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BMW 525i 1981-1991 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 525i Codes Chassis Code: E28 Generation Generation Name: Second Generation (E28) 👋 Introduction Market Position Segment: Executive Sedan Positioning: BMW's mid-size luxury sedan,...
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UGS: 390628
BMW 525i 1981-1991 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
525i
Codes
Chassis Code:
E28
Generation
Generation Name:
Second Generation (E28)
👋 Introduction
Market Position
Segment:
Executive Sedan
Positioning:
BMW's mid-size luxury sedan, known for performance, handling, and build quality.
Competitive Analysis
Key Competitors:
Mercedes-Benz W123/W124 E-Class, Audi 100/200, Volvo 700 Series, Jaguar XJ6.
Key Features
Driving Dynamics:
Renowned 'Ultimate Driving Machine' characteristics, balanced chassis, responsive steering.
Engine Smoothness:
M30 inline-six engine is a benchmark for smoothness and power delivery.
Build Quality:
Solid construction, high-quality materials, and durable engineering.
Design:
Iconic Bertone-influenced styling, understated elegance.
📋 Manual Details
Coverage Areas
Model Years Covered:
1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Page Count
Estimated Page Count:
Approximately 1000+
Manual Type
Manual Type:
Full Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF likely, though physical copy implied by sales context)
📖 Manual Coverage
Systems Covered
Engine:
M30 2.5L Inline-6 Engine (M30B25)
Fuel System:
Bosch L-Jetronic Fuel Injection System
Ignition System:
Electronic Ignition (Distributor-based)
Transmission:
4-Speed Automatic (e.g., ZF 4HP22) and 5-Speed Manual Transmissions (e.g., Getrag 260)
Drivetrain:
Rear-Wheel Drive (RWD)
Suspension:
Front: MacPherson Struts with Lower Control Arms. Rear: Semi-Trailing Arms, Compensating Spring.
Brakes:
Front: Ventilated Discs. Rear: Solid Discs. (ABS may be optional/standard depending on year/market)
Steering:
Recirculating Ball Steering System, Power Assisted
Electrical System:
12V System, Alternator, Starter, Battery, Fuses, Relays, Wiring Diagrams
Body And Chassis:
Body Panel Removal/Installation, Frame Repair, Corrosion Protection
Climate Control:
HVAC System Diagnosis and Repair
Interior:
Trim, Seating, Dashboard Components
Procedures Included
Scheduled Maintenance:
Oil Changes, Filter Replacements, Fluid Checks/Flushes, Tune-ups, Belt Inspections/Replacements
Engine Repair:
Top-end Overhaul, Bottom-end Rebuild, Component Replacement (e.g., Pistons, Rings, Bearings, Valves)
Fuel System Repair:
Injector Testing/Replacement, Fuel Pump Diagnosis, Fuel Pressure Regulator Servicing
Transmission Repair:
Clutch Replacement (Manual), Valve Body Servicing (Automatic), Seal Replacements
Brake System Repair:
Pad/Rotor Replacement, Caliper Rebuild, Fluid Bleeding, ABS System Diagnosis
Suspension And Steering Repair:
Component Replacement (Ball Joints, Bushings, Shocks/Struts), Alignment Procedures
Electrical Diagnostics:
Troubleshooting Short Circuits, Open Circuits, Component Testing
Troubleshooting:
Diagnostic Flowcharts, Common Problem Identification and Resolution
Bodywork:
Panel Alignment, Dent Repair, Rust Mitigation
Technical Depth
Diagnostic Capability:
Advanced Diagnostics, Component Level Troubleshooting
Repair Scope:
Complete Overhaul, Component Replacement, System Rebuilding
Technical Drawings:
Detailed Exploded Views, Torque Specifications, Measurement Data
📊 Manual Specifications
File Format
File Type:
Likely PDF
Searchable Text:
Expected for quality digital manuals
Printable:
Yes
Print Quality
Diagram Clarity:
High (Expected for OEM-level manuals)
Text Readability:
Excellent
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M30B25
Engine Type:
Naturally Aspirated Inline 6-Cylinder, SOHC
Displacement:
2494 cc (2.5 Liters)
