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BMW 5-Series (E28) 528i 1981-1988 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5-Series (E28) Variant: 528i Production Years: 1981-1988 Codes Chassis Code: E28 Engine Code Typical: M30B28 (2.8L Inline-6) 👋 Introduction Market Position Positioning: Premium executive sedan targeting discerning drivers Brand Image: Reputation for performance, luxury, and build quality Competitive Analysis Competitors: Mercedes-Benz W123/W124, Audi 5000, Jaguar XJ6 Key Differentiators: Superior driving dynamics, sophisticated engineering, inline-6 engine refinement Key Features Vehicle Focus: Performance, comfort, and driver engagement Manual Value Proposition: Empowers owners to maintain and repair their classic BMW, preserving value and performance 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance Secondary Coverage: Troubleshooting, diagnostics, electrical system diagrams Page Count Estimated Page Count: Comprehensive (exact count not specified, but implied to be extensive for full factory coverage) Manual Type Type: Factory Service Repair Manual (Workshop Manual) Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, assembly, timing, valve train, cylinder head, block, crankshaft, pistons, connecting rods Fuel System: Fuel injection system (Bosch L-Jetronic), fuel pump, injectors, fuel pressure regulator, throttle body Cooling System: Radiator, thermostat, water pump, coolant passages, fan, hoses Lubrication System: Oil pump, oil filter, oil pan, lubrication passages, oil pressure Ignition System: Distributor, spark plugs, ignition coils, control module (if applicable) Chassis: Suspension (front and rear), steering system, braking system (including ABS if equipped), driveshaft, differential Electrical System: Starter motor, alternator, battery, lighting, dashboard instruments, power windows, central locking, fuse box locations, relays Emission Control: Air injection system, catalytic converter, EGR system (if applicable), emission control related sensors and valves Body And Interior: Body panels, doors, windows, seats, trim components (general repair and adjustment) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups Repair: Step-by-step repair instructions for all major components and systems Troubleshooting: Diagnostic procedures for common problems, fault finding, troubleshooting charts Diagnostics: Inspection and testing procedures for various systems Rebuilds: Complete engine and transmission rebuild procedures Adjustments: Carburetor (if applicable), ignition timing, valve clearances, parking brake Technical Depth Depth: Comprehensive factory-level detail suitable for both DIY and professional mechanics Detail Level: Includes exploded views, detailed diagrams, torque specifications, and precise measurements 📊 Manual Specifications File Format Format: PDF Searchability: Text-searchable PDF Print Quality Printability: Printable without restriction Diagram Quality: Top quality diagrams and illustrations Binding Type Binding: Digital download (N/A for physical binding) Paper Type Paper: N/A (Digital PDF) Requirements Software Requirement: Adobe PDF Reader Delivery Delivery Method: Instant download ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-6 Cylinder Displacement: 2.8 Liters (2788 cc) Bore X Stroke: 86.0 mm x 98.0 mm (Typical for M30B28) Compression Ratio: 8.3:1 or 9.2:1 (Depending on variant/market) Valvetrain: SOHC (Single Overhead Camshaft), 2 valves per cylinder Performance Horsepower: 181 hp @ 5800 rpm (Approximate for M30B28) Torque: 230 Nm (169 lb-ft) @ 3500 rpm (Approximate for M30B28) Fuel System Fuel Delivery: Bosch L-Jetronic Fuel Injection Fuel Type Recommendation: Unleaded Premium Gasoline Fuel Pump Type: In-tank electric fuel pump 🔧 Transmission Standard Transmission Type: 4-speed Manual (Getrag 265) Optional Transmission Type: 3-speed ZF 3HP22 Automatic Features Manual Gear Ratios: Specific ratios detailed in manual (e.g., 3.77:1 - 1st, 2.11:1 - 2nd, 1.40:1 - 3rd, 1.00:1 - 4th) Automatic Features: Torque converter lock-up, hydraulic control Fluid Type Manual Transmission Fluid: BMW Approved MTF LT-2 or equivalent (Refer to manual for exact spec and capacity) Automatic Transmission Fluid: ZF Lifeguardfluid 5 or equivalent (Refer to manual for exact spec and capacity) 📐 Dimensions Exterior Length: 4700 mm (185.0 in) Width: 1700 mm (66.9 in) Height: 1420 mm (55.9 in) Wheelbase: 2795 mm (110.0 in) Weights Curb Weight: Approx. 