🏷️ Basic Information Identification Make: BMW Model: 525i Generation: E28 Codes Chassis Code: E28 Engine Code: M20B25 (2.5L Inline-6) 👋 Introduction Market Position Segment: Executive Sedan / Luxury Mid-size Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6, Volvo 740/760. Competitive Analysis Key Strengths: Renowned BMW driving dynamics, build quality, inline-six engine smoothness, sophisticated engineering for its era. Key Features Design Philosophy: The E28 generation represented a refinement of BMW's traditional 'Ultimate Driving Machine' ethos with improved aerodynamics and modern amenities. Manual Value Proposition: Essential for owners and technicians looking to maintain, repair, and restore the E28 525i, preserving its performance and longevity. 📋 Manual Details Coverage Areas Applicable Years: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988 Page Count Estimated Pages: Comprehensive (typically 500+ pages for this era) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing belt/chain, lubrication system, cooling system. Engine Management: Fuel injection (Bosch L-Jetronic/Motronic), ignition system, sensors (MAF, O2, coolant temp), troubleshooting, component testing. Transmission: Manual and Automatic transmission overhaul, clutch, driveshafts, differential. Suspension: Front and rear suspension, shock absorbers, springs, bushings, control arms, steering linkage. Brakes: Front and rear brake systems (discs), hydraulic lines, master cylinder, calipers, ABS (if equipped), bleeding procedures. Electrical: Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, power windows, door locks, instrument cluster. Body And Chassis: Body panel removal/installation, interior trim, bumpers, glass, seals, frame alignment (basic). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plugs, coolant flushes, brake fluid changes. Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD I era). Repair: Step-by-step repair instructions for all major systems. Rebuilds: Engine and transmission overhaul procedures with detailed component specifications. Adjustments: Valve adjustments, idle speed adjustments, timing adjustments. Technical Depth Depth: Comprehensive, from basic maintenance to full mechanical rebuilds and advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Quality: High-resolution scanned pages for clear text and diagrams. Binding Type Binding: N/A (Downloadable PDF) Paper Type Paper: N/A (Downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-6 Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 8.5:1 (typical) Performance Horsepower: 168 hp @ 5800 rpm (approx.) Torque: 164 lb-ft @ 4000 rpm (approx.) Fuel System Fuel Delivery: Bosch L-Jetronic or Motronic electronic fuel injection Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Cooling System Coolant Type: BMW recommends BMW Coolant/Antifreeze or equivalent ethylene glycol-based with corrosion inhibitors. (Refer to manual for specific BMW part number) Lubrication System Oil Capacity: Approximately 5.5 Liters (5.8 US Quarts) with filter change. Recommended Oil Viscosity: SAE 20W-50 or 15W-40 depending on climate (Refer to manual for specific API service classification and BMW LL-XX approval codes). Timing System Timing Drive: Timing Chain 🔧 Transmission Standard Type: Getrag 260 5-speed Manual Transmission Optional Type: ZF 4HP22 4-speed Automatic Transmission Manual Transmission Fluid Fluid Type: GL-4 or GL-5 Manual Transmission Fluid (refer to manual for specific viscosity and BMW approval). Automatic Transmission Fluid Fluid Type: Dexron III / Mercon or equivalent (refer to manual for specific BMW approval and capacity). Features Clutch: Hydraulically actuated single dry plate clutch. 📐 Dimensions Exterior Length: 4,725 mm (186.0 in) Width: 1,700 mm (66.9 in) Height: 1,415 mm (55.7 in) Wheelbase: 2,794 mm (110.0 in) Weights Curb Weight: Approximately 1,450 kg (3,200 lbs) Tires Standard Front: 205/60 VR 14 Standard Rear: 205/60 VR 14 Wheels Bolt Pattern: 5 x 120 mm Center Bore: 72.5 mm 🛡️ Safety Features Ratings NHTSA Front Impact: Not rated by modern standards (1980s era vehicle). IIHS Crash Tests: Not rated by modern standards (1980s era vehicle). Active Features ABS: Optional Anti-lock Braking System (ABS) Passive Features Airbags: Driver airbag became standard in later years of the E28 production. Passenger airbag not generally available on this model. Seatbelts: 3-point inertia-reel seatbelts with pretensioners (driver/front passenger). Chassis Design: Unitized steel body with crumple zones. 💡 Technology Features Infotainment Audio System: Factory fitted cassette player with AM/FM radio, optional CD changer. Climate Control: Manual or optional automatic climate control system. Driver Assistance Cruise Control: Standard cruise control system. Connectivity Diagnostics Port: Early OBD I system, accessed via diagnostic connector under the hood or dash (refer to manual for location and procedure). 🔧 Maintenance Service Intervals Oil Change: Every 7,500 - 10,000 miles or 12 months, whichever comes first (depending on driving conditions). Spark Plugs: Inspect every 15,000 miles, replace as needed (recommend high-quality platinum or iridium plugs, e.g., Bosch W8AC or equivalent). Coolant Flush: Every 2 years or 30,000 miles. Brake Fluid: Flush and replace every 2 years. Fluid Specifications Power Steering Fluid: BMW Power Steering Fluid or ATF Dexron III / Mercon (Refer to manual...