🏷️ Basic Information

Make:

BMW

Model:

525i

Year:

1982

Chassis Code:

E28

👋 Introduction

Market Position Era:

The BMW 5 Series (E28) in 1982 represented BMW's mid-size luxury sedan, competing with models from Mercedes-Benz (W123), Audi, and other European and American manufacturers. It was positioned as a driver-focused, technologically advanced, and well-engineered vehicle.

Competitive Analysis:

The E28 generation offered a blend of performance and comfort that appealed to a discerning buyer. Its inline-six engines were renowned for smoothness and durability. The 525i, in particular, offered a potent combination of performance and efficiency for its class.

Key Features Vehicle:

The 1982 BMW 525i (E28) featured BMW's characteristic build quality, sophisticated handling for its time, and a focus on driver engagement. It often included features like independent suspension, four-wheel disc brakes, and a refined interior.

Key Features Manual:

This workshop manual is essential for owners and technicians seeking to maintain and repair the E28 525i. Its comprehensive coverage ensures that virtually any aspect of the vehicle can be addressed, from routine checks to major overhauls.

📋 Manual Details

Covered Models:

BMW 525, 525i (E28 chassis)

Covered Engines:

All engines for 1982 BMW 525/525i

Covered Transmissions:

All transmission types (manual and automatic)

Covered Trims:

All trim levels

Page Count Estimate:

High (typical workshop manuals for this era are extensive, often 500+ pages)

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system (chain, tensioners, guides), lubrication system (oil pump, oil filter housing), cooling system (radiator, water pump, thermostat, hoses).

Fuel System:

Fuel injection system (Bosch L-Jetronic), fuel pump, fuel injectors, fuel pressure regulator, fuel filter, fuel lines, intake manifold, air flow meter.

Transmission Manual:

Clutch operation, clutch replacement, gearbox overhaul, gear selection mechanism, driveshafts, universal joints.

Transmission Automatic:

Automatic transmission (e.g., ZF 4HP22) operation, fluid checks, filter replacement, shift control, torque converter, potential troubleshooting of common issues.

Drivetrain:

Rear axle assembly, differential, half-shafts, wheel bearings.

Suspension:

Front suspension (MacPherson struts, control arms, sway bar), rear suspension (semi-trailing arms, shock absorbers, springs), bushings, ball joints.

Steering:

Power steering system, steering rack, tie rods, steering column, steering angle sensor (if applicable).

Brakes:

Front disc brakes (ventilated), rear disc brakes, brake hydraulic system, master cylinder, brake booster, ABS (if equipped), parking brake, brake fluid specifications.

Electrical System:

12V electrical system, battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior lights), horn.

Climate Control:

HVAC system, blower motor, heater core, A/C system components (compressor, condenser, evaporator - service procedures might be less detailed for A/C systems in early manuals), ventilation controls.

Body And Interior:

Body panel removal and installation, door mechanisms, window regulators, seat removal, dashboard disassembly, interior trim.

Body Electrical:

Power windows, power locks, central locking system, mirrors, instrument cluster, warning lights.

Ignition System:

Distributor, ignition coil, spark plugs, spark plug wires, ignition control module, timing adjustments.

Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flush, brake fluid replacement, differential fluid change, transmission fluid change, lubrication points, belt inspection and replacement.

Troubleshooting:

Diagnostic procedures for common starting issues, engine performance problems, electrical faults, braking system anomalies, transmission shifting issues.

Repair:

Detailed step-by-step repair instructions for all major mechanical and electrical components, including engine rebuild, transmission overhaul, suspension component replacement, brake caliper rebuilding.

Diagnostics:

Diagnostic charts, fault finding trees, component testing procedures, resistance and voltage checks.

Technical Depth:

Comprehensive, covering from routine maintenance to full engine and transmission rebuilds, including detailed torque specifications and clearance measurements.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Likely searchable, depending on the quality of the scan/OCR.

Print Quality Consideration:

Digital format allows for high-quality printing of individual pages or sections.

