BMW 5 Series E28 E34 (518 518i 520i 525i 528i 530i 535i M535i) 1981-1991 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Codes: E28, E34 Model Years Covered: 1981-1991 Codes Engine Codes E28: M20B18 (518), M20B20 (520i), M30B25 (525i), M30B28 (528i), M30B32 (533i), M30B34 (535i), M88/3 (M535i/M5) Engine Codes E34: M20B18 (518i), M20B20 (520i), M30B35 (535i), M60B30 (530i), M60B40 (540i - though not explicitly listed in product name, common for the era) 👋 Introduction Market Position Era Context: The BMW 5 Series (E28 and E34) represented the pinnacle of executive and sporting sedans in their respective eras, known for performance, luxury, and engineering prowess. This manual provides essential factory information for owners and technicians maintaining these classic vehicles. Competitive Analysis Rivals E28: Mercedes-Benz W123/W124, Audi 100/200, Jaguar XJ-S (sedan versions). Rivals E34: Mercedes-Benz W124, Audi V8 Quattro, Lexus LS 400, Jaguar XJ (XJ40). Key Features Vehicle Attributes: Renowned for their balanced handling (often praised as the benchmark), powerful straight-six engines, driver-focused cockpits, and solid build quality. The E34 introduced more advanced electronics and aerodynamic styling. Manual Value Proposition: Provides indispensable factory-level data for DIY mechanics, independent repair shops, and enthusiasts seeking to maintain, diagnose, and repair these complex and rewarding vehicles. 📋 Manual Details Coverage Areas Chassis Models Covered: BMW 5 Series E28 and E34 generations Specific Models Covered: 518, 518i, 520i, 525i, 528i, 530i, 535i, M535i International Markets: While the product description doesn't specify, factory manuals often cover specifications and procedures relevant to multiple international markets, though language is typically localized. Page Count Estimated Pages: Over 1000 pages (typical for factory service manuals of this scope) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English (assumed for this market product description) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (M10, M20, M30, M60 families), fuel injection systems (K-Jetronic, L-Jetronic, Motronic), cooling system, exhaust system, engine management, transmission (manual and automatic), clutch, driveshafts, differentials. Chassis: Suspension (front and rear), steering system (power steering, steering rack), brakes (hydraulic, ABS systems), wheels, tires, chassis components. Electrical: Wiring diagrams, starter system, charging system (alternator, battery), ignition system, lighting systems (headlights, taillights, interior), instrument cluster, gauges, power windows, central locking, climate control electronics, fuse boxes, relays. Bodywork: Body shell structure, interior trim, exterior trim, doors, hood, trunk, bumpers, glass, seals, body repair procedures. Fuel Delivery: Detailed procedures for fuel pump testing, fuel pressure regulation, fuel injector diagnosis and replacement, fuel filter replacement. Exhaust System: Catalytic converter operation (where applicable), muffler and pipe replacement, oxygen sensor testing and replacement. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, fluid level checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/rotor replacement, coolant flush. Repair: Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service, transmission rebuilds, clutch replacement, suspension component replacement, brake caliper overhaul, steering rack replacement, electrical component diagnosis and replacement. Diagnostics: Troubleshooting guides for common symptoms, diagnostic fault codes (where applicable for the era), electrical system testing procedures, fuel system pressure testing. Engine Timing: Belt and chain timing procedures, valve adjustment (where applicable), camshaft timing adjustments. Body Repair: Information on panel alignment, welding procedures (for structural repairs), and trim piece installation/removal. Technical Depth Depth: Comprehensive factory-level detail, including specifications, torque values, clearance measurements, diagnostic procedures, and repair sequences for all major vehicle systems. Diagnostic Tools: Information on using basic diagnostic tools relevant to the era, such as multimeters, fuel pressure gauges, and oscilloscope interpretation for ignition systems. Manual Completeness Completeness: Factory-sourced, comprehensive coverage for repair, maintenance, troubleshooting, and specifications. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF (typical for professional downloads), allowing for easy navigation and printing. Print Quality Printability: Designed for high-quality printing of individual pages or sections. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine E28 Engine Options: M20 2.0L (121 hp), M20 2.3L (141 hp - 523i, not in product name but relevant), M30 2.5L (148 hp - 525i), M30 2.7L (170 hp - 528i), M30 3.2L (182 hp - 533i), M30 3.4L (189 hp - 535i), M88/3 3.5L Turbocharged (282 hp - M535i/M5). E34 Engine Options: M20 1.8L (113 hp - 518i), M20 2.0L (126 hp - 520i), M30 3.5L (208 hp - 535i), M60B30 3.0L V8 (215 hp - 530i), M60B40 4.0L V8 (282 hp - 540i). Performance E28 M535I Performance: 0-60 mph: approx. 7.0 seconds; Top Speed: approx. 150 mph (electronically limited on some models). E34 535I Performance: 0-60 mph: approx. 7.5 seconds; Top Speed: approx. 145 mph. Fuel System Injection Systems: Bosch K-Jetronic (CIS), Bosch L-Jetronic, Bosch Motronic (early electronic fuel injection and ignition control), Bosch Motronic M1.2, M2.1, M2.5, M2.7, M3.3 for later models. Carbureted models (e.g., 518) also existed but are less common in the covered range. Fuel Type: Premium Unleaded Gasoline (Octane rating typically 91 RON/87 AKI or higher) Engine Management E34...

