1982-2002 BMW 5 Series Workshop Service Repair Manuals

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation E28: 1981-1988 E34: 1987-1996 E39: 1995-2003 Codes E28 Primary Models Covered: 528e, 535i, M5 E34 Primary Models Covered: 525i, 530i, 535i, 540i, M5 E39 Primary Models Covered: 525i, 528i, 530i, 540i, M5 👋 Introduction Market Position Brand Heritage: BMW's reputation for engineering excellence, performance, and luxury is firmly established in these eras. Model Positioning: The 5 Series represented BMW's executive sedan offering, balancing sportiness with comfort and technology. Competitive Analysis E28 Competitors: Mercedes-Benz W124 E-Class, Audi 100, Jaguar XJ6. E34 Competitors: Mercedes-Benz W124 E-Class, Audi V8/A6, Lexus LS400, Volvo 960. E39 Competitors: Mercedes-Benz W210 E-Class, Audi A6 C5, Lexus GS300/400, Volvo S80. Key Features E28 Innovations: Introduction of the 'Eta' engine (M20B27) for fuel efficiency, aerodynamic styling. E34 Innovations: More advanced chassis dynamics, introduction of V8 engines (M60), advanced electronics (ABS, ASC, OBC), improved interior ergonomics. E39 Innovations: Significant advances in safety (side airbags), handling (double-wishbone front suspension), powertrain (variable valve timing - VANOS, M54 engines), and electronics (CAN bus integration, improved infotainment). 📋 Manual Details Coverage Areas Included Manuals: E28 Electrical Troubleshooting, E34 Electrical Troubleshooting, E34 Workshop Service Manual, E39 Workshop Service Manual (partial coverage indicated) Page Count E28 Electrical Troubleshooting: Estimated 200+ pages (typical for BMW ETMs of this era) E34 Electrical Troubleshooting: Estimated 300+ pages E34 Workshop Service Manual: Estimated 1500+ pages (typical for comprehensive BMW workshop manuals) E39 Workshop Service Manual: Coverage for 1997-2002 indicates a substantial volume, likely 1000+ pages Manual Type Primary Manual Type: Workshop Service Manuals & Electrical Troubleshooting Manuals (ETM) Language Language: English Format Format: Likely PDF digital format, based on common aftermarket manual availability. 📖 Manual Coverage Systems Covered E28 Electrical: Wiring diagrams, component locations, troubleshooting charts for engine management, lighting, HVAC, power accessories, and instrumentation. E34 Electrical: Comprehensive coverage of all electrical systems including DME, ABS, ASC, SRS, climate control, OBC, power seats, windows, mirrors, central locking, and sound systems. E34 Mechanical: Engine mechanical (M20, M30, M50, S38), drivetrain (manual & automatic transmissions, differentials), suspension, steering, brakes (ABS/ASC systems), fuel system, exhaust, cooling system, HVAC, body and chassis. E39 Mechanical (Implied): Expect coverage of M52, M54, M62 engines, Getrag 5-speed and ZF 5HP/6HP automatic transmissions, DSC, ASC+T, electronic throttle control, advanced HVAC, and updated electrical architectures. Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid replacement, belt replacement, battery checks. Diagnostic Procedures: Troubleshooting flowcharts, symptom-based diagnostics, component testing, diagnostic trouble code (DTC) interpretation (where applicable). Repair Procedures: Step-by-step instructions for engine overhaul, transmission rebuilds, suspension component replacement, brake caliper and rotor replacement, electrical component repair, body panel repair, and interior trim removal. Component Removal & Installation: Detailed instructions for removing and reinstalling major and minor components, including torque specifications and special tool requirements. Technical Depth Diagnostic Depth: Advanced diagnostic procedures for complex electronic systems, including signal tracing, multimeter usage, and interpretation of sensor data. Repair Detail: Comprehensive rebuild procedures for engines and transmissions, detailed diagrams for component disassembly and reassembly, and specifications for critical tolerances. Electrical Expertise: In-depth electrical system analysis, including power distribution, ground points, signal integrity, and logic functions of ECUs. 📊 Manual Specifications File Format Digital File Type: PDF (Portable Document Format) Searchability: Likely text-searchable PDF, allowing for quick keyword lookup of specific components or procedures. Print Quality Print Capability: Designed for clear printing of text and diagrams, with high-resolution images where available. Binding Type Physical Manual Binding (If Applicable): Typically spiral-bound or perfect-bound for ease of use and lay-flat capability. Paper Type Physical Manual Paper Quality (If Applicable): Durable, high-quality paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine E28 Engine Options: M20B27 2.7L I6 (528e), M30B34 3.4L I6 (535i), S38B35 3.5L I6 (M5). E34 Engine Options: M20B25 2.5L I6 (525i), M30B35 3.5L I6 (535i), M50B25 2.5L I6 (525i - later), M60B30 3.0L V8 (530i), M60B40 4.0L V8 (540i), S38B36 3.6L I6 (M5). E39 Engine Options: M52B25/B28 2.5L/2.8L I6 (525i/528i), M54B30 3.0L I6 (530i), M62B44 4.4L V8 (540i), S38B32 3.2L I6 (M5 - Euro Spec E34 M5 shares engine with some E39 chassis variations in early development). Performance E28 528E Power Output: Approx. 121 hp @ 4250 rpm, 170 lb-ft @ 2500 rpm (revised for durability/economy). E34 535I Power Output: Approx. 208 hp @ 5700 rpm, 225 lb-ft @ 4000 rpm. E39 540I Power Output: Approx. 282 hp @ 5400 rpm, 324 lb-ft @ 3600 rpm (M62B44). Fuel System Fuel Delivery: Bosch Motronic electronic fuel injection (EFI) across all models, with variations in sensor types and ECU logic depending on generation and engine. 🔧 Transmission Standard E28 Standard Transmission: Getrag 260 5-speed manual. E34 Standard Transmission: Getrag 260 5-speed manual (most models), Getrag 280 5-speed manual (some higher torque models). E39 Standard Transmission: Getrag 5-speed manual (e.g., GS5-39DZ), ZF 5HP19 5-speed automatic (on 6-cylinder models). Optional E28 Optional...