Binding Type Irrelevant:

N/A (Digital PDF format)

Paper Type Irrelevant:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

Inline 6-cylinder, SOHC (M30 engine family)

Engine Code:

M30B25

Displacement:

2.5 Liters (2494 cc)

Horsepower:

Approx. 150 hp (110 kW) at 5500 rpm (varied slightly by market and emissions controls)

Torque:

Approx. 167 lb-ft (227 Nm) at 3500 rpm (varied slightly)

Fuel Injection:

Bosch L-Jetronic (Lambda Sensor Control for emissions management)

Fuel Type:

Unleaded Gasoline

Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Cooling Type:

Liquid-cooled

🔧 Transmission

Standard Transmission:

4-speed Manual Transmission

Optional Transmission:

ZF 4HP22 4-speed Automatic Transmission

Clutch Type:

Single dry plate, hydraulically operated

Final Drive Ratio:

Typically around 3.45:1 (may vary slightly by transmission and market)

📐 Dimensions

Wheelbase:

Approximately 2770 mm (109.1 inches)

Length:

Approximately 4725 mm (186.0 inches)

Width:

Approximately 1700 mm (66.9 inches)

Height:

Approximately 1415 mm (55.7 inches)

Curb Weight:

Approx. 1450-1550 kg (3197-3417 lbs) depending on options and transmission

🛡️ Safety Features

Safety Ratings Era:

Safety standards and testing were less stringent in 1982 compared to modern vehicles. Official NCAP ratings were not yet established. However, the E28 was known for its robust chassis and driver-oriented safety features for its time.

Active Safety Features:

Four-wheel disc brakes, optional Anti-lock Braking System (ABS) available on some models/markets later in the E28 lifecycle, precise steering, stable chassis.

Passive Safety Features:

Reinforced passenger cell, energy-absorbing steering column, padded dashboard, seat belts (three-point in front, two-point in rear, with optional three-point in rear later), deep-set windshield.

💡 Technology Features

Infotainment System Era:

Basic for its time. Typically featured an AM/FM radio, often with a cassette player. Analog displays for speed, RPM, fuel, temperature. Manual climate controls.

Driver Assistance Features:

Limited by modern standards. Cruise control was an option on many models. ABS was an emerging technology and an optional feature.

Connectivity Features:

N/A. No integrated Bluetooth, USB, or cellular connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, whichever comes first. The manual will provide specific recommendations based on driving conditions.

Spark Plug Replacement Interval:

Approximately every 20,000-30,000 miles (32,000-48,000 km), depending on spark plug type and quality.

Timing Belt Or Chain Interval:

The M30 engine uses a timing chain, which is designed to last the life of the engine but requires periodic inspection for tensioner wear and guide condition. The manual will detail inspection intervals.

Engine Oil Specification:

API SF or SG, SAE 15W-40 or 20W-50 (depending on climate). BMW approved oils would be specified. Check manual for exact grades.

Coolant Specification:

Ethylene Glycol based antifreeze, mixed 50/50 with distilled water. BMW coolant (or equivalent conforming to BMW standards) recommended.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Manual:

GL-4 Gear Oil, SAE 75W-90 or 80W-90.

Transmission Fluid Automatic:

ATF Dexron II or III (check manual for specific ZF fluid specification for 4HP22).

Differential Fluid Specification:

Hypoid gear oil GL-5, SAE 80W-90.

Known Issues Common:

Rust (especially wheel arches, rocker panels, trunk lid), aging rubber components (hoses, bushings, mounts), potential fuel distributor issues on L-Jetronic, electrical connector corrosion, weak fuel pumps, differential seal leaks, worn shifter bushings.

Maintenance Importance:

Due to the age of these vehicles, adherence to the maintenance schedule outlined in the manual is critical for longevity and reliability.

📚 Vehicle History

Brand Heritage:

BMW, Bayerische Motoren Werke AG, has a long history of producing high-performance, luxury vehicles with a focus on driving dynamics and engineering excellence. The 'Ultimate Driving Machine' slogan was gaining traction during this period.

Model Evolution:

The E28 succeeded the E12 5 Series and introduced more advanced aerodynamics and technology. It was the first 5 Series generation to offer a diesel engine and an M version (the M535i and later the iconic M5).

Production Years E28:

1981-1988

Manufacturing Locations:

Mainly Dingolfing, Germany, with some assembly in other BMW facilities globally.

🏆 Awards & Recognition

Recognitions Era:

While specific awards for the 1982 525i might not be as widely documented as modern cars, the E28 generation was generally praised for its driving dynamics, build quality, and engineering. It contributed to BMW's reputation as a manufacturer of premium, sporty sedans.