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BMW 525 E28 Service Repair Workshop Manual 1981-1988
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🏷️ Basic Information Identification Make: BMW Model: 525 Chassis Code: E28 Production Years Covered: 1981-1988 👋 Introduction Market Position Historical Context: The BMW 525 E28 represented BMW's commitment to luxury,...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
525
Chassis Code:
E28
Production Years Covered:
1981-1988
👋 Introduction
Market Position
Historical Context:
The BMW 525 E28 represented BMW's commitment to luxury, performance, and engineering in the executive sedan segment during the 1980s.
Target Audience:
Enthusiasts, independent repair shops, and owners seeking to maintain and repair their E28 525 models.
Competitive Analysis
Segment:
Mid-size luxury sedan
Competitors:
Mercedes-Benz W123/W124, Audi 100/200, Volvo 240/740
Key Features
Brand Philosophy:
Sheer Driving Pleasure, advanced engineering, and quality construction.
Model Highlights:
Balanced chassis, powerful inline-six engines, driver-focused interior, robust build quality.
Manual Value Proposition
Quality Assurance:
Advertised as the 'Best Manual Available,' 'Complete Manual - No Missing Pages,' and 'Customer Satisfaction Guaranteed,' indicating a focus on quality and completeness.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English
Format:
Digital (likely PDF)
Completeness:
Complete, no missing pages
📖 Manual Coverage
Systems Covered
Engine:
M30 inline-six gasoline engines (e.g., M30B25)
Fuel System:
Bosch L-Jetronic fuel injection system
Ignition System:
Electronic ignition control
Cooling System:
Radiator, fan, thermostat, water pump
Exhaust System:
Catalytic converter (if applicable by market), mufflers, pipes
Transmission Manual:
Getrag 5-speed manual transmission (e.g., Getrag 265)
Transmission Automatic:
ZF 4-speed automatic transmission (e.g., ZF 4HP22)
Drivetrain:
Rear-wheel drive (RWD), driveshaft, differential
Suspension Front:
Independent suspension, MacPherson struts, control arms, anti-roll bar
Suspension Rear:
Independent trailing arm suspension, shock absorbers, coil springs
Steering:
Recirculating ball steering, power steering system
Brakes Front:
Ventilated discs, caliper specifications
Brakes Rear:
Solid discs, caliper specifications
Electrical System:
Wiring diagrams, fuse box layout, component testing
Lighting:
Headlights, taillights, interior lighting
HVAC:
Heating, ventilation, and air conditioning (A/C) system
Body And Frame:
Body panel removal/installation, structural components
Interior:
Trim panels, seats, dashboard components
Diagnostics:
Troubleshooting guides, fault codes (if applicable)
Procedures Included
Maintenance Routine:
Oil changes, filter replacements, fluid checks, belt inspections
Engine Overhaul:
Engine removal, disassembly, inspection, reassembly, torque specifications
Transmission Service:
Clutch replacement (manual), torque converter service (automatic), fluid changes
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, brake fluid bleeding
Suspension Component Replacement:
Strut and shock absorber replacement, ball joint service, bushing replacement
Steering System Repair:
Power steering pump and rack replacement, steering linkage service
Electrical Component Replacement:
Alternator, starter motor, battery, sensors, relays
Fuel System Troubleshooting:
Injector testing, fuel pump pressure checks, fuel filter replacement
Cooling System Repair:
Radiator replacement, thermostat testing, water pump service
HVAC System Service:
Compressor replacement, evaporator and condenser service, refrigerant charging
Body Repair:
Door hinge adjustment, panel alignment, minor dent repair guidance
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon faults
Technical Depth
Depth Level:
Comprehensive, from basic maintenance to major component overhaul
Diagnostic Capabilities:
Detailed diagnostic flowcharts and specifications for testing components
Rebuild Procedures:
In-depth instructions for rebuilding engines, transmissions, and other major systems
Specifications Inclusion:
Includes critical torque values, clearances, fluid capacities, and electrical resistance values
📊 Manual Specifications
File Format
File Type:
PDF (assumed)
Searchability:
Likely text-searchable for efficient information retrieval
Print Quality:
High-resolution scans, suitable for printing key sections or the entire manual
Print Quality
Image Clarity:
Clear diagrams, schematics, and photographs (if present in original)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M30B25
Configuration:
Inline 6-cylinder, DOHC (Dual Overhead Camshaft)
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84.0 mm x 75.0 mm
Compression Ratio:
8.8:1 (typical)
Power Output:
Approx. 150-155 hp (110-114 kW) at 5500-6000 rpm (depending on market and configuration)
Torque Output:
Approx. 205-210 Nm (151-155 lb-ft) at 3500-4000 rpm
Fuel System
Injection Type:
Bosch L-Jetronic electronic fuel injection
Fuel Type:
Unleaded Gasoline (premium recommended)
Ignition System
Ignition Type:
Electronic Ignition (Distributorless in later iterations of M30, but likely distributor for E28 generation)
