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BMW 528i 1981-1988 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Generation: E28 Production Years Covered: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988 Codes Chassis Code: E28 👋 Introduction Market Position Segment: Executive Sedan / Mid-size Luxury Sedan Target Audience: Affluent buyers seeking performance, luxury, and German engineering. Competitive Analysis Key Competitors: Mercedes-Benz W123/W124 E-Class, Audi 100/200, Volvo 700 series. Key Features Driving Dynamics: Renowned for its balanced chassis, rear-wheel drive, and engaging driving experience. Build Quality: Exceptional build quality and robust engineering characteristic of BMW's 'Ultimate Driving Machine' philosophy. Engine Performance: Smooth, powerful inline-six engines providing ample torque and refinement. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Page Count: Comprehensive (specific count not provided in product info, but implies extensive coverage typical of workshop manuals) Manual Type Type: Workshop Manual / Service Repair Manual Language Language: English Format Format: Digital (likely PDF, based on typical sales of such manuals) 📖 Manual Coverage Systems Covered Engine: Complete engine systems, including M30B34 engine disassembly, assembly, tuning, and component specifications. Fuel System: Bosch L-Jetronic fuel injection system, fuel pump, injectors, fuel pressure regulator, and troubleshooting. Ignition System: Electronic ignition system, coil, distributor, spark plugs, and timing procedures. Transmission: Manual (Getrag 260) and Automatic (ZF 4HP22) transmissions, clutch service, driveline, driveshaft, and differential. Suspension: Front and rear suspension, struts, shocks, control arms, bushings, ball joints, and wheel alignment specifications. Brakes: Front and rear disc brakes, hydraulic system, ABS (if equipped), brake lines, pads, rotors, and caliper service. Steering: Power steering system, steering box, tie rods, and power steering pump. Electrical System: Complete electrical system, wiring diagrams, battery, alternator, starter, fuses, relays, lighting, and accessory circuits. Cooling System: Radiator, fan, water pump, thermostat, coolant hoses, and heating system. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, and pipes. Body And Chassis: Body panels, doors, windows, locks, interior trim, and chassis components. HVAC: Heating, ventilation, and air conditioning system service and repair. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement, belt adjustments. Diagnostic Procedures: Troubleshooting charts, symptom-based diagnostics for engine, electrical, and mechanical issues. Repair Procedures: Step-by-step instructions for component removal, installation, and overhaul. Rebuild Procedures: Detailed instructions for engine and transmission rebuilds. Technical Specifications: Torque values, clearances, tolerances, fluid capacities, and electrical specifications. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Aimed at professional mechanics and advanced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: Likely PDF, optimized for digital viewing and printing. Searchable text is a common feature. Print Quality Resolution: High-resolution, ensuring clarity of diagrams and text. Binding Type Binding: N/A (digital format) Paper Type Paper: N/A (digital format) ⚙️ Engine Specifications Primary Engine Engine Code Variant: M30B34 Engine Type: Naturally Aspirated Inline-6 Cylinder Displacement: 3.4 Liters (3430 cc) Bore X Stroke: 92.0 mm x 86.0 mm Performance Horsepower: Approx. 182-189 hp @ 5500 rpm (depending on market and specific tune) Torque: Approx. 214-220 lb-ft @ 3500 rpm (depending on market and specific tune) Fuel System Fuel Delivery: Bosch Motronic electronic fuel injection (EFI) with L-Jetronic Fuel Type: Unleaded Gasoline (Premium) Engine Management ECU: Bosch Motronic Cooling System Coolant Type: BMW recommended ethylene glycol/water mixture (typically 50/50) 🔧 Transmission Standard Type: Getrag 260 5-speed Manual Transmission Optional Type: ZF 4HP22 4-speed Automatic Transmission Features Manual Clutch: Hydraulically operated single dry plate clutch Automatic Features Torque Converter: Lock-up torque converter Fluid Specifications Manual Gear Oil: GL-4 rated manual transmission fluid (e.g., Castrol TWS 5W-30 or equivalent) Fluid Specifications Automatic Atf: Dexron-III (or equivalent ATF specification) 📐 Dimensions Exterior Length: Approx. 