Positioning:
The BMW 535i/M535i (E28) represented the pinnacle of BMW's mid-size luxury sport sedan offering in the mid-1980s, competing with Mercedes-Benz E-Class and Audi models.
Key Competitors:
Mercedes-Benz W124 (300E), Audi 100/200 Quattro, Jaguar XJ6.
Performance Focus:
Known for its powerful inline-six engines, refined handling, and driver-oriented cockpit. The M535i offered enhanced performance and styling cues.
Purpose:
To provide technicians and owners with the complete information required to diagnose, maintain, and repair the BMW 535i and M535i E28 models.
Primary Coverage:
Comprehensive service, repair, and maintenance for BMW 535i and M535i models.
Secondary Coverage:
Troubleshooting, diagnostics, technical specifications, wiring diagrams.
Estimated Page Count:
Likely 500-800 pages (typical for a comprehensive workshop manual of this era).
Type:
Service and Repair Workshop Manual
Format:
Likely Printed; digital formats (PDF) also common for historical manuals.
Powertrain:
Engine mechanical, fuel injection, ignition, exhaust, transmission (manual & automatic).
Chassis:
Suspension (front & rear), steering, brakes (hydraulic & ABS if equipped), drivetrain (driveshaft, differential).
Electrical:
Complete wiring diagrams, lighting, instrumentation, accessories, starter, alternator, battery.
Body:
Body panels, doors, windows, seats, interior trim, HVAC system.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication.
Repair:
Engine overhaul, cylinder head, crankshaft, pistons, valve train, fuel system diagnosis & repair, transmission overhaul, brake caliper rebuild, suspension component replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, electrical fault finding procedures.
Special Tools:
Identification and usage of special tools required for specific procedures.
Depth:
Detailed, professional-level coverage suitable for experienced mechanics and serious DIY enthusiasts. Includes torque specifications, clearances, and diagnostic values.
Digital Quality:
If PDF, expect searchable text and clear image reproduction of diagrams. Scan quality may vary if from an original print.
Original Print:
High-quality paper and printing typical of OEM manuals from the era, featuring detailed line drawings and schematics.
Original Binding:
Typically a sturdy, sewn or glued binding suitable for frequent use in a workshop environment.
Original Paper:
Durable, often matte-finish paper to reduce glare and withstand shop conditions.
Engine Type:
Inline 6-Cylinder, SOHC (M30 family)
Displacement 535I:
3.430 cc (3.4 L)
Displacement M535I:
3.453 cc (3.5 L)
Horsepower 535I:
Approx. 182 hp @ 5400 rpm (varies by market/emission controls)
Torque 535I:
Approx. 214 lb-ft @ 3600 rpm
Horsepower M535I:
Approx. 192 hp @ 5400 rpm (varies by market/emission controls)
Torque M535I:
Approx. 219 lb-ft @ 3600 rpm
Fuel Delivery:
Bosch L-Jetronic or Motronic (depending on specific build date/market) Electronic Fuel Injection
Fuel Type:
Unleaded premium gasoline (91+ octane recommended)
Coolant Type:
BMW Blue Antifreeze/Coolant or equivalent ethylene glycol-based, silicate-free coolant.
Oil Type:
SAE 20W-50 or 15W-40 (API SF or SG rated) recommended for general use; consult manual for specific temperature ranges.
Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change.
Transmission Type 535I:
Getrag 260 5-speed manual transmission
Transmission Type M535I:
Getrag 280 5-speed manual transmission (specific for M-Sport)
Transmission Type Optional:
ZF 4HP22 4-speed automatic transmission
Transmission Fluid:
Dexron II or equivalent for automatic; Manual transmission fluid (MTF) specification in manual.
Length:
Approx. 4,620 mm (181.9 in)
Width:
Approx. 1,700 mm (66.9 in)
Height:
Approx. 1,415 mm (55.7 in)
Curb Weight:
Approx. 1,450-1,550 kg (3,197-3,417 lbs) depending on options.
Wheelbase:
Approx. 2,795 mm (110.0 in)
Wheel Bolt Pattern:
5x120mm
Standard Tire Size:
205/70VR14 or 220/55VR390 (Michelin TRX for some models)
Crash Testing:
No official NHTSA/Euro NCAP ratings from this era. Safety was primarily passive (seatbelts, crumple zones).
ABS:
Optional ABS (Anti-lock Braking System) was available on some models.
Restraints:
Three-point inertia-reel seatbelts, front and rear. Optional driver's airbag was not standard for this model year.
Construction:
Reinforced passenger cell, energy-absorbing steering column, crumple zones front and rear.
Audio System:
Optional premium sound systems, often with cassette player and analog tuning.
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control).
Cruise Control:
Standard or optional cruise control system.
Trip Computer:
Basic trip computer functions often integrated into the instrument cluster.
OBD:
No standard OBD-II or advanced electronic diagnostics. Diagnostics rely on early analog systems and manual troubleshooting.
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, whichever comes first. Consult manual for specific recommendations.
Transmission Fluid Change Auto:
Recommended every 30,000-50,000 miles (48,000-80,000 km), or based on driving conditions.
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF Dexron II or equivalent.
Common Problems:
Cooling system (radiator, hoses, water pump), fuel distributor issues (K-Jetronic), electrical gremlins (wiring harness degradation), differential seals, differential backlash.
M535I Specific:
M-tuned engine may require specialized knowledge; sport suspension components wear.
Parts Notes:
Many common wear items are still available, but some specialized M-parts or trim pieces can be rare and expensive.
Bmw Legacy:
BMW's reputation for performance, luxury, and engineering excellence was firmly established by the 1980s.
E28 Development:
The E28 was an evolution of the E12 chassis, featuring more advanced aerodynamics, updated suspension, and improved interior ergonomics. It introduced the concept of the 'Executive Sport Sedan'.
M535I Origin:
The M535i was a performance variant developed by BMW M GmbH, featuring the larger M30 engine, sport suspension, and distinctive body kit.
Production Years:
E28 series produced from 1981 to 1987. 535i and M535i variants were key models within this generation.
Manufacturing Location:
Germany (primarily Dingolfing plant).
