Market Positioning:
The E28 generation BMW 5 Series represented a refined evolution of BMW's executive sedan. The M5 variant, in particular, solidified BMW's reputation for creating potent performance sedans, bridging the gap between luxury and motorsport heritage. The available models catered to a range of preferences, from fuel-efficient diesels to potent six-cylinder gasoline engines.
Competitors:
Competed against other premium European sedans like Mercedes-Benz E-Class (W124), Audi 100/200, and Jaguar XJ.
Key Selling Points:
Renowned for its superior handling dynamics, powerful inline-six engines, solid build quality, and driver-focused cockpit. The M5 variant offered supercar-level performance in a sedan package.
Applicable Models:
BMW M5, 528e, 524TD, 533i, 535i
Engine Variants Covered:
BMW 528e, BMW 524TD, BMW 533i, BMW 535i
Manual Type:
Workshop Service Repair Manual
Print Capability:
Printable (selected pages or whole manual)
Engine And Related Systems:
Engine overhaul, maintenance, fuel system, fuel tank and lines, radiator, exhaust system, engine electrical equipment
Drivetrain:
Clutch, manual transmission (Getrag 260, Getrag 265/6), automatic transmission (3 HP-22, 4 HP-22), gearshift mechanism, propeller shaft
Suspension And Steering:
Front axle, rear axle, steering and wheel alignment
Brakes And Wheels:
Brakes, pedals, wheel and tires
Body And Interior:
Body, body equipment, seats, hood, sunroof, body cavity sealing and undercoating
Electrical And Accessories:
Electrical system, instruments, lights, heating and air conditioning, radio and special equipment, equipment and accessories for body
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, inspections
Diagnostic Procedures:
Troubleshooting guides, diagnostic flowcharts
Repair Procedures:
Step-by-step repair instructions for all major systems
Rebuild Procedures:
Comprehensive rebuild procedures for engines and transmissions
Depth Of Coverage:
Detailed and complete step-by-step written procedures with pictures and diagrams. Equivalent to factory technician manual.
Illustrations:
Detailed exploded views, diagrams, and pictures
Engine Type:
Inline-6 Cylinder Petrol
528E Engine:
M20B27 'Eta' (Economy) engine, 2.7L, known for smooth power delivery and efficiency. Typically produced around 121-127 hp depending on market and specific configuration.
524Td Engine:
M21D24 2.4L Turbocharged Diesel engine, offering good torque and fuel economy. Typically produced around 115 hp.
533I Engine:
M30B32 3.2L Inline-6 Petrol engine. A robust and powerful engine, typically producing around 189 hp.
535I Engine:
M30B34 3.4L Inline-6 Petrol engine. The most powerful of the standard gasoline engines, typically producing around 211 hp.
M5 Engine:
S38B35 3.5L Inline-6 Motorsport engine. Hand-built, motorsport-derived engine producing approximately 286 hp (DIN) or 256 hp (SAE), featuring individual throttle bodies for enhanced performance.
Fuel Delivery:
Bosch L-Jetronic or Motronic fuel injection system (depending on engine variant and year), with specific ECU and injector configurations.
Manual Transmission Options:
Getrag 260 (5-speed) and Getrag 265/6 (5-speed, typically found in M5 and some high-performance variants). Known for their precise shift feel and durability.
Automatic Transmission Options:
ZF 3 HP-22 (3-speed) and ZF 4 HP-22 (4-speed). Robust and reliable automatic transmissions for a smoother driving experience.
Clutch Type:
Single dry plate, hydraulically actuated.
Wheelbase:
Approx. 103.5 inches (2629 mm) - may vary slightly between models.
Length:
Approx. 188.2 inches (4780 mm) - may vary slightly.
Width:
Approx. 68.1 inches (1730 mm).
Height:
Approx. 54.7 inches (1390 mm).
Curb Weight:
Ranges from approx. 3,100 lbs (1406 kg) for lighter models to over 3,600 lbs (1633 kg) for the M5.
Seat Belts:
Three-point inertia-reel seat belts for front and rear occupants.
Body Construction:
Reinforced passenger cell, crumple zones front and rear for impact energy absorption.
Braking System:
Four-wheel disc brakes (ventilated front, solid rear on most models). ABS (Anti-lock Braking System) became available and standard on some later E28 models, particularly the M5.
Steering System:
Power-assisted recirculating ball steering. Servotronic power steering (speed-sensitive) was an option on some models.
Audio System:
Factory-installed cassette or radio systems, often with premium speaker options. Aftermarket upgrades are common.
ABS:
Anti-lock Braking System (ABS) was an option and later standard on some E28s, significantly improving braking control.
Power Accessories:
Power windows, power locks, power mirrors, cruise control were available as options or standard on higher trims.
HVAC System:
Manual or automatic climate control (air conditioning and heating) was a key feature for passenger comfort.
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions and oil used. Manual will provide specific recommendations.
Coolant Flush Interval:
Recommended every 2-3 years or as per manual instructions.
Spark Plug Replacement:
Varies by engine, typically 30,000-60,000 miles for standard spark plugs. Manual will list specific types and intervals.
Engine Oil Type:
Varies by engine and climate. Common recommendations include SAE 15W-40, 10W-40, or 20W-50. Manual will specify exact API service classification and viscosity grade (e.g., API SG or SF).
Coolant Type:
Ethylene glycol-based coolant. Manual will specify the correct mix ratio and BMW-approved coolant type.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (viscosity typically 75W-90 or 80W-90) for manual transmissions. Manual will specify exact type and capacity.
Transmission Fluid Automatic:
Dexron II or equivalent ATF fluid for automatic transmissions. Manual will specify the exact type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify the correct type and replacement interval.
Common E28 Issues:
Rust (wheel arches, rocker panels, door bottoms), cooling system leaks (hoses, water pump, radiator), fuel pump failures, vacuum leaks causing rough idle, differential seal leaks, front suspension bushings wear, seized sunroof mechanisms, and potential for head gasket issues on higher mileage engines.
M5 Specific Issues:
S38 engine can be prone to valve guide wear and timing chain issues if not properly maintained. Clutch and transmission wear can be accelerated by spirited driving.
Bmw Heritage:
BMW, founded in 1916, has a rich history in aircraft engine manufacturing, transitioning to motorcycles and then automobiles. Known for its 'Ultimate Driving Machine' philosophy, emphasizing performance, engineering, and driver engagement.
E28 Evolution:
The E28 succeeded the E12 5 Series and introduced a more modern, aerodynamic design. It was BMW's first 5 Series to offer a diesel engine and the first to feature the iconic M5 performance variant.
E28 Production Timeline:
Produced from 1981 to 1988. The specific models covered in this manual (528e, 524TD, 533i, 535i, and M5) were prominent during the 1985-1988 period.
M5 Significance:
The E28 M5 (S38 engine) is considered a legendary model, a homologation special built for racing regulations, blending everyday usability with track-ready performance.
