Era Positioning:
The BMW 5 Series (E28) was BMW's executive sedan, positioned as a sportier, more driver-focused alternative to its German luxury competitors, emphasizing performance and build quality.
Competitors:
Mercedes-Benz W123/W124, Audi 100, Jaguar XJ
Model Highlights:
Balanced chassis, powerful inline-six engines, refined interior, excellent build quality, driver engagement.
Value:
Essential for owners and independent workshops to maintain, diagnose, and repair the classic BMW 525i (E28) accurately and efficiently.
Primary Coverage:
Service, Repair, Maintenance, Troubleshooting, Diagnostics
Secondary Coverage:
Electrical Diagrams, Component Removal/Installation, Specifications
Estimated Pages:
Comprehensive (exact count not specified in product info, typical for workshop manuals of this era is 800-1200 pages)
Type:
Workshop Service Repair Manual
Format:
Likely PDF or digitally scanned document (based on typical modern offerings of historical manuals)
Engine:
BMW M30 inline-six engine (M30B25), including fuel injection (Bosch L-Jetronic/Motronic), ignition, cooling, lubrication, emissions control
Transmission:
4-speed automatic (e.g., ZF 4HP22) and 5-speed manual transmissions, clutch, driveline, differential
Brakes:
Front ventilated discs, rear discs, hydraulic system, parking brake
Suspension:
Front MacPherson struts, rear semi-trailing arms, springs, shock absorbers, anti-roll bars
Steering:
Power-assisted recirculating ball steering system
Electrical:
12V electrical system, battery, alternator, starter, lighting, instrumentation, power accessories, fuse/relay box, wiring diagrams
Bodywork:
Chassis, body panels, doors, windows, glass, interior trim, HVAC system
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and changes, belt inspections
Repair And Rebuild:
Engine component overhaul, transmission repair, brake caliper rebuild, suspension component replacement, electrical component diagnosis and repair
Troubleshooting:
Diagnostic flowcharts for common driveability, electrical, and mechanical issues
Diagnostics:
Detailed symptom analysis and component testing procedures
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts; covers full vehicle disassembly, repair, and reassembly.
Digital Format Notes:
Searchable text, printable pages, high-resolution scans
Quality Description:
Assumed to be high-quality reproduction if digital, mirroring original factory manual clarity
Binding Type If Printed:
Spiral-bound or perfect-bound for lay-flat usability in a workshop environment
Paper Type If Printed:
Durable, possibly coated paper to withstand workshop conditions
Engine Type:
SOHC Inline 6-cylinder
Displacement:
2494 cc (2.5 Liters)
Horsepower:
Approx. 150-155 hp @ 5500 rpm (varies slightly by market and specific tune)
Torque:
Approx. 164-168 lb-ft @ 3500 rpm
Fuel Injection:
Bosch L-Jetronic or early Motronic (M1.1/M1.3) electronic fuel injection
Fuel Type:
Unleaded gasoline (premium recommended)
Bore X Stroke:
84.0 mm x 75.0 mm
Ignition System:
Electronic ignition with distributor
Transmission Type:
4-speed manual (Getrag 260) or 4-speed automatic (ZF 4HP22)
Optional Transmission:
5-speed manual (Getrag 260/5)
Clutch:
Single dry plate, hydraulically actuated
Driveline:
Rear-wheel drive (RWD)
Manual Transmission Fluid:
GL-4 gear oil (e.g., Castrol EPX 80W/90)
Automatic Transmission Fluid:
Dexron III (or equivalent for ZF 4HP22)
Length:
Approx. 4,700 mm (185 in)
Width:
Approx. 1,700 mm (67 in)
Height:
Approx. 1,415 mm (55.7 in)
Curb Weight:
Approx. 1,450-1,550 kg (3,197-3,417 lbs)
Gross Vehicle Weight Rating:
Approx. 2,000 kg (4,409 lbs)
Crash Test Data:
Limited official crash test data from this era, but known for robust construction.
Active Safety:
Four-wheel disc brakes, independent suspension for predictable handling
Passive Safety:
Safety cage construction, crumple zones, padded interior surfaces, seat belts
Audio System:
Typically an AM/FM radio with cassette player, often with optional premium sound systems (e.g., Blaupunkt, Becker).
Driver Assistance Features:
Basic features for the era, primarily focused on the driving experience rather than electronic aids. Power steering was common.
Connectivity Features:
None by modern standards; designed for mechanical and analog operation.
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil quality.
Spark Plug Replacement:
Approximately every 30,000 miles for standard plugs, higher for platinum/iridium.
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Engine Oil Type:
API SF/SG, SAE 15W-40 or 20W-50 (depending on climate), or synthetic equivalent. Check manual for specific BMW approvals.
Engine Oil Capacity:
Approx. 5.7 Liters (6.0 US Quarts) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze (BMW Blue or Green concentrate diluted with distilled water at 50/50 ratio)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Engine Common Problems:
Oil leaks from valve cover gasket and oil pan, coolant leaks from hoses and expansion tank, timing chain wear (though M30 is generally robust).
Fuel System Common Problems:
Clogged fuel injectors, failing fuel pumps, worn fuel pressure regulators.
Electrical Common Problems:
Failing alternator, starter motor issues, corroded wiring harnesses, intermittent electrical faults due to age.
Suspension Common Problems:
Worn control arm bushings, worn tie rod ends, leaking shock absorbers, sagging rear springs.
Exhaust Common Problems:
Rust and corrosion on exhaust system components.
Bmw Philosophy:
BMW's reputation for building driver-focused, reliable, and high-performance vehicles.
E28 Introduction:
The E28 generation replaced the E12 5 Series and was produced from 1981 to 1988. It introduced significant updates in chassis design, aerodynamics, and engine technology.
E28 Design:
Designed by Claus Luthe, featuring a more modern, angular, and aerodynamic design compared to its predecessor.
Production Period:
1981-1988
Manufacturing Locations:
Germany (Dingolfing plant), South Africa, Mexico, Thailand
