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BMW 5 Series E28 E34 Digital Workshop Repair Manual 1981-91

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation E-Code Designation: E28 (1981-1988), E34 (1988-1996, with 1991 being the cutoff for this manual) Codes Applicable Years: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 👋 Introduction Market Position Target Audience: BMW enthusiasts, DIY mechanics, owners seeking to maintain or restore their E28 or E34 5 Series. Competitive Analysis Value Proposition: Provides professional-level repair information at a fraction of dealership service costs, enabling significant savings on maintenance and repairs. Key Features Comprehensiveness: Covers all diagnostic and repair procedures from A-Z for a wide range of models and engine variants within the E28 and E34 generations. Usability: Easy to use, view, and print specific procedures without requiring advanced computer skills. 📋 Manual Details Coverage Areas Geographic Coverage: Global (reflects common BMW specifications) Page Count Estimated Page Count: Likely several thousand pages (typical for comprehensive digital workshop manuals covering multiple models and years) Manual Type Type: Digital Workshop Repair Manual Language Language: English Format Format: Digital (likely PDF or similar, viewable and printable) 📖 Manual Coverage Systems Covered Mechanical Systems: Engine (M10, M20, M30, M88, S38, M50), Fuel System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission (ZF, Getrag), Drive Axles, Differential, Suspension (Front & Rear), Steering System, Braking System (ABS variations), Wheels & Tires Electrical Systems: Engine Management (Motronic variations), Ignition System, Fuel Injection, Lighting System, Instrumentation, Audio System, HVAC Controls, Power Accessories (windows, locks, mirrors), Body Electronics, Diagnostics (OBD-I) Procedures Included Maintenance Procedures: Oil Changes, Filter Replacements, Fluid Checks & Replenishments, Spark Plug Replacement, Belt Inspection & Replacement, Brake Pad & Rotor Service, Tire Rotation, Battery Service, Wiper Blade Replacement Repair & Rebuild Procedures: Engine Overhaul (top-end and full rebuild), Transmission Rebuild (manual and automatic), Clutch Replacement, Differential Overhaul, Suspension Component Replacement (bushings, ball joints, shocks, struts), Brake Caliper Rebuild, Steering Rack Replacement, Fuel Pump & Injector Service, Cooling System Repairs (radiator, water pump), Electrical Component Diagnosis & Replacement (alternator, starter, sensors), Body Panel Repair & Replacement Diagnostic Procedures: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) for OBD-I systems, electrical circuit tracing, component testing procedures Technical Depth Diagnostic Capability: Advanced diagnostics, including sensor data interpretation, actuator testing, and wiring diagram analysis for troubleshooting electrical and engine performance issues. Rebuild Specifications: Detailed internal component specifications for engine and transmission rebuilds, including torque values, clearances, and assembly procedures. Information Source: Mirrors information used by professional BMW technicians. 📊 Manual Specifications File Format Digital Format: Searchable text, printable pages, high-resolution images and diagrams. Print Quality Diagram Quality: High-quality photos, illustrations, and diagrams for clarity in repair procedures. Binding Type Digital Nature: No physical binding; digital format prevents wear and tear. Paper Type Digital Format: N/A (digital document) Computer Requirements Operating System Compatibility: Microsoft Windows (95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7) and all Mac computers. ⚙️ Engine Specifications Primary Engine E28 Engine Variants: M10 (2.0L, 2.3L), M20 (2.5L, 2.7L 'eta'), M30 (2.8L, 3.2L, 3.5L), M88/S38 (3.5L for M5) E34 Engine Variants (Up To '91): M20 (2.0L, 2.5L), M30 (3.0L, 3.5L), M50 (2.5L, 3.0L, 3.5L - early versions) Performance Power Output Range: Approximately 105 hp (2.0L M10) to 310 hp (M88/S38 M5) Torque Output Range: Approximately 120 lb-ft to 330 lb-ft, depending on engine variant. Fuel System Fuel Delivery Systems: Carbureted (early E28), Bosch L-Jetronic, Motronic (various versions including LH-Jetronic and DME) Fuel Type: Unleaded gasoline (Premium recommended) 🔧 Transmission Standard E28 Standard Transmission: 4-speed manual (common), 5-speed manual (optional on many models) E34 Standard Transmission (Up To '91): 5-speed manual (Getrag 260/5 common) Optional Automatic Transmission Options: ZF 4HP22 (E28), ZF 4HP24 (E34), Getrag 4HP22 EH (E34 - Electronic Hydraulic) Features Clutch System: Hydraulically actuated diaphragm spring clutch. 📐 Dimensions Exterior E28 Overall Length: Approx. 188 inches (4785 mm) E34 Overall Length: Approx. 191 inches (4850 mm) Wheelbase: E28: 103.7 inches (2635 mm), E34: 111.5 inches (2832 mm) Weights Curb Weight Range: Approx. 3,100 lbs to 3,800 lbs (depending on model and engine) Gross Vehicle Weight Rating (Gvwr): Varies by model, typically 4,000 - 4,600 lbs. 🛡️ Safety Features Ratings Crash Safety: Both generations featured robust unibody construction for their era, with significant advances in crumple zones and structural integrity from E28 to E34. Specific NHTSA/Euro NCAP ratings are not as detailed as modern vehicles but were considered high for their time. Active Features Anti-Lock Braking System (ABS): Optional or standard on higher trims and later models (e.g., E34 predominantly offered ABS). Traction Control: Rarely available on E28, early forms (ASR) introduced on some E34 models towards the end of the covered period. Passive Features Seat Belts: Three-point seat belts with pretensioners (introduced later in the E28 lifecycle and standard on E34). Body Structure: Reinforced passenger cell, energy-absorbing steering column, side-impact protection beams (more advanced on E34). 💡 Technology Features Infotainment Audio...
