🏷️ Basic Information

Make:

BMW

Model:

525i

Model Variant:

525

Year:

1982

Chassis Code:

E28

Engine Code:

M30B25

👋 Introduction

Positioning:

The BMW 525i (E28) was positioned as a premium sports sedan, offering a blend of performance, luxury, and advanced engineering for its era. It competed with other executive sedans but emphasized driver engagement and build quality.

Competitors:

Mercedes-Benz W123/W124, Audi 5000 (Typ 43), Jaguar XJ6, Volvo 740/760.

Vehicle Features:

Robust M30 inline-six engine, refined handling, rear-wheel drive, high-quality interior materials, advanced (for the time) safety features.

Value:

Provides essential, detailed information for maintaining and repairing the classic BMW 525i (E28), empowering owners and mechanics to keep these vehicles in top condition.

Audience:

BMW enthusiasts, professional automotive technicians, DIY mechanics with experience in European vehicles.

📋 Manual Details

Systems Covered:

Engine mechanical, fuel system (carbureted and early injection), ignition system, cooling system, exhaust system, lubrication system, transmission (manual and automatic), clutch, driveline, suspension (front and rear), steering, brakes (hydraulic, disc/drum), electrical system (charging, starting, lighting, instrumentation, ancillaries), body (interior, exterior, trim, glass), HVAC, diagnostics, troubleshooting.

Special Tools:

Likely lists required special tools for specific repair procedures, such as engine timing tools, spring compressors, bearing pullers.

Estimated Page Count:

500-800 (estimated for a comprehensive workshop manual of this era)

Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (PDF) - presumed for sale, likely based on original print.

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, and reassembly procedures for engine block, cylinder head, crankshaft, connecting rods, pistons, camshafts, valve train.

Fuel System:

Information on Solex carburetors (likely Zenith/Stromberg for some markets), fuel pump, fuel lines, and potentially early Bosch L-Jetronic fuel injection systems.

Ignition System:

Distributor, ignition coil, spark plugs, high-tension leads, timing adjustments.

Cooling System:

Radiator, fan, water pump, thermostat, coolant hoses, system pressure testing.

Lubrication System:

Oil pump, oil filter, oil pan, oil pressure testing, lubrication points.

Transmission:

Manual transmission: clutch, gearbox assembly, shift linkage. Automatic transmission: torque converter, hydraulic system, gearbox assembly.

Driveline:

Driveshafts, universal joints, differential, rear axle assembly.

Suspension:

Front suspension (MacPherson struts, control arms, anti-roll bar), rear suspension (semi-trailing arms, shock absorbers, springs).

Steering:

Steering rack, tie rods, power steering system (if equipped), steering column.

Brakes:

Front disc brakes, rear disc or drum brakes (depending on market/spec), brake fluid specifications, bleeding procedures, parking brake.

Electrical System:

Wiring diagrams, battery, starter motor, alternator, fuses, relays, lighting circuits, horn, wipers, power windows, instrumentation.

Bodywork And Interior:

Panel removal/installation, door mechanisms, window regulators, seat adjustments, trim components, weatherstripping.

HVAC:

Heating system, ventilation, blower motor, controls, potentially early air conditioning system.

Maintenance:

Oil change, filter replacement, spark plug replacement, tune-up procedures, fluid checks and changes, belt inspection and replacement.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting for common issues across all major systems.

Repair:

Step-by-step instructions for component removal, overhaul, and installation for most mechanical and electrical parts.

Diagnostics:

Includes specifications for checking component operation, pressures, resistances, and voltages.

Electrical Diagnostics:

Detailed wiring diagrams, component location, troubleshooting flowcharts for electrical faults.

Body Repair:

Information on panel alignment, rust repair considerations, glass replacement, bumper repair/replacement.

Depth:

Comprehensive, covering routine maintenance, component-level repair, and major overhauls. Suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Techniques:

Includes methods for testing electrical components (multimeter usage), mechanical pressures (compression, fuel pressure), and visual inspections.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable if digitized from a well-formatted source.

Quality:

High quality scans or original digital files, ensuring readability of text and diagrams.

Type:

N/A (Digital)

Type:

N/A (Digital)

Completeness:

Designed to be a comprehensive workshop manual, covering all aspects of vehicle service and repair required by professional technicians.

⚙️ Engine Specifications

Engine Type:

Inline-6, SOHC (Single Overhead Camshaft)

Displacement:

2494 cc (2.5 Liters)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

8.0:1 or 8.5:1 (depending on market/spec)

Horsepower:

Approx. 150-170 hp @ 5500-6000 rpm (varies by market and specific engine variant)

Torque:

Approx. 205-220 Nm (151-162 lb-ft) @ 3500-4500 rpm (varies by market and specific engine variant)

Fuel Delivery:

Dual Solex carburetors (e.g., 40 DIDTA) or Bosch L-Jetronic fuel injection

Fuel Type:

Unleaded gasoline (RON 91/95 equivalent)

Oil Capacity:

Approx. 5.7 Liters (6.0 US quarts) with filter change.

