BMW 528i 1981 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 1981 Codes Chassis Code: E28 Engine Code: M30B28 👋 Introduction Market Position Segment: Luxury Mid-size Sedan Era: Late 1970s / Early 1980s performance luxury Competitive Analysis Key Competitors: Mercedes-Benz W123, Audi 5000, Volvo 240, Cadillac Seville Key Features Performance Orientation: Known for its strong inline-six engine and sporty handling characteristics. Build Quality: Renowned BMW build quality and driver-focused ergonomics. Longevity: Designed for durability and long-term ownership. 📋 Manual Details Coverage Areas General Coverage: Complete service, repair, and maintenance for the 1981 BMW 528i (E28 chassis). Page Count Estimated Pages: 800+ Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, rebuild, cylinder head, block, pistons, crankshaft, camshaft, timing system, lubrication, cooling. Fuel System: Fuel injection system (Bosch L-Jetronic), fuel pump, injectors, fuel pressure regulator, fuel lines, fuel tank. Ignition System: Ignition coil, distributor, spark plugs, ignition timing, control unit. Exhaust System: Exhaust manifold, catalytic converter (if applicable for the market), muffler, pipes. Transmission Manual: Clutch operation, manual gearbox (Getrag 260), disassembly, assembly, fluid changes, common issues. Transmission Automatic: Automatic gearbox (ZF 4HP22), disassembly, assembly, fluid changes, torque converter, control systems. Drivetrain: Driveshafts, universal joints, differential, rear axle assembly, wheel bearings. Suspension Front: MacPherson struts, control arms, ball joints, sway bar, bushings, shock absorbers, springs. Suspension Rear: Independent rear suspension, trailing arms, shock absorbers, springs, sway bar, bushings. Steering System: Steering rack, power steering pump, fluid, steering column, tie rods, linkage. Brakes Front: Disc brakes, calipers, pads, rotors, brake lines, master cylinder. Brakes Rear: Disc brakes, calipers, pads, rotors, brake lines, parking brake mechanism. Wheels Tires: Wheel bolt patterns, tire sizes, pressure recommendations. Electrical System Overview: Wiring diagrams, fuse box locations, relay functions, battery, alternator, starter motor....

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code:

M30B28

👋 Introduction

Market Position

Segment:

Luxury Mid-size Sedan

Late 1970s / Early 1980s performance luxury

Competitive Analysis

Key Competitors:

Mercedes-Benz W123, Audi 5000, Volvo 240, Cadillac Seville

Key Features

Performance Orientation:

Known for its strong inline-six engine and sporty handling characteristics.

Build Quality:

Renowned BMW build quality and driver-focused ergonomics.

Longevity:

Designed for durability and long-term ownership.

📋 Manual Details

Coverage Areas

General Coverage:

Complete service, repair, and maintenance for the 1981 BMW 528i (E28 chassis).

Page Count

Estimated Pages:

Manual Type

Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, rebuild, cylinder head, block, pistons, crankshaft, camshaft, timing system, lubrication, cooling.

Fuel System:

Fuel injection system (Bosch L-Jetronic), fuel pump, injectors, fuel pressure regulator, fuel lines, fuel tank.

Ignition System:

Ignition coil, distributor, spark plugs, ignition timing, control unit.

Exhaust System:

Exhaust manifold, catalytic converter (if applicable for the market), muffler, pipes.

Transmission Manual:

Clutch operation, manual gearbox (Getrag 260), disassembly, assembly, fluid changes, common issues.

Transmission Automatic:

Automatic gearbox (ZF 4HP22), disassembly, assembly, fluid changes, torque converter, control systems.

Drivetrain:

Driveshafts, universal joints, differential, rear axle assembly, wheel bearings.

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar, bushings, shock absorbers, springs.

Suspension Rear:

Independent rear suspension, trailing arms, shock absorbers, springs, sway bar, bushings.

Steering System:

Steering rack, power steering pump, fluid, steering column, tie rods, linkage.

Brakes Front:

Disc brakes, calipers, pads, rotors, brake lines, master cylinder.

Brakes Rear:

Disc brakes, calipers, pads, rotors, brake lines, parking brake mechanism.

Wheels Tires:

Wheel bolt patterns, tire sizes, pressure recommendations.

Electrical System Overview:

Wiring diagrams, fuse box locations, relay functions, battery, alternator, starter motor.

Lighting System:

Headlights, taillights, turn signals, interior lighting, bulb types.

Instrument Panel:

Gauges, warning lights, speedometer, tachometer, fuel gauge, temperature gauge.

Comfort Systems:

HVAC (Heating, Ventilation, Air Conditioning) system, blower motor, heater core, A/C compressor, refrigerant.

Bodywork Exterior:

Body panel removal and installation, door mechanisms, hood, trunk, bumpers, trim.

Bodywork Interior:

Seat removal, dashboard disassembly, door panel removal, headliner, carpeting.

Glass Seals:

Windshield, side windows, rear window replacement, seals, weatherstripping.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid level checks, brake inspections.

Troubleshooting:

Diagnostic procedures for common problems, fault finding techniques, error code interpretation (where applicable).

Engine Repair:

Complete engine rebuild procedures, gasket replacement, seal replacement, component testing.

Transmission Repair:

Manual and automatic transmission overhaul, gear replacement, clutch replacement, torque converter replacement.

