Basic Information Identification Make: BMW Model: 525i Year: 1982 Codes Chassis Code: E28 Engine Code: M30B25 Generation Chassis Generation: E28 (First generation of the 5 Series to use this designation) Introduction Market Position Vehicle Segment: Luxury/Executive Sedan Target Audience: Affluent consumers seeking a blend of performance, comfort, and sophisticated engineering. Competitive Analysis Key Competitors: Mercedes-Benz W123/W124 series, Audi 100, Volvo 240/700 series, Jaguar XJ-S. Key Features Vehicle Highlights: Rear-wheel drive dynamics, refined inline-six engine, excellent build quality, comfortable interior, advanced (for its time) engineering, sophisticated styling. Manual Value Proposition Why This Manual: Essential for owners and independent repair shops to maintain, diagnose, and repair the complex systems of the BMW 525i (E28) accurately and efficiently. Manual Details Coverage Areas Manual Type: Full Service Repair Manual Language: English Format: Digital (likely PDF) Specific Models Covered: Specifically covers the BMW 525i model for the 1982 model year within the E28 chassis designation. Page Count Estimated Page Count: Detailed, likely 500+ pages (typical for full service manuals of this era) Format File Format: Digital (e.g., PDF). Searchable text and printable pages expected. Print Quality: High resolution for clear diagrams and text. Binding Type: N/A (Digital Product) Paper Type: N/A (Digital Product) Searchability: If a PDF, it should have selectable text for easy searching of specific terms and components. Manual Coverage Systems Covered Engine Systems: Engine mechanical (assembly, disassembly, timing, valve train, pistons, crankshaft), Fuel system (carburetor/injection system specifics, fuel pump, lines, filter), Ignition system (distributor, coils, plugs, timing), Cooling system (radiator, thermostat, water pump, hoses), Lubrication system (oil pump, filter, oil passages), Exhaust system (manifold, catalytic converter, muffler, pipes), Emissions control systems. Drivetrain Systems: Transmission (manual & automatic), Clutch system (components, adjustment, replacement), Driveshafts, Differential (rear axle), Axles. Chassis Systems: Suspension (front & rear components, springs, shocks, control arms, bushings), Steering (steering rack, linkages, power steering system), Brakes (hydraulic system, master cylinder, calipers, pads, rotors, parking brake), Wheels and tires. Electrical Systems: Battery, Charging system (alternator, regulator), Starting system (starter motor), Lighting (headlights, taillights, interior), Ignition switch, Fuses and relays, Wiring diagrams for all circuits, Instrument cluster, Gauges, Wiper and washer system, Horn, Power windows, Power mirrors, Central locking. Body And Interior: Body panels (removal, installation, alignment), Doors, Hood, Trunk lid, Bumpers, Glass (windshield, side, rear), Seats, Interior trim panels, Dashboard, HVAC system (heater core, blower motor, controls, A/C system components). Procedures Included Maintenance Procedures: Oil and filter changes, Air filter replacement, Spark plug replacement, Coolant flush and fill, Brake fluid flush, Transmission fluid and filter service, Differential fluid change, Battery maintenance, Wiper blade replacement, Tire rotation and balancing. Repair Procedures: Engine overhaul and rebuild, Transmission overhaul (manual & automatic), Clutch replacement, Brake caliper and master cylinder rebuild/replacement, Suspension component replacement (shocks, struts, bushings, ball joints), Steering rack repair/replacement, Fuel pump replacement, Alternator and starter replacement, Radiator and water pump replacement, Heater core replacement, Electrical component diagnosis and repair, Body panel repair and replacement, Door and window mechanism repair. Diagnostic Procedures: Troubleshooting common faults, Component testing, Circuit testing using multimeters and test lights, Ignition timing adjustment, Carburetor adjustment (if applicable), Fuel injection system diagnostics (if applicable), Vacuum leak detection, Engine performance diagnostics. Troubleshooting Charts: Comprehensive troubleshooting charts organized by symptom and system for efficient diagnosis of common and uncommon issues. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, Fault code lookup (if applicable to the system), Circuit tracing, Component resistance and voltage testing. Rebuild Capabilities: Complete engine rebuild procedures, Transmission overhaul specifications and procedures, Differential rebuilds. Specifications And Tolerances: Detailed torque specifications for all fasteners, Engine component clearances (piston ring gap, bearing clearance, valve lash), Brake system specifications (pad thickness, rotor runout), Suspension geometry settings. Wiring Diagrams: Detailed, factory-quality wiring diagrams for all electrical systems, crucial for electrical diagnostics and repairs. Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, Naturally Aspirated Displacement: 2.5 Liters (2494 cc) Bore X Stroke: 84.0 mm x 75.0 mm Compression Ratio: 8.8:1 Valvetrain: SOHC (Single Overhead Camshaft), 2 valves per cylinder Performance Horsepower: 150 PS (148 hp; 110 kW) at 5500 rpm (approx.) Torque: 220 N⋅m (162 lb⋅ft) at 4000 rpm (approx.) Fuel System Fuel Delivery: Bosch L-Jetronic Fuel Injection (standard) Fuel Type: Unleaded Gasoline (Premium) Cooling System Cooling Medium: Water/Glycol Mixture Transmission Standard Transmission Type: 4-speed Manual Optional Transmission Type: 3-speed ZF 3HP22 Automatic Transmission Features Rear Axle Ratio: 3.45:1 (typical for manual transmission) Clutch Type: Dry single plate, hydraulically operated Dimensions Exterior Length: 4620 mm (181.9 in) Width: 1700 mm (66.9 in) Height: 1415 mm (55.7 in) Wheelbase: 2700 mm (106.3 in) Front Track: 1430 mm (56.3 in) Rear Track: 1470 mm (57.9 in) Weights Curb Weight: Approx. 1400-1500 kg (3086-3307 lbs) Gross Vehicle Weight Rating: Approx. 1900 kg (4189 lbs) Fuel Capacity: 70 Liters (18.5 US gal) Safety Features Ratings Crash Test History: No formal crash test ratings readily available from modern standards for this specific model year, but generally considered a robustly built vehicle for its era. Active Features Braking System: Power-assisted hydraulic disc brakes front and rear, Anti-lock Braking System (ABS) was optional or standard on later models. Suspension Features: Independent front suspension (MacPherson struts), Independent rear suspension (Semi-trailing arms) providing good handling characteristics. Passive Features Seat Belts: 3-point inertia-reel seat belts front and rear (standard). Body Structure: Reinforced safety cell, crumple zones front and rear. Headlights: Halogen headlights for improved nighttime visibility. Technology Features Infotainment Audio System: Typically a factory AM/FM radio with cassette player, possibly with amplifier and upgraded speakers. Aftermarket head units are common upgrades. Driver Assistance ABS Availability: Optional on early models, potentially standard on later 1982 models or specific trims. Connectivity Connectivity Features: None in the modern sense. Basic connectivity via analog radio signals. Climate Control HVAC System: Manual or optional automatic climate control, featuring heating and ventilation. Air conditioning was a common option. Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 miles (or annually), depending on driving conditions. Refer to manual for precise intervals. Spark Plug Replacement: Every 20,000 - 30,000 miles (approx., depending on plug type). Coolant Flush: Every 2 years or 30,000 miles. Transmission...