1480-1550 kg (3260-3417 lbs) depending on options 🛡️ Safety Features Ratings Crash Test Ratings: No standardized ratings from modern bodies like NHTSA/Euro NCAP were common for this era; structural integrity generally considered robust for its time. Active Features ABS: Optional ABS (Anti-lock Braking System) available on some models Passive Features Seatbelts: 3-point inertia-reel seatbelts Headrests: Front and rear headrests Safety Cage: Reinforced passenger safety cell 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player, often with upgrade options for higher trim levels Dashboard: Classic analog gauges for speed, RPM, fuel, temperature, oil pressure; driver information system on some later models Driver Assistance Cruise Control: Optional cruise control system Connectivity Connectivity Features: N/A by modern standards; focus on core automotive engineering 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000-7,500 miles (8,000-12,000 km) or annually (refer to manual for specific guidance) Spark Plug Replacement: Approximately 20,000-30,000 miles (30,000-50,000 km) Coolant Flush: Every 2 years or 30,000 miles (48,000 km) Fluid Specifications Engine Oil Type: API SG or SH, SAE 10W-40 or 15W-50 (Refer to manual for exact viscosity based on temperature) Engine Oil Capacity: Approx. 6.5 liters (6.9 US quarts) with filter change Coolant Type: BMW Blue Antifreeze/Coolant or equivalent ethylene...
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BMW 5-Series (E28) 528i 1981-1988 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5-Series (E28)
Variant:
528i
Production Years:
1981-1988
Codes
Chassis Code:
E28
Engine Code Typical:
M30B28 (2.8L Inline-6)
👋 Introduction
Market Position
Positioning:
Premium executive sedan targeting discerning drivers
Brand Image:
Reputation for performance, luxury, and build quality
Competitive Analysis
Competitors:
Mercedes-Benz W123/W124, Audi 5000, Jaguar XJ6
Key Differentiators:
Superior driving dynamics, sophisticated engineering, inline-6 engine refinement
Key Features
Vehicle Focus:
Performance, comfort, and driver engagement
Manual Value Proposition:
Empowers owners to maintain and repair their classic BMW, preserving value and performance
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service, repair, and maintenance
Secondary Coverage:
Troubleshooting, diagnostics, electrical system diagrams
Page Count
Estimated Page Count:
Comprehensive (exact count not specified, but implied to be extensive for full factory coverage)
Manual Type
Type:
Factory Service Repair Manual (Workshop Manual)
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full disassembly, assembly, timing, valve train, cylinder head, block, crankshaft, pistons, connecting rods
Fuel System:
Fuel injection system (Bosch L-Jetronic), fuel pump, injectors, fuel pressure regulator, throttle body
Cooling System:
Radiator, thermostat, water pump, coolant passages, fan, hoses
Lubrication System:
Oil pump, oil filter, oil pan, lubrication passages, oil pressure
Ignition System:
Distributor, spark plugs, ignition coils, control module (if applicable)
Chassis:
Suspension (front and rear), steering system, braking system (including ABS if equipped), driveshaft, differential
Electrical System:
Starter motor, alternator, battery, lighting, dashboard instruments, power windows, central locking, fuse box locations, relays
Emission Control:
Air injection system, catalytic converter, EGR system (if applicable), emission control related sensors and valves
Body And Interior:
Body panels, doors, windows, seats, trim components (general repair and adjustment)
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups
Repair:
Step-by-step repair instructions for all major components and systems
Troubleshooting:
Diagnostic procedures for common problems, fault finding, troubleshooting charts
Diagnostics:
Inspection and testing procedures for various systems
Rebuilds:
Complete engine and transmission rebuild procedures
Adjustments:
Carburetor (if applicable), ignition timing, valve clearances, parking brake
Technical Depth
Depth:
Comprehensive factory-level detail suitable for both DIY and professional mechanics
Detail Level:
Includes exploded views, detailed diagrams, torque specifications, and precise measurements
