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BMW 5 series E28 Service Repair Manual Workshop

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Code: E28 Codes Chassis Code: E28 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, BMW owners Competitive Analysis Value Proposition: Provides OEM-level information at a fraction of the cost of professional dealership service Key Features Accessibility: Instant download, printable format, cross-platform compatibility Completeness: Most comprehensive OEM manual available for the E28 generation 📋 Manual Details Coverage Areas Engine Coverage: All gasoline engines for E28 chassis Transmission Coverage: Manual and Automatic transmissions Chassis Coverage: Suspension, Steering, Brakes, Body structure Electrical Coverage: Wiring diagrams, ECU diagnostics, lighting, accessories Page Count Estimated Page Count: Approximately 1000+ Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, lubrication, cooling Engine Management: Fuel injection systems (K-Jetronic, L-Jetronic variants), ignition systems, emission controls Transmission Drivetrain: Clutch, gearbox disassembly/assembly, differential, driveshafts Suspension Steering: Front/rear suspension components, shock absorbers, springs, steering rack, power steering Brake System: Brake pad/disc replacement, hydraulic system, ABS (if equipped), parking brake Body Interior: Body panel removal/installation, interior trim, seats, glass, doors, locks Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, fluid checks and changes, belt replacement Repair Procedures: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds Diagnostic Procedures: Troubleshooting common faults, diagnostic trouble codes (where applicable), electrical system testing Component Replacement: Detailed instructions for replacing virtually all wear and tear items and major components Technical Depth Diagnostic Capabilities: Advanced diagnostics, including component testing and system troubleshooting Rebuild Instructions: Comprehensive step-by-step instructions for rebuilding engines, transmissions, and major assemblies Specification Detail: Torque specifications, clearances, timing settings, fluid capacities, and other critical data 📊 Manual Specifications File Format Print Quality: High-resolution, suitable for printing all pages Searchability: Fully searchable text content for quick information retrieval Print Quality Illustrations Quality: Clear, detailed diagrams and photographs Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Variants Covered: M20 (2.0L, 2.3L, 2.5L, 2.7L eta), M30 (3.2L, 3.5L) Performance Typical Horsepower Range: 120 HP to 215 HP (depending on engine variant) Typical Torque Range: 180 Nm to 300 Nm (depending on engine variant) Fuel System Fuel Injection Systems: Bosch K-Jetronic (CIS), Bosch L-Jetronic (EFI), Bosch Motronic Ignition System: Electronic ignition, distributor-based systems 🔧 Transmission Standard Standard Transmission Type: Getrag 5-speed manual (e.g., 260/5, 265/5) Optional Optional Transmission Type: ZF 3-speed or 4-speed automatic (e.g., 3HP22, 4HP22) Features Clutch Type: Single dry plate, hydraulic actuation 📐 Dimensions Exterior Wheelbase: Approx. 2,795 mm (110.0 inches) Length: Approx. 4,620 mm (181.9 inches) Width: Approx. 1,700 mm (66.9 inches) Height: Approx. 1,415 mm (55.7 inches) Weights Curb Weight: Approx. 1,300 - 1,500 kg (2,866 - 3,307 lbs), depending on model and options 🛡️ Safety Features Ratings Crash Test Information: While official NHTSA/Euro NCAP ratings for this era are less detailed, E28 was built to high German safety standards of the time. Active Features ABS Availability: Optional on many models, standard on later high-performance variants (e.g., M5) Passive Features Seatbelts: Front 3-point inertia reel seatbelts, rear lap and diagonal belts Body Structure: Reinforced passenger cell, crumple zones 💡 Technology Features Infotainment Radio Options: Aftermarket head units commonly installed, original BMW Bavaria C or similar cassette/radio units available Speaker System: Standard 2-way or 4-way speaker configurations Driver Assistance Cruise Control: Optional feature on many models Connectivity Early Tech Features: Power windows, central locking, electric sunroof (optional), trip computer (optional on some models) 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500 - 15,000 miles (12,000 - 24,000 km) or annually, depending on oil type and driving conditions. Timing Belt Service: M20 and M30 engines use timing chains, not belts. Fluid Specifications Engine Oil Type: API SG/SH or ACEA A2-96, viscosity SAE 10W-40 or 15W-40 (check specific engine and climate) Coolant Type: BMW antifreeze/coolant concentrate, mixed 1:1 with distilled water (typically ethylene glycol based) Brake Fluid Type: DOT 3 or DOT 4 brake fluid Transmission Fluid Manual: API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 Transmission Fluid Automatic: Dexron-II or equivalent (e.g., ATF Type 7045E/LT71141 for later models) Known Issues Common Problems Engine: Oil leaks (valve cover, oil pan), cooling system component failure (water pump, thermostat), fuel distributor issues (K-Jetronic), starter solenoid failure Common Problems Electrical: Instrument cluster issues (e.g., tachometer, fuel gauge), wiring harness degradation, headlight switch failure Common Problems Chassis: Bushings wear (control arms, subframe), strut mount failure, brake wear, rust (especially in wheel arches, rocker panels) 📚 Vehicle History Brand Heritage Bmw Legacy: Continuation of BMW's reputation for luxury, performance, and engineering excellence in the executive sedan segment. Model Evolution Predecessor: BMW E12 (First generation 5 Series) Successor: BMW E34 (Third generation 5 Series) Production Production Years: 1981–1987...