191.1 inches (4854 mm) Width: Approx. 68.9 inches (1750 mm) Height: Approx. 55.0 inches (1397 mm) Wheelbase: Approx. 104.3 inches (2649 mm) Weights Curb Weight: Approx. 3400-3600 lbs (1542-1633 kg), varies by transmission and options Gross Vehicle Weight Rating: Approx. 4450-4550 lbs (2018-2064 kg) 🛡️ Safety Features Ratings Crash Test Data: Limited specific official crash test data available from this era; however, known for robust construction. Active Features ABS: Available as an option on later models and standard on some configurations. System: Bosch ABS II Passive Features Airbags: Driver-side airbag became available as an option towards the end of the E28's production run. Seatbelts: Three-point seatbelts with pretensioners Rollover Protection: Reinforced A and B pillars, strong roof structure 💡 Technology Features Infotainment Audio System: Factory fitted cassette player with AM/FM radio, optional CD player. Climate Control: Manual or optional automatic climate control (ECC - Electronic Climate Control). Driver Assistance Cruise Control: Standard on most 528i models. Connectivity Communications: N/A (No integrated Bluetooth or telematics from factory) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil used. Refer to manual for specific recommendations. Coolant Flush: Every 2-3 years or 30,000-50,000 miles Transmission Fluid...
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BMW 528i 1981-1988 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
528i
Generation:
E28
Production Years Covered:
1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988
Codes
Chassis Code:
E28
👋 Introduction
Market Position
Segment:
Executive Sedan / Mid-size Luxury Sedan
Target Audience:
Affluent buyers seeking performance, luxury, and German engineering.
Competitive Analysis
Key Competitors:
Mercedes-Benz W123/W124 E-Class, Audi 100/200, Volvo 700 series.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel drive, and engaging driving experience.
Build Quality:
Exceptional build quality and robust engineering characteristic of BMW's 'Ultimate Driving Machine' philosophy.
Engine Performance:
Smooth, powerful inline-six engines providing ample torque and refinement.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul
Page Count
Estimated Page Count:
Comprehensive (specific count not provided in product info, but implies extensive coverage typical of workshop manuals)
Manual Type
Type:
Workshop Manual / Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, based on typical sales of such manuals)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine systems, including M30B34 engine disassembly, assembly, tuning, and component specifications.
Fuel System:
Bosch L-Jetronic fuel injection system, fuel pump, injectors, fuel pressure regulator, and troubleshooting.
Ignition System:
Electronic ignition system, coil, distributor, spark plugs, and timing procedures.
Transmission:
Manual (Getrag 260) and Automatic (ZF 4HP22) transmissions, clutch service, driveline, driveshaft, and differential.
Suspension:
Front and rear suspension, struts, shocks, control arms, bushings, ball joints, and wheel alignment specifications.
Brakes:
Front and rear disc brakes, hydraulic system, ABS (if equipped), brake lines, pads, rotors, and caliper service.
Steering:
Power steering system, steering box, tie rods, and power steering pump.
Electrical System:
Complete electrical system, wiring diagrams, battery, alternator, starter, fuses, relays, lighting, and accessory circuits.
Cooling System:
Radiator, fan, water pump, thermostat, coolant hoses, and heating system.
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, and pipes.
Body And Chassis:
Body panels, doors, windows, locks, interior trim, and chassis components.
HVAC:
Heating, ventilation, and air conditioning system service and repair.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, belt adjustments.
Diagnostic Procedures:
Troubleshooting charts, symptom-based diagnostics for engine, electrical, and mechanical issues.
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul.
Rebuild Procedures:
Detailed instructions for engine and transmission rebuilds.
Technical Specifications:
Torque values, clearances, tolerances, fluid capacities, and electrical specifications.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Aimed at professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for digital viewing and printing. Searchable text is a common feature.