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Tags: 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 5 Series 518 518i 520i 525i 528i 530i 535i BMW Car Cars E28 E34 M535i Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Generation

Chassis Codes:

E28, E34

Model Years Covered:

1981-1991

Codes

Engine Codes E28:

M20B18 (518), M20B20 (520i), M30B25 (525i), M30B28 (528i), M30B32 (533i), M30B34 (535i), M88/3 (M535i/M5)

Engine Codes E34:

M20B18 (518i), M20B20 (520i), M30B35 (535i), M60B30 (530i), M60B40 (540i - though not explicitly listed in product name, common for the era)

👋 Introduction

Market Position

Era Context:

The BMW 5 Series (E28 and E34) represented the pinnacle of executive and sporting sedans in their respective eras, known for performance, luxury, and engineering prowess. This manual provides essential factory information for owners and technicians maintaining these classic vehicles.

Competitive Analysis

Rivals E28:

Mercedes-Benz W123/W124, Audi 100/200, Jaguar XJ-S (sedan versions).

Rivals E34:

Mercedes-Benz W124, Audi V8 Quattro, Lexus LS 400, Jaguar XJ (XJ40).

Key Features

Vehicle Attributes:

Renowned for their balanced handling (often praised as the benchmark), powerful straight-six engines, driver-focused cockpits, and solid build quality. The E34 introduced more advanced electronics and aerodynamic styling.

Manual Value Proposition:

Provides indispensable factory-level data for DIY mechanics, independent repair shops, and enthusiasts seeking to maintain, diagnose, and repair these complex and rewarding vehicles.

📋 Manual Details

Coverage Areas

Chassis Models Covered:

BMW 5 Series E28 and E34 generations

Specific Models Covered:

518, 518i, 520i, 525i, 528i, 530i, 535i, M535i

International Markets:

While the product description doesn't specify, factory manuals often cover specifications and procedures relevant to multiple international markets, though language is typically localized.

Page Count

Estimated Pages:

Over 1000 pages (typical for factory service manuals of this scope)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English (assumed for this market product description)

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (M10, M20, M30, M60 families), fuel injection systems (K-Jetronic, L-Jetronic, Motronic), cooling system, exhaust system, engine management, transmission (manual and automatic), clutch, driveshafts, differentials.

Chassis:

Suspension (front and rear), steering system (power steering, steering rack), brakes (hydraulic, ABS systems), wheels, tires, chassis components.

Electrical:

Wiring diagrams, starter system, charging system (alternator, battery), ignition system, lighting systems (headlights, taillights, interior), instrument cluster, gauges, power windows, central locking, climate control electronics, fuse boxes, relays.

Bodywork:

Body shell structure, interior trim, exterior trim, doors, hood, trunk, bumpers, glass, seals, body repair procedures.

