BMW 525 E28 Service Repair Workshop Manual 1981-1988

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🏷️ Basic Information Identification Make: BMW Model: 525 Chassis Code: E28 Production Years Covered: 1981-1988 👋 Introduction Market Position Historical Context: The BMW 525 E28 represented BMW's commitment to luxury, performance, and engineering in the executive sedan segment during the 1980s. Target Audience: Enthusiasts, independent repair shops, and owners seeking to maintain and repair their E28 525 models. Competitive Analysis Segment: Mid-size luxury sedan Competitors: Mercedes-Benz W123/W124, Audi 100/200, Volvo 240/740 Key Features Brand Philosophy: Sheer Driving Pleasure, advanced engineering, and quality construction. Model Highlights: Balanced chassis, powerful inline-six engines, driver-focused interior, robust build quality. Manual Value Proposition Quality Assurance: Advertised as the 'Best Manual Available,' 'Complete Manual - No Missing Pages,' and 'Customer Satisfaction Guaranteed,' indicating a focus on quality and completeness. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: Digital (likely PDF) Completeness: Complete, no missing pages 📖 Manual Coverage Systems Covered Engine: M30 inline-six gasoline engines (e.g., M30B25) Fuel System: Bosch L-Jetronic fuel injection system Ignition System: Electronic ignition control Cooling System: Radiator, fan, thermostat, water pump Exhaust System: Catalytic converter (if applicable by market), mufflers, pipes Transmission Manual: Getrag 5-speed manual transmission (e.g., Getrag 265) Transmission Automatic: ZF 4-speed automatic transmission (e.g., ZF 4HP22) Drivetrain: Rear-wheel drive (RWD), driveshaft, differential Suspension Front: Independent suspension, MacPherson struts, control arms, anti-roll bar Suspension Rear: Independent trailing arm suspension, shock absorbers, coil springs Steering: Recirculating ball steering, power steering system Brakes Front: Ventilated discs, caliper specifications Brakes Rear: Solid discs, caliper specifications Electrical System: Wiring diagrams, fuse box layout, component testing Lighting: Headlights, taillights, interior lighting HVAC: Heating, ventilation, and air conditioning (A/C) system Body And Frame: Body panel removal/installation, structural components Interior: Trim panels, seats, dashboard components Diagnostics: Troubleshooting guides, fault codes (if applicable) Procedures Included Maintenance Routine: Oil changes, filter replacements, fluid checks, belt inspections Engine Overhaul: Engine removal, disassembly, inspection, reassembly, torque specifications Transmission Service: Clutch replacement (manual), torque converter service (automatic), fluid changes Brake System Repair: Brake pad and rotor replacement, caliper overhaul, brake fluid bleeding Suspension Component Replacement: Strut and shock absorber replacement, ball joint service, bushing replacement Steering System Repair: Power steering pump and rack replacement, steering linkage service Electrical Component Replacement: Alternator, starter motor, battery, sensors, relays Fuel System Troubleshooting: Injector testing, fuel pump pressure checks, fuel filter replacement Cooling System Repair: Radiator replacement, thermostat testing, water pump service HVAC System Service: Compressor replacement, evaporator and condenser service, refrigerant charging Body Repair: Door hinge adjustment, panel alignment, minor dent repair guidance Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon faults Technical Depth Depth Level: Comprehensive, from basic maintenance to major component overhaul Diagnostic Capabilities: Detailed diagnostic flowcharts and specifications for testing components Rebuild Procedures: In-depth instructions for rebuilding engines, transmissions, and other major systems Specifications Inclusion: Includes critical torque values, clearances, fluid capacities, and electrical resistance values 📊 Manual Specifications File Format File Type: PDF (assumed) Searchability: Likely text-searchable for efficient information retrieval Print Quality: High-resolution scans, suitable for printing key sections or the entire manual Print Quality Image Clarity: Clear diagrams, schematics, and photographs (if present in original) Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: M30B25 Configuration: Inline 6-cylinder, DOHC (Dual Overhead Camshaft) Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 8.8:1 (typical) Power Output: Approx. 150-155 hp (110-114 kW) at 5500-6000 rpm (depending on market and configuration) Torque Output: Approx. 205-210 Nm (151-155 lb-ft) at 3500-4000 rpm Fuel System Injection Type: Bosch L-Jetronic electronic fuel injection Fuel Type: Unleaded Gasoline (premium recommended) Ignition System Ignition Type: Electronic Ignition (Distributorless in later iterations of M30, but likely distributor for E28 generation) Lubrication Oil Type: API SG or higher, SAE 15W-40 or 10W-40 recommended (refer to manual for specific BMW approvals) Oil Capacity: Approx. 5.7 Liters (6.0 US quarts) with filter change 🔧 Transmission Standard Manual Transmission: Getrag 265 5-speed manual gearbox Optional Automatic Transmission: ZF 4HP22 4-speed automatic transmission Features Clutch Type: Single dry plate, hydraulically actuated Manual Gear Ratios: Close-ratio or standard (e.g., close-ratio 0.81:1 5th gear for highway cruising) Automatic Features: Lock-up torque converter, Sport/Economy mode selector Fluid Specs Manual Transmission Fluid: GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (refer to manual for specific BMW approvals) Automatic Transmission Fluid: Dexron III (or equivalent ATF, refer to manual for specific BMW approval) 📐 Dimensions Exterior Length: Approx. 4725 mm (186.0 in) Width: Approx. 1700 mm (66.9 in) Height: Approx. 1415 mm (55.7 in) Wheelbase: Approx. 2794 mm (110.0 in) Weights Curb Weight: Approx. 1450-1550 kg (3197-3417 lbs) depending on transmission and options Gross Vehicle Weight Rating: Refer to vehicle data plate (typically around 2000 kg) Cargo Trunk Capacity: Approx. 460 Liters (16.2 cu ft) 🛡️ Safety Features Ratings Crash Test Data: Limited...

