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BMW 528i 1981 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 1981 Codes Chassis Code: E28 👋 Introduction Market Position Positioning: The BMW 528i (E28) represented the pinnacle of BMW's mid-size luxury sedan offerings in the early 1980s, emphasizing performance, comfort, and build quality. It was positioned as a premium executive sedan with sporting credentials. Competitive Analysis Competitors: Competed against vehicles like the Mercedes-Benz W123/W124 series, Audi 100, Volvo 740/760, and American luxury sedans such as Cadillac Sedan de Ville and Lincoln Continental. Key Features Vehicle Highlights: Renowned for its robust M30 engine, refined handling, sophisticated interior, and excellent build quality. The E28 generation marked a significant evolution in BMW's design language. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Diagnostics, Troubleshooting Secondary Coverage: Wiring Diagrams, Specifications, Procedures Page Count Estimated Pages: 900+ Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Print (likely digital scan of original printed manual) 📖 Manual Coverage Systems Covered Engine: M30B28 inline-six engine (engine management, fuel injection, ignition, cooling, lubrication, exhaust) Transmission: Getrag 260 5-speed manual, ZF 4HP22 4-speed automatic (operation, removal, installation, overhaul, fluid specifications) Drivetrain: Rear-wheel drive system, driveshaft, differential, axles Suspension: Front MacPherson struts, rear semi-trailing arms, springs, shock absorbers, bushings, alignment specifications Brakes: Front ventilated discs, rear solid discs, hydraulic system, ABS (if equipped), parking brake Steering: Power-assisted recirculating ball steering system Electrical: 12V system, battery, alternator, starter, lighting, dashboard instrumentation, L-Jetronic fuel injection control unit, ignition system, fuses, relays, wiring diagrams Body And Chassis: Body construction, doors, windows, glass, body panels, interior trim, sound deadening Heating And Air Conditioning: HVAC system operation and repair Procedures Included Engine Overhaul: Complete engine rebuild procedures, including cylinder head, block, crankshaft, camshaft, pistons, rings, bearings Fuel System Service: Fuel pump testing and replacement, fuel injector cleaning and replacement, fuel pressure regulation Ignition System Diagnosis: Spark plug replacement, ignition coil testing, distributor maintenance Brake System Maintenance: Brake pad and rotor replacement, brake fluid flush, caliper and master cylinder overhaul Suspension Component Replacement: Strut and shock absorber replacement, control arm bushing replacement, ball joint inspection Transmission Fluid Change: Procedure for changing transmission fluid and filter Troubleshooting: Systematic diagnostic procedures for common issues, fault codes (if applicable) Technical Depth Depth: Comprehensive: Covers routine maintenance to complete engine and transmission overhauls, detailed electrical diagnostics, and bodywork repairs. Diagnostic Capability: Advanced: Includes specifications for testing sensors, actuators, and engine control units, along with troubleshooting flowcharts. 📊 Manual Specifications File Format Digital Format: Likely PDF, potentially image-based scans or searchable text. Print Quality Quality: Variable (depends on original printing and scanning quality, expect clarity for diagrams and text). Binding Type Binding: N/A (for printed version, typically perfect bound or spiral) Paper Type Paper: N/A (for printed version, typically durable paper stock suitable for workshop use) ⚙️ Engine Specifications Primary Engine Engine Code And Type: M30B28, 2.8-liter (2788 cc) SOHC inline-six Performance Horsepower: 181 hp (135 kW) @ 5800 rpm (approximate, may vary by market/emission standards) Torque: 230 Nm (170 lb-ft) @ 4000 rpm (approximate) Fuel System Fuel Injection: Bosch L-Jetronic (or Motronic, depending on exact market/year evolution) fuel injection Engine Components Bore X Stroke: 86 mm x 80 mm Compression Ratio: 8.0:1 or 8.1:1 Cooling System Cooling Type: Liquid-cooled Lubrication System Oil Capacity: 6.5 liters (6.9 US quarts) 🔧 Transmission Standard Transmission Type: Getrag 260 5-speed manual Optional Transmission Type: ZF 4HP22 4-speed automatic Features Gear Ratios Manual: Refer to manual for specific ratios; typically close-ratio Fluid Type Manual: BMW MTF LT-2 or equivalent (GL-4 spec) Fluid Type Automatic: Dexron II or equivalent 📐 Dimensions