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Tags: 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 5 Series BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Generation

1981-1988

1987-1996

1995-2003

Codes

E28 Primary Models Covered:

528e, 535i, M5

E34 Primary Models Covered:

525i, 530i, 535i, 540i, M5

E39 Primary Models Covered:

525i, 528i, 530i, 540i, M5

👋 Introduction

Market Position

Brand Heritage:

BMW's reputation for engineering excellence, performance, and luxury is firmly established in these eras.

Model Positioning:

The 5 Series represented BMW's executive sedan offering, balancing sportiness with comfort and technology.

Competitive Analysis

E28 Competitors:

Mercedes-Benz W124 E-Class, Audi 100, Jaguar XJ6.

E34 Competitors:

Mercedes-Benz W124 E-Class, Audi V8/A6, Lexus LS400, Volvo 960.

E39 Competitors:

Mercedes-Benz W210 E-Class, Audi A6 C5, Lexus GS300/400, Volvo S80.

Key Features

E28 Innovations:

Introduction of the 'Eta' engine (M20B27) for fuel efficiency, aerodynamic styling.

E34 Innovations:

More advanced chassis dynamics, introduction of V8 engines (M60), advanced electronics (ABS, ASC, OBC), improved interior ergonomics.

E39 Innovations:

Significant advances in safety (side airbags), handling (double-wishbone front suspension), powertrain (variable valve timing - VANOS, M54 engines), and electronics (CAN bus integration, improved infotainment).

📋 Manual Details

Coverage Areas

Included Manuals:

E28 Electrical Troubleshooting, E34 Electrical Troubleshooting, E34 Workshop Service Manual, E39 Workshop Service Manual (partial coverage indicated)

Page Count

E28 Electrical Troubleshooting:

Estimated 200+ pages (typical for BMW ETMs of this era)

E34 Electrical Troubleshooting:

Estimated 300+ pages

E34 Workshop Service Manual:

Estimated 1500+ pages (typical for comprehensive BMW workshop manuals)

E39 Workshop Service Manual:

Coverage for 1997-2002 indicates a substantial volume, likely 1000+ pages

Manual Type

Primary Manual Type:

Workshop Service Manuals & Electrical Troubleshooting Manuals (ETM)

Language

Language:

English

Format

Format:

Likely PDF digital format, based on common aftermarket manual availability.

📖 Manual Coverage

Systems Covered

E28 Electrical:

Wiring diagrams, component locations, troubleshooting charts for engine management, lighting, HVAC, power accessories, and instrumentation.

E34 Electrical:

Comprehensive coverage of all electrical systems including DME, ABS, ASC, SRS, climate control, OBC, power seats, windows, mirrors, central locking, and sound systems.

