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BMW 518 518i 1985-1988 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 518, 518i Model Generation: E28 Production Years Covered: 1985-1988 👋 Introduction Market Position Positioning: The BMW 5 Series (E28)...
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BMW 518 518i 1985-1988 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Variant:
518, 518i
Model Generation:
E28
Production Years Covered:
1985-1988
👋 Introduction
Market Position
Positioning:
The BMW 5 Series (E28) represented BMW's entry into the mid-size luxury sedan market, offering a blend of performance, comfort, and sophisticated engineering.
Competitive Analysis
Competitors:
Competed with models like the Mercedes-Benz W124 E-Class, Audi 100, and Volvo 240/740 series.
Key Features
Engineering Philosophy:
Emphasized the 'ultimate driving machine' philosophy with a focus on driver engagement and superior chassis dynamics.
Design Era:
Reflected the sharp, angular design language prevalent in BMWs of the 1980s.
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
Full service, repair, and maintenance instructions
Page Count
Estimated Pages:
500-700
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, timing belt/chain, pistons, rings, bearings, cylinder head, valve train
Fuel System:
Fuel injection systems (Bosch L-Jetronic/Motronic), fuel pumps, injectors, fuel pressure regulators, fuel lines
Ignition System:
Ignition coils, spark plugs, distributor, ignition control module, timing
Cooling System:
Radiator, water pump, thermostat, hoses, fan, coolant specifications
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, emissions control
Transmission Manual:
Clutch operation, gear shifting mechanisms, transmission overhaul, fluid specifications
Transmission Automatic:
Automatic transmission operation, torque converter, hydraulic systems, fluid specifications, control mechanisms
Drivetrain:
Driveshafts, universal joints, differential, axle shafts
Suspension Front:
MacPherson struts, control arms, sway bars, bushings, alignment specifications
Suspension Rear:
Independent suspension, shock absorbers, trailing arms, bushings, alignment specifications
Steering System:
Steering rack, power steering pump, hydraulic lines, tie rods, steering wheel linkage
Brakes Front:
Brake calipers, rotors, brake pads, brake lines, ABS components (if applicable)
Brakes Rear:
Brake calipers/drums, rotors/shoes, brake pads, brake lines, parking brake system
Electrical System:
Wiring diagrams, fuses, relays, battery, charging system (alternator), starter motor
Lighting System:
Headlights, taillights, interior lights, turn signals, wiring
HVAC System:
Heating, ventilation, and air conditioning (AC) system components, refrigerant, operation
Body And Chassis:
Body panels, doors, hood, trunk, bumpers, chassis repair, rust prevention
Interior Trim:
Dashboard, seats, door panels, headliner removal and installation
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and changes, brake inspection
Troubleshooting Guides:
Diagnostic procedures for common and uncommon faults across all systems
Engine Repair:
Engine rebuilding procedures, component replacement, gasket and seal replacement
Transmission Repair:
Transmission disassembly, assembly, and repair of both manual and automatic units
Brake Repair:
Brake pad and rotor replacement, caliper service, bleeding procedures
Electrical Diagnostics:
Tracing electrical faults using wiring diagrams, component testing
Suspension Alignment:
Adjustment procedures and specifications for wheel alignment
Bodywork Repair:
Minor dent repair, panel replacement, rust treatment procedures
Technical Depth
Depth:
Detailed step-by-step instructions for both basic maintenance and complex overhauls
Diagnostics:
Extensive troubleshooting charts and symptom-based diagnostic trees
Torque Specifications:
Precise torque values for all critical fasteners
Schematics:
Detailed wiring diagrams and vacuum routing diagrams
📊 Manual Specifications
File Format
Compatibility:
PDF readers (Adobe Acrobat, Foxit Reader, etc.)
Print Quality
Searchability:
Searchable text for quick information retrieval
Printable:
Printable pages for convenient workshop use
Binding Type
Digital Format:
N/A (Digital)
Paper Type
Digital Format:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code 518:
M10B18 (1.8L SOHC Inline-4)
Engine Code 518I:
M10B18 (1.8L SOHC Inline-4 with fuel injection)
Performance 518
Horsepower Approx:
90-99 hp
Torque Approx:
100-105 lb-ft
Performance 518I
Horsepower Approx:
105-115 hp
Torque Approx:
110-115 lb-ft
Fuel System
Carbureted Models:
Solex carburetor (typical for 518 non-'i' models)
Injected Models:
Bosch L-Jetronic or Motronic fuel injection (518i)
🔧 Transmission
Standard
Transmission Type:
4-speed manual transmission
Optional
Transmission Type:
3-speed ZF automatic transmission (optional, model 3HP22)
Features
Manual Gear Ratios:
Specific ratios detailed in manual
Automatic Shift Points:
Adjustable for economy or performance (typically via vacuum modulator)
📐 Dimensions
Exterior
Length:
Approximately 4,715 mm (185.6 in)
Width:
Approximately 1,700 mm (66.9 in)
Height:
Approximately 1,415 mm (55.7 in)
Weights
Curb Weight Approx:
1,300 - 1,400 kg (2,866 - 3,086 lbs)
🛡️ Safety Features
Ratings
Crash Testing:
Euro NCAP ratings not available for this era; relied on passive safety design principles.
Active Features
ABS:
Optional on some models, standard on later E28s, but likely not on base 518/518i variants of this period.
Passive Features
Seat Belts:
Three-point seat belts with automatic tensioners (front).
Body Structure:
Reinforced passenger cell, crumple zones.
💡 Technology Features
Infotainment
Head Unit:
Original cassette/radio units, often with limited features by modern standards.
Driver Assistance
Cruise Control:
Optional feature on most models, operated via a stalk on the steering column.
Connectivity
Basic Features:
Limited to power windows, mirrors, and central locking (depending on trim level).
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10,000 km (6,000 miles) or 12 months, whichever comes first.
Air Filter:
Every 20,000-30,000 km (12,000-18,000 miles) or annually.
Spark Plugs:
Every 30,000-40,000 km (18,000-24,000 miles).
Fluid Specifications
Engine Oil Type:
API SF/SG, SAE 15W-40 or 10W-40 (check manual for specific ambient temperature recommendations).
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Transmission Fluid Manual:
GL-4 gear oil, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
ZF TE-ML 04D, TE-ML 14A, or Dexron II/III compatible.
Known Issues
Rust Corrosion:
Common in wheel arches, rocker panels, and around window seals due to age.
Cooling System Leaks:
Hose degradation, radiator leaks, and water pump failures are common with age.
Fuel Injector Clogging:
Can occur on injected models due to fuel degradation over time or poor fuel quality.
Dashboard Cracking:
The dashboard material is susceptible to UV damage and can crack over time.
Suspension Bushings:
Rubber bushings in control arms and sway bars wear out, leading to poor handling and noise.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long history of producing driver-focused sedans known for their engineering prowess and sporting pedigree.
Model Evolution
E28 Development:
The E28 was the second generation of the BMW 5 Series, succeeding the E12 and preceding the E34. It introduced significant upgrades in technology and refinement.
E28 518 Positioning:
The 518 and 518i models served as the entry-level variants of the E28 range, offering BMW's characteristic handling and build quality at a more accessible price point.
Production
Manufacturing Locations:
Primarily produced in Dingolfing, Germany.
🏆 Awards & Recognition
Recognitions
Automotive Press Reviews:
Consistently praised by automotive journalists for its driving dynamics, build quality, and comfort, solidifying BMW's reputation in the executive sedan segment.
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