Print Quality
Resolution:
High-resolution, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (digital format)
Paper Type
Paper:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code Variant:
M30B34
Engine Type:
Naturally Aspirated Inline-6 Cylinder
Displacement:
3.4 Liters (3430 cc)
Bore X Stroke:
92.0 mm x 86.0 mm
Performance
Horsepower:
Approx. 182-189 hp @ 5500 rpm (depending on market and specific tune)
Torque:
Approx. 214-220 lb-ft @ 3500 rpm (depending on market and specific tune)
Fuel System
Fuel Delivery:
Bosch Motronic electronic fuel injection (EFI) with L-Jetronic
Fuel Type:
Unleaded Gasoline (Premium)
Engine Management
ECU:
Bosch Motronic
Cooling System
Coolant Type:
BMW recommended ethylene glycol/water mixture (typically 50/50)
🔧 Transmission
Standard
Type:
Getrag 260 5-speed Manual Transmission
Optional
Type:
ZF 4HP22 4-speed Automatic Transmission
Features
Manual Clutch:
Hydraulically operated single dry plate clutch
Automatic Features
Torque Converter:
Lock-up torque converter
Fluid Specifications Manual
Gear Oil:
GL-4 rated manual transmission fluid (e.g., Castrol TWS 5W-30 or equivalent)
Fluid Specifications Automatic
Atf:
Dexron-III (or equivalent ATF specification)
📐 Dimensions
Exterior
Length:
Approx. 191.1 inches (4854 mm)
Width:
Approx. 68.9 inches (1750 mm)
Height:
Approx. 55.0 inches (1397 mm)
Wheelbase:
Approx. 104.3 inches (2649 mm)
Weights
Curb Weight:
Approx. 3400-3600 lbs (1542-1633 kg), varies by transmission and options
Gross Vehicle Weight Rating:
Approx. 4450-4550 lbs (2018-2064 kg)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited specific official crash test data available from this era; however, known for robust construction.
Active Features
ABS:
Available as an option on later models and standard on some configurations. System: Bosch ABS II
Passive Features
Airbags:
Driver-side airbag became available as an option towards the end of the E28's production run.
Seatbelts:
Three-point seatbelts with pretensioners
Rollover Protection:
Reinforced A and B pillars, strong roof structure
💡 Technology Features
Infotainment
Audio System:
Factory fitted cassette player with AM/FM radio, optional CD player.
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control).
Driver Assistance
Cruise Control:
Standard on most 528i models.
Connectivity
Communications:
N/A (No integrated Bluetooth or telematics from factory)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil used. Refer to manual for specific recommendations.
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles
Transmission Fluid Change:
Manual: Every 50,000-60,000 miles. Automatic: Every 30,000-50,000 miles
Fluid Specifications
Engine Oil Type:
Synthetic or high-quality conventional oil, viscosity typically 15W-40, 10W-40, or 20W-50 depending on climate. Refer to manual for precise BMW specifications (e.g., BMW Longlife-98 or equivalent).
Engine Oil Capacity:
Approx. 6.5 quarts (6.2 liters) with filter change
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
ATF Dexron-II/III or specific BMW fluid
Known Issues
Common Problems:
Cooling system leaks (hose degradation, plastic radiator tanks), fuel injector seal leaks, worn front suspension bushings, seized heater control valves, fuel pump strain, potential for rust in common areas (wheel wells, rocker panels), ABS sensor issues.
Common Issues
Engine Performance:
Idle control valve issues, vacuum leaks, distributor cap/rotor wear.
Electrical Quirks:
Corrosion on connectors, failing dashboard warning lights, intermittent power to accessories.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for building sporty, driver-focused luxury sedans, carrying forward the legacy of models like the Neue Klasse.
Model Evolution
E28 Development:
Successor to the E12 5 Series, introducing significant advancements in technology, aerodynamics, and safety.
E28 Design:
Designed by Paul Bracq, featuring a more angular and aerodynamically refined 'Bangle-era' precursor design.
Production
Production Period:
1981-1988
Manufacturing Locations:
Dingolfing, Germany; Born, Netherlands; and assembly plants in South Africa and the USA.
Key Variants:
528e (Eta), 524td (Diesel), 535i, M535i, and the iconic E28 M5.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Frequently appeared on Car and Driver's Ten Best lists in its production years, lauded for its driving dynamics and value.
Ratings
Performance Reviews:
Consistently praised by automotive journalists for its performance, handling, and build quality.
Certifications
Safety Standards:
Met all applicable safety standards of the era for its target markets.
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