BMW 5 Series E28 E34 Service Repair Manual 1981-1991

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E28, E34 Years Covered: 1981-1991 👋 Introduction Market Position Market Position: The BMW 5 Series (E28 and E34) represented the pinnacle of executive sedans in their respective eras, blending sporty performance with luxury and sophisticated engineering. These vehicles were aimed at discerning drivers who valued driving dynamics and build quality. Competitive Analysis Competitors: Competed with other premium executive sedans like the Mercedes-Benz W123/W124 E-Class, Audi 100/200, and Jaguar XJ6. Key Features Key Features: Renowned for their straight-six engines, balanced chassis, driver-focused interiors, and advanced (for the time) technology. Manual Value Proposition Value Proposition: Empowers owners and technicians to perform comprehensive maintenance, diagnosis, and repair, significantly reducing reliance on dealership service and saving considerable costs. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Workshop Manual Language: English Format: Downloadable PDF Page Count Estimated Page Count: Likely extensive, thousands of pages for full coverage of both generations. Specific count not provided but implied comprehensive. 📖 Manual Coverage Systems Covered Engine: Detailed repair and overhaul procedures for M20, M30, M88, S38, and M21 diesel engines. Fuel System: Bosch L-Jetronic, LE-Jetronic, Motronic fuel injection systems, carburetor maintenance (where applicable). Ignition System: Electronic ignition, spark plug service, coil and distributor troubleshooting. Cooling System: Radiator, water pump, thermostat, fan, hoses, and coolant specifications. Exhaust System: Catalytic converter, muffler, exhaust manifold repair, and gasket replacement. Transmission Manual: Getrag 260, 265, 280 manual transmission overhaul, clutch service, and shift linkage adjustment. Transmission Automatic: ZF 4HP22, 4HP24 automatic transmission service, fluid replacement, and common troubleshooting. Drivetrain: Driveshaft, universal joints, driveshaft center bearing, and differential service. Suspension Front: MacPherson struts, control arms, ball joints, sway bars, and alignment procedures. Suspension Rear: Trailing arms, shock absorbers, springs, bushings, and alignment procedures. Steering System: Power steering pump, steering rack, tie rods, and steering column repair. Brake System: Disc brake service (front and rear), caliper repair, master cylinder, ABS system troubleshooting (where applicable). Electrical System: Starter, alternator, battery, wiring diagrams, fuse box, and lighting system diagnostics. Body And Trim: Door panel removal, window regulator repair, seat adjustment, exterior trim replacement. HVAC: Heater core replacement, A/C system service, blower motor troubleshooting. Electrical Diagrams: Comprehensive wiring diagrams for various electrical circuits, aiding in diagnosis and repair. Body And Paint: Includes basic bodywork repair guidance, panel gap information, and potentially paint codes for touch-ups. Procedures Included Maintenance: Oil change, filter replacement, coolant flush, spark plug replacement, brake fluid flush, belt inspection and replacement. Troubleshooting: Diagnostic charts for common engine, electrical, and mechanical issues. Repair: Step-by-step instructions for component removal, overhaul, and reinstallation. Rebuild: Detailed engine and transmission rebuild procedures, including torque specifications and clearances. Installation: Procedures for installing aftermarket parts or replacing major components. Alignment: Front and rear wheel alignment specifications and adjustment procedures. Torque Specifications: Detailed torque specifications for critical fasteners in engine, transmission, suspension, and chassis components. Technical Depth Depth: Comprehensive, covering basic to advanced repair and diagnostic procedures, suitable for professional mechanics and advanced DIY enthusiasts. Diagnostic Procedures: Covers diagnostic trouble codes (DTCs) where applicable, along with systematic troubleshooting guides for electrical and mechanical systems. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, designed for clear printing of diagrams, illustrations, and text. Binding Type Binding Type: N/A (Downloadable Digital Format) Paper Type Paper Type: N/A (Digital Format) File Organization Searchability: High. Typically includes a searchable PDF with a table of contents for easy navigation of sections and procedures. Diagrams And Illustrations: Includes detailed diagrams, exploded views, and schematics crucial for understanding complex systems and assembly procedures. ⚙️ Engine Specifications Primary Engine E28 Engine Variants E28: M20B20 (2.0L), M20B23 (2.3L), M20B25 (2.7L), M30B30 (3.0L), M30B32 (3.2L), M30B35 (3.5L), S38B35 (3.5L - M5), M88B35 (3.5L - M5), M21D24 (2.4L Diesel). Primary Engine E34 Engine Variants E34: M20B20 (2.0L), M20B25 (2.7L), M30B30 (3.0L), M30B35 (3.5L), M30B34 (3.4L), M60B30 (3.0L V8), M60B40 (4.0L V8), S38B36 (3.6L - M5), S38B38 (3.8L - M5), M21D24 (2.4L Diesel), M51D25 (2.5L Turbo Diesel). Performance Typical Horsepower Range: Approximately 115 hp to 310 hp (M5 models). Torque Range: Approximately 180 Nm to 360 Nm (M5 models). Fuel System Fuel Injection: Bosch L-Jetronic, LE-Jetronic, Motronic electronic fuel injection (EFI). Engine Management ECU Types: Various Bosch Motronic variants (e.g., Motronic ML4.1, ML3.1, M3.3) depending on engine and model year. 🔧 Transmission Standard Transmission Standard Transmission E28: 4-speed or 5-speed Getrag manual transmission. Optional Transmission Optional Transmission E28: ZF 3HP22 or 4HP22 automatic transmission. Standard Transmission E34 Standard Transmission E34: Getrag 260 (5-speed) manual transmission. Optional Transmission E34 Optional Transmission E34: ZF 4HP22 EH or 4HP24 EH automatic transmission. Features Clutch Type: Hydraulically actuated single-plate dry clutch. Fluid Specifications Manual Transmission Fluid: Typically SAE 75W-90 or 80W-90 API GL-4 or GL-5 gear oil (refer to specific vehicle manual for exact grade). Automatic Transmission Fluid:...

