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BMW 5 Series E28 E34 (518 518i 520i 525i 528i 530i 535i M535i) Complete Workshop Service Repair Manual 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation E Code: E28 & E34 Codes E28 Production Years: 1981-1988 E34 Production Years: 1987-1996 (manual covers up to 1991) 👋...
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BMW 5 Series E28 E34 (518 518i 520i 525i 528i 530i 535i M535i) Complete Workshop Service Repair Manual 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Generation
E Code:
E28 & E34
Codes
E28 Production Years:
1981-1988
E34 Production Years:
1987-1996 (manual covers up to 1991)
👋 Introduction
Market Position
Segment:
Executive Sedan
Reputation:
Renowned for driving dynamics, build quality, and sophisticated engineering.
Competitive Analysis
Key Competitors E28:
Mercedes-Benz W124 E-Class, Audi 100/200, Volvo 700 Series.
Key Competitors E34:
Mercedes-Benz W124 E-Class, Audi V8/A8, Lexus LS 400.
Key Features
E28 Highlights:
Introduction of the E28 marked BMW's transition to more modern styling and a focus on improved aerodynamics and comfort while retaining sporty characteristics.
E34 Highlights:
The E34 brought significant advancements in technology, safety, and refinement, including improved aerodynamics, a more sophisticated suspension, and wider engine options.
E34 M5:
The E34 M5 is a celebrated performance icon, featuring the powerful S38 inline-six engine and enhanced chassis dynamics.
📋 Manual Details
Coverage Areas
Engine Variants:
518, 518i, 520i, 525i, 528i, 530i, 535i, M535i
Page Count
Estimated Pages:
Extensive (typical for comprehensive factory manuals, likely 1000+ pages)
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English (assumed for primary market)
Format
Format:
Digital (PDF implied by typical sales of such manuals)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine diagnostics, overhaul, tuning, fuel injection, ignition, cooling, lubrication for M10, M20, M30, and S38 engines.
Transmission:
Manual and automatic transmission service, repair, clutch, and differential overhaul.
Drivetrain:
Driveshaft, CV joints, axles, and final drive maintenance and repair.
Suspension:
Front and rear suspension components, alignment, shock absorbers, struts, bushings, and steering rack.
Brakes:
Hydraulic system, ABS (where applicable), disc and drum brake servicing, rotor and pad replacement.
Electrical:
Complete electrical system diagrams, starter, alternator, battery, lighting, HVAC controls, power windows, central locking, and ECU troubleshooting.
Bodywork:
Body panel removal and installation, door mechanisms, glass replacement, and interior trim.
Heating Cooling Ac:
HVAC system diagnostics, refrigerant handling, blower motor, heater core, and A/C compressor service.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, timing belt/chain service.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, fault code interpretation (where applicable).
Repair:
Step-by-step instructions for component replacement and repair, including engine rebuilds, transmission overhauls, and electrical system repairs.
Diagnostics:
Detailed diagnostic flowcharts, testing procedures for sensors and actuators, and engine control unit (ECU) diagnosis.
Technical Depth
Level:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including wiring diagrams and component specifications.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Fully searchable text for quick access to information.
Printability:
Printable pages for on-the-go reference.
Print Quality
Image Resolution:
High-resolution diagrams and illustrations.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
E28 Engine Options:
Inline-4 (M10: 518, 518i), Inline-6 (M20: 520i, 525i, 528i; M30: 535i, M535i)
E34 Engine Options:
Inline-6 (M20: 520i, 525i; M30: 530i, 535i, M535i; M50: 520i, 525i; S38: M5)
Performance
E28 535I Horsepower:
Approx. 182 hp (136 kW)
E28 M535I Horsepower:
Approx. 182 hp (136 kW) (European spec), 192 hp (143 kW) (US spec)
E34 535I Horsepower:
Approx. 208 hp (155 kW)
E34 M5 Horsepower:
Approx. 310 hp (232 kW) (S38B36)
Fuel System
Injection Type:
Bosch L-Jetronic/Motronic fuel injection (depending on model and year).
Fuel Type:
Unleaded gasoline (Premium/Super Unleaded recommended for most variants).