Fuel Delivery:

Detailed procedures for fuel pump testing, fuel pressure regulation, fuel injector diagnosis and replacement, fuel filter replacement.

Exhaust System:

Catalytic converter operation (where applicable), muffler and pipe replacement, oxygen sensor testing and replacement.

Procedures Included

Maintenance:

Routine checks, oil changes, filter replacements, fluid level checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/rotor replacement, coolant flush.

Repair:

Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service, transmission rebuilds, clutch replacement, suspension component replacement, brake caliper overhaul, steering rack replacement, electrical component diagnosis and replacement.

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic fault codes (where applicable for the era), electrical system testing procedures, fuel system pressure testing.

Engine Timing:

Belt and chain timing procedures, valve adjustment (where applicable), camshaft timing adjustments.

Body Repair:

Information on panel alignment, welding procedures (for structural repairs), and trim piece installation/removal.

Technical Depth

Depth:

Comprehensive factory-level detail, including specifications, torque values, clearance measurements, diagnostic procedures, and repair sequences for all major vehicle systems.

Diagnostic Tools:

Information on using basic diagnostic tools relevant to the era, such as multimeters, fuel pressure gauges, and oscilloscope interpretation for ignition systems.

Manual Completeness

Completeness:

Factory-sourced, comprehensive coverage for repair, maintenance, troubleshooting, and specifications.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable PDF (typical for professional downloads), allowing for easy navigation and printing.

Print Quality

Printability:

Designed for high-quality printing of individual pages or sections.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

E28 Engine Options:

M20 2.0L (121 hp), M20 2.3L (141 hp - 523i, not in product name but relevant), M30 2.5L (148 hp - 525i), M30 2.7L (170 hp - 528i), M30 3.2L (182 hp - 533i), M30 3.4L (189 hp - 535i), M88/3 3.5L Turbocharged (282 hp - M535i/M5).

E34 Engine Options:

M20 1.8L (113 hp - 518i), M20 2.0L (126 hp - 520i), M30 3.5L (208 hp - 535i), M60B30 3.0L V8 (215 hp - 530i), M60B40 4.0L V8 (282 hp - 540i).

Performance

E28 M535I Performance:

0-60 mph: approx. 7.0 seconds; Top Speed: approx. 150 mph (electronically limited on some models).

E34 535I Performance:

0-60 mph: approx. 7.5 seconds; Top Speed: approx. 145 mph.

Fuel System

Injection Systems:

Bosch K-Jetronic (CIS), Bosch L-Jetronic, Bosch Motronic (early electronic fuel injection and ignition control), Bosch Motronic M1.2, M2.1, M2.5, M2.7, M3.3 for later models. Carbureted models (e.g., 518) also existed but are less common in the covered range.

Fuel Type:

Premium Unleaded Gasoline (Octane rating typically 91 RON/87 AKI or higher)

Engine Management

E34 Motronic Versions:

Manual will cover nuances of Motronic M1.2, M2.1, M2.5, M2.7, M3.3, detailing sensor inputs, actuator outputs, and basic fault diagnosis.

🔧 Transmission

Standard

E28 Standard Transmission:

Getrag 260 5-speed manual transmission.

E34 Standard Transmission:

Getrag 260 5-speed manual transmission (common on 6-cylinder models).

Optional

E28 Optional Transmission:

ZF 4HP22 4-speed automatic transmission.

E34 Optional Transmission:

ZF 4HP22 EH 4-speed automatic transmission (later with electronic control), ZF 5HP18 5-speed automatic (on some 6-cylinder models), ZF 5HP30 5-speed automatic (on V8 models).

Features

Limited Slip Differential:

Optional on many models, particularly performance variants like the M535i and M5, providing enhanced traction and handling.

📐 Dimensions

Exterior

E28 Dimensions Approx:

Length: 189.0 in (4800 mm), Width: 69.1 in (1755 mm), Height: 55.9 in (1420 mm), Wheelbase: 104.3 in (2650 mm).

E34 Dimensions Approx:

Length: 189.5 in (4814 mm), Width: 70.1 in (1781 mm), Height: 55.3 in (1405 mm), Wheelbase: 111.5 in (2833 mm).