Exterior Length: 4700 mm (185.0 in) Width: 1700 mm (66.9 in) Height: 1420 mm (55.9 in) Weights Curb Weight: 1450-1500 kg (3197-3307 lbs) Wheelbase: 2700 mm (106.3 in) Track Width Front: 1450 mm (57.1 in) Track Width Rear: 1460 mm (57.5 in) 🛡️ Safety Features Ratings Crash Testing Era: Safety standards of the early 1980s; extensive independent crash testing data may be limited. Active Features ABS: Optional Anti-lock Braking System (ABS) available on some models. Passive Features Seatbelts: Three-point inertia-reel seatbelts Crumple Zones: Designed with energy-absorbing crumple zones Steering Column: Collapsible steering column 💡 Technology Features Infotainment Audio System: Factory-installed analog radio, cassette player, and speaker systems. Instrument Cluster: Analog gauges for speedometer, tachometer, fuel level, engine temperature, oil pressure; warning lights for various systems. Driver Assistance ABS: Optional ABS system Connectivity Original Connectivity: Limited to basic vehicle functions; no modern digital connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, consult manual for specifics. Spark Plug Replacement: Approx. 30,000 miles (48,000 km) Timing Belt Chain: M30 engines use a timing chain, which is designed to last the life of the engine but requires periodic inspection for tensioner wear. Fluid Specifications Engine Oil Spec: API SG or SH, SAE 10W-40 or 20W-50 recommended (check...
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Labels: 1981 528i BMW Car Cars Misc
BMW 528i 1981 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
528i
Year:
1981
Codes
Chassis Code:
E28
👋 Introduction
Market Position
Positioning:
The BMW 528i (E28) represented the pinnacle of BMW's mid-size luxury sedan offerings in the early 1980s, emphasizing performance, comfort, and build quality. It was positioned as a premium executive sedan with sporting credentials.
Competitive Analysis
Competitors:
Competed against vehicles like the Mercedes-Benz W123/W124 series, Audi 100, Volvo 740/760, and American luxury sedans such as Cadillac Sedan de Ville and Lincoln Continental.
Key Features
Vehicle Highlights:
Renowned for its robust M30 engine, refined handling, sophisticated interior, and excellent build quality. The E28 generation marked a significant evolution in BMW's design language.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Maintenance, Diagnostics, Troubleshooting
Secondary Coverage:
Wiring Diagrams, Specifications, Procedures
Page Count
Estimated Pages:
900+
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Print (likely digital scan of original printed manual)
📖 Manual Coverage
Systems Covered
Engine:
M30B28 inline-six engine (engine management, fuel injection, ignition, cooling, lubrication, exhaust)
Transmission:
Getrag 260 5-speed manual, ZF 4HP22 4-speed automatic (operation, removal, installation, overhaul, fluid specifications)
Drivetrain:
Rear-wheel drive system, driveshaft, differential, axles
Suspension:
Front MacPherson struts, rear semi-trailing arms, springs, shock absorbers, bushings, alignment specifications
Brakes:
Front ventilated discs, rear solid discs, hydraulic system, ABS (if equipped), parking brake
Steering:
Power-assisted recirculating ball steering system
Electrical:
12V system, battery, alternator, starter, lighting, dashboard instrumentation, L-Jetronic fuel injection control unit, ignition system, fuses, relays, wiring diagrams
Body And Chassis:
Body construction, doors, windows, glass, body panels, interior trim, sound deadening
Heating And Air Conditioning:
HVAC system operation and repair
Procedures Included
Engine Overhaul:
Complete engine rebuild procedures, including cylinder head, block, crankshaft, camshaft, pistons, rings, bearings
Fuel System Service:
Fuel pump testing and replacement, fuel injector cleaning and replacement, fuel pressure regulation
Ignition System Diagnosis:
Spark plug replacement, ignition coil testing, distributor maintenance
Brake System Maintenance:
Brake pad and rotor replacement, brake fluid flush, caliper and master cylinder overhaul
Suspension Component Replacement:
Strut and shock absorber replacement, control arm bushing replacement, ball joint inspection
Transmission Fluid Change:
Procedure for changing transmission fluid and filter
Troubleshooting:
Systematic diagnostic procedures for common issues, fault codes (if applicable)
Technical Depth
Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission overhauls, detailed electrical diagnostics, and bodywork repairs.