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BMW 5 Series E28 E34 Digital Workshop Repair Manual 1981-91
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Generation
E-Code Designation:
E28 (1981-1988), E34 (1988-1996, with 1991 being the cutoff for this manual)
Codes
Applicable Years:
1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
👋 Introduction
Market Position
Target Audience:
BMW enthusiasts, DIY mechanics, owners seeking to maintain or restore their E28 or E34 5 Series.
Competitive Analysis
Value Proposition:
Provides professional-level repair information at a fraction of dealership service costs, enabling significant savings on maintenance and repairs.
Key Features
Comprehensiveness:
Covers all diagnostic and repair procedures from A-Z for a wide range of models and engine variants within the E28 and E34 generations.
Usability:
Easy to use, view, and print specific procedures without requiring advanced computer skills.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (reflects common BMW specifications)
Page Count
Estimated Page Count:
Likely several thousand pages (typical for comprehensive digital workshop manuals covering multiple models and years)
Manual Type
Type:
Digital Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF or similar, viewable and printable)
📖 Manual Coverage
Systems Covered
Mechanical Systems:
Engine (M10, M20, M30, M88, S38, M50), Fuel System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission (ZF, Getrag), Drive Axles, Differential, Suspension (Front & Rear), Steering System, Braking System (ABS variations), Wheels & Tires
Electrical Systems:
Engine Management (Motronic variations), Ignition System, Fuel Injection, Lighting System, Instrumentation, Audio System, HVAC Controls, Power Accessories (windows, locks, mirrors), Body Electronics, Diagnostics (OBD-I)
Procedures Included
Maintenance Procedures:
Oil Changes, Filter Replacements, Fluid Checks & Replenishments, Spark Plug Replacement, Belt Inspection & Replacement, Brake Pad & Rotor Service, Tire Rotation, Battery Service, Wiper Blade Replacement
Repair & Rebuild Procedures:
Engine Overhaul (top-end and full rebuild), Transmission Rebuild (manual and automatic), Clutch Replacement, Differential Overhaul, Suspension Component Replacement (bushings, ball joints, shocks, struts), Brake Caliper Rebuild, Steering Rack Replacement, Fuel Pump & Injector Service, Cooling System Repairs (radiator, water pump), Electrical Component Diagnosis & Replacement (alternator, starter, sensors), Body Panel Repair & Replacement
Diagnostic Procedures:
Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) for OBD-I systems, electrical circuit tracing, component testing procedures
Technical Depth
Diagnostic Capability:
Advanced diagnostics, including sensor data interpretation, actuator testing, and wiring diagram analysis for troubleshooting electrical and engine performance issues.
Rebuild Specifications:
Detailed internal component specifications for engine and transmission rebuilds, including torque values, clearances, and assembly procedures.
Information Source:
Mirrors information used by professional BMW technicians.
📊 Manual Specifications
File Format
Digital Format:
Searchable text, printable pages, high-resolution images and diagrams.
Print Quality
Diagram Quality:
High-quality photos, illustrations, and diagrams for clarity in repair procedures.
Binding Type
Digital Nature:
No physical binding; digital format prevents wear and tear.
Paper Type
Digital Format:
N/A (digital document)
Computer Requirements
Operating System Compatibility:
Microsoft Windows (95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7) and all Mac computers.
⚙️ Engine Specifications
Primary Engine
E28 Engine Variants:
M10 (2.0L, 2.3L), M20 (2.5L, 2.7L 'eta'), M30 (2.8L, 3.2L, 3.5L), M88/S38 (3.5L for M5)
E34 Engine Variants (Up To '91):
M20 (2.0L, 2.5L), M30 (3.0L, 3.5L), M50 (2.5L, 3.0L, 3.5L - early versions)
Performance
Power Output Range:
Approximately 105 hp (2.0L M10) to 310 hp (M88/S38 M5)
Torque Output Range:
Approximately 120 lb-ft to 330 lb-ft, depending on engine variant.
Fuel System
Fuel Delivery Systems:
Carbureted (early E28), Bosch L-Jetronic, Motronic (various versions including LH-Jetronic and DME)
Fuel Type:
Unleaded gasoline (Premium recommended)
🔧 Transmission
Standard
E28 Standard Transmission:
4-speed manual (common), 5-speed manual (optional on many models)
E34 Standard Transmission (Up To '91):
5-speed manual (Getrag 260/5 common)
Optional
Automatic Transmission Options:
ZF 4HP22 (E28), ZF 4HP24 (E34), Getrag 4HP22 EH (E34 - Electronic Hydraulic)
Features
Clutch System:
Hydraulically actuated diaphragm spring clutch.
