🏷️ Basic Information

Make:

BMW

Model:

635CSi

Body Style:

Grand Tourer Coupe

E24:

Second Generation (Late Model)

Chassis Code:

E24

👋 Introduction

Class:

Luxury Grand Tourer / Sports Coupe

Target Audience:

Discerning buyers seeking performance, luxury, and distinctive styling. Often favored by enthusiasts and those appreciating classic European automotive engineering.

Competitors:

Mercedes-Benz SEC models (W126), Porsche 944, Jaguar XJS.

Styling:

Distinctive Bangle-era 'shark nose' design, long hood, Hofmeister kink rear window, elegant and timeless proportions.

Performance Orientation:

Powerful inline-six engine, RWD layout, balanced chassis, offering a blend of comfortable touring and spirited driving.

Build Quality:

Renowned BMW build quality and engineering, durable powertrains, and premium interior materials.

Primary Use:

To provide comprehensive technical guidance for the maintenance, repair, and diagnosis of the BMW 635CSi (E24) models from 1983-1989, intended for mechanical technicians and skilled home mechanics.

📋 Manual Details

Covered Years:

1983, 1984, 1985, 1986, 1987, 1988, 1989

Estimated Pages:

1500+

Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

M30B34 inline-six, including: Engine mechanicals, lubrication, cooling, fuel injection (Bosch Motronic), ignition system, exhaust system, engine diagnostics, tuning.

Transmission:

Getrag 265 5-speed manual and ZF 4HP-22 4-speed automatic transmissions, including: removal, installation, overhaul, clutch, torque converter, shift mechanisms, fluid specifications, troubleshooting.

Drivetrain:

Rear-wheel drive, driveshaft, differential (limited-slip optional), axles, CV joints, propeller shaft, universal joints.

Suspension:

Front McPherson struts, rear semi-trailing arms, springs, shock absorbers, control arms, sway bars, bushings, ball joints, steering knuckles, wheel bearings.

Steering:

Power-assisted recirculating ball steering system, steering box, pump, hoses, steering column, tie rods, power steering fluid specifications.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System - optional), brake calipers, rotors, pads, lines, master cylinder, parking brake, brake fluid specifications, bleeding procedures.

Electrical:

12-volt system, battery, alternator, starter motor, wiring diagrams for all circuits, fuses, relays, lighting (headlights, taillights, interior), instrumentation, horn, power windows, mirrors, seats, sunroof.

Climate Control:

Heating, ventilation, and air conditioning (HVAC) system, blower motor, heater core, evaporator, refrigerant (R-12), compressor, controls, troubleshooting.

Body And Chassis:

Body panel removal/installation, door mechanisms, hood, trunk, bumpers, glass, seals, interior trim, sound deadening, corrosion prevention, chassis lubrication points.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulator, emission control systems.

Cooling System:

Radiator, fan, water pump, thermostat, hoses, coolant type and capacity, pressure testing.

Maintenance:

Routine maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspection and adjustment, chassis lubrication.

Diagnostics:

Troubleshooting guides for common and uncommon issues, symptom-based diagnostics, electrical system diagnostics, engine performance diagnostics, diagnostic trouble codes (if applicable to the era/system).

Repair:

Step-by-step repair instructions for all major systems, component removal and installation, rebuilding procedures for engines and transmissions, bodywork repair techniques, electrical component replacement.

Overhaul:

Detailed instructions for complete engine and transmission overhauls, including specifications for wear limits and tolerances.

Adjustments:

Valve adjustments (if applicable to the specific M30 variant), idle speed adjustments, ignition timing adjustments, brake adjustments, clutch adjustments.

Torque Specifications:

Comprehensive torque specifications for all critical fasteners throughout the vehicle.

Depth:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

Quality:

High-resolution PDF, generally scanned from original factory manuals. Searchable text is often available depending on the scan quality.

Usability:

Printable for use in a workshop environment. Allows users to print specific sections as needed.

Type:

N/A (Digital PDF format)

Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Code:

M30B34

Configuration:

Inline 6-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

3430 cc (3.4 liters)

Bore X Stroke:

92 mm x 86 mm

Compression Ratio:

8.0:1 or 8.5:1 (depending on market and specific revision)

Horsepower:

Approx. 218 hp @ 5700 rpm (DIN)

Torque:

Approx. 340 Nm (251 lb-ft) @ 3500 rpm (DIN)

Injection:

Bosch Motronic (L-Jetronic variant with electronic ignition control)

Fuel Type:

Unleaded Gasoline (RON 95/98 recommended)

Type:

Electronic ignition with knock control (Motronic)

🔧 Transmission

Type:

Getrag 265 5-speed manual transmission

Type:

ZF 4HP-22 4-speed automatic transmission

Manual Gear Ratios:

1st: 3.72, 2nd: 2.40, 3rd: 1.57, 4th: 1.19, 5th: 1.00; Reverse: 3.15 (typical)

Automatic Gear Ratios:

1st: 2.48, 2nd: 1.48, 3rd: 1.00, 4th: 0.72; Reverse: 2.08 (typical)

Manual Fluid:

GL-4 75W-90 or 80W-90 gear oil (e.g., Castrol EPX 80W-90)

Automatic Fluid:

ATF Dexron III (or equivalent)

📐 Dimensions

Length:

4755 mm (187.2 in)

Width:

1720 mm (67.7 in)

Height:

1360 mm (53.5 in)

Wheelbase:

2627 mm (103.4 in)

Front Track:

1445 mm (56.9 in)

Rear Track:

1465 mm (57.7 in)

Curb Weight:

Approx. 1550-1650 kg (3417-3638 lbs), depending on transmission and equipment.

