BMW 5 Series E28 E34 Service Repair Workshop Manual 1981

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Codes Chassis Code Covered: E28, E34 Production Years Covered: 1981 - 1996 (across both generations) 👋 Introduction Market Position Vehicle Segment: Luxury/Executive Sedan (BMW 5 Series E28/E34). Target Audience: Enthusiasts, DIY mechanics, and professional workshops servicing these iconic BMW models. Competitive Analysis Manual Competitors: Haynes, Chilton, factory service manuals (often harder to source or more expensive). Value Proposition: Comprehensive coverage, potentially more detailed than aftermarket competitors, at a competitive price point. Emphasized completeness ('no missing pages') against cheaper, incomplete manuals. Key Features Manual Quality Claim: Rated as 'Best Manual Available' on Tradebit, emphasizing superior quality and completeness. Customer Satisfaction: Guaranteed, indicating confidence in the product's accuracy and usability. 📋 Manual Details Coverage Areas Manual Type: Comprehensive Service, Repair, and Workshop Manual Language: English Format: Digital (likely PDF, based on common digital manual offerings) Completeness: Full, no missing pages as per product description 📖 Manual Coverage Systems Covered Engine Mechanics: Detailed disassembly, inspection, reassembly, and torque specifications for all engine variants (e.g., M30, M20, M50, M52). Fuel System: Bosch L-Jetronic, Motronic (various versions), fuel injectors, fuel pumps, fuel pressure regulators, exhaust systems (including catalytic converters). Ignition System: Distributor systems, coil-on-plug, ignition timing, troubleshooting of electronic ignition components. Cooling System: Radiator, water pump, thermostat, coolant types, capacities, bleeding procedures, fan systems (mechanical and electric). Lubrication System: Oil pump, oil filter, oil cooler, oil pressure specifications, oil change procedures, fluid capacities. Transmission Manual: Getrag 5-speed (e.g., 260, 265), clutch assembly, flywheel, shift linkages, fluid types and capacities. Transmission Automatic: ZF 4HP22, ZF 4HP24, torque converter, valve body, transmission control units, fluid types and capacities. Drivetrain: Driveshafts, CV joints, limited-slip differentials (LSD), rear axle assembly, wheel bearings. Suspension Front: MacPherson struts, control arms, ball joints, sway bars, bushings, alignment specifications. Suspension Rear: Trailing arms, semi-trailing arms, shock absorbers, springs, bushings, alignment specifications. Steering System: Power steering pump, steering rack, tie rods, steering column, fluid types and capacities. Brakes Front: Ventilated discs, calipers, brake pads, rotor specifications, ABS system components. Brakes Rear: Solid or ventilated discs, calipers, brake pads, rotor specifications, parking brake mechanism. Wheels Tires: Wheel bolt patterns, torque specifications, tire pressure recommendations, tire size compatibility. Electrical System Overview: Wiring diagrams, fuse box layouts, relay locations, component identification. Battery Charging: Alternator specifications, battery types, charging system troubleshooting. Lighting System: Headlights, taillights, interior lighting, bulb types and specifications. Instrument Panel: Gauges, warning lights, speedometer, tachometer troubleshooting. Comfort Controls: HVAC system, blower motor, heater core, A/C system (refrigerant types, capacities), climate control panels. Body Exterior: Door mechanisms, window regulators, sunroof operation, bumper removal and installation, trim pieces. Body Interior: Seat removal, dashboard disassembly, carpet replacement, headliner installation. Safety Systems: Seat belt mechanisms, airbag system (basic information, caution regarding SRS), ABS diagnostics. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults across all major vehicle systems. Component Replacement: Step-by-step guides for replacing virtually every component, from minor sensors to major engine and transmission overhauls. Rebuilds: Detailed instructions for rebuilding engines, transmissions, steering racks, and brake calipers. Diagnostics Electrical: Wiring diagrams, pinout data, resistance checks, voltage tests for electronic control units (ECUs) and sensors. Diagnostics Mechanical: Compression testing, leak-down testing, timing checks, pressure tests. Alignment Adjustment: Specifications and procedures for wheel alignment adjustments (camber, caster, toe). Emission Control: Diagnosis and repair of emission control systems, including catalytic converters, O2 sensors, and secondary air injection. Technical Depth Level Of Detail: Professional technician level, covering everything from basic maintenance to complete engine and transmission rebuilds. Diagrams Illustrations: Likely includes detailed exploded diagrams, schematic drawings, and step-by-step photographic or line-art illustrations. Torque Specifications: Comprehensive list of torque values for all critical fasteners across the vehicle. Special Tools: Identification of any specialized tools required for specific repair procedures. 📊 Manual Specifications File Format Digital Format: Likely PDF, ensuring searchability and widespread compatibility. Print Quality Digital Resolution: Assumed high resolution for clarity of diagrams and text, suitable for printing. Binding Type Digital Format Advantage: No physical binding concerns; accessible on multiple devices. Paper Type Digital Format Advantage: N/A (digital format) ⚙️ Engine Specifications Primary Engine E28 Engine Options: 2.8L M30B28, 3.5L M30B35 (528i, 535i); 3.5L M106 (M models); Diesel variants (524td). E34 Engine Options: 2.0L M20B20, 2.5L M20B25 (520i, 525i); 3.0L M30B30, 3.4L M30B34 (530i, 535i); 3.5L S38B35 (M5); Later models featured M50/M52 6-cylinders (2.5L, 2.8L) and M60 V8s (3.0L, 4.0L). Diesel variants (524td, 525td/tds). Performance E28 M30 Power Output: Approx. 181 hp for M30B28, 182 hp for M30B35 (varies by market/tune). E34 M50 Power Output: Approx. 189 hp for M50B25, 190 hp for M50B25TU. E34 M5 Power Output: Approx. 286 hp for S38B35. Fuel System E28 Fuel Injection: Bosch L-Jetronic or Motronic (e.g., Motronic 1.0, 1.1, 1.3). E34 Fuel Injection: Bosch Motronic (various generations: 1.1, 1.3,...

