BMW 535I E28 Service Repair Manual 1985-1988

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🏷️ Basic Information Identification Make: BMW Model: 535i Chassis Code: E28 Generation Generation Name: Second Generation (E28) Codes Engine Code Prefix: M30 Transmission Code Manual: Getrag 260/5 Transmission Code Automatic:...

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Taper: Car

Distributeur:

UGS: 319603

Mots clés: 1985 1986 1987 1988 535I E28 BMW Car Cars Misc

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Generation

Generation Name:

Second Generation (E28)

Codes

Engine Code Prefix:

Transmission Code Manual:

Getrag 260/5

Transmission Code Automatic:

ZF 4HP22

👋 Introduction

Market Position

Segment:

Executive Luxury Sedan

Target Audience:

Discerning drivers valuing performance, build quality, and technological advancement for its era

Competitive Analysis

Key Competitors:

Mercedes-Benz W124 E-Class, Audi 5000/100, Jaguar XJ

Key Features

Engine Performance:

Smooth and powerful M30 inline-six, renowned for torque and linear power delivery

Handling And Dynamics:

Balanced chassis, sophisticated suspension, precise steering contributing to BMW's 'Ultimate Driving Machine' reputation

Build Quality:

Exceptional fit and finish, durable materials characteristic of BMW's construction standards

Technological Advancements:

Early adoption of Motronic fuel injection and engine management, optional ABS and onboard computer

📋 Manual Details

Coverage Areas

Model Years Covered:

1985, 1986, 1987, 1988

Engine Variants Covered:

3.5L M30B34 inline-6

Trim Levels Covered:

All E28 535i trims

Page Count

Estimated Page Count:

Over 1000 pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (PDF assumed, based on product description)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshaft, valve train, timing components

Engine Fuel System:

Bosch Motronic fuel injection, fuel pump, injectors, fuel lines, pressure regulator, ECU diagnostics

Engine Ignition System:

Ignition coil, distributor (if applicable), spark plugs, ignition timing, Motronic control

Engine Cooling System:

Radiator, water pump, thermostat, hoses, fan clutch, coolant specifications

Engine Exhaust System:

Exhaust manifold, catalytic converter, muffler, oxygen sensors

Transmission Manual:

Clutch, gearbox removal and installation, internal component overhaul, gear shift linkage

Transmission Automatic:

Transmission removal and installation, torque converter, internal components, hydraulic circuits, shift control

Drivetrain:

Driveshaft, universal joints, differential, axle shafts, wheel bearings

Suspension:

Front suspension (MacPherson struts, control arms, sway bar), rear suspension (semi-trailing arms, coil springs, shock absorbers, sway bar), alignment specifications

Steering:

Power steering system, steering rack, tie rods, steering column, power steering fluid specifications

Brakes:

Front and rear disc brakes, ABS (if equipped), brake system bleeding, caliper and master cylinder overhaul, brake fluid specifications

Electrical System:

Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams, lighting, instrumentation

Engine Management:

Motronic ECU, sensors (CTS, MAF, TPS, O2), actuators, diagnostic trouble codes (DTCs)

Body And Chassis:

Body panel removal and installation, door mechanisms, glass, seals, chassis components

Climate Control:

HVAC system, blower motor, heater core, A/C compressor, refrigerant, controls

Interior:

Seats, dashboard, trim panels, seat belts

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, tune-ups, fluid checks, inspections

Engine Repairs:

Top-end rebuilds, bottom-end rebuilds, gasket replacements, timing belt/chain service (if applicable, though M30 is chain driven)

Transmission Repairs:

Clutch replacement, gearbox overhaul, automatic transmission service

Suspension And Steering Repairs:

Component replacement (struts, shocks, bushings, ball joints, tie rods), power steering pump and rack service, wheel alignment procedures

Brake System Repairs:

Brake pad and rotor replacement, caliper rebuild, brake line replacement, ABS component diagnostics

Electrical Diagnostics:

Troubleshooting wiring faults, component testing, starter/alternator replacement, headlamp and taillight service

Fuel System Service:

Fuel pump replacement, injector cleaning/replacement, fuel filter replacement

Bodywork And Trim:

Removal and installation of exterior and interior trim, body panel adjustments

Troubleshooting Guides:

Diagnostic flowcharts for common problems, symptom-based troubleshooting

Technical Depth

Depth Of Information:

Comprehensive from basic maintenance to complete engine and transmission rebuilds

Diagnostic Procedures:

Detailed diagnostic steps for all major systems, including electrical and fuel injection

Torque Specifications:

Extensive torque values for all fasteners and critical components

Clearances And Tolerances:

Specific measurements for engine parts, bearing clearances, etc.

