🏷️ Basic Information Identification Make: BMW Model: 525i Codes Chassis Code: E28 👋 Introduction Market Position Segment: Executive Sedan, Luxury Mid-size Car Brand Perception: Known for sporty driving dynamics, build quality, and refined engineering. Competitive Analysis Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Volvo 740/760, Jaguar XJ Series. Key Features Design: Iconic Chris Bangle-influenced styling, clean lines, driver-focused interior. Powertrain: Smooth and powerful M30 inline-six engines, renowned for durability and performance. Handling: Excellent balance, sophisticated independent rear suspension, precise steering. 📋 Manual Details Coverage Areas Model Years Covered: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF, though not explicitly stated, common for workshop manuals of this era) 📖 Manual Coverage Systems Covered Engine: M30B25 engine series (2.5L inline-6), including fuel injection (L-Jetronic/Motronic), ignition, cooling, lubrication, exhaust, and emissions control systems. Transmission: Manual (Getrag 260) and Automatic (ZF 4HP22) transmissions, including clutch, driveshaft, differential, and axle assemblies. Brakes: Front and rear disc brakes, hydraulic system, parking brake, ABS (where equipped). Suspension: Front strut suspension (MacPherson type), rear semi-trailing arm independent suspension, shock absorbers, springs, bushings, anti-roll bars. Steering: Power steering system, steering rack and pinion, steering column, universal joints. Electrical: Battery, alternator, starter motor, lighting system, wiring harnesses, fuses, relays, instrumentation, electronic control units (ECUs), diagnostics. Bodywork: Body panel repair, door mechanisms, window regulators, seals, body trim, rust prevention, underbody coatings. Interior: Seating systems, dashboard, climate control (HVAC), sound insulation, interior trim, headliner. Procedures Included Maintenance: Routine maintenance (oil changes, filter replacements, fluid checks), tune-ups, lubrication schedules, belt and hose inspections. Troubleshooting: Diagnostic procedures for common and uncommon faults, fault code interpretation (where applicable for the era), symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major mechanical and electrical systems, including component removal, overhaul, and reinstallation. Specifications: Torque specifications for critical fasteners, engine clearances, valve timings, fluid capacities, electrical resistance values. Special Tools: Identification and usage of specialized BMW tools required for specific repair procedures. Technical Depth Depth: Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, detailed electrical diagnostics, and body repair. 📊 Manual Specifications File Format Type: Digital (likely PDF) Searchability: Likely text-searchable if a well-produced PDF, allowing quick access to specific topics. Print Quality Quality: Varies by source; typically faithful reproduction of original BMW factory manuals, often with clear diagrams and schematics. Binding Type Type: N/A (Digital format) Paper Type Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Code: M30B25 Configuration: 2.5-liter (2494 cc) SOHC Inline-6 Performance Horsepower: Approximately 150-170 hp (varies slightly by year and market) Torque: Approximately 165-175 lb-ft (varies slightly by year and market) Fuel System Type: Bosch L-Jetronic or Motronic electronic fuel injection. Maintenance Spark Plugs: Recommended: Bosch W8AC or equivalent. Torque: 25 Nm (18 lb-ft). Engine Oil: Recommended: 20W-50 or 10W-40 synthetic/mineral blend. Capacity: Approx. 5.5 liters (5.8 US quarts) with filter change. Coolant: Recommended: BMW Blue Antifreeze/Coolant or equivalent ethylene glycol based. Mixture: 50/50 with distilled water. 🔧 Transmission Standard Type: Getrag 260 5-speed manual transmission. Optional Type: ZF 4HP22 4-speed automatic transmission. Features Manual Fluid: Recommended: MTF LT-2 or equivalent GL-4 75W-90 gear oil. Capacity: Approx. 1.5 liters (1.6 US quarts). Automatic Fluid: Recommended: Dexron II or equivalent. Capacity: Approx. 3.5 liters (3.7 US quarts) for torque converter refill. 📐 Dimensions Exterior Length: Approx. 4620 mm (181.9 in) Width: Approx. 1700 mm (66.9 in) Height: Approx. 1380 mm (54.3 in) Weights Curb Weight: Approx. 1400-1500 kg (3086-3307 lbs) depending on equipment. Wheelbase: Approx. 2795 mm (110.0 in) Wheels Tires Wheel Size: Commonly 14-inch or 15-inch alloy or steel wheels. Tire Size: Commonly 195/70VR14 or 205/60VR15. Bolt Pattern: 5x120 mm 🛡️ Safety Features Ratings Crash Tests: No formal standardized crash test ratings available for this era (e.g., NHTSA, Euro NCAP). Designed to meet contemporary safety standards of the early 1980s. Active Features ABS: Anti-lock Braking System (ABS) was available as an option on later models. Traction Control: Not typically available on this model. Passive Features Airbags: Driver airbag became standard on later E28 models (post-1987). Seatbelts: Three-point seatbelts in the front and rear. Body Structure: Reinforced passenger compartment, energy-absorbing steering column. 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM cassette players, often with amplifier systems. Upgraded head units are common modifications. Driver Assistance Cruise Control: Available as an optional feature. Climate Control HVAC: Manual or automatic climate control systems were available. Blower motor resistors and heater control valves are common failure points. 🔧 Maintenance Service Intervals Oil Change: Every 7,500-10,000 miles (12,000-16,000 km) or 12 months, whichever comes first, depending on driving conditions and oil type used. Air Filter: Replace every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection. Fuel Filter: Replace every 30,000-45,000 miles (48,000-72,000 km). Coolant Flush: Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km). Timing Belt:...