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BMW 528 528i 1981-1988 Service Repair Manual

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Basic Information Identification Make: BMW Model: 528 / 528i Model Code: E28 Production Years Covered: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988 Codes Engine Codes Covered: M30B28 Introduction Market Position Vehicle Segment: Executive/Luxury Sedan Target Audience: Owners seeking to maintain and repair their E28 chassis BMWs, automotive enthusiasts, independent repair shops Competitive Analysis Contemporary Competitors: Mercedes-Benz W123/W124, Audi 5000, Volvo 700 Series, Jaguar XJ6 Key Features Bmw Philosophy: Emphasis on driving dynamics, refined engineering, and driver engagement, hallmarks of BMW's 'Ultimate Driving Machine' ethos Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: Thousands of pages (typical for comprehensive factory-level manuals) Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnosis, repair of M30B28 engine (cylinders, pistons, crankshaft, camshaft, valves, timing system, lubrication, cooling) Engine Management And Fuel: L-Jetronic fuel injection system (injectors, fuel pump, pressure regulator, sensors), ignition system (coil, distributor, spark plugs), emissions control Transmission Manual: Diagnosis, repair, and overhaul of Getrag 260 5-speed manual transmission, clutch system Transmission Automatic: Diagnosis, repair, and overhaul of ZF 4HP22 automatic transmission (if applicable to specific 528i variants) Drivetrain: Driveshaft, universal joints, differential, rear axle, wheel bearings Suspension: Front MacPherson struts, rear semi-trailing arm suspension, springs, shock absorbers, control arms, bushings, sway bars Steering: Power steering system (pump, gearbox, hoses), steering column, tie rods Brakes: Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), master cylinder, brake lines, parking brake system Electrical System: 12V electrical system, battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting (headlights, taillights, interior), instrumentation, warning lights Body And Chassis: Body construction, body panels, doors, windows, sunroof, interior trim, corrosion protection, chassis components Heating Ventilation And Air Conditioning: HVAC system operation, diagnosis, repair of blower motor, heater core, A/C compressor, refrigerant system, climate controls Fuel Tank And Exhaust: Fuel tank, fuel lines, exhaust system (manifold, catalytic converter, mufflers), emissions components Procedures Included Routine Maintenance: Oil change, filter replacement, fluid checks and changes (coolant, brake fluid, power steering fluid), spark plug replacement, air filter replacement, belt inspection and replacement Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting charts, error code interpretation (if applicable) Component Removal And Installation: Step-by-step instructions for removing and installing virtually every major and minor component of the vehicle Engine Rebuilding: Detailed procedures for engine disassembly, inspection, measurement, machining, and reassembly Transmission Overhaul: Complete breakdown and reassembly instructions for both manual and automatic transmissions Brake System Service: Pad and rotor replacement, caliper service, bleeding the brake system, master cylinder replacement Electrical Diagnosis And Repair: Reading and interpreting wiring diagrams, tracing electrical faults, component testing Suspension And Steering Alignment: Inspection and adjustment procedures for wheel alignment parameters Bodywork And Cosmetic Repair: Minor body panel repairs, door adjustment, glass replacement (likely limited scope for body panels) Technical Depth Depth Of Information: Factory-level technical detail, suitable for professional technicians and serious DIY enthusiasts Diagnostic Capabilities: Extensive diagnostic information, including fault codes, sensor data interpretation, and systematic troubleshooting approaches Specification Data: Includes torque specifications, clearances, tolerances, fluid capacities, and electrical resistance values Diagrams And Illustrations: Richly illustrated with exploded views, detailed diagrams of systems and components, and wiring schematics Manual Specifications File Format Digital Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval Print Quality Digital Resolution: High resolution for clarity of text and diagrams Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, DOHC (Double Overhead Camshaft), M30 family Displacement: 2.8 Liters (2788 cc) Bore X Stroke: 86 mm x 80 mm Compression Ratio: 8.0:1 or 8.8:1 (depending on market and specific model variant) Performance Horsepower Peak: Approximately 181 hp @ 5800 rpm (for European spec, US spec may vary slightly) Torque Peak: Approximately 230 Nm (170 lb-ft) @ 3500 rpm (for European spec, US spec may vary slightly) Fuel System Fuel Delivery: Bosch L-Jetronic (or Motronic for later models/variants) Fuel Injection Fuel Type: Unleaded Gasoline (Premium Octane Recommended) Transmission Standard Standard Transmission: Getrag 260 5-speed Manual Transmission Optional Optional Transmission: ZF 4HP22 4-speed Automatic Transmission Features Clutch Type: Hydraulically actuated single-plate dry clutch Rear Axle Ratio: Typically 3.46:1 or 3.25:1 (depending on transmission and market) Dimensions Exterior Length: 4725 mm (186.0 inches) Width: 1700 mm (66.9 inches) Height: 1415 mm (55.7 inches) Wheelbase: 2775 mm (109.3 inches) Weights Curb Weight: Approximately 1400-1500 kg (3086-3307 lbs) Safety Features Ratings Crash Test Ratings: No standardized crash test ratings comparable to modern standards (e.g., NHTSA, Euro NCAP) were prevalent for vehicles of this era. Active Features ABS: Anti-lock Braking System (ABS) often optional or standard on later models/higher trims Passive Features Seatbelts: Three-point seatbelts for front and rear occupants Crumple Zones: Designed with front and rear crumple zones for energy absorption Technology Features Infotainment Infotainment System: Basic analog and digital displays, cassette player,...
