🏷️ Basic Information Identification Make: BMW Model: 525i Chassis Code: E28 Production Years Covered: 1981-1988 Codes Engine Codes: M30B25 (2.5L Inline-6) 👋 Introduction Market Position Positioning: The BMW E28 525i was a significant model in the executive sedan segment, known for its blend of performance, comfort, and build quality. Competitive Analysis Competitors: Competed against models like the Mercedes-Benz W123/W124 E-Class, Audi 100, and Jaguar XJ6. Key Features Design Philosophy: Emphasized driver engagement, balanced handling, and robust engineering, reflecting BMW's 'Ultimate Driving Machine' ethos. Manual Purpose: Provides comprehensive technical information for maintaining, diagnosing, and repairing the E28 525i to dealership standards. 📋 Manual Details Coverage Areas Coverage: Comprehensive workshop service and repair for BMW 525i E28 (1981-1988). Page Count Page Count: Estimated 1000+ pages (typical for comprehensive workshop manuals). Manual Type Type: Professional Workshop Service & Repair Manual. Language Language: English Format Format: Downloadable (Digital Format, typically PDF). 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel system (injection), ignition system, cooling system, lubrication system, exhaust system. Drivetrain Systems: Transmission (manual and automatic), clutch, driveshafts, differential, axles. Suspension Steering: Front and rear suspension, steering system, power steering. Braking Systems: Brake system components (discs, calipers, master cylinder), ABS (if equipped), parking brake. Electrical Systems: Wiring diagrams, battery, alternator, starter, lighting, instruments, control modules, fuses, relays. Body Chassis: Body panels, doors, windows, interior trim, chassis components, frame alignment. Procedures Included Maintenance: Routine maintenance procedures, lubrication, fluid changes, filter replacements, inspections. Repair Rebuild: Detailed repair and overhaul instructions for all major mechanical and electrical components. Diagnostics Troubleshooting: Diagnostic procedures, fault finding, troubleshooting guides, symptom-based repair advice. Specifications Tolerances: Tightening torques, clearances, alignment specifications, measurements. Body Repair: Includes procedures for bodywork, paint, and rust repair common to vehicles of this era. Technical Depth Depth: In-depth, professional-level coverage suitable for dealership technicians and experienced DIY mechanics. Engine Rebuild: Detailed procedures for engine disassembly, inspection, measurement, and reassembly. Electrical Diagnostics: Comprehensive wiring diagrams and troubleshooting guides for all electrical systems. 📊 Manual Specifications File Format File Type: PDF (typically). Print Quality Quality: High-resolution scans with clear text and diagrams. Binding Type Binding: N/A (Digital Download). Paper Type Paper Type: N/A (Digital Download). Content Completeness Coverage Scope: Full workshop manual, including detailed exploded diagrams, torque specifications, and diagnostic flowcharts. ⚙️ Engine Specifications Primary Engine Engine Type: M30B25 - Inline 6-cylinder, SOHC. Displacement: 2.5 Liters (2494 cc). Performance Horsepower: Approx. 150-170 hp (depending on market and specific configuration). Torque: Approx. 165-185 lb-ft (depending on market and specific configuration). Acceleration: 0-60 mph in approximately 8.5-9.5 seconds (for manual transmission). Fuel System Injection System: Bosch L-Jetronic or Motronic fuel injection. Cooling System Cooling Type: Water-cooled, pressurized system. Lubrication System Oil Capacity: Approx. 5.7 Liters (6.0 US Quarts) with filter change. Engine Management ECU: Bosch Motronic (later models) or L-Jetronic. 🔧 Transmission Standard Transmission Type: 4-speed Getrag 260 manual transmission. Optional Transmission Type: 3-speed ZF 3HP22 automatic transmission. Features Clutch Type: Dry single-plate clutch. Fluid Specifications Manual Transmission Fluid: Dexron III ATF or equivalent (check specific manual for exact spec). Automatic Transmission Fluid: Dexron III ATF or equivalent (check specific manual for exact spec). 📐 Dimensions Exterior Length: Approx. 4620 mm (181.9 in). Width: Approx. 1700 mm (66.9 in). Height: Approx. 1380 mm (54.3 in). Wheelbase: 2795 mm (110.0 inches) Track Width Front: Approx. 1430 mm (56.3 inches) Track Width Rear: Approx. 1448 mm (57.0 inches) Weights Curb Weight: Approx. 1400-1500 kg (3086-3307 lbs). Gross Vehicle Weight: Approx. 1900-2000 kg (4189-4409 lbs). Wheelbase Wheelbase: Approx. 2795 mm (110.0 in). 🛡️ Safety Features Ratings Crash Safety: Good structural integrity for its era; specific crash test ratings are less common for this period but reflect robust construction. Active Features Braking System: Four-wheel disc brakes, ABS optional/standard on later models. Passive Features Seat Belts: Three-point inertia reel seat belts. Steering Column: Collapsible steering column. 💡 Technology Features Infotainment Audio System: Factory installed AM/FM stereo cassette player, often with premium sound options (e.g., Bavaria). Climate Control: Manual or automatic climate control (ECC - Electronic Climate Control) on higher trims. Driver Assistance Cruise Control: Available as an option or standard on some trims. Connectivity Early Features: Limited by era; primary focus on mechanical and chassis technology. 🔧 Maintenance Service Intervals Oil Change: Typically every 5,000 - 10,000 miles or 6-12 months, depending on driving conditions (check manual for exact intervals). Spark Plug Replacement: Intervals vary; typically around 20,000-30,000 miles for standard plugs. Timing Belt Chain: M30 engines use a timing chain, which is designed for the life of the engine but may require tensioner checks. Fluid Specifications Engine Oil Type: API SG or higher, viscosity typically 10W-40 or 15W-50 (check manual for climate-specific recommendations). Coolant Type: Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Brake Fluid Type: DOT 3 or DOT 4 brake fluid. Known Issues Common Problems: Cooling system components (hoses, radiator, water...