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Codes

Chassis Code Covered:

E28, E34

Production Years Covered:

1981 - 1996 (across both generations)

👋 Introduction

Market Position

Vehicle Segment:

Luxury/Executive Sedan (BMW 5 Series E28/E34).

Target Audience:

Enthusiasts, DIY mechanics, and professional workshops servicing these iconic BMW models.

Competitive Analysis

Manual Competitors:

Haynes, Chilton, factory service manuals (often harder to source or more expensive).

Value Proposition:

Comprehensive coverage, potentially more detailed than aftermarket competitors, at a competitive price point. Emphasized completeness ('no missing pages') against cheaper, incomplete manuals.

Key Features

Manual Quality Claim:

Rated as 'Best Manual Available' on Tradebit, emphasizing superior quality and completeness.

Customer Satisfaction:

Guaranteed, indicating confidence in the product's accuracy and usability.

📋 Manual Details

Coverage Areas

Manual Type:

Comprehensive Service, Repair, and Workshop Manual

Language:

English

Format:

Digital (likely PDF, based on common digital manual offerings)

Completeness:

Full, no missing pages as per product description

📖 Manual Coverage

Systems Covered

Engine Mechanics:

Detailed disassembly, inspection, reassembly, and torque specifications for all engine variants (e.g., M30, M20, M50, M52).

Fuel System:

Bosch L-Jetronic, Motronic (various versions), fuel injectors, fuel pumps, fuel pressure regulators, exhaust systems (including catalytic converters).

Ignition System:

Distributor systems, coil-on-plug, ignition timing, troubleshooting of electronic ignition components.

Cooling System:

Radiator, water pump, thermostat, coolant types, capacities, bleeding procedures, fan systems (mechanical and electric).

Lubrication System:

Oil pump, oil filter, oil cooler, oil pressure specifications, oil change procedures, fluid capacities.

Transmission Manual:

Getrag 5-speed (e.g., 260, 265), clutch assembly, flywheel, shift linkages, fluid types and capacities.

Transmission Automatic:

ZF 4HP22, ZF 4HP24, torque converter, valve body, transmission control units, fluid types and capacities.

Drivetrain:

Driveshafts, CV joints, limited-slip differentials (LSD), rear axle assembly, wheel bearings.

