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BMW 525I E28 Service Repair Manual 1981-1988

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🏷️ Basic Information Identification Make: BMW Model: 525i Chassis Code: E28 Generation Generation Designation: Second Generation E28 Production Years Covered: 1981-1988 👋 Introduction Market Position Target Audience: BMW enthusiasts, independent...
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Sku: 314759
BMW 525I E28 Service Repair Manual 1981-1988
🏷️ Basic Information
Identification
Make:
BMW
Model:
525i
Chassis Code:
E28
Generation
Generation Designation:
Second Generation E28
Production Years Covered:
1981-1988
👋 Introduction
Market Position
Target Audience:
BMW enthusiasts, independent repair shops, DIY mechanics
Competitive Analysis
Value Proposition:
Enables DIY repairs, reduces reliance on expensive dealership service, extends vehicle lifespan
Key Features
Primary Benefit:
Empowers owners to perform repairs themselves, saving time and money
Content Quality:
Professional quality, highly detailed, factory-type information
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive Service and Repair
Page Count
Estimated Page Count:
Extensive (typical for factory manuals covering this range)
Manual Type
Manual Classification:
Factory-Type Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (M30B25), transmission, drivetrain, cooling, fuel, exhaust
Chassis:
Suspension (front/rear), steering, brakes (hydraulic, parking), wheels, tires
Electrical System:
Wiring diagrams, lighting, ignition, starting, charging, battery, instrument cluster, ECU
Body And Interior:
Body panels, doors, windows, interior trim, seating, HVAC (heating, ventilation, air conditioning)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, belt adjustments
Major Repairs:
Engine overhaul, transmission rebuild, brake system repair, suspension component replacement
Troubleshooting:
Diagnostic procedures, fault finding for various systems, electrical system diagnostics
Component Replacement:
Detailed step-by-step guides for replacing specific parts
Technical Depth
Diagnostic Level:
Advanced diagnostic procedures and fault code interpretation (where applicable for the era)
Repair Scope:
Complete rebuilds, component-level repairs, and system overhauls
Technical Data:
Torque specifications, clearances, timing data, electrical resistance values, schematics
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, enabling clear viewing and printing
Searchability:
Likely searchable text content for efficient information retrieval
Print Quality
Printable:
Yes, pages are designed to be printed
Binding Type
Digital Binding:
N/A (Digital PDF format)
Paper Type
Digital Paper Simulation:
Simulates high-quality workshop manual pages
⚙️ Engine Specifications
Primary Engine
Engine Code:
M30B25 (straight-six)
Engine Type:
Naturally Aspirated, Inline 6-Cylinder
Displacement:
2.5 Liters (2494 cc)
Performance
Horsepower:
Approx. 150 hp @ 5500 rpm (European spec: 170 hp)
Torque:
Approx. 164 lb-ft @ 3500 rpm (European spec: 177 lb-ft)
Fuel System
Fuel Delivery:
Bosch L-Jetronic (early) or Motronic (later) electronic fuel injection
Fuel Type:
Unleaded gasoline (premium recommended)
Technical Specs
Bore X Stroke:
86.0 mm x 71.0 mm
Compression Ratio:
8.8:1
🔧 Transmission
Standard
Transmission Type:
4-speed manual (early models) or 5-speed manual (later models)
Optional
Transmission Type:
ZF 4HP22 4-speed automatic
Features
Manual Gear Ratios:
Specific ratios vary by year and transmission option, detailed in manual
Automatic Features:
Lock-up torque converter for improved efficiency
📐 Dimensions
Exterior
Length:
Approx. 4,755 mm (187.2 in)
Width:
Approx. 1,700 mm (66.9 in)
Height:
Approx. 1,410 mm (55.5 in)
Wheelbase:
Approx. 2,795 mm (110.0 in)
Weights
Curb Weight:
Approx. 1,450 - 1,550 kg (3,197 - 3,417 lbs)
🛡️ Safety Features
Ratings
Crash Test Results:
No modern standardized crash test data available, but designed with robust safety features for its era
Active Features
Braking System:
Front: Ventilated discs; Rear: Solid discs (ABS optional/standard on later models)
Steering:
Recirculating ball with power assist
Passive Features
Seat Belts:
Three-point front seat belts, two-point rear seat belts
Body Structure:
Reinforced passenger cell, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional premium sound systems
Climate Control:
Manual or automatic climate control system
Driver Assistance
ABS:
Anti-lock Braking System available as an option or standard on later models
Connectivity
Original Features:
Limited by era; focus on mechanical and electrical systems, not digital connectivity
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles or 6-12 months, refer to manual for exact schedule
Coolant Flush Interval:
Every 2 years or as specified in manual
Spark Plug Replacement:
Refer to manual; typically 30,000 miles depending on plug type
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-40 or 15W-40 recommended (consult manual for climate-specific viscosity)
Engine Oil Capacity:
Approx. 5.7 Liters (6.0 US Quarts) with filter
Coolant Type:
BMW Antifreeze/Coolant (Ethylene Glycol based) or equivalent
Transmission Fluid Type Manual:
GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90)
Transmission Fluid Type Automatic:
Dexron II or equivalent
Known Issues
Engine M30 Common:
Head gasket leaks, valve stem seals, timing chain wear, fuel injection system maintenance
Suspension Common:
Worn control arm bushings, shock absorber fatigue, rear subframe mounts
Electrical Common:
Corroded wiring connectors, fuel pump relays, instrument cluster issues, alternator/starter problems
Rust Prone Areas:
Wheel wells, rocker panels, trunk lid edges, jacking points
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Known for engineering excellence, driver-focused dynamics, and premium quality
Model Evolution
E28 Introduction:
Introduced in 1981 as a successor to the E12 5 Series, featuring significant aerodynamic and styling updates
E28 Styling:
Designed by Claus Luthe, characterized by its sharp lines and functional aerodynamics
Production
Production Period:
1981-1988
Manufacturing Locations:
Germany (Dingolfing)
🏆 Awards & Recognition
Recognitions
Car And Driver 5 Best Cars:
E28 5 Series models frequently appeared on Car and Driver's '10Best' lists during its production run, highlighting its performance and handling
Ratings
Market Perception:
Widely regarded as a benchmark for sports sedans of its era, praised for its driving dynamics and build quality
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