.

Brakes And Drivetrain:

Repair and overhaul of braking systems, transmission, differential, and driveshafts.

Estimated Page Count:

250-300 pages (estimated based on comprehensive coverage)

Manual Type:

Restoration Guide / Technical Manual

Language:

English

Format:

Printed Book

📖 Manual Coverage

Engine Families:

M10 (4-cylinder), M20 (6-cylinder), M30 (6-cylinder), M88/S38 (6-cylinder performance), M21 (Diesel)

Fuel Delivery:

Carbureted (Zenith, Solex) and Fuel Injection (Bosch L-Jetronic, K-Jetronic, Motronic) systems.

Cooling System:

Radiator, water pump, thermostat, heater core, and associated plumbing.

Exhaust System:

Catalytic converters, mufflers, exhaust manifolds, and pipework.

Transmission Systems:

Getrag 4-speed, 5-speed manual transmissions, and ZF automatic transmissions.

Suspension And Steering:

MacPherson struts, trailing arms, wishbones, power steering systems, and steering racks.

Braking System:

Disc brakes (front and rear), ABS systems (where applicable), brake lines, and master cylinder.

Electrical Components:

Alternator, starter motor, battery, ignition system (points, electronic), ECUs (Motronic), fuse boxes, relays.

Body And Trim:

Door mechanisms, window regulators, sunroofs, bumpers, grilles, and badging.

Engine Rebuild:

Complete engine disassembly, cleaning, inspection, component replacement (pistons, rings, bearings, valves), and reassembly with torque specifications.

Transmission Overhaul:

Manual transmission gearset inspection and replacement, clutch assembly, and automatic transmission valve body and torque converter service.

Suspension Reconditioning:

Replacement of bushings, ball joints, tie rod ends, shock absorbers, and springs.

Brake System Repair:

Brake pad and rotor replacement, caliper rebuilding, brake line flaring and replacement, and bleeding procedures.

Electrical Troubleshooting:

Diagnostic techniques using multimeters, wiring diagrams interpretation, and common fault finding for ignition, fuel injection, and lighting.

Body Panel Replacement:

Techniques for cutting out rusted metal, welding new panels, fitting fenders, doors, hood, and trunk lids.

Interior Refurbishment:

Seat repair, headliner replacement, dashboard crack repair, and gauge cluster refurbishment.

Fuel System Service:

Fuel pump testing, injector cleaning (where applicable), carburetor adjustment and rebuilding.

Depth Level:

Advanced restoration and comprehensive repair, suitable for experienced DIY mechanics and professional restorers.

Diagrams And Illustrations:

Likely includes detailed diagrams, exploded views, and step-by-step illustrations for complex procedures.

Torque Specifications:

Extensive torque values for engine, chassis, and driveline components.

Wiring Schematics:

Inclusion of electrical wiring diagrams for various models and options.

Troubleshooting Guides:

Diagnostic flowcharts and symptom-based troubleshooting for common issues.

📊 Manual Specifications

File Format:

Printed Book

Print Quality:

Professional quality printing with clear text and images suitable for workshop use.

Binding Type:

Perfect bound or stitched paperback, designed for durability.

Paper Type:

Durable, possibly gloss or semi-gloss paper suitable for diagrams and frequent handling.

⚙️ Engine Specifications

Common Engines E12:

M10B20 (2.0L I4), M30B25 (2.5L I6), M30B28 (2.8L I6)

Common Engines E24:

M30B30 (3.0L I6), M30B32 (3.2L I6), M30B33 (3.3L I6), M30B35 (3.5L I6), S38B35 (3.5L I6 DOHC - M6/M635CSi)

Common Engines E28:

M10B18 (1.8L I4), M20B20 (2.0L I6), M20B23 (2.3L I6), M20B25 (2.5L I6), M30B32 (3.2L I6), M30B34 (3.4L I6 - M5), M88/S38 (3.5L I6 DOHC - M5)

Common Engines E34:

M20B20 (2.0L I6), M20B25 (2.5L I6), M30B30 (3.0L I6), M30B35 (3.5L I6), M50B20 (2.0L I6 DOHC), M50B25 (2.5L I6 DOHC), S38B36 (3.6L I6 DOHC - M5), S38B38 (3.8L I6 DOHC - M5)

Common Engines E34 Diesel:

M21D24 (2.4L I6 Turbo Diesel)

Power Range:

Approximately 90 hp (518, M10) to 315 hp (S38B38 - E34 M5).

