Era Context:
The BMW 5 Series (E28 and E34) represented the pinnacle of executive and sporting sedans in their respective eras, known for performance, luxury, and engineering prowess. This manual provides essential factory information for owners and technicians maintaining these classic vehicles.
Rivals E28:
Mercedes-Benz W123/W124, Audi 100/200, Jaguar XJ-S (sedan versions).
Rivals E34:
Mercedes-Benz W124, Audi V8 Quattro, Lexus LS 400, Jaguar XJ (XJ40).
Vehicle Attributes:
Renowned for their balanced handling (often praised as the benchmark), powerful straight-six engines, driver-focused cockpits, and solid build quality. The E34 introduced more advanced electronics and aerodynamic styling.
Manual Value Proposition:
Provides indispensable factory-level data for DIY mechanics, independent repair shops, and enthusiasts seeking to maintain, diagnose, and repair these complex and rewarding vehicles.
Chassis Models Covered:
BMW 5 Series E28 and E34 generations
Specific Models Covered:
518, 518i, 520i, 525i, 528i, 530i, 535i, M535i
International Markets:
While the product description doesn't specify, factory manuals often cover specifications and procedures relevant to multiple international markets, though language is typically localized.
Estimated Pages:
Over 1000 pages (typical for factory service manuals of this scope)
Type:
Factory Service Repair Workshop Manual
Language:
English (assumed for this market product description)
Powertrain:
Engine mechanical (M10, M20, M30, M60 families), fuel injection systems (K-Jetronic, L-Jetronic, Motronic), cooling system, exhaust system, engine management, transmission (manual and automatic), clutch, driveshafts, differentials.
Chassis:
Suspension (front and rear), steering system (power steering, steering rack), brakes (hydraulic, ABS systems), wheels, tires, chassis components.
Electrical:
Wiring diagrams, starter system, charging system (alternator, battery), ignition system, lighting systems (headlights, taillights, interior), instrument cluster, gauges, power windows, central locking, climate control electronics, fuse boxes, relays.
Bodywork:
Body shell structure, interior trim, exterior trim, doors, hood, trunk, bumpers, glass, seals, body repair procedures.
Fuel Delivery:
Detailed procedures for fuel pump testing, fuel pressure regulation, fuel injector diagnosis and replacement, fuel filter replacement.
Exhaust System:
Catalytic converter operation (where applicable), muffler and pipe replacement, oxygen sensor testing and replacement.
Maintenance:
Routine checks, oil changes, filter replacements, fluid level checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/rotor replacement, coolant flush.
Repair:
Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service, transmission rebuilds, clutch replacement, suspension component replacement, brake caliper overhaul, steering rack replacement, electrical component diagnosis and replacement.
Diagnostics:
Troubleshooting guides for common symptoms, diagnostic fault codes (where applicable for the era), electrical system testing procedures, fuel system pressure testing.
Engine Timing:
Belt and chain timing procedures, valve adjustment (where applicable), camshaft timing adjustments.
Body Repair:
Information on panel alignment, welding procedures (for structural repairs), and trim piece installation/removal.
Depth:
Comprehensive factory-level detail, including specifications, torque values, clearance measurements, diagnostic procedures, and repair sequences for all major vehicle systems.
Diagnostic Tools:
Information on using basic diagnostic tools relevant to the era, such as multimeters, fuel pressure gauges, and oscilloscope interpretation for ignition systems.
Completeness:
Factory-sourced, comprehensive coverage for repair, maintenance, troubleshooting, and specifications.
E28 Engine Options:
M20 2.0L (121 hp), M20 2.3L (141 hp - 523i, not in product name but relevant), M30 2.5L (148 hp - 525i), M30 2.7L (170 hp - 528i), M30 3.2L (182 hp - 533i), M30 3.4L (189 hp - 535i), M88/3 3.5L Turbocharged (282 hp - M535i/M5).
E34 Engine Options:
M20 1.8L (113 hp - 518i), M20 2.0L (126 hp - 520i), M30 3.5L (208 hp - 535i), M60B30 3.0L V8 (215 hp - 530i), M60B40 4.0L V8 (282 hp - 540i).
E28 M535I Performance:
0-60 mph: approx. 7.0 seconds; Top Speed: approx. 150 mph (electronically limited on some models).
E34 535I Performance:
0-60 mph: approx. 7.5 seconds; Top Speed: approx. 145 mph.