Suspension Front:

MacPherson struts, control arms, ball joints, sway bars, bushings, alignment specifications.

Suspension Rear:

Trailing arms, semi-trailing arms, shock absorbers, springs, bushings, alignment specifications.

Steering System:

Power steering pump, steering rack, tie rods, steering column, fluid types and capacities.

Brakes Front:

Ventilated discs, calipers, brake pads, rotor specifications, ABS system components.

Brakes Rear:

Solid or ventilated discs, calipers, brake pads, rotor specifications, parking brake mechanism.

Wheels Tires:

Wheel bolt patterns, torque specifications, tire pressure recommendations, tire size compatibility.

Electrical System Overview:

Wiring diagrams, fuse box layouts, relay locations, component identification.

Battery Charging:

Alternator specifications, battery types, charging system troubleshooting.

Lighting System:

Headlights, taillights, interior lighting, bulb types and specifications.

Instrument Panel:

Gauges, warning lights, speedometer, tachometer troubleshooting.

Comfort Controls:

HVAC system, blower motor, heater core, A/C system (refrigerant types, capacities), climate control panels.

Body Exterior:

Door mechanisms, window regulators, sunroof operation, bumper removal and installation, trim pieces.

Body Interior:

Seat removal, dashboard disassembly, carpet replacement, headliner installation.

Safety Systems:

Seat belt mechanisms, airbag system (basic information, caution regarding SRS), ABS diagnostics.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults across all major vehicle systems.

Component Replacement:

Step-by-step guides for replacing virtually every component, from minor sensors to major engine and transmission overhauls.

Rebuilds:

Detailed instructions for rebuilding engines, transmissions, steering racks, and brake calipers.

Diagnostics Electrical:

Wiring diagrams, pinout data, resistance checks, voltage tests for electronic control units (ECUs) and sensors.

Diagnostics Mechanical:

Compression testing, leak-down testing, timing checks, pressure tests.

Alignment Adjustment:

Specifications and procedures for wheel alignment adjustments (camber, caster, toe).

Emission Control:

Diagnosis and repair of emission control systems, including catalytic converters, O2 sensors, and secondary air injection.

Technical Depth

Level Of Detail:

Professional technician level, covering everything from basic maintenance to complete engine and transmission rebuilds.

Diagrams Illustrations:

Likely includes detailed exploded diagrams, schematic drawings, and step-by-step photographic or line-art illustrations.

Torque Specifications:

Comprehensive list of torque values for all critical fasteners across the vehicle.

Special Tools:

Identification of any specialized tools required for specific repair procedures.

📊 Manual Specifications

File Format

Digital Format:

Likely PDF, ensuring searchability and widespread compatibility.

Print Quality

Digital Resolution:

Assumed high resolution for clarity of diagrams and text, suitable for printing.

Binding Type

Digital Format Advantage:

No physical binding concerns; accessible on multiple devices.

Paper Type

Digital Format Advantage:

N/A (digital format)

⚙️ Engine Specifications

Primary Engine

E28 Engine Options:

2.8L M30B28, 3.5L M30B35 (528i, 535i); 3.5L M106 (M models); Diesel variants (524td).

E34 Engine Options:

2.0L M20B20, 2.5L M20B25 (520i, 525i); 3.0L M30B30, 3.4L M30B34 (530i, 535i); 3.5L S38B35 (M5); Later models featured M50/M52 6-cylinders (2.5L, 2.8L) and M60 V8s (3.0L, 4.0L). Diesel variants (524td, 525td/tds).

Performance

E28 M30 Power Output:

Approx. 181 hp for M30B28, 182 hp for M30B35 (varies by market/tune).

E34 M50 Power Output:

Approx. 189 hp for M50B25, 190 hp for M50B25TU.

E34 M5 Power Output:

Approx. 286 hp for S38B35.

Fuel System

E28 Fuel Injection:

Bosch L-Jetronic or Motronic (e.g., Motronic 1.0, 1.1, 1.3).

E34 Fuel Injection:

Bosch Motronic (various generations: 1.1, 1.3, 1.4, 1.5, 1.7, 3.1, 3.3) for 6-cylinder and V8 models.

