🏷️ Basic Information

Make:

BMW

Model:

525i

Year:

1982

Chassis Code:

E28

Engine Code:

M30B25

Chassis Generation:

E28 (First generation of the 5 Series to use this designation)

👋 Introduction

Vehicle Segment:

Luxury/Executive Sedan

Target Audience:

Affluent consumers seeking a blend of performance, comfort, and sophisticated engineering.

Key Competitors:

Mercedes-Benz W123/W124 series, Audi 100, Volvo 240/700 series, Jaguar XJ-S.

Vehicle Highlights:

Rear-wheel drive dynamics, refined inline-six engine, excellent build quality, comfortable interior, advanced (for its time) engineering, sophisticated styling.

Why This Manual:

Essential for owners and independent repair shops to maintain, diagnose, and repair the complex systems of the BMW 525i (E28) accurately and efficiently.

📋 Manual Details

Manual Type:

Full Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

Specific Models Covered:

Specifically covers the BMW 525i model for the 1982 model year within the E28 chassis designation.

Estimated Page Count:

Detailed, likely 500+ pages (typical for full service manuals of this era)

File Format:

Digital (e.g., PDF). Searchable text and printable pages expected.

Print Quality:

High resolution for clear diagrams and text.

Binding Type:

N/A (Digital Product)

Paper Type:

N/A (Digital Product)

Searchability:

If a PDF, it should have selectable text for easy searching of specific terms and components.

📖 Manual Coverage

Engine Systems:

Engine mechanical (assembly, disassembly, timing, valve train, pistons, crankshaft), Fuel system (carburetor/injection system specifics, fuel pump, lines, filter), Ignition system (distributor, coils, plugs, timing), Cooling system (radiator, thermostat, water pump, hoses), Lubrication system (oil pump, filter, oil passages), Exhaust system (manifold, catalytic converter, muffler, pipes), Emissions control systems.

Drivetrain Systems:

Transmission (manual & automatic), Clutch system (components, adjustment, replacement), Driveshafts, Differential (rear axle), Axles.

Chassis Systems:

Suspension (front & rear components, springs, shocks, control arms, bushings), Steering (steering rack, linkages, power steering system), Brakes (hydraulic system, master cylinder, calipers, pads, rotors, parking brake), Wheels and tires.

Electrical Systems:

Battery, Charging system (alternator, regulator), Starting system (starter motor), Lighting (headlights, taillights, interior), Ignition switch, Fuses and relays, Wiring diagrams for all circuits, Instrument cluster, Gauges, Wiper and washer system, Horn, Power windows, Power mirrors, Central locking.

Body And Interior:

Body panels (removal, installation, alignment), Doors, Hood, Trunk lid, Bumpers, Glass (windshield, side, rear), Seats, Interior trim panels, Dashboard, HVAC system (heater core, blower motor, controls, A/C system components).

Maintenance Procedures:

Oil and filter changes, Air filter replacement, Spark plug replacement, Coolant flush and fill, Brake fluid flush, Transmission fluid and filter service, Differential fluid change, Battery maintenance, Wiper blade replacement, Tire rotation and balancing.

Repair Procedures:

Engine overhaul and rebuild, Transmission overhaul (manual & automatic), Clutch replacement, Brake caliper and master cylinder rebuild/replacement, Suspension component replacement (shocks, struts, bushings, ball joints), Steering rack repair/replacement, Fuel pump replacement, Alternator and starter replacement, Radiator and water pump replacement, Heater core replacement, Electrical component diagnosis and repair, Body panel repair and replacement, Door and window mechanism repair.

Diagnostic Procedures:

Troubleshooting common faults, Component testing, Circuit testing using multimeters and test lights, Ignition timing adjustment, Carburetor adjustment (if applicable), Fuel injection system diagnostics (if applicable), Vacuum leak detection, Engine performance diagnostics.

Troubleshooting Charts:

Comprehensive troubleshooting charts organized by symptom and system for efficient diagnosis of common and uncommon issues.

Diagnostic Capabilities:

Advanced diagnostic procedures, Fault code lookup (if applicable to the system), Circuit tracing, Component resistance and voltage testing.

Rebuild Capabilities:

Complete engine rebuild procedures, Transmission overhaul specifications and procedures, Differential rebuilds.

Specifications And Tolerances:

Detailed torque specifications for all fasteners, Engine component clearances (piston ring gap, bearing clearance, valve lash), Brake system specifications (pad thickness, rotor runout), Suspension geometry settings.

Wiring Diagrams:

Detailed, factory-quality wiring diagrams for all electrical systems, crucial for electrical diagnostics and repairs.