Torque Range:

Approximately 160 Nm to 380 Nm, depending on engine and model.

Fuel Injection Systems:

Bosch L-Jetronic, K-Jetronic (CIS), Motronic (early generations).

Carburetors:

Solex 40 DIDTA, Zenith 35/40 INAT, Solex 40 PDIT (for specific models).

🔧 Transmission

Standard Transmission:

Getrag 4-speed and 5-speed manual transmissions (e.g., 260, 265).

Optional Transmission:

ZF 3-speed and 4-speed automatic transmissions (e.g., 4HP22).

Clutch System:

Hydraulically actuated single dry plate clutch.

📐 Dimensions

Body Styles:

E12/E28/E34: 4-door Sedan. E24: 2-door Coupe.

Curb Weight Range:

Approximately 1300 kg to 1700 kg, depending on model, engine, and equipment.

🛡️ Safety Features

Crash Testing:

Limited formal crash test data from the era, but generally robust body structures for their time.

Braking Assistance:

Optional ABS (Anti-lock Braking System) available on later models (E24, E28, E34).

Occupant Protection:

Seat belts (three-point front, lap rear), energy-absorbing steering column, reinforced door beams, and crumple zones.

💡 Technology Features

Audio Systems:

Factory cassette players, optional CD changers on later E34 models. Basic AM/FM radio.

ABS:

Available on higher-trim models and later production runs.

Early Systems:

Limited connectivity, primarily focused on vehicle diagnostics via OBD-I on later models (E34).

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-10,000 miles or 6-12 months, depending on driving conditions and oil type used.

Spark Plug Replacement:

Varies by engine and plug type (e.g., copper: 10k-20k miles; platinum/iridium: 30k-60k miles).

Timing Belt Replacement:

M10/M20/M30 engines: typically 30,000-50,000 miles or 3-5 years. M50/S38 engines: timing chain, requiring inspection but not regular replacement.

Engine Oil Type:

API SG or higher. Viscosity varies by climate: 15W-40, 10W-40, 5W-30 (consult manual for specific engine/temperature charts).

Coolant Type:

Ethylene glycol based antifreeze mixed 50/50 with distilled water. BMW blue or green coolant compatible.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil (e.g., SAE 75W-90 or 80W-90).

Transmission Fluid Automatic:

Dexron III or equivalent ATF (e.g., ZF Lifeguardfluid 5).

Brake Fluid Type:

DOT 3 or DOT 4.

Rust Prone Areas:

Wheel arches, rocker panels, floor pans, rear window surrounds, jacking points, strut towers.

Engine Common Problems:

Oil leaks (valve cover gaskets, oil pan gaskets, rear main seals), cooling system issues (cracked manifolds, failing water pumps, radiator leaks), M20/M30 timing belt tensioner failure, idle control valve issues (M20/M30).

Electrical Common Problems:

Degrading wiring insulation, faulty headlight relays, alternator issues, instrument cluster failures, door lock actuator problems.

Suspension Wear:

Worn control arm bushings, ball joints, tie rod ends, and sagging springs.

Fuel System Issues:

Clogged fuel injectors, failing fuel pumps, vacuum leaks in fuel injected models.

📚 Vehicle History

Bmw Legacy:

BMW's reputation for building driver-focused, high-performance luxury sedans and coupes.

E12 Genesis:

The first generation 5 Series, establishing the benchmark for executive sedans with advanced engineering and driving dynamics.

E24 Introduction:

The 'Gran Turismo' coupe based on the 6 Series platform, offering sporty performance and elegant styling.

E28 Advancement:

Second generation 5 Series, introducing more sophisticated electronics, aerodynamic improvements, and the iconic M5 variant.

E34 Refinement:

Third generation 5 Series, representing a significant leap in technology, safety, and refinement, including M5 derivatives with advanced engines and chassis.

Manufacturing Locations:

Primarily Germany (Dingolfing, Munich).

Key Milestones:

Introduction of the first M5 models, significant engine advancements, and increasing electronic integration.

🏆 Awards & Recognition

Performance Awards:

BMW's M models (M5, M635CSi) consistently received accolades for performance and handling from automotive publications of their eras.

Critical Reception:

Praised for build quality, driving dynamics, and luxury appointments for their respective decades.