Diagnostic Capability:
Advanced: Includes specifications for testing sensors, actuators, and engine control units, along with troubleshooting flowcharts.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, potentially image-based scans or searchable text.
Print Quality
Quality:
Variable (depends on original printing and scanning quality, expect clarity for diagrams and text).
Binding Type
Binding:
N/A (for printed version, typically perfect bound or spiral)
Paper Type
Paper:
N/A (for printed version, typically durable paper stock suitable for workshop use)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
M30B28, 2.8-liter (2788 cc) SOHC inline-six
Performance
Horsepower:
181 hp (135 kW) @ 5800 rpm (approximate, may vary by market/emission standards)
Torque:
230 Nm (170 lb-ft) @ 4000 rpm (approximate)
Fuel System
Fuel Injection:
Bosch L-Jetronic (or Motronic, depending on exact market/year evolution) fuel injection
Engine Components
Bore X Stroke:
86 mm x 80 mm
Compression Ratio:
8.0:1 or 8.1:1
Cooling System
Cooling Type:
Liquid-cooled
Lubrication System
Oil Capacity:
6.5 liters (6.9 US quarts)
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-speed manual
Optional
Transmission Type:
ZF 4HP22 4-speed automatic
Features
Gear Ratios Manual:
Refer to manual for specific ratios; typically close-ratio
Fluid Type Manual:
BMW MTF LT-2 or equivalent (GL-4 spec)
Fluid Type Automatic:
Dexron II or equivalent
📐 Dimensions
Exterior
Length:
4700 mm (185.0 in)
Width:
1700 mm (66.9 in)
Height:
1420 mm (55.9 in)
Weights
Curb Weight:
1450-1500 kg (3197-3307 lbs)
Wheelbase:
2700 mm (106.3 in)
Track Width Front:
1450 mm (57.1 in)
Track Width Rear:
1460 mm (57.5 in)
🛡️ Safety Features
Ratings
Crash Testing Era:
Safety standards of the early 1980s; extensive independent crash testing data may be limited.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on some models.
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts
Crumple Zones:
Designed with energy-absorbing crumple zones
Steering Column:
Collapsible steering column
💡 Technology Features
Infotainment
Audio System:
Factory-installed analog radio, cassette player, and speaker systems.
Instrument Cluster:
Analog gauges for speedometer, tachometer, fuel level, engine temperature, oil pressure; warning lights for various systems.
Driver Assistance
ABS:
Optional ABS system
Connectivity
Original Connectivity:
Limited to basic vehicle functions; no modern digital connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, consult manual for specifics.
Spark Plug Replacement:
Approx. 30,000 miles (48,000 km)
Timing Belt Chain:
M30 engines use a timing chain, which is designed to last the life of the engine but requires periodic inspection for tensioner wear.
Fluid Specifications
Engine Oil Spec:
API SG or SH, SAE 10W-40 or 20W-50 recommended (check manual for exact viscosity based on climate)
Coolant Spec:
Ethylene glycol-based antifreeze, typically 50/50 mix with distilled water
Brake Fluid Spec:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Cooling system components (radiator, hoses, water pump), fuel distributor seals, suspension bushings, rear subframe mounts, O-rings in fuel system.
Electrical Gremlins:
Aging wiring harnesses, faulty relays, and corrosion in connectors can lead to intermittent electrical issues.
Maintenance Tasks In Manual
Tasks:
Oil and filter changes, air filter replacement, fuel filter replacement, spark plug inspection/replacement, coolant system flush, brake pad/rotor service, transmission fluid service, differential fluid service.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's reputation for engineering excellence, 'The Ultimate Driving Machine' slogan, and commitment to sporty yet luxurious vehicles.
Model Evolution
E28 Generation:
The E28 was the second generation of the BMW 5 Series, succeeding the E12. It introduced a more aerodynamic design, improved chassis dynamics, and advanced technology for its time.
Production
Production Years:
1981-1988 (E28 generation)
Manufacturing Location:
Dingolfing, Germany, and other BMW assembly plants worldwide.
🏆 Awards & Recognition
Recognitions
Contemporary Acclaim:
Consistently praised by automotive journalists for its driving dynamics, build quality, and luxury appointments. Often cited as a benchmark in its class.
Ratings
Reliability Perception:
Generally considered reliable with proper maintenance, though specific components can be costly to repair due to complexity and parts availability.
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