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Tipo: Car

Fabricante:

Sku: 319619

Coleções: ALL BMW

Disponibilidade: Em estoque

Tag: 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 5 Series E28 5 Series E34 BMW Car Cars Misc

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

E28, E34

Years Covered:

1981-1991

👋 Introduction

Market Position

Market Position:

The BMW 5 Series (E28 and E34) represented the pinnacle of executive sedans in their respective eras, blending sporty performance with luxury and sophisticated engineering. These vehicles were aimed at discerning drivers who valued driving dynamics and build quality.

Competitive Analysis

Competitors:

Competed with other premium executive sedans like the Mercedes-Benz W123/W124 E-Class, Audi 100/200, and Jaguar XJ6.

Key Features

Key Features:

Renowned for their straight-six engines, balanced chassis, driver-focused interiors, and advanced (for the time) technology.

Manual Value Proposition

Value Proposition:

Empowers owners and technicians to perform comprehensive maintenance, diagnosis, and repair, significantly reducing reliance on dealership service and saving considerable costs.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Workshop Manual

Language:

English

Format:

Downloadable PDF

Page Count

Estimated Page Count:

Likely extensive, thousands of pages for full coverage of both generations. Specific count not provided but implied comprehensive.

📖 Manual Coverage

Systems Covered

Engine:

Detailed repair and overhaul procedures for M20, M30, M88, S38, and M21 diesel engines.

Fuel System:

Bosch L-Jetronic, LE-Jetronic, Motronic fuel injection systems, carburetor maintenance (where applicable).

Ignition System:

Electronic ignition, spark plug service, coil and distributor troubleshooting.

Cooling System:

Radiator, water pump, thermostat, fan, hoses, and coolant specifications.

Exhaust System:

Catalytic converter, muffler, exhaust manifold repair, and gasket replacement.

Transmission Manual:

Getrag 260, 265, 280 manual transmission overhaul, clutch service, and shift linkage adjustment.

Transmission Automatic:

ZF 4HP22, 4HP24 automatic transmission service, fluid replacement, and common troubleshooting.

Drivetrain:

Driveshaft, universal joints, driveshaft center bearing, and differential service.

Suspension Front:

MacPherson struts, control arms, ball joints, sway bars, and alignment procedures.

Suspension Rear:

Trailing arms, shock absorbers, springs, bushings, and alignment procedures.

Steering System:

Power steering pump, steering rack, tie rods, and steering column repair.

Brake System:

Disc brake service (front and rear), caliper repair, master cylinder, ABS system troubleshooting (where applicable).

Electrical System:

Starter, alternator, battery, wiring diagrams, fuse box, and lighting system diagnostics.

Body And Trim:

Door panel removal, window regulator repair, seat adjustment, exterior trim replacement.

HVAC:

Heater core replacement, A/C system service, blower motor troubleshooting.