E34 Mechanical:

Engine mechanical (M20, M30, M50, S38), drivetrain (manual & automatic transmissions, differentials), suspension, steering, brakes (ABS/ASC systems), fuel system, exhaust, cooling system, HVAC, body and chassis.

E39 Mechanical (Implied):

Expect coverage of M52, M54, M62 engines, Getrag 5-speed and ZF 5HP/6HP automatic transmissions, DSC, ASC+T, electronic throttle control, advanced HVAC, and updated electrical architectures.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid replacement, belt replacement, battery checks.

Diagnostic Procedures:

Troubleshooting flowcharts, symptom-based diagnostics, component testing, diagnostic trouble code (DTC) interpretation (where applicable).

Repair Procedures:

Step-by-step instructions for engine overhaul, transmission rebuilds, suspension component replacement, brake caliper and rotor replacement, electrical component repair, body panel repair, and interior trim removal.

Component Removal & Installation:

Detailed instructions for removing and reinstalling major and minor components, including torque specifications and special tool requirements.

Technical Depth

Diagnostic Depth:

Advanced diagnostic procedures for complex electronic systems, including signal tracing, multimeter usage, and interpretation of sensor data.

Repair Detail:

Comprehensive rebuild procedures for engines and transmissions, detailed diagrams for component disassembly and reassembly, and specifications for critical tolerances.

Electrical Expertise:

In-depth electrical system analysis, including power distribution, ground points, signal integrity, and logic functions of ECUs.

📊 Manual Specifications

File Format

Digital File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable PDF, allowing for quick keyword lookup of specific components or procedures.

Print Quality

Print Capability:

Designed for clear printing of text and diagrams, with high-resolution images where available.

Binding Type

Physical Manual Binding (If Applicable):

Typically spiral-bound or perfect-bound for ease of use and lay-flat capability.

Paper Type

Physical Manual Paper Quality (If Applicable):

Durable, high-quality paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

E28 Engine Options:

M20B27 2.7L I6 (528e), M30B34 3.4L I6 (535i), S38B35 3.5L I6 (M5).

E34 Engine Options:

M20B25 2.5L I6 (525i), M30B35 3.5L I6 (535i), M50B25 2.5L I6 (525i - later), M60B30 3.0L V8 (530i), M60B40 4.0L V8 (540i), S38B36 3.6L I6 (M5).

E39 Engine Options:

M52B25/B28 2.5L/2.8L I6 (525i/528i), M54B30 3.0L I6 (530i), M62B44 4.4L V8 (540i), S38B32 3.2L I6 (M5 - Euro Spec E34 M5 shares engine with some E39 chassis variations in early development).

Performance

E28 528E Power Output:

Approx. 121 hp @ 4250 rpm, 170 lb-ft @ 2500 rpm (revised for durability/economy).

E34 535I Power Output:

Approx. 208 hp @ 5700 rpm, 225 lb-ft @ 4000 rpm.

E39 540I Power Output:

Approx. 282 hp @ 5400 rpm, 324 lb-ft @ 3600 rpm (M62B44).

Fuel System

Fuel Delivery:

Bosch Motronic electronic fuel injection (EFI) across all models, with variations in sensor types and ECU logic depending on generation and engine.

🔧 Transmission

Standard

E28 Standard Transmission:

Getrag 260 5-speed manual.

E34 Standard Transmission:

Getrag 260 5-speed manual (most models), Getrag 280 5-speed manual (some higher torque models).

E39 Standard Transmission:

Getrag 5-speed manual (e.g., GS5-39DZ), ZF 5HP19 5-speed automatic (on 6-cylinder models).

Optional

E28 Optional Transmission:

ZF 4HP22 4-speed automatic.

E34 Optional Transmission:

ZF 4HP22 4-speed automatic, ZF 5HP30 5-speed automatic (on V8 models).

E39 Optional Transmission:

ZF 5HP24 5-speed automatic (on 8-cylinder models), Steptronic 5-speed automatic (E39, later models), 6-speed manual (M5).

Features

Transmission Fluid Specifications:

Specific ATF grades required (e.g., Dexron III for ZF 4HP22, ATF LT-71141 for ZF 5HP series). Manual gearbox oil: typically GL-4 or GL-5 75W-90 synthetic.

📐 Dimensions

Exterior

E34 Length:

Approx. 4733 mm (186.3 in)

E34 Width:

Approx. 1751 mm (68.9 in)

E34 Height:

Approx. 1410 mm (55.5 in)

E39 Length:

Approx. 4770 mm (187.8 in)

E39 Width:

Approx. 1799 mm (70.8 in)

E39 Height:

Approx. 1440 mm (56.7 in)

Weights

E34 Curb Weight:

Approx. 1500-1700 kg (3300-3750 lbs) depending on engine and equipment.

