🏷️ Basic Information

Make:

BMW

Model:

5-Series

Chassis Code:

E28

Product Name:

1981-1998 BMW 5-Series E28 Workshop Repair & Service Manual

👋 Introduction

E28 Market Segment:

Executive/Luxury Sedan segment, known for sporty handling and build quality.

Competitors Of The Era:

Mercedes-Benz W124 E-Class, Audi 100/200, Volvo 240/740, Jaguar XJ, and American luxury sedans like Cadillac DeVille and Lincoln Town Car.

Design Philosophy:

A blend of luxury, performance, and driver-centric ergonomics, continuing BMW's 'Ultimate Driving Machine' ethos.

Manual Advantage:

Provides essential technical data and repair procedures for a classic European vehicle, enabling owners to maintain its performance and longevity.

📋 Manual Details

Vehicle Production Years Covered:

1981-1998

Specific Models Covered:

518, 518i, 520i, 520e, 524td, 525i, 528i, 535i

Estimated Page Count:

Extensive (typically 1000+ pages for comprehensive workshop manuals)

Manual Type:

Workshop Repair & Service Manual

Language:

German

Format:

Digital (likely PDF or similar electronic format)

📖 Manual Coverage

Engine Mechanical:

Full engine overhaul, timing, valve train, cooling system, lubrication, fuel injection (Bosch L-Jetronic, Motronic), carburetors (where applicable), emissions control.

Engine Electrical:

Ignition system, starting system, charging system (alternator), engine control unit (ECU) diagnostics and component testing.

Transmission Manual:

Clutch system, gearbox overhaul, shift linkage, torque specifications, fluid types.

Transmission Automatic:

Automatic gearbox overhaul (ZF 4HP series), hydraulic control, valve body, torque converter, cooling, fluid specifications, electronic control (where applicable).

Drivetrain:

Driveshafts, differential, rear axle, wheel bearings, seals.

Suspension:

Front and rear suspension components (struts, control arms, bushings, anti-roll bars), geometry settings, shock absorber replacement.

Steering:

Power steering system, steering rack, tie rods, steering column, alignment specifications.

Brakes:

Front and rear brake systems (disc brakes, calipers, pads, rotors), hydraulic system, ABS (where equipped), parking brake, bleeding procedures, fluid specifications (DOT 3/4).

Electrical System Body:

Lighting systems (headlights, taillights, interior), wiring diagrams, fuse box locations, relays, horns, wipers, washers, power windows, central locking.

Climate Control:

Heating system, ventilation, air conditioning (A/C) system diagnosis and repair, refrigerant types, component replacement.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass replacement, sealing, rust prevention, chassis components.

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant checks, belt inspections and replacement, brake fluid flush, transmission fluid change.

Diagnostic Procedures:

Troubleshooting guides for common problems, symptom-based diagnostics, electrical system testing, engine performance checks.

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all major vehicle systems.

Overhaul Procedures:

Detailed instructions for complete engine rebuilds, transmission overhauls, and differential rebuilds.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle circuits, color-coded for clarity.

Torque Specifications:

Precise torque values for all critical fasteners throughout the vehicle.

Depth Of Coverage:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Tools:

Information on diagnostic procedures and potential use of early electronic diagnostic tools (though advanced OBD-II is not applicable to this era).

📊 Manual Specifications

Digital Format:

PDF (most probable), DjVu, or similar electronic format.

Searchability:

Likely text-searchable if the original was scanned with OCR.

Image Quality:

Dependent on the original source and scanning quality, but expected to be clear enough for diagrams and text.

Binding Type:

N/A (Digital format)

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Engine Variants:

M10 (4-cylinder, 1.8L), M20 (6-cylinder, 2.0L, 2.5L, 2.7L eta), M30 (6-cylinder, 3.5L), M21 (Diesel, 2.4L turbodiesel).

535I Power Output:

Approx. 211 hp (DIN) @ 5500 rpm for the M30B34 engine.

524Td Power Output:

Approx. 115 hp (DIN) @ 4800 rpm for the M21D24 engine.