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BMW 528 528i 1981-1988 Service Repair Manual
Basic Information
Identification
Make: BMW
Model: 528 / 528i
Model Code: E28
Production Years Covered: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988
Codes
Engine Codes Covered: M30B28
Introduction
Market Position
Vehicle Segment: Executive/Luxury Sedan
Target Audience: Owners seeking to maintain and repair their E28 chassis BMWs, automotive enthusiasts, independent repair shops
Competitive Analysis
Contemporary Competitors: Mercedes-Benz W123/W124, Audi 5000, Volvo 700 Series, Jaguar XJ6
Key Features
Bmw Philosophy: Emphasis on driving dynamics, refined engineering, and driver engagement, hallmarks of BMW's 'Ultimate Driving Machine' ethos
Manual Details
Coverage Areas
Manual Type: Service and Repair Manual
Language: English
Format: PDF Download
Page Count
Estimated Page Count: Thousands of pages (typical for comprehensive factory-level manuals)
Manual Coverage
Systems Covered
Engine Mechanical: Complete overhaul, diagnosis, repair of M30B28 engine (cylinders, pistons, crankshaft, camshaft, valves, timing system, lubrication, cooling)
Engine Management And Fuel: L-Jetronic fuel injection system (injectors, fuel pump, pressure regulator, sensors), ignition system (coil, distributor, spark plugs), emissions control
Transmission Manual: Diagnosis, repair, and overhaul of Getrag 260 5-speed manual transmission, clutch system
Transmission Automatic: Diagnosis, repair, and overhaul of ZF 4HP22 automatic transmission (if applicable to specific 528i variants)
Drivetrain: Driveshaft, universal joints, differential, rear axle, wheel bearings
Suspension: Front MacPherson struts, rear semi-trailing arm suspension, springs, shock absorbers, control arms, bushings, sway bars
Steering: Power steering system (pump, gearbox, hoses), steering column, tie rods
Brakes: Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), master cylinder, brake lines, parking brake system
Electrical System: 12V electrical system, battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting (headlights, taillights, interior), instrumentation, warning lights
Body And Chassis: Body construction, body panels, doors, windows, sunroof, interior trim, corrosion protection, chassis components
Heating Ventilation And Air Conditioning: HVAC system operation, diagnosis, repair of blower motor, heater core, A/C compressor, refrigerant system, climate controls
Fuel Tank And Exhaust: Fuel tank, fuel lines, exhaust system (manifold, catalytic converter, mufflers), emissions components
Procedures Included
Routine Maintenance: Oil change, filter replacement, fluid checks and changes (coolant, brake fluid, power steering fluid), spark plug replacement, air filter replacement, belt inspection and replacement
Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting charts, error code interpretation (if applicable)
Component Removal And Installation: Step-by-step instructions for removing and installing virtually every major and minor component of the vehicle
Engine Rebuilding: Detailed procedures for engine disassembly, inspection, measurement, machining, and reassembly
Transmission Overhaul: Complete breakdown and reassembly instructions for both manual and automatic transmissions
Brake System Service: Pad and rotor replacement, caliper service, bleeding the brake system, master cylinder replacement
Electrical Diagnosis And Repair: Reading and interpreting wiring diagrams, tracing electrical faults, component testing
Suspension And Steering Alignment: Inspection and adjustment procedures for wheel alignment parameters
Bodywork And Cosmetic Repair: Minor body panel repairs, door adjustment, glass replacement (likely limited scope for body panels)
Technical Depth
Depth Of Information: Factory-level technical detail, suitable for professional technicians and serious DIY enthusiasts
Diagnostic Capabilities: Extensive diagnostic information, including fault codes, sensor data interpretation, and systematic troubleshooting approaches
Specification Data: Includes torque specifications, clearances, tolerances, fluid capacities, and electrical resistance values
Diagrams And Illustrations: Richly illustrated with exploded views, detailed diagrams of systems and components, and wiring schematics
Manual Specifications
File Format
Digital Format: PDF
Searchability: Likely text-searchable PDF for efficient information retrieval
Print Quality
Digital Resolution: High resolution for clarity of text and diagrams
Binding Type
Binding: N/A (Digital PDF)
Paper Type
Paper Type: N/A (Digital PDF)
Engine Specifications
Primary Engine
Engine Type: Inline 6-cylinder, DOHC (Double Overhead Camshaft), M30 family