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Type: Car

Verkoper:

Sku: 280045

Collecties: ALL BMW

Beschikbaarheid: Op voorraad

Labels: 1981 1982 1983 1984 1985 1986 1987 1988 525 E28 BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Production Years Covered:

1981-1988

👋 Introduction

Market Position

Historical Context:

The BMW 525 E28 represented BMW's commitment to luxury, performance, and engineering in the executive sedan segment during the 1980s.

Target Audience:

Enthusiasts, independent repair shops, and owners seeking to maintain and repair their E28 525 models.

Competitive Analysis

Segment:

Mid-size luxury sedan

Competitors:

Mercedes-Benz W123/W124, Audi 100/200, Volvo 240/740

Key Features

Brand Philosophy:

Sheer Driving Pleasure, advanced engineering, and quality construction.

Model Highlights:

Balanced chassis, powerful inline-six engines, driver-focused interior, robust build quality.

Manual Value Proposition

Quality Assurance:

Advertised as the 'Best Manual Available,' 'Complete Manual - No Missing Pages,' and 'Customer Satisfaction Guaranteed,' indicating a focus on quality and completeness.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF)

Completeness:

Complete, no missing pages

📖 Manual Coverage

Systems Covered

Engine:

M30 inline-six gasoline engines (e.g., M30B25)

Fuel System:

Bosch L-Jetronic fuel injection system

Ignition System:

Electronic ignition control

Cooling System:

Radiator, fan, thermostat, water pump

Exhaust System:

Catalytic converter (if applicable by market), mufflers, pipes

Transmission Manual:

Getrag 5-speed manual transmission (e.g., Getrag 265)

Transmission Automatic:

ZF 4-speed automatic transmission (e.g., ZF 4HP22)

Drivetrain:

Rear-wheel drive (RWD), driveshaft, differential

Suspension Front:

Independent suspension, MacPherson struts, control arms, anti-roll bar

Suspension Rear:

Independent trailing arm suspension, shock absorbers, coil springs

Steering:

Recirculating ball steering, power steering system

Brakes Front:

Ventilated discs, caliper specifications

Brakes Rear:

Solid discs, caliper specifications

Electrical System:

Wiring diagrams, fuse box layout, component testing

Lighting:

Headlights, taillights, interior lighting

HVAC:

Heating, ventilation, and air conditioning (A/C) system

Body And Frame:

Body panel removal/installation, structural components

Interior:

Trim panels, seats, dashboard components

Diagnostics:

Troubleshooting guides, fault codes (if applicable)

Procedures Included

Maintenance Routine:

Oil changes, filter replacements, fluid checks, belt inspections

Engine Overhaul:

Engine removal, disassembly, inspection, reassembly, torque specifications

Transmission Service:

Clutch replacement (manual), torque converter service (automatic), fluid changes

Brake System Repair:

Brake pad and rotor replacement, caliper overhaul, brake fluid bleeding

Suspension Component Replacement:

Strut and shock absorber replacement, ball joint service, bushing replacement

Steering System Repair:

Power steering pump and rack replacement, steering linkage service

Electrical Component Replacement:

Alternator, starter motor, battery, sensors, relays

Fuel System Troubleshooting:

Injector testing, fuel pump pressure checks, fuel filter replacement

Cooling System Repair:

Radiator replacement, thermostat testing, water pump service

HVAC System Service:

Compressor replacement, evaporator and condenser service, refrigerant charging

Body Repair:

Door hinge adjustment, panel alignment, minor dent repair guidance

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon faults

Technical Depth

Depth Level:

Comprehensive, from basic maintenance to major component overhaul

Diagnostic Capabilities:

Detailed diagnostic flowcharts and specifications for testing components

Rebuild Procedures:

In-depth instructions for rebuilding engines, transmissions, and other major systems

Specifications Inclusion:

Includes critical torque values, clearances, fluid capacities, and electrical resistance values

📊 Manual Specifications

File Format

File Type:

PDF (assumed)

Searchability:

Likely text-searchable for efficient information retrieval

Print Quality:

High-resolution scans, suitable for printing key sections or the entire manual

Print Quality

Image Clarity:

Clear diagrams, schematics, and photographs (if present in original)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B25

Configuration:

Inline 6-cylinder, DOHC (Dual Overhead Camshaft)

Displacement:

2.5 Liters (2494 cc)

Bore X Stroke:

84.0 mm x 75.0 mm

Compression Ratio:

8.8:1 (typical)

Power Output:

Approx. 150-155 hp (110-114 kW) at 5500-6000 rpm (depending on market and configuration)

Torque Output:

Approx. 205-210 Nm (151-155 lb-ft) at 3500-4000 rpm

Fuel System

Injection Type:

Bosch L-Jetronic electronic fuel injection

Fuel Type:

Unleaded Gasoline (premium recommended)

Ignition System

Ignition Type:

Electronic Ignition (Distributorless in later iterations of M30, but likely distributor for E28 generation)

Lubrication

Oil Type:

API SG or higher, SAE 15W-40 or 10W-40 recommended (refer to manual for specific BMW approvals)

Oil Capacity:

Approx. 5.7 Liters (6.0 US quarts) with filter change

🔧 Transmission

Standard

Manual Transmission:

Getrag 265 5-speed manual gearbox

Optional

Automatic Transmission:

ZF 4HP22 4-speed automatic transmission

Features

Clutch Type:

Single dry plate, hydraulically actuated

Manual Gear Ratios:

Close-ratio or standard (e.g., close-ratio 0.81:1 5th gear for highway cruising)

Automatic Features:

Lock-up torque converter, Sport/Economy mode selector

Fluid Specs

Manual Transmission Fluid:

GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (refer to manual for specific BMW approvals)

Automatic Transmission Fluid:

Dexron III (or equivalent ATF, refer to manual for specific BMW approval)

📐 Dimensions

Exterior

Length:

Approx. 4725 mm (186.0 in)

Width:

Approx. 1700 mm (66.9 in)

Height:

Approx. 1415 mm (55.7 in)

Wheelbase:

Approx. 2794 mm (110.0 in)

Weights

Curb Weight:

Approx. 1450-1550 kg (3197-3417 lbs) depending on transmission and options

Gross Vehicle Weight Rating:

Refer to vehicle data plate (typically around 2000 kg)

Cargo

Trunk Capacity:

Approx. 460 Liters (16.2 cu ft)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited formal crash test data from modern standards, but known for robust safety cage and build quality for its era.