Wiring Diagrams:

Full color, detailed electrical wiring schematics for all vehicle systems

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format) - assumed

Searchable Text:

High quality PDFs are typically searchable, enabling quick access to information

Print Quality

Illustrations Quality:

Clear line drawings, diagrams, and potentially photographs (depending on original source)

Binding Type

Binding Style:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B34

Engine Type:

SOHC Inline-6 (24-valve)

Displacement:

3430 cc (3.4 Liters)

Performance

Horsepower:

Approx. 182 hp @ 5500 rpm (Euro spec higher, US spec detuned slightly)

Torque:

Approx. 214 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Bosch Motronic LH Jetronic Fuel Injection

Fuel Type:

Premium Unleaded Gasoline

Engine Management

Engine Control Unit:

Bosch Motronic

🔧 Transmission

Standard

Transmission Type Std:

5-speed Manual (Getrag 260/5)

Optional

Transmission Type Opt:

4-speed Automatic (ZF 4HP22)

Features

Clutch Type:

Hydraulically operated single dry plate clutch

Automatic Transmission Features:

Lock-up torque converter, sport mode

📐 Dimensions

Exterior

Length:

Approx. 187.2 inches (4755 mm)

Width:

Approx. 69.3 inches (1760 mm)

Height:

Approx. 55.3 inches (1405 mm)

Wheelbase:

Approx. 104.3 inches (2650 mm)

Weights

Curb Weight:

Approx. 3400-3600 lbs (1542-1633 kg), depending on options

🛡️ Safety Features

Ratings

Safety Ratings Era:

Good for its time, though crash test methodologies were less stringent than today

Active Features

Optional Anti-lock Braking System (ABS)

Traction Control:

Not typically available on this model

Passive Features

Airbags:

Driver's side airbag optional, not standard

Seat Belts:

3-point inertia-reel seat belts front and rear

Crumple Zones:

Designed with front and rear crumple zones

💡 Technology Features

Infotainment

Radio System:

Factory AM/FM stereo with cassette player, often with upgraded speaker systems

Navigation:

Not available on this model

Driver Assistance

Cruise Control:

Standard or optional depending on trim and market

Onboard Computer:

Optional 'Check Control' system for monitoring fluid levels, lights, and basic diagnostics

Connectivity

Bluetooth Connectivity:

Not available on this model

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles or annually, consult manual for exact specification

Spark Plug Replacement:

Around 30,000 miles, depending on plug type (e.g., platinum)

Transmission Fluid Change Auto:

Every 30,000 - 50,000 miles, crucial for longevity

Transmission Fluid Change Manual:

Every 50,000 - 75,000 miles

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 15W-40 or 20W-50 depending on climate (check manual for precise grade)

Engine Oil Capacity:

Approx. 6.7 US quarts (6.3 Liters) with filter

Coolant Type:

BMW Blue Coolant or equivalent ethylene glycol based antifreeze

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

BMW Power Steering Fluid or Pentosin CHF 11 S (check specific model requirements)

Known Issues

Engine Gaskets:

Oil leaks from valve cover, oil pan, and front/rear main seals are common due to age and material degradation

Suspension Bushings:

Worn control arm bushings, trailing arm bushings, and sway bar bushings can lead to poor handling and noise

Electrical Connections:

Corrosion and degradation of wiring connectors and grounds can cause intermittent electrical issues

Fuel Injectors:

Clogged or faulty fuel injectors can lead to rough idle, misfires, and poor performance

Cooling System Components:

Radiator, water pump, and hoses can degrade over time, leading to leaks and overheating

Digital Pmod Module:

The 'Digital Motor Electronics' or 'Power Module' can be a failure point in the engine management system

📚 Vehicle History

Brand Heritage

Brand Focus:

BMW is renowned for engineering, performance, and driver-focused automobiles

Model Evolution

Predecessor:

E12 5 Series

Successor:

E34 5 Series

E28 Introduction:

Introduced in 1981 (for the 1982 model year) and produced until 1988

Production

Production Period:

1981-1988

Manufacturing Locations:

Germany (Dingolfing plant)

🏆 Awards & Recognition

Recognitions

Automotive Journalism Accolades:

Consistently praised by automotive journalists for its blend of performance, luxury, and build quality in its class during its production run

Ratings

Consumer Reports Ratings Era:

Generally rated well for reliability and performance by consumer organizations of the time, with typical aging issues for a car of its complexity