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BMW 535 535i 1991 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 535i Year: 1991 Codes Chassis Code: E34 Engine Code: M30B35 👋 Introduction Market Position Vehicle Segment: Executive/Luxury Sedan Target...
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Mots clés: 1991 535 535i BMW Car Cars Misc
BMW 535 535i 1991 Workshop Repair Service ManualBMW 535 535i 1991 Workshop Repair Service ManualBMW 535 535i 1991 Workshop Repair Service ManualBMW 535 535i 1991 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Variant:
535i
Year:
1991
Codes
Chassis Code:
E34
Engine Code:
M30B35
👋 Introduction
Market Position
Vehicle Segment:
Executive/Luxury Sedan
Target Audience:
Luxury vehicle enthusiasts, independent repair shops, DIY mechanics
Competitive Analysis
Key Competitors:
Mercedes-Benz W124 E-Class, Audi V8 Quattro, Lexus LS400
Key Features
Vehicle Selling Points:
Refined driving dynamics, potent inline-six engine, luxurious interior, advanced engineering for its era
Manual Value Proposition:
Comprehensive technical resource for maintaining and repairing a classic BMW luxury sedan
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models/Engines/Trim/Transmissions Types
Page Count
Estimated Page Count:
800-1200 (typical for comprehensive E34 workshop manuals)
Manual Type
Manual Classification:
Workshop Repair Service Manual
Language
Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel injection (Bosch Motronic), ignition, cooling, exhaust systems
Drivetrain:
Manual and automatic transmission overhaul, differential, driveshafts, clutch
Chassis:
Suspension (front MacPherson struts, rear semi-trailing arms), steering (power assisted), brakes (ABS, ventilated front discs)
Electrical:
Wiring diagrams, lighting, starting/charging system, instrument cluster, EML (Engine Management Light), OBC (On-Board Computer), body electronics
Body And Interior:
Body panel removal/installation, interior trim, seats, HVAC system (climate control), sunroof, power windows/locks
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections
Troubleshooting:
Diagnostic procedures, fault code interpretation (OBD I), symptom-based troubleshooting guides
Repair:
Component removal, disassembly, inspection, repair, and reassembly for all major systems
Installation:
Guidance on installing replacement parts and accessories
Technical Depth
Diagnostic Level:
Advanced diagnostics, including component testing, circuit tracing, and diagnostic trouble codes (DTCs)
Rebuild Procedures:
Detailed procedures for engine, transmission, and differential rebuilds
Torque Specifications:
Comprehensive torque specifications for all critical fasteners
Alignment Data:
Wheel alignment specifications and adjustment procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, allowing for quick information retrieval
Print Quality
Image Clarity:
Typically high-resolution scans of original manuals, ensuring clear diagrams and text
Binding Type
Binding For Digital:
N/A (Digital format)
Paper Type
Paper For Digital:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Displacement:
3.5 Liters (3430 cc)
Bore X Stroke:
92.0 mm x 86.0 mm
Compression Ratio:
8.0:1
Valvetrain:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
Performance
Horsepower:
208 hp @ 5700 rpm (approx.)
Torque:
214 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch Motronic M3.3 Fuel Injection and Ignition Control
Fuel Type:
Unleaded Premium Gasoline (91+ octane)
Other
Engine Orientation:
Longitudinal
Engine Block Material:
Cast Iron
Cylinder Head Material:
Aluminum Alloy
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-Speed Manual Transmission
Optional
Transmission Type:
ZF 4HP22 4-Speed Automatic Transmission
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Rear Axle Ratio:
3.15:1 (typical for manual, varies with diff options)
📐 Dimensions
Exterior
Length:
4734 mm (186.4 in)
Width:
1751 mm (68.9 in)
Height:
1410 mm (55.5 in)
Wheelbase:
2799 mm (110.2 in)
Weights
Curb Weight:
1600-1700 kg (approx.)
🛡️ Safety Features
Ratings
Passive Safety Features:
Reinforced safety cage, front and rear crumple zones, driver's side airbag (often optional or standard late in the model year)
Active Features
Braking System:
Four-wheel disc brakes with ABS (Anti-lock Braking System)
Traction Control:
ASC (Automatic Stability Control) available on some models
💡 Technology Features
Infotainment
Audio System:
BMW Bavaria C or similar premium audio systems, often with cassette player and optional CD changer.
Driver Assistance
ABS:
Standard Anti-lock Braking System (ABS) for enhanced braking control.
Connectivity
Onboard Computer:
Optional On-Board Computer (OBC) providing fuel consumption, range, and diagnostic information.
Other
Engine Management:
Bosch Motronic M3.3 electronic engine management system for fuel injection and ignition timing.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles or 12 months, whichever comes first, depending on driving conditions and oil type.
Spark Plug Replacement:
Every 30,000-50,000 miles (check manual for specific plug type recommendations).
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil:
BMW Longlife-98 (or equivalent API SJ/SL rated synthetic oil), viscosity typically 5W-30 or 5W-40. Check manual for exact specification.
Coolant:
BMW Blue Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors), typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 4 (High-performance synthetic brake fluid)
Transmission Fluid Manual:
MTF LT-2 (or equivalent synthetic manual transmission fluid)
Transmission Fluid Automatic:
Dexron III (or equivalent ATF)
Known Issues
Common Problems:
Cooling system leaks (hoses, water pump, expansion tank), VANOS (Variable Valve Timing) on later M30 engines (though M30B35 does not have VANOS), fuel pump failures, dashboard pixelation, power steering hose leaks, rear main seal oil leaks, vacuum leaks leading to rough idle.
Part Numbers
Oil Filter Example:
Mann-Filter HU 718/1 Y or Mahle OX 36D (verify with specific VIN)
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused luxury sedans with excellent engineering and performance.
Model Evolution
E34 Introduction:
The E34 generation of the 5 Series was introduced in 1988 (as a 1989 model year in North America) and replaced the E28. It was lauded for its improved aerodynamics, chassis dynamics, and technological advancements.
535I Positioning:
The 535i was positioned as a potent and luxurious model within the E34 lineup, bridging the gap between the inline-four/six-cylinder 525i and the V8-powered 540i.
Production
Production Years E34:
1988-1996
🏆 Awards & Recognition
Recognitions
Automotive Press:
The E34 generation was widely praised by automotive journalists for its blend of luxury, performance, and handling, often appearing on 'best cars' lists of its time.
Ratings
Performance Benchmarks:
Generally considered a benchmark for sports sedans in its class during the early 1990s.
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