Displacement: 2.8 Liters (2788 cc)
Bore X Stroke: 86 mm x 80 mm
Compression Ratio: 8.0:1 or 8.8:1 (depending on market and specific model variant)
Performance
Horsepower Peak: Approximately 181 hp @ 5800 rpm (for European spec, US spec may vary slightly)
Torque Peak: Approximately 230 Nm (170 lb-ft) @ 3500 rpm (for European spec, US spec may vary slightly)
Fuel System
Fuel Delivery: Bosch L-Jetronic (or Motronic for later models/variants) Fuel Injection
Fuel Type: Unleaded Gasoline (Premium Octane Recommended)
Transmission
Standard
Standard Transmission: Getrag 260 5-speed Manual Transmission
Optional
Optional Transmission: ZF 4HP22 4-speed Automatic Transmission
Features
Clutch Type: Hydraulically actuated single-plate dry clutch
Rear Axle Ratio: Typically 3.46:1 or 3.25:1 (depending on transmission and market)
Dimensions
Exterior
Length: 4725 mm (186.0 inches)
Width: 1700 mm (66.9 inches)
Height: 1415 mm (55.7 inches)
Wheelbase: 2775 mm (109.3 inches)
Weights
Curb Weight: Approximately 1400-1500 kg (3086-3307 lbs)
Safety Features
Ratings
Crash Test Ratings: No standardized crash test ratings comparable to modern standards (e.g., NHTSA, Euro NCAP) were prevalent for vehicles of this era.
Active Features
ABS: Anti-lock Braking System (ABS) often optional or standard on later models/higher trims
Passive Features
Seatbelts: Three-point seatbelts for front and rear occupants
Crumple Zones: Designed with front and rear crumple zones for energy absorption
Technology Features
Infotainment
Infotainment System: Basic analog and digital displays, cassette player, AM/FM radio. Optional period-specific amenities like power windows, power locks, cruise control, and sunroof.
Driver Assistance
Driver Assistance Features: Limited by era; ABS was the primary advanced safety feature. Cruise control was a common convenience option.
Connectivity
Connectivity Features: None by modern standards; reliance on analog systems and basic electronic controls.
Maintenance
Service Intervals
Oil Change Interval: Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, whichever comes first, using synthetic oil is recommended.
Coolant Flush Interval: Every 2 years or 30,000 miles (48,000 km)
Brake Fluid Flush Interval: Every 2 years
Fluid Specifications
Engine Oil Type: API SG/SH or higher, SAE 10W-40 or 15W-50 (depending on climate). Check manual for specific viscosity recommendations.
Engine Oil Capacity: Approx. 6.5 liters (6.9 US quarts) with filter change
Coolant Type: BMW Blue Antifreeze/Coolant (Glysantin G48 equivalent) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Dilution 50/50 with distilled water.
Power Steering Fluid Type: ATF Dexron II (or equivalent)
Manual Transmission Fluid Type: SAE 75W-90 synthetic gear oil (GL-4 rated)
Automatic Transmission Fluid Type: ATF Dexron II (or equivalent)
Differential Fluid Type: SAE 80W-90 gear oil (GL-5 rated)
Known Issues
Common Issues Engine: Oil leaks (valve cover gasket, oil pan gasket), cooling system degradation (radiator, hoses, water pump), vacuum hose deterioration leading to idle issues, fuel distributor issues on L-Jetronic
Common Issues Suspension: Worn front control arm bushings, worn rear trailing arm bushings, shock absorber degradation
Common Issues Electrical: Corroded grounds, failing alternator, aging wiring harnesses, instrument cluster issues, headlight switch failure
Common Issues Body: Rust in common areas like rocker panels, wheel arches, and jacking points
Vehicle History
Brand Heritage
Bmw Heritage: BMW has a long-standing reputation for engineering excellence, performance, and driver-focused vehicles, dating back to its origins in aircraft engine manufacturing.
Model Evolution
E28 Development: The E28 succeeded the E12 5 Series and was a significant evolution, featuring improved aerodynamics, enhanced chassis dynamics, and more advanced technology. It represented BMW's commitment to refining its mid-size luxury sedan offering.
Production
Production Period: 1981-1988
Manufacturing Locations: Primarily Dingolfing, Germany; also produced in other BMW plants and licensed assembly operations globally.
Awards & Recognition
Recognitions
Automotive Journalism Accolades: While specific awards for the 528/528i of this era might not be as widely publicized as modern vehicles, the E28 platform as a whole was highly regarded for its driving dynamics, build quality, and performance, often appearing on 'best of' lists for sports sedans of the 1980s.
Ratings
Owner Satisfaction: Owners typically lauded the E28 for its robust engineering, driving pleasure, and longevity when properly maintained, though early models could be sensitive to deferred maintenance.
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