Positioning:
The BMW E28 525i was a significant model in the executive sedan segment, known for its blend of performance, comfort, and build quality.
Competitors:
Competed against models like the Mercedes-Benz W123/W124 E-Class, Audi 100, and Jaguar XJ6.
Design Philosophy:
Emphasized driver engagement, balanced handling, and robust engineering, reflecting BMW's 'Ultimate Driving Machine' ethos.
Manual Purpose:
Provides comprehensive technical information for maintaining, diagnosing, and repairing the E28 525i to dealership standards.
Coverage:
Comprehensive workshop service and repair for BMW 525i E28 (1981-1988).
Page Count:
Estimated 1000+ pages (typical for comprehensive workshop manuals).
Type:
Professional Workshop Service & Repair Manual.
Format:
Downloadable (Digital Format, typically PDF).
Engine Systems:
Engine mechanical, fuel system (injection), ignition system, cooling system, lubrication system, exhaust system.
Drivetrain Systems:
Transmission (manual and automatic), clutch, driveshafts, differential, axles.
Suspension Steering:
Front and rear suspension, steering system, power steering.
Braking Systems:
Brake system components (discs, calipers, master cylinder), ABS (if equipped), parking brake.
Electrical Systems:
Wiring diagrams, battery, alternator, starter, lighting, instruments, control modules, fuses, relays.
Body Chassis:
Body panels, doors, windows, interior trim, chassis components, frame alignment.
Maintenance:
Routine maintenance procedures, lubrication, fluid changes, filter replacements, inspections.
Repair Rebuild:
Detailed repair and overhaul instructions for all major mechanical and electrical components.
Diagnostics Troubleshooting:
Diagnostic procedures, fault finding, troubleshooting guides, symptom-based repair advice.
Specifications Tolerances:
Tightening torques, clearances, alignment specifications, measurements.
Body Repair:
Includes procedures for bodywork, paint, and rust repair common to vehicles of this era.
Depth:
In-depth, professional-level coverage suitable for dealership technicians and experienced DIY mechanics.
Engine Rebuild:
Detailed procedures for engine disassembly, inspection, measurement, and reassembly.
Electrical Diagnostics:
Comprehensive wiring diagrams and troubleshooting guides for all electrical systems.
Engine Type:
M30B25 - Inline 6-cylinder, SOHC.
Displacement:
2.5 Liters (2494 cc).
Horsepower:
Approx. 150-170 hp (depending on market and specific configuration).
Torque:
Approx. 165-185 lb-ft (depending on market and specific configuration).
Acceleration:
0-60 mph in approximately 8.5-9.5 seconds (for manual transmission).
Injection System:
Bosch L-Jetronic or Motronic fuel injection.
Cooling Type:
Water-cooled, pressurized system.
Oil Capacity:
Approx. 5.7 Liters (6.0 US Quarts) with filter change.
ECU:
Bosch Motronic (later models) or L-Jetronic.
Transmission Type:
4-speed Getrag 260 manual transmission.
Transmission Type:
3-speed ZF 3HP22 automatic transmission.
Clutch Type:
Dry single-plate clutch.
Manual Transmission Fluid:
Dexron III ATF or equivalent (check specific manual for exact spec).
Automatic Transmission Fluid:
Dexron III ATF or equivalent (check specific manual for exact spec).
Length:
Approx. 4620 mm (181.9 in).
Width:
Approx. 1700 mm (66.9 in).
Height:
Approx. 1380 mm (54.3 in).
Wheelbase:
2795 mm (110.0 inches)
Track Width Front:
Approx. 1430 mm (56.3 inches)
Track Width Rear:
Approx. 1448 mm (57.0 inches)
Curb Weight:
Approx. 1400-1500 kg (3086-3307 lbs).
Gross Vehicle Weight:
Approx. 1900-2000 kg (4189-4409 lbs).
Wheelbase:
Approx. 2795 mm (110.0 in).
Crash Safety:
Good structural integrity for its era; specific crash test ratings are less common for this period but reflect robust construction.
Braking System:
Four-wheel disc brakes, ABS optional/standard on later models.
Seat Belts:
Three-point inertia reel seat belts.
Steering Column:
Collapsible steering column.
Audio System:
Factory installed AM/FM stereo cassette player, often with premium sound options (e.g., Bavaria).
Climate Control:
Manual or automatic climate control (ECC - Electronic Climate Control) on higher trims.
Cruise Control:
Available as an option or standard on some trims.
Early Features:
Limited by era; primary focus on mechanical and chassis technology.
Oil Change:
Typically every 5,000 - 10,000 miles or 6-12 months, depending on driving conditions (check manual for exact intervals).
Spark Plug Replacement:
Intervals vary; typically around 20,000-30,000 miles for standard plugs.
Timing Belt Chain:
M30 engines use a timing chain, which is designed for the life of the engine but may require tensioner checks.
Engine Oil Type:
API SG or higher, viscosity typically 10W-40 or 15W-50 (check manual for climate-specific recommendations).
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Problems:
Cooling system components (hoses, radiator, water pump), fuel accumulator issues, fuel injector seal leaks, door seal degradation, rear subframe mounting points, instrument cluster electronics.
Engine Management:
Idle control valve issues, MAF sensor (if applicable) calibration, distributor cap and rotor wear.
Electrical:
Corrosion in connectors, aging wiring insulation, headlight switch issues, central locking problems.
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused, high-performance luxury vehicles.
E28 Generation:
The E28 was the second generation of the BMW 5 Series, produced from 1981 to 1988. It evolved from the E12, featuring significant updates in styling, engineering, and technology.
Manufacturing Locations:
Primarily manufactured in Germany (Dingolfing plant).