🔧 Transmission

Standard

E28 Standard Transmission:

4-speed manual (early models), 5-speed Getrag 260 manual (later/most models).

E34 Standard Transmission:

5-speed Getrag 260 manual (most 6-cylinder models), Getrag 265 manual (M5).

Optional

E28 Optional Transmission:

ZF 3HP22 automatic transmission.

E34 Optional Transmission:

ZF 4HP22 automatic (common), ZF 4HP24 automatic (later/higher torque applications).

Features

Transmission Fluid Type:

ATF Dexron III (or equivalent) for automatics, Gear oil GL-4/GL-5 for manuals (specific grades vary).

📐 Dimensions

Exterior

E28 Length:

Approx. 4,755 mm (187.2 in)

E34 Length:

Approx. 4,730 mm (186.2 in) for sedan, 4,970 mm (195.7 in) for Touring.

E34 Width:

Approx. 1,751 mm (68.9 in)

E34 Height:

Approx. 1,410 mm (55.5 in) for sedan.

Weights

E28 Curb Weight:

Approx. 1,450 - 1,650 kg (3,200 - 3,600 lbs) depending on engine/options.

E34 Curb Weight:

Approx. 1,550 - 1,850 kg (3,400 - 4,080 lbs) depending on engine/options.

🛡️ Safety Features

Ratings

E28 Safety Features:

Designed with crumple zones, safety steering column, laminated front windshield.

E34 Safety Features:

Improved crumple zones, optional driver airbag (later models), ABS standard on many models, reinforced passenger cell.

Active Features

ABS Availability:

Optional on many E28 models, standard on most E34 models.

Passive Features

Seatbelts:

3-point front and rear seat belts; early E28 models may have manual rear belts.

💡 Technology Features

Infotainment

E28 Infotainment:

Basic AM/FM radio with cassette player; optional premium sound systems.

E34 Infotainment:

More advanced multi-speaker audio systems, optional CD players, early forms of 'premium' sound. Some models had basic onboard computers displaying fuel consumption and range.

Driver Assistance

Cruise Control:

Available on many E28 and E34 models.

Traction Control:

Optional on some E34 models (ASC or ASC+T).

Connectivity

Phone Integration:

N/A for E28; rudimentary car phone options on very early E34 models, generally not integrated with modern standards.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, though modern synthetic oils can extend this. The manual will provide specific BMW recommendations.

Coolant Flush:

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

Spark Plugs:

Varies by plug type (copper, platinum, iridium); typically 30,000-60,000 miles (48,000-96,000 km). Manual will specify exact types and intervals.

Fluid Specifications

Engine Oil Type:

API SF/SG or higher, viscosity dependent on climate (e.g., 10W-40, 15W-50, 20W-50). Manual will confirm BMW LL-98 or similar specifications for later models.

Coolant Type:

Ethylene glycol-based antifreeze, typically blue or green (BMW specific color coding may apply). Manual will specify BMW part numbers or equivalent.

Known Issues

E28 Common Problems:

Rust (wheel arches, rocker panels), fuel accumulator failure, vacuum leaks, headliner sagging, front suspension bushings, driveshaft flex disc wear.

E34 Common Problems:

Cooling system failures (plastic components, expansion tank), VANOS issues (M50/M52 engines), ABS sensor failures, door seal leaks, headliner sagging, window regulator failures, heater control valve issues.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's 'Ultimate Driving Machine' ethos, focusing on performance, handling, and driver engagement.

Model Evolution

E28 Generation:

Second generation 5 Series, introduced 1981, replacing the E12. Known for its sharp styling and improved dynamics.

E34 Generation:

Third generation 5 Series, introduced 1987, replacing the E28. Characterized by sleeker aerodynamics, improved interior space, and advanced technology (e.g., V8 engines, complex electronics).

Production

E28 Production Years:

1981–1988

E34 Production Years:

1987–1996 (sedan), 1991–1996 (Touring)

🏆 Awards & Recognition

Recognitions

E28 Market Reception:

Praised for its driving dynamics and build quality, solidifying BMW's reputation in the executive sedan segment.

E34 Market Reception:

Widely regarded as a benchmark in its class for performance, comfort, and engineering. Car and Driver's 'Ten Best' list multiple times.