BMW 528e, 533i, 535i, 535is (E28 5 Series) Repair Manual 1982-1988

• BMW 528e
• BMW 533i
• BMW 535i
• BMW 535is

CYLINDER BLOCK AND PISTON RECONDITIONING

All of the disassembled parts should be thoroughly cleaned before inspection.


CONNECTING RODS AND PISTONS

If pistons, piston pins, piston rings, connecting rods, and bearings are to be reused, they should always be reinstalled in their exact positions. Parts should never be interchanged between cylinders.

Before removing the pistons, mark the cylinder numbers on connecting rods and connecting rod caps if they have not been previously marked at the factory. Mark each connecting rod's position on the crankshaft so that they are not reversed during installation. The matching numbers on the side of the connecting rod and rod cap should all be facing the same side of the engine (i.e., all marked numbers face exhaust side of engine). Mark the top of the pistons.

The piston pin should fit without any play. No specifications for the pin-to-rod fit are provided by BMW. The fit can be checked by pushing the pin through the rod by hand. There should be slight resistance as the pin moves through the rod. If there is any play at all, replace the connecting rod bushing or the connecting rod.

If the piston pin is worn, the piston with pin will have to be replaced as an assembly. Piston pins are machined to match the piston. The piston pin circlips should be replaced with new circlips anytime they are removed.

When replacing the connecting rods, use only ones having the same weight class. The weight class is either stamped into the bottom of the connecting rod cap (alphanumeric code) or painted (colored dot) onto the side of the rod.

REMOVING AND INSTALLING TRANSMISSION SHAFTS
(GETRAG 265)

Removing the transmission shafts from the intermediate case requires that 5th gear be pressed off the layshaft. This pressing on and off operation requires considerable force (in excess of 9 tons). It is recommended that 5th gear be pressed off by an authorized BMW dealer or a qualified machine shop with the appropriate equipment. The remainder of the procedure can be accomplished using standard pullers.

WARNING! When pressing or pulling is required, always use tools having a higher capacity rating than that required to remove the part. Power tools, such as air impact tools, should not be used on press equipment.

Also covered under this heading is the removal of the shift forks, shafts and shift rods. Installation of the transmission shafts into the transmission assembly requires precision measuring equipment (micrometer and vernier caliper), new rolled pins, and possibly a new shim to correctly set the axial play of the 5th/reverse gear guide sleeve (synchronizer hub).

• Fundamentals
• Lubrication and Maintenance
• Engine Management: Driveability
• Engine Service and Repair
• Fuel Supply
• Fuel Injection
• Battery, Starter, Alternator
• Cooling System
• Exhaust System
• Manual Transmisssion and Clutch
• Manual Transmission Overhaul
• Automatic Transmission
• Driveshaft and Final Drive
• Front Suspension
• Rear Suspension
• Steering and Wheel Alignment
• Brakes
• Body and Interior
• Heating and Air Conditioning
• Electrical System