Injection Systems:
Bosch K-Jetronic (CIS), Bosch L-Jetronic, Bosch Motronic (early electronic fuel injection and ignition control), Bosch Motronic M1.2, M2.1, M2.5, M2.7, M3.3 for later models. Carbureted models (e.g., 518) also existed but are less common in the covered range.
Fuel Type:
Premium Unleaded Gasoline (Octane rating typically 91 RON/87 AKI or higher)
E34 Motronic Versions:
Manual will cover nuances of Motronic M1.2, M2.1, M2.5, M2.7, M3.3, detailing sensor inputs, actuator outputs, and basic fault diagnosis.
E28 Standard Transmission:
Getrag 260 5-speed manual transmission.
E34 Standard Transmission:
Getrag 260 5-speed manual transmission (common on 6-cylinder models).
E28 Optional Transmission:
ZF 4HP22 4-speed automatic transmission.
E34 Optional Transmission:
ZF 4HP22 EH 4-speed automatic transmission (later with electronic control), ZF 5HP18 5-speed automatic (on some 6-cylinder models), ZF 5HP30 5-speed automatic (on V8 models).
Limited Slip Differential:
Optional on many models, particularly performance variants like the M535i and M5, providing enhanced traction and handling.
Era Safety Standards:
Safety standards of the 1980s and early 1990s, generally good for their time. E28 focused on occupant protection via structural integrity and seatbelts. E34 introduced optional ABS and driver-side airbags later in its production run.
ABS:
Optional Anti-lock Braking System (ABS) available on many E34 models, standard on some later E28 M5 variants.
Traction Control:
Optional ASC (Automatic Stability Control) or ASC+T (with engine torque reduction) became available on later E34 models.
Airbags:
Driver-side airbag optional on later E34 models, not typically available on E28.
Seatbelts:
Three-point seatbelts with pretensioners in the front, standard.
E28 Infotainment:
Basic analog radio, cassette player, optional premium sound systems (e.g., Harman Kardon on some models). Minimal electronic integration.
E34 Infotainment:
More advanced Blaupunkt or BMW branded stereo systems, optional CD changers, climate control modules, trip computers, and early onboard diagnostics (OBD).
E28 Driver Features:
Power steering, cruise control (optional), central locking.
E34 Driver Features:
Optional ABS, ASC/ASC+T, heated seats, power adjustable seats with memory, sunroof, self-leveling suspension (optional on touring models).
Era Connectivity:
Limited to basic telephone options on some later E34 models. No modern Bluetooth or smartphone integration.
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions and oil type used. Check manual for specific recommendations.
Coolant Flush Interval:
Every 2 years or 30,000 miles (48,000 km).
Spark Plug Replacement:
Varies by plug type (standard, platinum, iridium); typically 30,000-60,000 miles (48,000-96,000 km). Refer to manual for specific plug type and interval.
Engine Oil Type:
API SG or higher, SAE 10W-40 or 15W-40 recommended for most models. Consult manual for specific viscosity based on climate. Synthetic oils are often preferred for modern use.
Coolant Type:
BMW Blue (G48) or equivalent ethylene glycol-based coolant with corrosion inhibitors.
Transmission Fluid Manual:
GL-4 SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron III/H or equivalent ATF.
Brake Fluid Type:
DOT 4 or DOT 3, low viscosity.
E28 Common Problems:
Fuel distributor leaks (K-Jetronic), vacuum line deterioration, headliner sagging, dashboard cracks, heater core leaks, rust in common areas (wheel wells, rocker panels).
E34 Common Problems:
Cooling system issues (radiator, water pump, expansion tank), OVP relay failure (E34 electrics), ABS sensor failures, window regulator failures, door seal deterioration, fuel pump issues, dashboard electronics failures.
Engine Oil Capacity:
Varies by engine: e.g., M20 approx. 4.5L, M30 approx. 6.5L, M60 approx. 6.5L. Exact figures detailed in manual.
Cooling System Capacity:
Approximately 8-10 liters depending on engine and radiator size. Details in manual.
Bmw Philosophy:
BMW's 'Ultimate Driving Machine' ethos is central to the 5 Series' development and appeal, emphasizing performance, handling, and driver engagement.
E28 Introduction:
Introduced in 1981, the E28 succeeded the E12 and brought significant updates in styling, aerodynamics, and engine technology, including the introduction of the M535i and the legendary M5.
E34 Introduction:
Launched in 1987, the E34 marked a complete redesign with a sleeker, more modern appearance and introduced new engine options like the V8s (M60 family), improved chassis dynamics, and increased electronic content.
E28 Production Years:
1981-1988.
E34 Production Years:
1987-1996 (with overlap in model years).