⚙️ Engine Specifications

Engine Type:

Inline 6-cylinder, Naturally Aspirated

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

8.8:1

Valvetrain:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Horsepower:

150 PS (148 hp; 110 kW) at 5500 rpm (approx.)

Torque:

220 N⋅m (162 lb⋅ft) at 4000 rpm (approx.)

Fuel Delivery:

Bosch L-Jetronic Fuel Injection (standard)

Fuel Type:

Unleaded Gasoline (Premium)

Cooling Medium:

Water/Glycol Mixture

🔧 Transmission

Transmission Type:

4-speed Manual

Transmission Type:

3-speed ZF 3HP22 Automatic Transmission

Rear Axle Ratio:

3.45:1 (typical for manual transmission)

Clutch Type:

Dry single plate, hydraulically operated

📐 Dimensions

Length:

4620 mm (181.9 in)

Width:

1700 mm (66.9 in)

Height:

1415 mm (55.7 in)

Wheelbase:

2700 mm (106.3 in)

Front Track:

1430 mm (56.3 in)

Rear Track:

1470 mm (57.9 in)

Curb Weight:

Approx. 1400-1500 kg (3086-3307 lbs)

Gross Vehicle Weight Rating:

Approx. 1900 kg (4189 lbs)

Fuel Capacity:

70 Liters (18.5 US gal)

🛡️ Safety Features

Crash Test History:

No formal crash test ratings readily available from modern standards for this specific model year, but generally considered a robustly built vehicle for its era.

Braking System:

Power-assisted hydraulic disc brakes front and rear, Anti-lock Braking System (ABS) was optional or standard on later models.

Suspension Features:

Independent front suspension (MacPherson struts), Independent rear suspension (Semi-trailing arms) providing good handling characteristics.

Seat Belts:

3-point inertia-reel seat belts front and rear (standard).

Body Structure:

Reinforced safety cell, crumple zones front and rear.

Headlights:

Halogen headlights for improved nighttime visibility.

💡 Technology Features

Audio System:

Typically a factory AM/FM radio with cassette player, possibly with amplifier and upgraded speakers. Aftermarket head units are common upgrades.

ABS Availability:

Optional on early models, potentially standard on later 1982 models or specific trims.

Connectivity Features:

None in the modern sense. Basic connectivity via analog radio signals.

HVAC System:

Manual or optional automatic climate control, featuring heating and ventilation. Air conditioning was a common option.

🔧 Maintenance

Oil Change Interval:

Every 5,000 - 7,500 miles (or annually), depending on driving conditions. Refer to manual for precise intervals.

Spark Plug Replacement:

Every 20,000 - 30,000 miles (approx., depending on plug type).

Coolant Flush:

Every 2 years or 30,000 miles.

Transmission Fluid Service:

Manual: Every 30,000-50,000 miles. Automatic: Fluid and filter change every 30,000 miles is recommended for longevity.

Engine Oil Type:

API SG or higher, SAE 15W-40 or 20W-50 (depending on climate). Check manual for precise viscosity and API rating.

Engine Oil Capacity:

Approx. 5.5 Liters (5.8 US Quarts) with filter change.

Coolant Type:

Ethylene Glycol based antifreeze, mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Transmission Fluid Manual:

API GL-4 SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

Dexron II or equivalent ATF.

Common Wear Items:

Front suspension bushings, rear subframe bushings, cooling system hoses, fuel lines, brake wear components, exhaust system components.

Engine Specific Concerns:

Timing chain guides (can wear and lead to noise/failure), oil leaks from the front and rear main seals, valve cover gasket, and oil pan gasket. Fuel injection system can require periodic maintenance.

Electrical System Concerns:

Degradation of wiring insulation over time, alternator brushes, starter motor wear, vacuum leaks affecting engine performance and idle.

Body Corrosion:

Rust can be an issue, particularly around wheel wells, rocker panels, and underbody components if not properly maintained.

📚 Vehicle History

Bmw Philosophy:

BMW's long-standing reputation for 'The Ultimate Driving Machine', focusing on performance, engineering excellence, and driver engagement.

E28 Introduction:

The E28 platform was introduced in 1981 as the successor to the E12. It represented a significant evolution in BMW's mid-size executive sedan offering.

E28 Design:

Characterized by a cleaner, more aerodynamic design penned by Paul Bracq, featuring sharper lines and a revised grille.

E28 Engines:

The E28 was offered with a range of inline-four and inline-six petrol engines, and a diesel engine. The 525i specifically utilized the robust M30 inline-six.

E28 Production Years:

1981-1988

E28 Manufacturing Locations:

Mainly Dingolfing, Germany.

🏆 Awards & Recognition

Automotive Press Accolades:

The E28 generation BMW 5 Series, including the 525i, was generally well-received by automotive journalists for its driving dynamics, build quality, and refined engineering. Often cited as a benchmark in its class.

Sales Performance:

Strong sales figures globally, contributing significantly to BMW's growth and reputation in the luxury sedan market.