📐 Dimensions
Exterior
E28 Overall Length:
Approx. 188 inches (4785 mm)
E34 Overall Length:
Approx. 191 inches (4850 mm)
Wheelbase:
E28: 103.7 inches (2635 mm), E34: 111.5 inches (2832 mm)
Weights
Curb Weight Range:
Approx. 3,100 lbs to 3,800 lbs (depending on model and engine)
Gross Vehicle Weight Rating (Gvwr):
Varies by model, typically 4,000 - 4,600 lbs.
🛡️ Safety Features
Ratings
Crash Safety:
Both generations featured robust unibody construction for their era, with significant advances in crumple zones and structural integrity from E28 to E34. Specific NHTSA/Euro NCAP ratings are not as detailed as modern vehicles but were considered high for their time.
Active Features
Anti-Lock Braking System (ABS):
Optional or standard on higher trims and later models (e.g., E34 predominantly offered ABS).
Traction Control:
Rarely available on E28, early forms (ASR) introduced on some E34 models towards the end of the covered period.
Passive Features
Seat Belts:
Three-point seat belts with pretensioners (introduced later in the E28 lifecycle and standard on E34).
Body Structure:
Reinforced passenger cell, energy-absorbing steering column, side-impact protection beams (more advanced on E34).
💡 Technology Features
Infotainment
Audio System:
Factory installed radios with cassette players, often with amplifier options. Analog tuning, basic EQ controls.
Driver Assistance
Cruise Control:
Standard or optional on most models.
On-Board Computer (Obc):
Optional on E28 and E34, providing basic trip computer functions (average speed, fuel consumption, range) and diagnostic readouts (check control messages).
Connectivity
Diagnostics:
OBD-I (On-Board Diagnostics - first generation) with diagnostic connectors allowing for basic engine fault code retrieval. The manual will cover how to access and interpret these codes.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (or annually), depending on driving conditions and oil used. Check manual for specific recommendations.
Spark Plug Replacement:
Varies by plug type; platinum plugs could last 60,000+ miles, while standard copper plugs around 30,000 miles.
Timing Belt/Chain:
E28 & E34 M20, M30 engines use timing chains (virtually maintenance-free). M50 engines use timing chains. Some early E34 models might have had different configurations, but generally no belt replacement is needed for these core engines.
Fluid Specifications
Engine Oil:
API SG or higher; SAE 10W-40 or 15W-50 depending on climate. BMW High Performance Synthetic is recommended. Refer to manual for precise grades.
Coolant:
BMW Blue or Green Antifreeze/Coolant (ethylene glycol based) mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 (or DOT 3 if specified for earlier models)
Transmission Fluid (Manual):
GL-4 or GL-5 gear oil (e.g., Castrol TWS or equivalent), specific viscosity depends on temperature.
Transmission Fluid (Automatic):
Dexron III (or equivalent ATF such as Mobil ATF 220, Pentosin ATF 14)
Known Issues
E28 Common Issues:
Cooling system leaks (radiator, hoses, water pump), fuel injector O-rings, vacuum leaks, sagging headliner, worn suspension bushings, rust (especially wheel arches and rocker panels).
E34 Common Issues (Early Models):
Cooling system issues (plastic expansion tanks, water pumps), fuel pump failures, ABS sensor issues, window regulator failures, blower motor resistor failure, rust ingress.
Engine Specific Concerns:
M20 engines: potential head gasket issues. M30 engines: can develop oil leaks. M50 engines: generally robust, but can experience VANOS issues in later years outside this manual's scope.
📚 Vehicle History
Brand Heritage
Bmw'S Executive Sedan Legacy:
The 5 Series has historically represented BMW's core offering in the executive sedan segment, known for blending luxury, performance, and advanced engineering.
Model Evolution
E28 (Second Generation 5 Series):
Introduced in 1981, the E28 was an evolution of the E12, featuring cleaner aerodynamics, improved suspension, and the introduction of the highly acclaimed M5 performance variant (E28S M5).
E34 (Third Generation 5 Series):
Launched in 1988, the E34 represented a significant leap forward with a more modern and aerodynamic design, advanced chassis dynamics, new engine options (including the M50 inline-six), and enhanced safety and luxury features. The covered period (up to 1991) captures the initial years of the E34's production.
Production
E28 Production Years:
1981-1988
E34 Production Years:
1988-1996 (E34 sedan), 1992-1996 (E34 Touring)
🏆 Awards & Recognition
Recognitions
E28 M5 Recognition:
Widely recognized as a 'supercar' of its era and a collector's item, lauded for its performance and handling.
E34 Series Reputation:
Praised for its sophisticated chassis, improved ride comfort over the E28, and powerful engine options, cementing BMW's reputation for driver-focused luxury sedans.
Certifications
Manual Quality:
Described as being of the same quality and detail as information used by professional technicians, implying high standards of accuracy and completeness.
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