Ignition Timing:

Static timing and dynamic timing specifications (BTDC) will be detailed in the manual.

Valve Lash:

Adjustment procedures and specifications for intake and exhaust valve clearance will be present.

🔧 Transmission

Type:

4-speed manual Getrag 260

Type:

3-speed or 4-speed automatic (ZF 4HP22)

Clutch:

Single dry plate, hydraulically operated.

Automatic Features:

Lock-up torque converter (on 4-speed auto), sport/economy modes (on later versions).

Manual Transmission Fluid:

BMW recommended manual transmission fluid (e.g., SAE 75W-90 GL-4)

Automatic Transmission Fluid:

Dexron III/IIE or equivalent automatic transmission fluid.

📐 Dimensions

Length:

Approx. 4620 mm (181.9 in)

Width:

Approx. 1700 mm (66.9 in)

Height:

Approx. 1415 mm (55.7 in)

Wheelbase:

Approx. 2795 mm (110.0 in)

Curb Weight:

Approx. 1350-1450 kg (2976-3197 lbs) depending on options and transmission.

Bolt Pattern:

5 x 120 mm

Tire Size Example:

195/70 HR 14 or 205/60 VR 14 (depending on trim and market).

🛡️ Safety Features

Era Assessment:

Designed to meet safety standards of the early 1980s. Modern crash test data is not directly applicable but the chassis structure was considered robust for its time.

Features:

Four-wheel disc brakes (front ventilated), independent suspension, limited-slip differential (optional).

Features:

Reinforced safety cage, impact-absorbing steering column, front seat belts, impact-resistant door beams.

💡 Technology Features

Features:

Analog instrumentation, AM/FM radio, cassette player (optional), basic climate controls.

Features:

ABS (Anti-lock Braking System) became available as an option later in the E28 production run, but may not be standard on all 1982 525i models.

Features:

No modern connectivity features (e.g., Bluetooth, USB) are present. Focus is on mechanical and electrical systems.

🔧 Maintenance

Oil Change:

Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first, using appropriate synthetic or mineral oil.

Spark Plugs:

Replace every 40,000-60,000 km (25,000-37,000 miles) for standard plugs, or as specified by the manual for performance plugs.

Transmission Fluid:

Manual: Check level periodically, change fluid every 60,000-100,000 km (37,000-62,000 miles). Automatic: Change fluid and filter every 50,000-80,000 km (31,000-50,000 miles).

Engine Oil:

API SG or SF, SAE 10W-40 or 20W-50 (depending on climate). Consult manual for specific BMW approvals.

Coolant:

Ethylene glycol based coolant, mixed 50/50 with distilled water. BMW P/N 81 22 9 407 001 (or equivalent).

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Power Steering Fluid:

ATF Dexron II/III or CHF 11S (depending on system, consult manual for certainty).

Common Problems:

Fuel distributor seals (for injection models), radiator leaks, headliner sagging, door panel separation, suspension bushings wear, front strut mount fatigue, rust in common areas (wheel wells, rocker panels, battery tray).

Oil Filter Example:

Mann-Filter W930/12, Mahle OC 28, Bosch 0 451 103 011 (verify compatibility).

Air Filter Example:

Mann-Filter C 23 401, Mahle LX 41 (verify compatibility).

Spark Plug Example:

Bosch W8AC, NGK BPR6ES (verify compatibility).

📚 Vehicle History

Heritage:

BMW, established in 1916, has a long history of producing sporty and luxurious vehicles with a focus on driving dynamics and engineering excellence.

E28 Generation:

The E28 generation (1981-1987) succeeded the E12 5 Series. It featured a more modern, angular design, improved aerodynamics, and a more refined chassis, establishing the modern BMW sedan formula.

Manufacturing Locations:

Primarily Dingolfing, Germany, with some assembly in other BMW plants globally.

Model Years:

The E28 generation was produced from 1981 to 1987. The 525i variant was a key model within this range.

🏆 Awards & Recognition

Automotive Press Awards:

While specific awards for the 1982 525i are hard to pinpoint, the E28 generation was generally praised by automotive journalists for its driving dynamics, build quality, and luxurious interior, earning accolades as a benchmark sports sedan.

Reliability Perception:

Regarded as a robust and reliable vehicle when properly maintained, characteristic of BMW's engineering in the 1980s.