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BMW 5-Series (E28) 528i 1981-1988 Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 5-Series Chassis Code: E28 Variant: 528i Production Years: 1981-1988 Region Of Origin: Germany 👋 Introduction Market Position Segment: Executive Sedan Target Audience: Automotive...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
5-Series
Chassis Code:
E28
Variant:
528i
Production Years:
1981-1988
Region Of Origin:
Germany
👋 Introduction
Market Position
Segment:
Executive Sedan
Target Audience:
Automotive enthusiasts, DIY mechanics, professional technicians seeking detailed information
Competitive Analysis
Competitors:
Mercedes-Benz W123/W124, Audi 100, Volvo 240/740
Key Features
Engine Smoothness:
Known for its refined inline-six engines and balanced chassis
Build Quality:
Renowned for BMW's characteristic build quality and driver engagement
Design:
Classic BMW design language with angular styling
📋 Manual Details
Coverage Areas
Engine Maintenance:
Complete
Transmission Service:
Complete
Brake System Repair:
Complete
Electrical Diagnostics:
Complete
Suspension And Steering:
Complete
Body And Chassis:
Complete
Fuel System Service:
Complete
Cooling System Repair:
Complete
Exhaust System Service:
Complete
HVAC System Repair:
Complete
Interior Component Service:
Complete
Troubleshooting Guides:
Comprehensive
Wiring Schematics:
Included
Page Count
Estimated Page Count:
Extensive (typically 1000+ pages for official BMW service manuals)
Manual Type
Type:
Official Full Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Disassembly, inspection, assembly of engine components (pistons, rings, bearings, valves, camshafts, crankshaft, cylinder head, block)
Engine Management:
Fuel injection system (Bosch Motronic), ignition system, emissions control systems, sensor diagnostics
Transmission Manual:
Clutch, gearbox disassembly, inspection, assembly, shift mechanism
Transmission Automatic:
Transmission operation, hydraulic control, valve body, torque converter, cooling, service procedures
Drivetrain:
Driveshafts, differential, axle shafts, universal joints
Brakes:
Front and rear disc brakes, brake hydraulics, ABS (if equipped), parking brake
Steering:
Power steering system, steering gear, steering column, tie rods
Suspension:
Front struts, rear shock absorbers, control arms, bushings, sway bars, wheel bearings
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting, wipers, horn, power windows, central locking, instrument cluster
Body And Chassis:
Body panel removal and installation, door mechanisms, hood, trunk, bumpers, glass, underbody protection
HVAC:
Heater core, blower motor, ventilation system, air conditioning (if equipped), refrigerant handling
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors
Cooling System:
Radiator, coolant hoses, thermostat, water pump, cooling fan
Procedures Included
Routine Maintenance:
Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, belt inspection and replacement
Diagnostic Procedures:
Troubleshooting common symptoms, diagnostic charts, identification of faulty components
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation for all covered systems
Adjustment Procedures:
Valve adjustment, idle speed adjustment, brake adjustment (if applicable)
Replacement Procedures:
Replacement of wear items such as gaskets, seals, hoses, belts, brake pads, shock absorbers
Engine Rebuild:
Detailed instructions for complete engine overhaul
Transmission Overhaul:
Detailed instructions for complete transmission rebuild
Electrical Troubleshooting:
Use of multimeters, reading wiring diagrams, tracing electrical faults
Technical Depth
Depth:
Factory-level diagnostics, repair, and maintenance procedures for all major vehicle systems.
📊 Manual Specifications
File Format
Readability:
High-resolution PDF, zoomable images and text
Print Quality
Printability:
Fully printable pages for workshop use
Binding Type
Binding:
Digital (PDF format), no physical binding
Paper Type
Paper Type:
N/A (Digital)
Software Requirements
Reader:
Adobe Acrobat Reader (or compatible PDF viewer)
Compression:
WinZip or compatible archive utility for download
Compatibility
Operating Systems:
All Windows and Mac operating systems
⚙️ Engine Specifications
Primary Engine
Engine Code:
M30B32
Engine Type:
Inline-6 Cylinder, Naturally Aspirated
Displacement:
3.2 Liters (3210 cc)
Bore X Stroke:
89.0 mm x 86.0 mm
Compression Ratio:
8.8:1 or 9.0:1 (depending on market/variant)
Performance
Horsepower Peak:
182 hp @ 5500 rpm (approx.)
