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BMW 525 525i 1981-1988 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 525i Model Code Series: E28 Model Years Covered: 1981-1988 Chassis Codes: E28 Engine Codes: M30B25 👋 Introduction Market Position Vehicle Segment: Executive Mid-size...
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BMW 525 525i 1981-1988 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
525i
Model Code Series:
E28
Model Years Covered:
1981-1988
Chassis Codes:
E28
Engine Codes:
M30B25
👋 Introduction
Market Position
Vehicle Segment:
Executive Mid-size Sedan
Competitive Analysis
Key Competitors Era:
Mercedes-Benz W123/W124 E-Class, Audi 100/200, Volvo 700 Series, Saab 9000.
Key Features
Bmw Philosophy:
The E28 5 Series represented BMW's focus on 'The Ultimate Driving Machine' with balanced handling, powerful inline-six engines, and a driver-oriented interior.
525I Distinction:
The 525i, with its 2.5-liter M30 engine, offered a strong blend of performance and refinement, slotting between the 520i/524td and the range-topping M535i/M5.
📋 Manual Details
Coverage Areas
Coverage Type:
Workshop Repair Service Manual
Page Count
Estimated Page Count:
800+
Manual Type
Manual Format Type:
Comprehensive Service and Repair Manual
Language
Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed rebuild procedures, component specifications, timing belt/chain service, cylinder head, piston, crankshaft, camshaft, valve train.
Engine Fuel System:
Bosch L-Jetronic fuel injection system diagnosis and repair, fuel pump, injectors, fuel pressure regulator, sensors (AFM, TPS, CTS, O2).
Engine Ignition System:
Ignition timing, spark plugs, coil packs, distributor (if applicable), ignition control module diagnostics.
Transmission Manual:
Clutch operation, gearbox overhaul, shift linkage, lubrication, common issues.
Transmission Automatic:
Transmission fluid service, hydraulic control, valve body diagnosis, torque converter, shift solenoids (for applicable models).
Drivetrain:
Driveshaft, universal joints, differential service and overhaul, rear axle components.
Brakes System:
Brake fluid specifications, hydraulic system components (master cylinder, calipers, wheel cylinders), ABS system (if equipped), rotor and pad replacement, bleeding procedures.
Suspension System:
Front and rear suspension component replacement (struts, shocks, control arms, bushings, ball joints), alignment specifications.
Steering System:
Power steering system diagnosis, pump, rack and pinion, steering linkage, fluid type and capacity.
Electrical System Power:
Battery, charging system (alternator), starter motor, wiring diagrams, fuses, relays.
Electrical System Lighting:
Headlights, taillights, interior lighting, bulb types and replacement.
Electrical System Accessories:
Wipers, horn, power windows, central locking (if equipped), heated seats, sunroof (if equipped).
HVAC System:
Heating, ventilation, and air conditioning system diagnosis, refrigerant types, compressor, blower motor, control head.
Body And Chassis:
Body panel removal and installation, door mechanisms, interior trim, glass replacement, rust prevention and repair basics.
Diagnostic Troubleshooting:
Systematic troubleshooting guides for common and complex issues, diagnostic charts, fault code interpretation (where applicable).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and top-offs, tire rotation.
Preventative Maintenance:
Scheduled maintenance tasks, component inspections, lubrication points.
Major Repairs:
Engine rebuilds, transmission overhauls, brake system overhauls, suspension and steering system replacements.
Component Replacement:
Step-by-step instructions for replacing individual parts within all covered systems.
Torque Specifications:
Detailed torque values for critical fasteners across all vehicle systems.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Technical Depth
Depth Level:
Full Workshop Level - Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Image Resolution:
High-resolution scans suitable for printing, ensuring clear diagrams and text.
Binding Type
Binding Method:
N/A (Digital PDF Download)
Paper Type
Paper Quality:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6, SOHC (M30 family)
Engine Displacement Cc:
2494 cc
Engine Bore Stroke Mm:
84.0 mm x 75.0 mm
Performance
Horsepower Ps:
184 PS (approx. 181 bhp) @ 5800 rpm (Euro spec)
Torque Nm:
240 Nm (approx. 177 lb-ft) @ 4000 rpm (Euro spec)
Fuel System
Fuel Delivery:
Bosch L-Jetronic Fuel Injection
Fuel Type:
Unleaded Gasoline (Premium)
Technical Details
Compression Ratio:
9.0:1
Engine Management:
Digital Engine Management System (DME for later models/updates)
🔧 Transmission
Standard
Standard Transmission:
Getrag 260 5-speed Manual
Optional
Optional Transmission:
ZF 4HP22 4-speed Automatic
Features
Transmission Fluid Manual:
BMW ATF D2 (or equivalent spec)
Transmission Fluid Automatic:
BMW ATF Dexron II (or equivalent spec)
📐 Dimensions
Exterior
Length Mm:
4620 mm
Width Mm:
1700 mm
Height Mm:
1410 mm
Wheelbase Mm:
2795 mm
Weights
Curb Weight Kg:
1400-1500 kg (approx. depending on equipment)
Gross Vehicle Weight Rating Kg:
1975 kg
Wheel Bolt Pattern:
5x120 mm
🛡️ Safety Features
Ratings
Safety Ratings Era:
Modern crash testing standards were less standardized. However, BMWs of this era were known for robust construction.
Active Features
ABS:
Optional ABS (Anti-lock Braking System) available on later models and specific trims.
Passive Features
Seatbelts:
Three-point seatbelts with front seatbelt pretensioners.
Body Structure:
Reinforced passenger cell, energy-absorbing crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette player, optional CD player on later models. Speaker configurations varied by trim.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
Onboard Diagnostics:
Limited OBD-I or proprietary diagnostic connectors for basic engine management and fault codes.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
Every 10,000-15,000 km or annually.
Air Filter Replacement:
Every 20,000-30,000 km or as needed based on conditions.
Fuel Filter Replacement:
Every 40,000-60,000 km.
Spark Plug Replacement:
Every 40,000-60,000 km (depending on plug type).
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 15W-40 or 20W-50 (depending on climate and manufacturer recommendation, consult manual for exact specs).
Coolant Type:
BMW Blue/Green Antifreeze (Ethylene Glycol based) mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common E28 Issues:
Fuel injector seal leaks, coolant leaks (especially around thermostat housing and head gasket), starter solenoid issues, aging rubber bushings (suspension/exhaust), fuel pump reliability, ABS sensor failures (if equipped).
M30 Engine Considerations:
Can develop oil leaks from various seals (valve cover, oil pan, front main seal). Timing chain tensioner should be monitored. Valve stem seals can degrade over time, leading to oil consumption.
📚 Vehicle History
Brand Heritage
Bmw History Focus:
Founded in 1916, BMW established a reputation for building high-performance, premium automobiles known for their engineering and driving dynamics.
Model Evolution
E28 Predecessor:
The E28 succeeded the E12 5 Series and was itself succeeded by the E34 5 Series.
E28 Development:
Developed as an evolution of the E12, the E28 featured improved aerodynamics, a revised chassis for better handling, and updated styling.
Production
Production Years:
1981-1988
Manufacturing Locations:
Dingolfing, Germany; various CKD assembly plants worldwide.
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
The E28 5 Series was widely praised by automotive journalists for its driving dynamics, build quality, and sophisticated engineering, often appearing on 'best of' lists for its era.
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