Electrical Diagrams:

Comprehensive wiring diagrams for various electrical circuits, aiding in diagnosis and repair.

Body And Paint:

Includes basic bodywork repair guidance, panel gap information, and potentially paint codes for touch-ups.

Procedures Included

Maintenance:

Oil change, filter replacement, coolant flush, spark plug replacement, brake fluid flush, belt inspection and replacement.

Troubleshooting:

Diagnostic charts for common engine, electrical, and mechanical issues.

Repair:

Step-by-step instructions for component removal, overhaul, and reinstallation.

Rebuild:

Detailed engine and transmission rebuild procedures, including torque specifications and clearances.

Installation:

Procedures for installing aftermarket parts or replacing major components.

Alignment:

Front and rear wheel alignment specifications and adjustment procedures.

Torque Specifications:

Detailed torque specifications for critical fasteners in engine, transmission, suspension, and chassis components.

Technical Depth

Depth:

Comprehensive, covering basic to advanced repair and diagnostic procedures, suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Procedures:

Covers diagnostic trouble codes (DTCs) where applicable, along with systematic troubleshooting guides for electrical and mechanical systems.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Print Quality:

High-resolution, designed for clear printing of diagrams, illustrations, and text.

Binding Type

Binding Type:

N/A (Downloadable Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

File Organization

Searchability:

High. Typically includes a searchable PDF with a table of contents for easy navigation of sections and procedures.

Diagrams And Illustrations:

Includes detailed diagrams, exploded views, and schematics crucial for understanding complex systems and assembly procedures.

⚙️ Engine Specifications

Primary Engine E28

Engine Variants E28:

M20B20 (2.0L), M20B23 (2.3L), M20B25 (2.7L), M30B30 (3.0L), M30B32 (3.2L), M30B35 (3.5L), S38B35 (3.5L - M5), M88B35 (3.5L - M5), M21D24 (2.4L Diesel).

Primary Engine E34

Engine Variants E34:

M20B20 (2.0L), M20B25 (2.7L), M30B30 (3.0L), M30B35 (3.5L), M30B34 (3.4L), M60B30 (3.0L V8), M60B40 (4.0L V8), S38B36 (3.6L - M5), S38B38 (3.8L - M5), M21D24 (2.4L Diesel), M51D25 (2.5L Turbo Diesel).

Performance Typical

Horsepower Range:

Approximately 115 hp to 310 hp (M5 models).

Torque Range:

Approximately 180 Nm to 360 Nm (M5 models).

Fuel System

Fuel Injection:

Bosch L-Jetronic, LE-Jetronic, Motronic electronic fuel injection (EFI).

Engine Management

ECU Types:

Various Bosch Motronic variants (e.g., Motronic ML4.1, ML3.1, M3.3) depending on engine and model year.

🔧 Transmission

Standard Transmission

Standard Transmission E28:

4-speed or 5-speed Getrag manual transmission.

Optional Transmission

Optional Transmission E28:

ZF 3HP22 or 4HP22 automatic transmission.

Standard Transmission E34

Standard Transmission E34:

Getrag 260 (5-speed) manual transmission.

Optional Transmission E34

Optional Transmission E34:

ZF 4HP22 EH or 4HP24 EH automatic transmission.

Features

Clutch Type:

Hydraulically actuated single-plate dry clutch.

Fluid Specifications

Manual Transmission Fluid:

Typically SAE 75W-90 or 80W-90 API GL-4 or GL-5 gear oil (refer to specific vehicle manual for exact grade).

Automatic Transmission Fluid:

Typically ZF TE-ML 09 or Dexron II/III (refer to specific vehicle manual for exact grade).

📐 Dimensions

Exterior E28

Length E28:

Approx. 4,720-4,770 mm (185.8-187.8 in)

Width E28:

Approx. 1,700 mm (66.9 in)

Height E28:

Approx. 1,400-1,420 mm (55.1-55.9 in)

Exterior E34

Length E34:

Approx. 4,720-4,870 mm (185.8-191.7 in)

Width E34:

Approx. 1,750-1,800 mm (68.9-70.9 in)

Height E34:

Approx. 1,410-1,430 mm (55.5-56.3 in)

Weights

Curb Weight:

Ranges from approx. 1,300 kg to 1,700 kg (2,866 to 3,748 lbs) depending on model and equipment.

Gross Vehicle Weight varies by model, typically around 1,800-2,000 kg.