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BMW 5 series E28 Service Repair Manual Workshop
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Code:
E28
Codes
Chassis Code:
E28
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent repair shops, BMW owners
Competitive Analysis
Value Proposition:
Provides OEM-level information at a fraction of the cost of professional dealership service
Key Features
Accessibility:
Instant download, printable format, cross-platform compatibility
Completeness:
Most comprehensive OEM manual available for the E28 generation
📋 Manual Details
Coverage Areas
Engine Coverage:
All gasoline engines for E28 chassis
Transmission Coverage:
Manual and Automatic transmissions
Chassis Coverage:
Suspension, Steering, Brakes, Body structure
Electrical Coverage:
Wiring diagrams, ECU diagnostics, lighting, accessories
Page Count
Estimated Page Count:
Approximately 1000+
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, lubrication, cooling
Engine Management:
Fuel injection systems (K-Jetronic, L-Jetronic variants), ignition systems, emission controls
Transmission Drivetrain:
Clutch, gearbox disassembly/assembly, differential, driveshafts
Suspension Steering:
Front/rear suspension components, shock absorbers, springs, steering rack, power steering
Brake System:
Brake pad/disc replacement, hydraulic system, ABS (if equipped), parking brake
Body Interior:
Body panel removal/installation, interior trim, seats, glass, doors, locks
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, fluid checks and changes, belt replacement
Repair Procedures:
Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds
Diagnostic Procedures:
Troubleshooting common faults, diagnostic trouble codes (where applicable), electrical system testing
Component Replacement:
Detailed instructions for replacing virtually all wear and tear items and major components
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, including component testing and system troubleshooting
Rebuild Instructions:
Comprehensive step-by-step instructions for rebuilding engines, transmissions, and major assemblies
Specification Detail:
Torque specifications, clearances, timing settings, fluid capacities, and other critical data
📊 Manual Specifications
File Format
Print Quality:
High-resolution, suitable for printing all pages
Searchability:
Fully searchable text content for quick information retrieval
Print Quality
Illustrations Quality:
Clear, detailed diagrams and photographs
Binding Type
Binding Type Digital:
N/A (Digital Download)
Paper Type
Paper Type Digital:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Variants Covered:
M20 (2.0L, 2.3L, 2.5L, 2.7L eta), M30 (3.2L, 3.5L)
Performance
Typical Horsepower Range:
120 HP to 215 HP (depending on engine variant)
Typical Torque Range:
180 Nm to 300 Nm (depending on engine variant)
Fuel System
Fuel Injection Systems:
Bosch K-Jetronic (CIS), Bosch L-Jetronic (EFI), Bosch Motronic
Ignition System:
Electronic ignition, distributor-based systems
🔧 Transmission
Standard
Standard Transmission Type:
Getrag 5-speed manual (e.g., 260/5, 265/5)
Optional
Optional Transmission Type:
ZF 3-speed or 4-speed automatic (e.g., 3HP22, 4HP22)
Features
Clutch Type:
Single dry plate, hydraulic actuation
📐 Dimensions
Exterior
Wheelbase:
Approx. 2,795 mm (110.0 inches)
Length:
Approx. 4,620 mm (181.9 inches)
Width:
Approx. 1,700 mm (66.9 inches)
Height:
Approx. 1,415 mm (55.7 inches)
Weights
Curb Weight:
Approx. 1,300 - 1,500 kg (2,866 - 3,307 lbs), depending on model and options
🛡️ Safety Features
Ratings
Crash Test Information:
While official NHTSA/Euro NCAP ratings for this era are less detailed, E28 was built to high German safety standards of the time.
Active Features
ABS Availability:
Optional on many models, standard on later high-performance variants (e.g., M5)
Passive Features
Seatbelts:
Front 3-point inertia reel seatbelts, rear lap and diagonal belts
Body Structure:
Reinforced passenger cell, crumple zones
💡 Technology Features
Infotainment
Radio Options:
Aftermarket head units commonly installed, original BMW Bavaria C or similar cassette/radio units available
Speaker System:
Standard 2-way or 4-way speaker configurations
Driver Assistance
Cruise Control:
Optional feature on many models
Connectivity
Early Tech Features:
Power windows, central locking, electric sunroof (optional), trip computer (optional on some models)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 - 15,000 miles (12,000 - 24,000 km) or annually, depending on oil type and driving conditions.
Timing Belt Service:
M20 and M30 engines use timing chains, not belts.
Fluid Specifications
Engine Oil Type:
API SG/SH or ACEA A2-96, viscosity SAE 10W-40 or 15W-40 (check specific engine and climate)
Coolant Type:
BMW antifreeze/coolant concentrate, mixed 1:1 with distilled water (typically ethylene glycol based)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90
Transmission Fluid Automatic:
Dexron-II or equivalent (e.g., ATF Type 7045E/LT71141 for later models)
Known Issues
Common Problems Engine:
Oil leaks (valve cover, oil pan), cooling system component failure (water pump, thermostat), fuel distributor issues (K-Jetronic), starter solenoid failure
Common Problems Electrical:
Instrument cluster issues (e.g., tachometer, fuel gauge), wiring harness degradation, headlight switch failure
Common Problems Chassis:
Bushings wear (control arms, subframe), strut mount failure, brake wear, rust (especially in wheel arches, rocker panels)
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Continuation of BMW's reputation for luxury, performance, and engineering excellence in the executive sedan segment.
Model Evolution
Predecessor:
BMW E12 (First generation 5 Series)
Successor:
BMW E34 (Third generation 5 Series)
Production
Production Years:
1981–1987 (Model years 1982-1988)
Assembly Locations:
Dingolfing, Germany; various CKD assembly plants globally
Notable Variants:
518i, 520i, 524d, 524td, 525e, 525i, 528i, 533i, 535i, M535i, M5 (E28 S38)
🏆 Awards & Recognition
Recognitions
Automotive Press Acclaim:
Widely praised by automotive press for its driving dynamics, build quality, and sporty luxury appeal of its era.
Ratings
Reliability Perception:
Generally considered a reliable vehicle with proper maintenance; however, age-related issues are common.
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