Performance
Horsepower:
Approximately 150-155 hp (varies by market and year)
Torque:
Approximately 165-170 lb-ft (varies by market and year)
Fuel System
Fuel Delivery:
Bosch L-Jetronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane minimum, premium recommended)
Fuel Tank Capacity:
Approximately 16.4 gallons (62 liters)
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual (Getrag 260)
Optional
Optional Transmission:
4-Speed Automatic (ZF 4HP22)
Features
Clutch Type:
Single Dry Plate (Manual)
Transmission Fluid Manual:
Dexron III (or equivalent ATF) for automatic; Manual requires specific gear oil (e.g., SAE 75W-90)
📐 Dimensions
Exterior
Length:
Approximately 188.2 inches (4780 mm)
Width:
Approximately 69.1 inches (1755 mm)
Height:
Approximately 54.7 inches (1390 mm)
Wheelbase:
Approximately 104.3 inches (2650 mm)
Weights
Curb Weight:
Approximately 3200-3400 lbs (1450-1540 kg)
🛡️ Safety Features
Ratings
NHTSA Ratings:
N/A (NHTSA ratings were not standardized in this format during the E28 era)
Active Features
ABS:
Optional or standard on later models (Bosch ABS II)
Passive Features
Seatbelts:
3-point front, 2-point rear (optional 3-point rear on some models)
Crumple Zones:
Designed with front and rear crumple zones for impact absorption.
💡 Technology Features
Infotainment
Radio:
AM/FM Radio with Cassette Player (often Blaupunkt or Becker units); optional CD player on later models.
Onboard Computer:
Optional On-Board Computer (OBC) providing trip data, fuel economy, and system checks.
Driver Assistance
Cruise Control:
Standard or optional, electronically controlled.
ABS:
See safety section; early implementation of ABS.
Connectivity
Antenna:
Power antenna (often electric)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first (depending on usage and oil quality)
Coolant Flush Interval:
Every 2 years or 30,000 miles
Spark Plug Replacement:
Every 30,000 miles (depending on plug type)
Fluid Specifications
Engine Oil:
15W-40 or 20W-50 (check owner's manual for specific viscosity based on temperature); API SF or SG rated
Coolant:
BMW Blue Coolant or equivalent ethylene glycol based antifreeze mixed 50/50 with distilled water
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron III ATF or specific BMW power steering fluid
Known Issues
Cooling System:
Plastic radiator end tanks can become brittle; water pump seals can leak; heater control valves are prone to failure.
Fuel System:
Injector O-rings can degrade; fuel accumulator can fail; fuel pump strainers can clog.
Electrical System:
Fuse box corrosion; aging wiring harness; OBC (On-Board Computer) failure; door seal water intrusion affecting electronics.
Suspension:
Front control arm bushings wear out; rear trailing arm bushings fail; differential mounts crack.
Interior:
Headliner sagging; dashboard cracks; seat bolster wear; A/C system recharge and leak issues.
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW, Bayerische Motoren Werke AG, established in 1916, renowned for performance-oriented vehicles.
Model Evolution
Predecessor:
BMW E12 (First generation 5 Series)
Successor:
BMW E34 (Third generation 5 Series)
Production
Production Years:
1981-1987 (for E28 generation, E34 began late 1987/early 1988 in some markets)
Manufacturing Locations:
Germany (Dingolfing plant primarily), South Africa, Mexico (CKD)
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
Frequently lauded by automotive publications of its era for performance and luxury balance. (Specific awards may require deeper historical research).
Ratings
Consumer Reports:
Consistently received positive reviews for reliability and driving pleasure, though repairs could be expensive.
Certifications
Emissions Standards:
Designed to meet US Federal and California emissions standards of the period.
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