Gross Vehicle Weight Rating:

Approx. 2000 kg (4409 lbs)

Payload Capacity:

Approx. 350-450 kg (772-992 lbs)

🛡️ Safety Features

Crash Testing:

As a vehicle from the 1980s, official crash test ratings from modern organizations like NHTSA or IIHS are generally not available or comparable. However, BMWs of this era were built with robust safety structures for their time.

ABS:

Optional Anti-lock Braking System (ABS) available on later models and certain markets.

Seatbelts:

Three-point inertia-reel seatbelts in the front, lap belts for rear passengers.

Body Structure:

Reinforced safety cell, crumple zones front and rear.

Headrests:

Front and rear headrests.

Lighting:

Halogen headlights, fog lights (optional/market dependent).

💡 Technology Features

Audio System:

Factory cassette tape player with AM/FM radio, often with amplifier and equalizer options. Speaker quality varies by trim. Aftermarket upgrades are common.

Instrumentation:

Comprehensive analog gauges including speedometer, tachometer, fuel level, oil temperature, coolant temperature, and trip computer (optional on some models).

ABS:

As mentioned, optional Anti-lock Braking System on later models for enhanced braking control.

Features:

Limited by era. Features primarily revolved around the car's mechanical and comfort systems. No modern digital connectivity or integrated navigation.

🔧 Maintenance

Oil Change:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, whichever comes first, depending on driving conditions and oil used.

Filter Replacement:

Oil filter with every oil change. Air filter and fuel filter typically every 15,000 - 30,000 miles (24,000 - 48,000 km).

Spark Plugs:

Inspect/replace every 20,000 - 30,000 miles (32,000 - 48,000 km).

Coolant Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Brake Fluid Flush:

Every 1-2 years.

Engine Oil:

API SG/SH or higher, SAE 20W-50 or 10W-40 recommended for most climates. Check manual for specific viscosity recommendations.

Coolant:

BMW antifreeze/coolant concentrate (blue or green ethylene glycol-based) mixed 50/50 with distilled water.

Power Steering Fluid:

ATF Dexron II/III or Pentosin CHF 11S (verify application).

Brake Fluid:

DOT 3 or DOT 4.

Rust Prone Areas:

Wheel arches, rocker panels, door bottoms, battery tray area, front fender liners, trunk floor, sunroof drain channels.

Engine M30:

Head gasket leaks, oil pan leaks, valve cover gasket leaks, oil sludge buildup if maintenance is neglected, starter motor issues, idle control valve problems.

Electrical System:

Wiring harness degradation (especially in engine bay), headlight switch failure, intermittent dashboard lights, relay failures, blower motor resistor issues.

Suspension And Steering:

Worn control arm bushings, ball joint wear, aging shock absorbers, power steering leaks, worn tie rod ends.

Interior:

Cracked dashboard, sagging headliner, wear on leather seats, malfunctioning power seat motors, door panel delamination.

📚 Vehicle History

Bmw Legacy:

BMW, Bayerische Motoren Werke AG, has a long history of producing luxurious and performance-oriented vehicles with a focus on engineering and driving dynamics. The '6 Series' lineage began with the E24.

E24 Introduction:

The E24 6 Series was introduced in 1976 as the successor to the E9 Coupe. The 635CSi was a significant evolution, introduced in 1978 with the larger 3.5-liter M30 engine.

Late E24 Facelift:

The E24 received a significant facelift in 1982 (for model year 1982.5 and later), which included updated aerodynamics, revised interior, and updated technology. The 1983-1989 models represent this updated, later generation.

Production Period:

1976-1989 (E24 generation). This manual specifically covers the later models from 1983 to 1989.

Assembly Locations:

Mainly assembled in Dingolfing, Germany.

🏆 Awards & Recognition

Automotive Press:

The E24 6 Series, and specifically the 635CSi, was widely praised by automotive journalists for its potent engine, sophisticated handling, luxurious interior, and iconic styling, often cited as one of the best GT cars of its era.

Enthusiast Following:

It has maintained a strong following among automotive enthusiasts and collectors, appreciated for its classic BMW driving experience and enduring design.

Manual Quality:

This workshop manual is designed to meet the rigorous standards of professional automotive repair and servicing documentation.