🔧 Transmission
Standard
E28 Transmission:
4-speed or 5-speed manual transmission.
E34 Transmission:
5-speed manual transmission.
Optional
E28 Transmission:
3-speed or 4-speed automatic transmission (ZF).
E34 Transmission:
4-speed automatic transmission (ZF 4HP22 or 4HP24).
Features
Transmission Fluid:
Specific ATF type required (e.g., Dexron III for automatics), Manual transmission fluid (e.g., Pentosin).
📐 Dimensions
Exterior
E28 Wheelbase Mm:
2625 mm (103.3 in)
E34 Wheelbase Mm:
2763 mm (108.8 in)
Weights
E28 Curb Weight Kg:
Approx. 1400-1550 kg (depending on model)
E34 Curb Weight Kg:
Approx. 1550-1750 kg (depending on model)
🛡️ Safety Features
Ratings
E28 Safety:
Designed with a strong unibody structure and crumple zones. Lacked modern electronic safety aids.
E34 Safety:
Improved safety cage, optional airbags (driver side from 1990), ABS standard on many models, traction control (ASC) optional.
Active Features
ABS Availability:
Available on later E28 models, standard on many E34 models.
Traction Control Availability:
Optional (ASC) on E34 models.
Passive Features
Airbags Availability:
Driver airbag optional on later E28 models, standard driver airbag from 1990 on E34.
💡 Technology Features
Infotainment
E28 Infotainment:
Basic AM/FM radio, cassette player, optional premium sound systems.
E34 Infotainment:
Advanced (for the era) cassette or CD players, upgraded sound systems, trip computer, optional on-board computer with basic diagnostics.
Driver Assistance
E28 Assistance:
Power steering, power brakes. No electronic driver aids.
E34 Assistance:
ABS, optional Traction Control (ASC), cruise control.
Connectivity
Connectivity Features:
Limited to basic diagnostics via OBD-I port (late E34 models), no modern Bluetooth or smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, depending on driving conditions and oil type.
Spark Plug Replacement:
Around 30,000 miles (48,000 km) for standard plugs, up to 60,000 miles (96,000 km) for platinum/iridium.
Timing Belt Replacement:
For M10 and M20 engines, typically every 40,000-60,000 miles (64,000-96,000 km). M30 and M50 have timing chains.
Fluid Specifications
Engine Oil Spec:
API SG/SH or ACEA A2/A3, SAE 0W-30, 5W-30, 5W-40, 10W-40, 10W-50 (refer to manual for specific engine and climate).
Coolant Spec:
BMW Longlife-01 (or compatible ethylene glycol based coolant with corrosion inhibitors), typically a 50/50 mix with distilled water.
Brake Fluid Spec:
DOT 4
Known Issues
E28 Common Problems:
Fuel distributor leaks (K-Jetronic), vacuum leaks, cooling system component degradation (hoses, water pump), rear axle bushings, early ECU failures.
E34 Common Problems:
Cooling system (plastic components, radiator), heater control valve issues, window regulator failures, ABS sensor failures, wiring harness degradation (engine bay).
M5 Common Problems:
S38 engine oil consumption, valve guide wear, clutch wear, differential output shaft seals.
📚 Vehicle History
Brand Heritage
Bmw Heritage:
BMW's legacy in performance sedans, sporty handling, and driver-focused engineering.
Model Evolution
E28 Introduction:
Successor to the E12, refined the executive sedan formula with a focus on handling and driver engagement.
E34 Introduction:
A complete redesign of the 5 Series, setting new benchmarks for class, technology, and performance in its era.
M5 Development:
The M5 variants represent the pinnacle of performance engineering for each generation, building on standard chassis with potent engines and upgraded components.
Production
E28 Production Run:
1981-1988
E34 Production Run:
1987-1996 (manual covers up to 1991)
🏆 Awards & Recognition
Recognitions
E28 Recognition:
Consistently praised for its driving dynamics and build quality by automotive journalists of its time.
E34 Recognition:
Widely acclaimed as one of the best luxury sport sedans of the late 1980s and early 1990s, lauded for its blend of performance, comfort, and technology.
E34 M5 Recognition:
Considered a benchmark performance sedan and a modern classic.
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