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BMW M535I E28 Service Repair Manual 1985-1988

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🏷️ Basic Information Identification Make: BMW Model: M535i Chassis Code: E28 Model Years Covered: 1985-1988 👋 Introduction Market Position Segment: Luxury Sport Sedan Target Audience: Enthusiasts and owners seeking to...
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BMW M535I E28 Service Repair Manual 1985-1988
🏷️ Basic Information
Identification
Make:
BMW
Model:
M535i
Chassis Code:
E28
Model Years Covered:
1985-1988
👋 Introduction
Market Position
Segment:
Luxury Sport Sedan
Target Audience:
Enthusiasts and owners seeking to maintain and repair their classic BMW M535i.
Competitive Analysis
Competitors:
Mercedes-Benz 300E, Audi 5000, Jaguar XJ6, Volvo 240 Turbo.
Key Features
Value Proposition:
Cost savings on maintenance and repairs, empowerment for DIY mechanics, preservation of a classic performance vehicle.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Workshop Manual
Language:
English
Format:
Downloadable Digital Format (likely PDF)
Page Count
Page Count Estimate:
500-1500 pages (typical for comprehensive manuals of this era)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul, timing belt/chain, cooling system, lubrication system, fuel injection (Bosch Motronic), emissions control.
Transmission:
Manual and Automatic transmission repair, clutch service, driveshaft, differential.
Brakes:
Hydraulic system, ABS (if equipped), brake pads, rotors, calipers, lines, bleeding procedures.
Electrical:
Wiring diagrams, starter, alternator, battery, lighting, ignition system, instrument cluster, power accessories, fuses, relays.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, bushings, steering rack, power steering system.
Body Chassis:
Body panel removal/installation, doors, hood, trunk, interior trim, chassis components, rust repair guidance.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting guides for common problems.
Repair Rebuild:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Technical Depth
Depth:
Comprehensive, suitable for DIY enthusiasts, independent repair shops, and even dealership technicians for reference. Covers everything from basic adjustments to full engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Likely searchable text for efficient information retrieval.
Print Quality
Printability:
Designed to be printable for workshop use.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6 Cylinder, Naturally Aspirated
Engine Code:
M30B34
Displacement:
3.4 Liters (3430 cc)
Performance
Horsepower:
182 hp @ 5500 rpm (Euro Spec: 218 hp)
Torque:
220 lb-ft @ 4000 rpm (Euro Spec: 232 lb-ft)
Fuel System
Fuel Delivery:
Bosch L-Jetronic Fuel Injection (later models may have Motronic)
Fuel Type:
Unleaded Gasoline (Premium)
Engine Components
Bore X Stroke:
92.0 mm x 84.0 mm
Compression Ratio:
8.0:1 (Euro Spec: 9.1:1)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (Getrag 265)
Optional
Transmission Type:
4-Speed Automatic (ZF 4HP22)
Features
Clutch Type:
Single dry plate, hydraulic actuation
Gear Ratios Manual:
3.72:1, 2.02:1, 1.33:1, 1.00:1, 0.81:1 (approximate, may vary by final drive)
Transmission Fluid
Manual Fluid Type:
API GL-5 SAE 75W-90 or 80W-90
Automatic Fluid Type:
Dexron II (or equivalent)
📐 Dimensions
Exterior
Length:
188.2 inches (4780 mm)
Width:
69.4 inches (1763 mm)
Height:
55.1 inches (1400 mm)
Wheelbase:
104.3 inches (2649 mm)
Weights
Curb Weight:
3450 lbs (1565 kg) (approximate, manual transmission)
Gross Vehicle Weight Rating:
4365 lbs (1980 kg)
Dimensions
Wheel Bolt Pattern:
5 x 120 mm
Wheel Offset:
ET 22 (common)
🛡️ Safety Features
Ratings
Crash Test Ratings:
NHTSA ratings from the era are generally not directly comparable to modern standards, but the E28 chassis was known for its robust structure.
Active Features
ABS:
Available option on some models.
Passive Features
Airbags:
Driver airbag standard from 1987 onwards; passenger airbag not typically available.
Seatbelts:
Three-point front seatbelts, two-point rear seatbelts.
Chassis Design:
Integral safety cage, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory fitted cassette player with AM/FM radio, often with upgraded speakers by brands like Blaupunkt or Alpine.
Climate Control:
Manual or automatic climate control systems.
Driver Assistance
Cruise Control:
Standard on most M535i models.
Connectivity
Original Connectivity:
Limited to basic diagnostics via OBD-I port (BMW proprietary)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions.
Air Filter Replacement:
Every 15,000-20,000 miles (24,000-32,000 km).
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for standard plugs, longer for platinum/iridium.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 15W-40 or 20W-50 (check manual for specific climate recommendations).
Engine Oil Capacity:
6.5 US quarts (6.2 liters) with filter change.
Coolant Type:
BMW Blue Antifreeze (G48 ethylene glycol based) mixed with distilled water (50/50 ratio).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Problems:
Head gasket leaks, coolant flange leaks, fuel pump failure, door panel warping, rust in common areas (wheel arches, rockers), vacuum hose degradation, ABS sensor issues, worn suspension bushings.
📚 Vehicle History
Brand Heritage
Brand Philosophy:
BMW's philosophy of 'The Ultimate Driving Machine' emphasizes performance, engineering, and driver engagement.
Model Evolution
E28 Introduction:
The E28 platform succeeded the E12 and was produced from 1981 to 1988. It represented a significant evolution in BMW sedan design and technology.
M535I Positioning:
The M535i was the performance flagship of the E28 range, bridging the gap between the standard 5 Series and the legendary M5. It featured sport-tuned suspension, aerodynamic enhancements, and more powerful engine options.
Production
Production Years:
1984-1987 (M535i model within the E28 generation)
Manufacturing Locations:
Germany, South Africa
🏆 Awards & Recognition
Recognitions
Reputation:
The E28 M535i is highly regarded as a modern classic, appreciated for its driving dynamics, robust engineering, and understated performance.
Ratings
Contemporary Reviews:
Praised by automotive press for its handling, powerful inline-6 engine, and luxurious yet sporty interior.
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