E39 Curb Weight:

Approx. 1550-1750 kg (3400-3850 lbs) depending on engine and equipment.

🛡️ Safety Features

Ratings

E28 Safety:

Designed to earlier safety standards; featured crumple zones and robust construction.

E34 Safety:

Improved passive safety with stronger A/B pillars, enhanced door beams, and available driver's airbag.

E39 Safety:

Excellent safety ratings for its time, featuring standard front airbags, optional side airbags, ABS, ASC+T, and later DSC (Dynamic Stability Control). Structural integrity was a major focus.

Active Features

Active Safety Systems:

Anti-lock Braking System (ABS) standard on later E34 and all E39 models. Traction control (ASC/ASC+T) optional/standard. Stability control (DSC) introduced on E39.

Passive Features

Passive Safety Features:

Reinforced passenger cell, crumple zones, dual front airbags (standard on E39), side airbags (optional on E39), pre-tensioned seatbelts.

💡 Technology Features

Infotainment

E28 Infotainment:

Basic AM/FM radio, optional cassette player, limited speaker options.

E34 Infotainment:

On-Board Computer (OBC) with basic diagnostics, improved radio/cassette systems, optional CD changer, premium sound systems (e.g., Bavaria C, Professional RDS).

E39 Infotainment:

BMW Business CD/Professional RDS radio, optional navigation system (MK-I, MK-II, MK-III), TV tuner, DSP (Digital Sound Processor), widescreen color display on premium systems, Bluetooth preparation.

Driver Assistance

E39 Driver Assistance:

Traction Control (ASC+T), Dynamic Stability Control (DSC), Cruise Control, Park Distance Control (PDC) introduced.

Connectivity

E39 Connectivity:

Pre-wiring for cellular phones, integration with navigation systems for traffic updates (later models).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or 12 months, depending on driving conditions and model year (check manual for specifics).

Coolant Flush Interval:

Every 2-3 years or 30,000 miles (48,000 km).

Brake Fluid Flush Interval:

Every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil Type:

Varies by engine and year, generally synthetic 5W-30 or 5W-40. Check manual for specific API/ACEA ratings (e.g., BMW Longlife-98, Longlife-01).

Coolant Type:

Ethylene glycol-based antifreeze. BMW recommends specific silicate-free coolants (e.g., BMW Blue or Pink coolant).

Power Steering Fluid:

Hydraulic fluid specified by BMW (e.g., CHF 11S for M models or certain E39s with Servotronic). Standard models may use Dexron III ATF.

Known Issues

E28 Common Issues:

Rust (wheel wells, rockers), fuel distributor diaphragm leaks (Bosch K-Jetronic), idle control valve issues, rear subframe mounting points, shifter bushings.

E34 Common Issues:

Cooling system leaks (plastic expansion tanks, hoses), head gasket failures (M50), VANOS seal failure (M50/M52), window regulators, OBC pixelation, front suspension wear (control arms, tie rods), rust.

E39 Common Issues:

Cooling system (plastic components, water pump, thermostat), VANOS seal failure (M54), oil leaks (valve cover gasket, oil pan gasket), "death rattle" (timing chain guides/tensioner), front suspension wear (control arms, sway bar links), ABS/DSC sensor failures, pixelation on instrument cluster/OBC, CCV system issues (M54).

📚 Vehicle History

Brand Heritage

Bmw Brand Philosophy:

Ultimate Driving Machine, focusing on performance, handling, and driver engagement.

Model Evolution

5 Series Evolution:

The 5 Series has consistently represented BMW's mid-size luxury sport sedan, evolving from robust engineering of the E28 to sophisticated electronics and comfort of the E39.

Production

E28 Production Years:

1981-1988.

E34 Production Years:

1987-1996 (North America: 1989-1995).

E39 Production Years:

1995-2003 (North America: 1997-2003).

🏆 Awards & Recognition

Recognitions

E28 Accolades:

Often praised for its driving dynamics and build quality, setting a benchmark for executive sedans.

E34 Accolades:

Widely acclaimed for its blend of performance, comfort, and technology. Consistently ranked highly in segment comparisons by automotive publications.

E39 Accolades:

Received numerous awards for its handling, comfort, safety, and technological advancements. Often cited as a benchmark for its class, particularly the 6-cylinder models.