Lubrication
Oil Type:
API SG or higher, SAE 15W-40 or 10W-40 recommended (refer to manual for specific BMW approvals)
Oil Capacity:
Approx. 5.7 Liters (6.0 US quarts) with filter change
🔧 Transmission
Standard
Manual Transmission:
Getrag 265 5-speed manual gearbox
Optional
Automatic Transmission:
ZF 4HP22 4-speed automatic transmission
Features
Clutch Type:
Single dry plate, hydraulically actuated
Manual Gear Ratios:
Close-ratio or standard (e.g., close-ratio 0.81:1 5th gear for highway cruising)
Automatic Features:
Lock-up torque converter, Sport/Economy mode selector
Fluid Specs
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (refer to manual for specific BMW approvals)
Automatic Transmission Fluid:
Dexron III (or equivalent ATF, refer to manual for specific BMW approval)
📐 Dimensions
Exterior
Length:
Approx. 4725 mm (186.0 in)
Width:
Approx. 1700 mm (66.9 in)
Height:
Approx. 1415 mm (55.7 in)
Wheelbase:
Approx. 2794 mm (110.0 in)
Weights
Curb Weight:
Approx. 1450-1550 kg (3197-3417 lbs) depending on transmission and options
Gross Vehicle Weight Rating:
Refer to vehicle data plate (typically around 2000 kg)
Cargo
Trunk Capacity:
Approx. 460 Liters (16.2 cu ft)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited formal crash test data from modern standards, but known for robust safety cage and build quality for its era.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on later models
Suspension Design:
Advanced independent suspension contributed to stability and handling
Passive Features
Airbags:
No driver or passenger airbags were standard; optional on very late models.
Seatbelts:
Three-point inertia-reel seatbelts in front and rear
Body Structure:
Reinforced passenger cell and crumple zones
💡 Technology Features
Infotainment
Audio System:
Original BMW Bavaria C series cassette/radio units. Upgrade options common.
Climate Control:
Manual climate control with optional automatic climate control on some models.
Driver Assistance
Cruise Control:
Optional cruise control system.
Trip Computer:
Optional onboard computer (check control) providing basic vehicle status information.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or USB were available. Basic antenna and speaker wiring.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 to 10,000 miles (12,000 to 16,000 km) or annually, whichever comes first. (Refer to manual for specific recommendations based on driving conditions.)
Spark Plug Replacement:
Approximately every 30,000 miles (48,000 km)
Coolant Flush:
Every 2 years or 30,000 miles (48,000 km)
Transmission Fluid Change:
Manual: Every 30,000-50,000 miles (48,000-80,000 km). Automatic: Every 30,000 miles (48,000 km) or as per manual. (Often overlooked, critical for longevity.)
Brake Fluid Flush:
Every 2 years (due to hygroscopic nature)
Fluid Specifications
Coolant Type:
BMW Blue or Green antifreeze (Ethylene Glycol based), typically a 50/50 mix with distilled water.
Power Steering Fluid:
ATF Dexron II or III (refer to manual for specific BMW approval)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual)
Known Issues
Engine Wear:
Oil leaks from valve cover gasket and oil pan gasket; potential head gasket issues if overheated.
Fuel System:
Clogged injectors, failing fuel pumps, and deteriorating fuel lines due to age.
Electrical:
Degraded wiring insulation, faulty relays, intermittent dashboard lights, failing alternator voltage regulator.
Suspension And Steering:
Worn control arm bushings, tie rod ends, and rear trailing arm bushings leading to vague steering and poor handling.
Cooling System:
Leaking radiator hoses, failing water pump, and brittle plastic expansion tanks.
Rust:
Common areas include wheel arches, rocker panels, and underbody due to age and environmental exposure.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused, performance-oriented luxury vehicles.
Model Evolution
E28 Introduction:
The E28 was the second generation of the BMW 5 Series, succeeding the E12 and preceding the E34. It marked a significant evolution in design and technology.
E28 Design:
Characterized by its crisp, angular styling penned by Claus Luthe, it offered a more aerodynamic and modern appearance than its predecessor.
Production
Production Dates:
1981-1988
Manufacturing Locations:
Mainly Dingolfing, Germany, with some assembly in other global locations.
E28 525 Significance:
The 525 served as a core model in the E28 lineup, balancing performance with luxury and a slightly more accessible price point than the larger-engined variants.
🏆 Awards & Recognition
Recognitions
Automotive Press:
The E28 generation was widely praised by automotive journalists for its driving dynamics, build quality, and refinement, often winning comparisons against its rivals.
Ratings
Owner Satisfaction:
The E28 is considered a benchmark for reliability and driver engagement by many long-term owners, often lauded for its classic BMW feel.
Certifications
Design Awards:
While specific design awards for the E28 might not be widely documented, its design contributed to BMW's growing reputation for sophisticated automotive styling.