Brake Service:

Brake pad/shoe replacement, rotor replacement, caliper overhaul, brake bleeding.

Suspension Service:

Strut/shock replacement, control arm bushing replacement, ball joint replacement, alignment specifications.

Electrical Diagnostics:

Wiring harness testing, component testing, starter/alternator testing, fuse/relay troubleshooting.

Fuel System Service:

Fuel injector cleaning/testing, fuel pump testing, fuel pressure checks, fuel filter replacement.

HVAC Service:

Refrigerant system servicing, blower motor replacement, heater core replacement, control valve testing.

Body Panel Replacement:

Procedures for replacing doors, fenders, hood, trunk lid, and associated hardware.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine and transmission rebuilds).

Diagnostic Capability:

Detailed diagnostic information for mechanical, electrical, and fuel systems.

Torque Specifications:

Includes critical torque specifications for all major fasteners and components.

Wiring Diagrams:

Full set of detailed electrical wiring diagrams.

Illustrations:

Includes step-by-step illustrations and exploded views of components.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Resolution:

High-resolution scans for clarity and readability.

Searchability:

Fully searchable text content for quick information retrieval.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-6 Cylinder, SOHC

Displacement:

2.8 Liters (2788 cc)

Bore X Stroke:

86 mm x 80 mm

Compression Ratio:

8.1:1

Performance

Horsepower Net:

169 hp @ 5800 rpm

Torque Net:

175 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Bosch L-Jetronic Fuel Injection

Fuel Type:

Unleaded Gasoline

Lubrication

Oil Type:

SAE 20W-50 (recommended by BMW at the time for typical operating temperatures)

Oil Capacity:

6.5 Liters (approx. 6.9 US quarts) with filter

Cooling

Coolant Type:

50/50 mix of ethylene glycol and distilled water

Coolant Capacity:

11.5 Liters (approx. 12.2 US quarts)

🔧 Transmission

Standard

Transmission Type:

4-Speed Manual (Getrag 260)

Optional

Transmission Type:

3-Speed Automatic (ZF 4HP22)

Features

Manual Gear Ratios:

1st: 3.84, 2nd: 2.22, 3rd: 1.34, 4th: 1.00, Reverse: 3.15

Automatic Fluid Type:

Dexron III (or equivalent ATF)

Manual Fluid Type:

SAE 75W-90 or SAE 80W-90 GL-4 gear oil

📐 Dimensions

Exterior

Length:

4725 mm (186.0 inches)

Width:

1700 mm (66.9 inches)

Height:

1420 mm (55.9 inches)

Wheelbase:

2795 mm (110.0 inches)

Weights

Curb Weight:

1450 kg (approx. 3197 lbs)

Gross Vehicle Weight Rating:

1900 kg (approx. 4189 lbs)

🛡️ Safety Features

Ratings

Crash Safety:

NHTSA/IIHS ratings for this era are less standardized; focus on passive safety features.

Active Features

Optional on some models, but not standard on all 1981 528i.

Traction Control:

Not available

Passive Features

Seat Belts:

Three-point inertia-reel seat belts in front, lap belts in rear.

Steering Column:

Collapsible steering column for improved crash protection.

Body Structure:

Reinforced safety cage and crumple zones.

💡 Technology Features

Infotainment

Audio System:

Typically an AM/FM radio with cassette player; premium sound options available.

Climate Control:

Manual or optional automatic climate control.

Driver Assistance

Cruise Control:

Available

Power Windows:

Standard

Power Mirrors:

Available

Connectivity

Bluetooth:

Not available

Not available

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500-10,000 miles or 6-12 months, whichever comes first (using high-quality synthetic or semi-synthetic oil recommended).

Air Filter Replacement:

Every 15,000-20,000 miles or annually.

Spark Plug Replacement:

Every 20,000-30,000 miles (depending on plug type, typically copper core for this era).

Coolant Flush:

Every 24 months or 30,000 miles.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4

Power Steering Fluid:

ATF Dexron II or III (check specific vehicle manual, often Mercon compatible too)

Known Issues

Rust Prone Areas:

Wheel arches, rocker panels, rear valence, battery tray, strut towers.

Fuel Injector Seals:

Can degrade, leading to fuel leaks or rough idle.

Rear Main Seal:

Common leak point on higher mileage engines.

Cooling System:

Plastic coolant reservoir and hoses can become brittle; thermostat housing gasket can leak.

Electrical Connectors:

Corrosion on grounds and connectors can cause intermittent issues.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's continued commitment to performance, luxury, and engineering excellence.

Model Evolution

E28 Introduction:

The E28 generation replaced the E12 5 Series and was produced from 1981 to 1988. The 528i was a key model in this lineup.

528I Significance:

The 528i represented the balance of performance and luxury in the early E28 range, preceding the more powerful M535i and M5 models.

Production

Manufacturing Location:

Dingolfing, Germany

Production Years E28:

1981-1988

🏆 Awards & Recognition

Recognitions

Contemporary Reviews:

Consistently praised by automotive journalists of its time for its performance and luxury refinement.

Club Recognition:

Highly regarded by BMW enthusiast clubs as a classic and capable driver's car.

Certifications

Emissions Standards:

Compliant with emissions standards for 1981 regulations in target markets (e.g., US EPA).