Torque Peak:
210 lb-ft @ 3500 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch LE2-Jetronic or Motronic fuel injection
Fuel Type
Fuel Requirement:
Unleaded Premium Gasoline (91+ Octane)
Ignition System
Ignition Type:
Electronic Ignition (Distributor-based)
🔧 Transmission
Standard
Transmission Type Std:
Getrag 260 5-speed Manual Transmission
Optional
Transmission Type Opt:
ZF 4HP22 4-speed Automatic Transmission
Features
Clutch Type:
Single dry plate clutch (manual)
Final Drive Ratio:
Typically 3.25:1 or 3.46:1 (depending on transmission and market)
📐 Dimensions
Exterior
Length:
4755 mm (187.2 in)
Width:
1700 mm (66.9 in)
Height:
1410 mm (55.5 in)
Wheelbase:
2795 mm (110.0 in)
Front Track:
1442 mm (56.8 in)
Rear Track:
1472 mm (57.9 in)
Weights
Curb Weight Manual:
1450 kg (3197 lbs) (approx.)
Curb Weight Automatic:
1480 kg (3263 lbs) (approx.)
Gross Vehicle Weight Rating:
1950 kg (approx.)
🛡️ Safety Features
Ratings
Crash Test Information:
Limited official crash test data from this era, but E28 chassis generally considered robust for its time. Focus on occupant protection through design and materials.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on later models and certain markets.
Traction Control:
Not typically available on E28 models.
Passive Features
Seatbelts:
3-point inertia-reel seatbelts front and rear
Head Restraints:
Front and rear head restraints
Crumple Zones:
Designed with front and rear crumple zones for energy absorption
Safety Cage:
Reinforced passenger safety cage structure
💡 Technology Features
Infotainment
Radio System:
Factory premium audio system with AM/FM radio, cassette player. Some models may have optional CD changers.
Speaker System:
Typically 4-6 speaker system (door speakers, rear parcel shelf speakers).
Driver Assistance
Cruise Control:
Standard on most 528i models.
Trip Computer:
Limited trip computer functions (e.g., fuel consumption) on some models.
Connectivity
Connectivity Options:
No modern connectivity features like Bluetooth or USB. Analog systems only.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles or 6-12 months, depending on driving conditions and oil used.
Air Filter Replacement:
Every 15,000 - 30,000 miles
Spark Plug Replacement:
Every 30,000 - 60,000 miles (depending on plug type)
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 recommended (check manual for exact specifications)
Engine Oil Capacity:
6.5 Liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze (BMW Blue or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
ATF Dexron II (or equivalent)
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or 80W-90
Automatic Transmission Fluid:
ATF Dexron II (or equivalent)
Known Issues
Heater Core Leaks:
Common issue due to age and material degradation, often leading to coolant smell inside the cabin.
Cracked Dashboard:
UV exposure can cause dashboards to crack over time.
Idle Control Valve:
Can become clogged or fail, leading to rough idle or stalling.
Fuel Injector Clogging:
Can affect performance and fuel economy, especially with fuel quality variations.
Suspension Bushings:
Wear and tear on control arm bushings and sway bar links can lead to sloppy handling and noise.
Oil Leaks:
Valve cover gaskets, oil pan gaskets, and rear main seals can leak with age.
Electrical Connectors:
Corrosion or looseness in electrical connectors can cause intermittent issues.
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW, Bayerische Motoren Werke AG, known for 'The Ultimate Driving Machine' ethos and motorsport success.
Model Evolution
E28 Introduction:
The E28 was the second generation of the 5 Series, succeeding the E12. Introduced in 1981.
E28 Significance:
The E28 introduced a more modern and aerodynamic design, advanced fuel injection, and the availability of ABS and a diesel engine option in some markets.
E28 Updates:
Received minor updates throughout its production run, including styling tweaks and powertrain enhancements.
Production
Production Period:
1981-1988
Manufacturing Locations:
Primary manufacturing in Dingolfing, Germany. CKD assembly in various international locations.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive journalists for its driving dynamics, build quality, and performance, often winning comparisons against its contemporaries.
Ratings
Reliability Reputation:
While requiring diligent maintenance, E28s are known for their long-term durability when properly cared for.
Certifications
Factory Certification:
The manual itself represents factory certification for service procedures and technical data.