🏷️ Basic Information Identification Make: BMW Model: 525 Model Variant: 525i Codes Chassis Code: E28 Engine Code: M30B25 👋 Introduction Market Position Target Audience: BMW enthusiasts, independent repair shops, DIY mechanics specializing in classic BMWs Competitive Analysis Value Proposition: Provides detailed, manufacturer-level repair information for a specific and beloved BMW model, crucial for maintaining its value and performance. Key Features Comprehensiveness: Covers all major mechanical and electrical systems, offering a complete guide for servicing and repair. 📋 Manual Details Coverage Areas Years Covered: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988 Page Count Estimated Pages: Hundreds of pages (exact count not specified, implies comprehensive) Manual Type Type: Complete Full Service Repair Manual Language Language: English Format Format: Download PDF 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel injection (Bosch L-Jetronic/Motronic), ignition, exhaust Transmission: Manual and Automatic transmissions (removal, installation, overhaul, clutch, driveshafts) Brakes: Hydraulic system, front and rear disc brakes, ABS (if equipped), parking brake Suspension Steering: Front and rear suspension, shock absorbers, springs, control arms, power steering system Electrical: Battery, charging system, starting system, lighting, instrumentation, wiring diagrams, fuses, relays Bodywork Chassis: Body panel repair, doors, windows, seats, interior trim, bumpers Climate Control: Heating, ventilation, air conditioning (HVAC) system diagnosis and repair Fuel System: Fuel tank, fuel pump, fuel lines, fuel injectors, fuel pressure regulation Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks, belt inspections Troubleshooting: Diagnostic charts for common problems, electrical system troubleshooting Repair: Step-by-step instructions for component removal, repair, and reinstallation Overhaul: Detailed procedures for engine and transmission overhauls Calibration Adjustment: Ignition timing, idle speed, fuel injection system adjustments Engine Diagnostics: Troubleshooting charts and specific diagnostic procedures for fuel injection and ignition systems. Chassis Alignment: Wheel alignment specifications and procedures. Body Repair Data: Information on panel replacement, welding, and repair of common body damage. Wiring Diagrams: Comprehensive electrical wiring diagrams for all systems. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Printability: Designed for printing, allowing users to create a physical copy Binding Type Suggested Binding: Spiral-bound or three-hole punched for easy page turning and reference Paper Type Recommended Paper: Durable, high-quality paper to withstand workshop use ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, SOHC (Single Overhead Camshaft) Displacement: 2.5 Liters (2494 cc) Performance Horsepower Est: 150-170 hp (depending on market and specific injection system) Torque Est: 165-180 lb-ft (depending on market and specific injection system) Fuel System Injection System: Bosch L-Jetronic or Motronic fuel injection Fuel Type: Unleaded gasoline Ignition Ignition System: Electronic ignition system with distributor 🔧 Transmission Standard Transmission Type: 4-speed or 5-speed Manual Transmission Optional Transmission Type: ZF 4HP22 4-speed Automatic Transmission Features Clutch Type: Hydraulically actuated single dry plate clutch 📐 Dimensions Exterior Wheelbase: Approx. 2794 mm (110.0 inches) Length: Approx. 4755 mm (187.2 inches) Width: Approx. 1700 mm (66.9 inches) Height: Approx. 1420 mm (55.9 inches) Weights Curb Weight Est: Approx. 1450-1550 kg (3197-3417 lbs) 🛡️ Safety Features Ratings Crash Test Era: Pre-modern crash testing standards, but known for robust chassis construction Active Features ABS: Anti-lock Braking System (ABS) optional or standard on later models Braking System: Four-wheel disc brakes (vented front, solid rear) Passive Features Seatbelts: Three-point seat belts Body Structure: Reinforced passenger cell 💡 Technology Features Infotainment Radio: Factory AM/FM radio with cassette player, optional premium sound systems Climate Control: Manual climate control, optional automatic climate control (ECC - Electronic Climate Control) on some models. Driver Assistance ABS: Anti-lock Braking System was an advanced feature for its time. Connectivity Onboard Computer: Optional 'Check Control' system for monitoring fluid levels and basic system status. 🔧 Maintenance Service Intervals Oil Change: Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions. Coolant Flush: Every 2 years or 30,000 miles Spark Plugs: Refer to manual; typically every 30,000-60,000 miles for standard plugs. Fluid Specifications Engine Oil: Refer to manual, typically 20W-50 or 10W-40 for this era, API SG or higher Coolant: Ethylene glycol-based coolant, typically 50/50 mix with distilled water Transmission Fluid Manual: GL-4 gear oil (e.g., 75W-90 or 80W-90) Transmission Fluid Automatic: Dexron II or equivalent ATF Brake Fluid: DOT 3 or DOT 4 brake fluid Known Issues Engine Oil Leaks: Common due to age of seals and gaskets (e.g., valve cover, oil pan, rear main seal) Cooling System: Radiator, hoses, and water pump can degrade over time. Overheating can occur. Electrical Gremlins: Corrosion in connectors, aging wiring, and failing relays can cause intermittent issues. Rust: Common areas include wheel arches, rocker panels, and trunk floor due to age and climate. Fuel Injection System: Faulty airflow meter, fuel injectors, or fuel pump can affect performance. 📚 Vehicle History Brand Heritage Bmw Philosophy: BMW's reputation for engineering excellence, performance, and...