Active Features

Optional Anti-lock Braking System (ABS) on later models

Suspension Design:

Advanced independent suspension contributed to stability and handling

Passive Features

Airbags:

No driver or passenger airbags were standard; optional on very late models.

Seatbelts:

Three-point inertia-reel seatbelts in front and rear

Body Structure:

Reinforced passenger cell and crumple zones

💡 Technology Features

Infotainment

Audio System:

Original BMW Bavaria C series cassette/radio units. Upgrade options common.

Climate Control:

Manual climate control with optional automatic climate control on some models.

Driver Assistance

Cruise Control:

Optional cruise control system.

Trip Computer:

Optional onboard computer (check control) providing basic vehicle status information.

Connectivity

Connectivity Features:

No modern connectivity features like Bluetooth or USB were available. Basic antenna and speaker wiring.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 to 10,000 miles (12,000 to 16,000 km) or annually, whichever comes first. (Refer to manual for specific recommendations based on driving conditions.)

Spark Plug Replacement:

Approximately every 30,000 miles (48,000 km)

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km)

Transmission Fluid Change:

Manual: Every 30,000-50,000 miles (48,000-80,000 km). Automatic: Every 30,000 miles (48,000 km) or as per manual. (Often overlooked, critical for longevity.)

Brake Fluid Flush:

Every 2 years (due to hygroscopic nature)

Fluid Specifications

Coolant Type:

BMW Blue or Green antifreeze (Ethylene Glycol based), typically a 50/50 mix with distilled water.

Power Steering Fluid:

ATF Dexron II or III (refer to manual for specific BMW approval)

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual)

Known Issues

Engine Wear:

Oil leaks from valve cover gasket and oil pan gasket; potential head gasket issues if overheated.

Fuel System:

Clogged injectors, failing fuel pumps, and deteriorating fuel lines due to age.

Electrical:

Degraded wiring insulation, faulty relays, intermittent dashboard lights, failing alternator voltage regulator.

Suspension And Steering:

Worn control arm bushings, tie rod ends, and rear trailing arm bushings leading to vague steering and poor handling.

Cooling System:

Leaking radiator hoses, failing water pump, and brittle plastic expansion tanks.

Rust:

Common areas include wheel arches, rocker panels, and underbody due to age and environmental exposure.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long-standing reputation for building driver-focused, performance-oriented luxury vehicles.

Model Evolution

E28 Introduction:

The E28 was the second generation of the BMW 5 Series, succeeding the E12 and preceding the E34. It marked a significant evolution in design and technology.

E28 Design:

Characterized by its crisp, angular styling penned by Claus Luthe, it offered a more aerodynamic and modern appearance than its predecessor.

Production

Production Dates:

1981-1988

Manufacturing Locations:

Mainly Dingolfing, Germany, with some assembly in other global locations.

E28 525 Significance:

The 525 served as a core model in the E28 lineup, balancing performance with luxury and a slightly more accessible price point than the larger-engined variants.

🏆 Awards & Recognition

Recognitions

Automotive Press:

The E28 generation was widely praised by automotive journalists for its driving dynamics, build quality, and refinement, often winning comparisons against its rivals.

Ratings

Owner Satisfaction:

The E28 is considered a benchmark for reliability and driver engagement by many long-term owners, often lauded for its classic BMW feel.

Certifications

Design Awards:

While specific design awards for the E28 might not be widely documented, its design contributed to BMW's growing reputation for sophisticated automotive styling.