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Text-searchable PDF
Print Quality
Printability:
Printable without restriction
Diagram Quality:
Top quality diagrams and illustrations
Binding Type
Binding:
Digital download (N/A for physical binding)
Paper Type
Paper:
N/A (Digital PDF)
Requirements
Software Requirement:
Adobe PDF Reader
Delivery
Delivery Method:
Instant download
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-6 Cylinder
Displacement:
2.8 Liters (2788 cc)
Bore X Stroke:
86.0 mm x 98.0 mm (Typical for M30B28)
Compression Ratio:
8.3:1 or 9.2:1 (Depending on variant/market)
Valvetrain:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
Performance
Horsepower:
181 hp @ 5800 rpm (Approximate for M30B28)
Torque:
230 Nm (169 lb-ft) @ 3500 rpm (Approximate for M30B28)
Fuel System
Fuel Delivery:
Bosch L-Jetronic Fuel Injection
Fuel Type Recommendation:
Unleaded Premium Gasoline
Fuel Pump Type:
In-tank electric fuel pump
🔧 Transmission
Standard
Transmission Type:
4-speed Manual (Getrag 265)
Optional
Transmission Type:
3-speed ZF 3HP22 Automatic
Features
Manual Gear Ratios:
Specific ratios detailed in manual (e.g., 3.77:1 - 1st, 2.11:1 - 2nd, 1.40:1 - 3rd, 1.00:1 - 4th)
Automatic Features:
Torque converter lock-up, hydraulic control
Fluid Type
Manual Transmission Fluid:
BMW Approved MTF LT-2 or equivalent (Refer to manual for exact spec and capacity)
Automatic Transmission Fluid:
ZF Lifeguardfluid 5 or equivalent (Refer to manual for exact spec and capacity)
📐 Dimensions
Exterior
Length:
4700 mm (185.0 in)
Width:
1700 mm (66.9 in)
Height:
1420 mm (55.9 in)
Wheelbase:
2795 mm (110.0 in)
Weights
Curb Weight:
Approx. 1480-1550 kg (3260-3417 lbs) depending on options
🛡️ Safety Features
Ratings
Crash Test Ratings:
No standardized ratings from modern bodies like NHTSA/Euro NCAP were common for this era; structural integrity generally considered robust for its time.
Active Features
ABS:
Optional ABS (Anti-lock Braking System) available on some models
Passive Features
Seatbelts:
3-point inertia-reel seatbelts
Headrests:
Front and rear headrests
Safety Cage:
Reinforced passenger safety cell
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player, often with upgrade options for higher trim levels
Dashboard:
Classic analog gauges for speed, RPM, fuel, temperature, oil pressure; driver information system on some later models
Driver Assistance
Cruise Control:
Optional cruise control system
Connectivity
Connectivity Features:
N/A by modern standards; focus on core automotive engineering
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles (8,000-12,000 km) or annually (refer to manual for specific guidance)
Spark Plug Replacement:
Approximately 20,000-30,000 miles (30,000-50,000 km)
Coolant Flush:
Every 2 years or 30,000 miles (48,000 km)
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-40 or 15W-50 (Refer to manual for exact viscosity based on temperature)
Engine Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change
Coolant Type:
BMW Blue Antifreeze/Coolant or equivalent ethylene glycol-based (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4 (Refer to manual for specific type and flush interval)
Known Issues
Common Complaints:
Cooling system leaks (hose degradation, head gasket), fuel pump failure, idle control issues, rust (wheel arches, sills), electrical gremlins
Preventative Maintenance:
Regular inspection of cooling system hoses and connections, keeping electrical contacts clean, timely replacement of wear items
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure, engineering excellence
Model Evolution
E28 Introduction:
Introduced in 1981 as the successor to the E12 5-Series, featuring significant styling and engineering updates.
E28 Updates:
Received updates throughout its production run, including engine refinements and cosmetic tweaks.
E28 Legacy:
Considered one of the most iconic BMW sedans, praised for its handling and build quality, laying the groundwork for future 5-Series generations.
Production
Manufacturing Location:
Germany (Dingolfing Plant)
Total Production E28:
Over 700,000 units worldwide across all variants
🏆 Awards & Recognition
Recognitions
Critical Acclaim:
Consistently praised by automotive journalists for its balanced chassis, powerful engine, and build quality, often cited as a benchmark for sports sedans of its era.
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