Injection Systems:

Bosch L-Jetronic, K-Jetronic, Motronic (electronic fuel injection and ignition control) depending on the model and year.

Fuel Type:

Unleaded gasoline (Octane rating typically 95 RON or higher for performance models), Diesel for 524td.

M20B25 Code:

M20B25 (2.5L inline-six)

M30B35 Code:

M30B35 (3.5L inline-six)

🔧 Transmission

Standard Transmission Type:

Getrag 5-speed manual transmission (e.g., Getrag 265) for most models.

Optional Transmission Type:

ZF 4-speed automatic transmission (e.g., ZF 4HP22).

Clutch Type:

Hydraulically operated single-plate dry clutch.

Manual Transmission Fluid:

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

Automatic Transmission Fluid:

Dexron III/Mercon specification ATF.

📐 Dimensions

Wheelbase:

Approx. 2770 mm (109.1 inches)

Length:

Approx. 4755 - 4800 mm (187.2 - 189.0 inches) depending on model.

Width:

Approx. 1700 mm (66.9 inches)

Height:

Approx. 1410 - 1430 mm (55.5 - 56.3 inches) depending on model.

Curb Weight Range:

Approx. 1400 - 1600 kg (3086 - 3527 lbs) depending on engine and options.

🛡️ Safety Features

Crash Test Era Availability:

Limited standardized crash testing data available for this era compared to modern standards. BMW's focus was on passive safety features.

ABS Availability:

Optional on many models, standard on later high-performance variants. Anti-lock Braking System (ABS).

Body Structure:

Reinforced passenger cell, energy-absorbing crumple zones, safety steering column.

Seatbelts:

Three-point inertia-reel seatbelts for front and rear occupants.

💡 Technology Features

Audio System:

Basic AM/FM radio, cassette player, optional premium sound systems with amplifiers.

Cruise Control:

Available as an option on many models.

Limited Driver Assistance:

No electronic driver-assistance systems common today (e.g., lane departure, adaptive cruise control).

Connectivity Features:

None beyond basic accessory power outlets and antenna connections.

🔧 Maintenance

Oil Change Interval:

Typically 10,000-15,000 km (6,000-9,000 miles) or annually, whichever comes first, depending on driving conditions.

Spark Plug Replacement Interval:

Approx. 30,000-40,000 km (18,000-25,000 miles) for standard spark plugs.

Timing Belt Interval:

N/A (All E28 engines use timing chains, except for some early M10 variants which might have chains or belts, but chains are prevalent).

Engine Oil Specification:

API SG or SF rated, SAE 10W-40 or 15W-50 depending on climate and engine condition. BMW recommends specific oils.

Coolant Specification:

BMW Blue (G48) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 3 or DOT 4.

Common E28 Issues Symptoms:

Cooling system leaks (radiator, hoses), fuel injector leaks, fuel pump failure, fuel accumulator issues, idle control valve problems (on EFI models), worn suspension bushings, differential pinion seal leaks, rust in common areas (wheel arches, sills), potential head gasket issues on high-mileage M30 engines.

E28 Diesel Specific Issues:

Glow plug system failures, injection pump seals, turbocharger wear (on 524td).

📚 Vehicle History

Bmw Heritage:

BMW, known for its engineering prowess, sporty sedans, and inline-six engines.

E28 Development:

Successor to the E12 5-Series, evolving the design and technology with a focus on aerodynamics and driver comfort while retaining sporty characteristics.

Production Period:

1981-1988 (with the E34 succeeding it in 1987 for some markets).

Manufacturing Locations:

Primarily Dingolfing, Germany.

🏆 Awards & Recognition

Critical Acclaim E28:

Consistently praised by automotive journalists for its driving dynamics, build quality, and performance, particularly the M535i and M5 variants (though the E28 M5 is a separate model, the M535i shares much).

Consumer Reports Era Standing:

Generally viewed favorably for performance and handling, with typical criticisms focused on maintenance costs and early electrical system complexities.