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BMW 525 525i 1981-1988 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: BMW Model: 525i Chassis Code: E28 Generation Generation Name: Second Generation E28 Generation Years: 1981-1988 Codes Engine Codes Covered: M30B25 (primarily) 👋 Introduction Market Position...
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类型: Car
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BMW 525 525i 1981-1988 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
BMW
Model:
525i
Chassis Code:
E28
Generation
Generation Name:
Second Generation E28
Generation Years:
1981-1988
Codes
Engine Codes Covered:
M30B25 (primarily)
👋 Introduction
Market Position
Market Segment:
Executive sedan, luxury sport sedan
Key Selling Points:
Driving dynamics, build quality, performance, luxury features, reputation for longevity.
Competitive Analysis
Primary Competitors:
Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, Volvo 740/760.
Key Features
Vehicle Philosophy:
'The Ultimate Driving Machine' – emphasis on performance, handling, and driver engagement.
Design Era:
Modern classic design, characterized by clean lines and functional aesthetics.
📋 Manual Details
Coverage Areas
Primary Coverage:
BMW 525i and 525 models (North American specifications where applicable)
Secondary Coverage:
General E28 chassis components applicable across various engine variants
Page Count
Page Count:
227
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system, engine assembly/disassembly.
Fuel System:
Fuel injection system (Bosch L-Jetronic/Motronic), fuel pump, injectors, fuel lines, fuel pressure regulator, fuel tank.
Ignition System:
Ignition coil, distributor, spark plugs, ignition timing, electronic ignition control.
Transmission:
Manual gearbox (Getrag 260) and automatic gearbox (ZF 4HP22) repair, removal/installation, fluid specifications, and troubleshooting.
Drivetrain:
Clutch, driveshaft, universal joints, differential, rear axle assembly, wheel bearings.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering knuckles, wheel alignment specifications.
Steering:
Power steering system, steering rack, steering column, steering linkage, hydraulic pump and hoses.
Brakes:
Front and rear disc brakes, brake calipers, master cylinder, brake lines, brake fluid specifications, ABS (if equipped), parking brake.
Electrical System:
Battery, charging system (alternator, regulator), starting system (starter motor), lighting systems, dashboard instrumentation, wiring diagrams, fuses, relays.
Body And Chassis:
Body panel removal/installation, doors, hood, trunk lid, bumpers, glass replacement, rust repair, chassis lubrication.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant types, service procedures.
Interior:
Seat removal/installation, interior trim, dashboard removal, headliner.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections.
Troubleshooting:
Diagnostic charts, common problems and solutions, symptom-based troubleshooting for various systems.
Repair And Overhaul:
Detailed step-by-step instructions for component repair, rebuilding, and replacement.
Diagnostics:
Basic diagnostic procedures for electrical and mechanical issues, including checking system pressures and resistances.
Installation Replacement:
Procedures for installing new or reconditioned parts and components.
Technical Depth
Depth Level:
Comprehensive, covering routine maintenance to major component overhauls and troubleshooting.
Detail Level:
Detailed technical procedures, torque specifications, clearances, and diagnostic data.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if scanned from a quality source, enabling quick access to specific information.
Print Quality
Print Quality:
Digital PDF format; print quality depends on the original source scan and user's printer.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6 Cylinder, Naturally Aspirated
Engine Code:
M30B25
Displacement:
2.5 Liters (2498 cc)
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
8.8:1 (typical)
Performance
Horsepower:
170 hp @ 5800 rpm (approximate, depending on market and specific tuning)
Torque:
210 Nm (155 lb-ft) @ 4000 rpm (approximate)
Fuel System
Fuel Delivery:
Bosch L-Jetronic or Motronic fuel injection
Fuel Type:
Unleaded Gasoline (Premium Octane Recommended)
Other
Engine Layout:
Front-engine, Rear-wheel drive
Valve Train:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
🔧 Transmission
Standard
Standard Transmission:
4-speed Manual (Getrag 260)
Optional
Optional Transmission:
3-speed Automatic (ZF 3HP22) or 4-speed Automatic (ZF 4HP22) later in production.
Features
Clutch Type:
Hydraulically actuated single dry plate clutch (manual transmission)
Rear Axle Ratio:
Typically 3.46:1 (manual) or 3.64:1 (automatic), can vary by market and options.
📐 Dimensions
Exterior
Length:
4620 mm (181.9 in)
Width:
1700 mm (66.9 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2795 mm (110.0 in)
Weights
Curb Weight:
Approximately 1450-1550 kg (3200-3400 lbs), depending on transmission and options.
🛡️ Safety Features
Ratings
Crash Test Results:
Data from this era is limited by modern standards; however, the E28 was known for its robust safety cage and good structural integrity for its time.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on later models.
Passive Features
Seatbelts:
Three-point seatbelts with front seatbelt tensioners (standard).
Head Restraints:
Adjustable front and rear head restraints.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional premium sound systems.
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control) on some models.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Check Control:
Advanced (for its time) Check Control system to monitor essential vehicle functions.
Connectivity
Connectivity Features:
No modern connectivity features; primarily analog systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions.
Coolant Flush Interval:
Every 2 years or 30,000 miles (48,000 km).
Timing Belt Or Chain:
The M30 engine utilizes a timing chain, which is designed to last the life of the engine but may require tensioner replacement.
Fluid Specifications
Engine Oil:
API SG or SH, SAE 20W-50 or 15W-40 (check manual for specific recommendations based on climate).
Coolant:
BMW Blue Antifreeze/Coolant (G48) or equivalent, mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 synthetic gear oil.
Transmission Fluid Automatic:
Dexron III or equivalent ATF (Automatic Transmission Fluid).
Known Issues
Common Wear Items:
Control arm bushings, sway bar links, fuel injectors (clogging), coolant hoses, accumulator sphere (hydropneumatic suspension, if equipped on specific models).
Engine Specific Concerns:
Oil leaks from the front or rear main seals, valve cover gasket leaks, potential head gasket issues if overheated.
Electrical Gremlins:
Aging wiring harnesses, corroded grounds, and failing relays can cause intermittent electrical issues.
📚 Vehicle History
Brand Heritage
Bmw Heritage:
BMW's legacy of engineering excellence, performance, and driver-focused vehicles.
Model Evolution
E28 Development:
Successor to the E12, the E28 introduced more advanced engineering, improved aerodynamics, and a focus on refinement while retaining BMW's sporty character.
Production
Production Period:
1981-1988
Manufacturing Locations:
Germany (Dingolfing plant)
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
Consistently praised by automotive journalists for its driving dynamics, build quality, and performance during its production run.
Ratings
Longevity Reputation:
Recognized as a durable and long-lasting vehicle when properly maintained, a hallmark of BMW engineering.
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