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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete overhaul, diagnosis, repair of M30B28 engine (cylinders, pistons, crankshaft, camshaft, valves, timing system, lubrication, cooling)
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Engine Management And Fuel:
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L-Jetronic fuel injection system (injectors, fuel pump, pressure regulator, sensors), ignition system (coil, distributor, spark plugs), emissions control
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Transmission Manual:
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Diagnosis, repair, and overhaul of Getrag 260 5-speed manual transmission, clutch system
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Transmission Automatic:
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Diagnosis, repair, and overhaul of ZF 4HP22 automatic transmission (if applicable to specific 528i variants)
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Drivetrain:
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Driveshaft, universal joints, differential, rear axle, wheel bearings
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Suspension:
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Front MacPherson struts, rear semi-trailing arm suspension, springs, shock absorbers, control arms, bushings, sway bars
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Steering:
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Power steering system (pump, gearbox, hoses), steering column, tie rods
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Brakes:
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Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), master cylinder, brake lines, parking brake system
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Electrical System:
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12V electrical system, battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting (headlights, taillights, interior), instrumentation, warning lights
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Body And Chassis:
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Body construction, body panels, doors, windows, sunroof, interior trim, corrosion protection, chassis components
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Heating Ventilation And Air Conditioning:
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HVAC system operation, diagnosis, repair of blower motor, heater core, A/C compressor, refrigerant system, climate controls
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Fuel Tank And Exhaust:
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Fuel tank, fuel lines, exhaust system (manifold, catalytic converter, mufflers), emissions components
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Procedures Included
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Routine Maintenance:
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Oil change, filter replacement, fluid checks and changes (coolant, brake fluid, power steering fluid), spark plug replacement, air filter replacement, belt inspection and replacement
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Troubleshooting:
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Diagnostic procedures for common problems, symptom-based troubleshooting charts, error code interpretation (if applicable)
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Component Removal And Installation:
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Step-by-step instructions for removing and installing virtually every major and minor component of the vehicle
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Engine Rebuilding:
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Detailed procedures for engine disassembly, inspection, measurement, machining, and reassembly
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Transmission Overhaul:
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Complete breakdown and reassembly instructions for both manual and automatic transmissions
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Brake System Service:
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Pad and rotor replacement, caliper service, bleeding the brake system, master cylinder replacement
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Electrical Diagnosis And Repair:
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Reading and interpreting wiring diagrams, tracing electrical faults, component testing
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Suspension And Steering Alignment:
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Inspection and adjustment procedures for wheel alignment parameters
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Bodywork And Cosmetic Repair:
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Minor body panel repairs, door adjustment, glass replacement (likely limited scope for body panels)
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Technical Depth
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Depth Of Information:
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Factory-level technical detail, suitable for professional technicians and serious DIY enthusiasts
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Diagnostic Capabilities:
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Extensive diagnostic information, including fault codes, sensor data interpretation, and systematic troubleshooting approaches
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Specification Data:
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Includes torque specifications, clearances, tolerances, fluid capacities, and electrical resistance values
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Diagrams And Illustrations:
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Richly illustrated with exploded views, detailed diagrams of systems and components, and wiring schematics
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, whichever comes first, using synthetic oil is recommended.
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Coolant Flush Interval:
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Every 2 years or 30,000 miles (48,000 km)
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Brake Fluid Flush Interval:
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Every 2 years
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Fluid Specifications
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Engine Oil Type:
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API SG/SH or higher, SAE 10W-40 or 15W-50 (depending on climate). Check manual for specific viscosity recommendations.
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Engine Oil Capacity:
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Approx. 6.5 liters (6.9 US quarts) with filter change
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Coolant Type:
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BMW Blue Antifreeze/Coolant (Glysantin G48 equivalent) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Dilution 50/50 with distilled water.
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Power Steering Fluid Type:
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ATF Dexron II (or equivalent)
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Manual Transmission Fluid Type:
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SAE 75W-90 synthetic gear oil (GL-4 rated)
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Automatic Transmission Fluid Type:
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ATF Dexron II (or equivalent)
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Differential Fluid Type:
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SAE 80W-90 gear oil (GL-5 rated)
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Known Issues
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Common Issues Engine:
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Oil leaks (valve cover gasket, oil pan gasket), cooling system degradation (radiator, hoses, water pump), vacuum hose deterioration leading to idle issues, fuel distributor issues on L-Jetronic
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Common Issues Suspension:
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Worn front control arm bushings, worn rear trailing arm bushings, shock absorber degradation
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Common Issues Electrical:
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Corroded grounds, failing alternator, aging wiring harnesses, instrument cluster issues, headlight switch failure
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Common Issues Body:
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Rust in common areas like rocker panels, wheel arches, and jacking points
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