Weights

Curb Weight Range:

Approximately 3100-3700 lbs (1400-1680 kg) depending on model and equipment.

Cargo

Trunk Capacity Approx:

Around 16-18 cubic feet (450-510 liters).

🛡️ Safety Features

Ratings

Era Safety Standards:

Safety standards of the 1980s and early 1990s, generally good for their time. E28 focused on occupant protection via structural integrity and seatbelts. E34 introduced optional ABS and driver-side airbags later in its production run.

Active Features

Optional Anti-lock Braking System (ABS) available on many E34 models, standard on some later E28 M5 variants.

Traction Control:

Optional ASC (Automatic Stability Control) or ASC+T (with engine torque reduction) became available on later E34 models.

Passive Features

Airbags:

Driver-side airbag optional on later E34 models, not typically available on E28.

Seatbelts:

Three-point seatbelts with pretensioners in the front, standard.

💡 Technology Features

Infotainment

E28 Infotainment:

Basic analog radio, cassette player, optional premium sound systems (e.g., Harman Kardon on some models). Minimal electronic integration.

E34 Infotainment:

More advanced Blaupunkt or BMW branded stereo systems, optional CD changers, climate control modules, trip computers, and early onboard diagnostics (OBD).

Driver Assistance

E28 Driver Features:

Power steering, cruise control (optional), central locking.

E34 Driver Features:

Optional ABS, ASC/ASC+T, heated seats, power adjustable seats with memory, sunroof, self-leveling suspension (optional on touring models).

Connectivity

Era Connectivity:

Limited to basic telephone options on some later E34 models. No modern Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions and oil type used. Check manual for specific recommendations.

Coolant Flush Interval:

Every 2 years or 30,000 miles (48,000 km).

Spark Plug Replacement:

Varies by plug type (standard, platinum, iridium); typically 30,000-60,000 miles (48,000-96,000 km). Refer to manual for specific plug type and interval.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-40 or 15W-40 recommended for most models. Consult manual for specific viscosity based on climate. Synthetic oils are often preferred for modern use.

Coolant Type:

BMW Blue (G48) or equivalent ethylene glycol-based coolant with corrosion inhibitors.

Transmission Fluid Manual:

GL-4 SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

Dexron III/H or equivalent ATF.

Brake Fluid Type:

DOT 4 or DOT 3, low viscosity.

Known Issues

E28 Common Problems:

Fuel distributor leaks (K-Jetronic), vacuum line deterioration, headliner sagging, dashboard cracks, heater core leaks, rust in common areas (wheel wells, rocker panels).

E34 Common Problems:

Cooling system issues (radiator, water pump, expansion tank), OVP relay failure (E34 electrics), ABS sensor failures, window regulator failures, door seal deterioration, fuel pump issues, dashboard electronics failures.

Fluid Capacities

Engine Oil Capacity:

Varies by engine: e.g., M20 approx. 4.5L, M30 approx. 6.5L, M60 approx. 6.5L. Exact figures detailed in manual.

Cooling System Capacity:

Approximately 8-10 liters depending on engine and radiator size. Details in manual.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's 'Ultimate Driving Machine' ethos is central to the 5 Series' development and appeal, emphasizing performance, handling, and driver engagement.

Model Evolution

E28 Introduction:

Introduced in 1981, the E28 succeeded the E12 and brought significant updates in styling, aerodynamics, and engine technology, including the introduction of the M535i and the legendary M5.

E34 Introduction:

Launched in 1987, the E34 marked a complete redesign with a sleeker, more modern appearance and introduced new engine options like the V8s (M60 family), improved chassis dynamics, and increased electronic content.

Production

E28 Production Years:

1981-1988.

E34 Production Years:

1987-1996 (with overlap in model years).

🏆 Awards & Recognition

Recognitions

E28 Awards:

The E28 M5 was widely acclaimed as 'The Fastest Production Sedan in the World' upon its release. Both E28 and E34 generations frequently appeared on 'Ten Best Cars' lists from various automotive publications.

Ratings

E34 Awards:

Praised for its driving dynamics, ride comfort balance, and sophisticated engineering. The V8 models were particularly well-received for their smooth power delivery.