🛡️ Safety Features

Ratings

Crash Test Results:

Modern crash test ratings (NHTSA, IIHS) are not directly applicable to vehicles of this vintage, but they were built to high safety standards for their time, featuring robust unibody construction and crumple zones.

Active Features

Anti-lock Braking System (ABS) became available and standard on many E34 models, and optional on later E28 models.

Traction Control:

ASC/ASC+T (Automatic Stability Control) was introduced as an option on later E34 models.

Passive Features

Airbags:

Driver-side airbag became available on later E34 models; not standard on most E28 models.

Seatbelts:

Three-point seatbelts with pretensioners (on later models) for front occupants.

Chassis Design:

Reinforced safety cage, energy-absorbing steering column.

💡 Technology Features

Infotainment E28

Infotainment Features E28:

Basic AM/FM radio with cassette player, optional premium sound systems.

Infotainment E34

Infotainment Features E34:

More advanced factory radio/cassette/CD systems, optional premium sound by Nakamichi or Harman Kardon, early forms of digital climate control.

Driver Assistance E34

Driver Assistance E34:

Traction control (ASC/ASC+T), cruise control, trip computer, power adjustable seats with memory.

Connectivity E28

Connectivity E28:

N/A (No integrated connectivity features).

Connectivity E34

Connectivity E34:

N/A (No integrated connectivity features in the modern sense; wired for optional car phones in some markets).

🔧 Maintenance

Service Intervals Engine Oil

Engine Oil And Filter Interval:

Typically every 7,500 to 10,000 miles or annually, whichever comes first (depending on driving conditions and oil used).

Service Intervals Spark Plugs

Spark Plug Replacement Interval:

Every 30,000 to 60,000 miles for standard spark plugs; platinum or iridium plugs may last longer.

Service Intervals Coolant

Coolant Flush Interval:

Every 2 years or 30,000 miles, or as specified by BMW coolant type.

Service Intervals Brakes

Brake Fluid Flush Interval:

Every 2 years to prevent moisture absorption.

Service Intervals Transmission Fluid

Manual Transmission Fluid Interval:

Recommended inspection at 30,000 miles, fluid change typically every 60,000 miles or as needed.

Automatic Transmission Fluid Interval:

Inspection at 30,000 miles, fluid and filter change typically every 50,000-75,000 miles, though BMW historically recommended 'lifetime' fluid which is now understood to require replacement.

Fluid Specifications

Engine Oil Specification:

Refer to owner's manual. Typically API SG/SH or higher. Viscosity grades like 10W-40, 15W-40, 5W-30, or 5W-40 depending on climate and specific engine. BMW Longlife-01 approved oils are backward compatible for many older models.

Coolant Specification:

BMW Blue Ethylene Glycol based coolant or equivalent. Mixture of 50/50 with distilled water.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Known Issues E28

Common Problems E28:

Oil leaks (valve cover gasket, oil pan gasket), coolant leaks (hose clamps, radiator), fuel pump issues, idle control valve problems, seized brake calipers, dashboard illumination failures, subframe bushings.

Known Issues E34

Common Problems E34:

Coolant leaks (plastic thermostat housing, expansion tank, heater core), radiator support cracks, fuel injector seal leaks, ABS sensor failures, window regulator failures, door seal degradation, climate control system issues.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's philosophy of 'The Ultimate Driving Machine' is evident in both the E28 and E34 generations, emphasizing driver engagement and performance.

Model Evolution E28

E28 Introduction:

Introduced in 1981, the E28 was a significant update to the 5 Series, featuring a more modern design and improved aerodynamics over its predecessor (E12).

E28 Key Models:

Notable models include the 528i, 535i, and the legendary M535i and M5 (E28 S38).

Model Evolution E34

E34 Introduction:

Launched in 1988, the E34 brought a sleeker, more aerodynamic design, a wider range of engines (including V8s), and significantly enhanced safety and comfort features.

E34 Key Models:

Included models like 525i, 535i, 540i, and the high-performance M5 (E34 S38).

Production Period

E28 Production Years:

1981-1988

E34 Production Years:

1987-1996 (manual covers up to 1991 for the early E34 models).

🏆 Awards & Recognition

Recognitions

E28 Recognitions:

The E28 M5 was widely acclaimed as the world's fastest production sedan upon its release. Both E28 and E34 were consistently praised by automotive journalists for their driving dynamics and build quality.

E34 Recognitions:

Car and Driver magazine's '10Best' list multiple times. Often cited for its blend of performance, luxury, and handling.