BMW 535 535i 1985-1988 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 535i Chassis Code: E28 Generation: Second Generation (E28) Model Years Covered: 1985, 1986, 1987, 1988 👋 Introduction Market Position Positioning: Premium executive sedan,...

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Type: Car

Vendor:

Sku: 431398

Tags: 1985 1986 1987 1988 535 535i BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Generation:

Second Generation (E28)

Model Years Covered:

1985, 1986, 1987, 1988

👋 Introduction

Market Position

Positioning:

Premium executive sedan, blending sporty performance with luxury and comfort.

Competitive Analysis

Competitors:

Mercedes-Benz W124 E-Class, Audi V8, Jaguar XJ6, Cadillac Sedan de Ville.

Key Features

Distinctive Aspects:

Renowned BMW driving dynamics, powerful inline-six engine, sophisticated engineering, driver-focused interior, high build quality.

Target Audience

Audience:

Enthusiasts, owners seeking to perform their own maintenance and repairs, independent repair shops specializing in European vehicles.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, implied by digital sales context)

Page Count Estimated:

High (typical for comprehensive workshop manuals, often 800+ pages)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, assembly, disassembly, timing, cooling system, lubrication system, fuel delivery, emission control systems, engine management (DME).

Engine Performance:

Diagnosis and tuning, power output specifications, performance enhancements.

Fuel System:

Fuel injection (Bosch Motronic), fuel pump, injectors, fuel pressure regulator, fuel tank, fuel lines, emissions control related to fuel system.

Transmission Manual:

Clutch, gearbox (Getrag 260/5), shift mechanism, drive shafts, differential, lubrication, repair procedures.

Transmission Automatic:

ZF 4HP22 automatic transmission, hydraulic control, torque converter, shift solenoids, valve body, repair, overhaul, fluid specifications.

Suspension:

Front suspension (MacPherson struts, control arms), rear suspension (semi-trailing arms), springs, shock absorbers, bushings, alignment specifications.

Steering:

Power steering system, steering rack, pump, hydraulic lines, steering column, steering angle sensor (if applicable).

Brakes:

Front disc brakes (vented), rear disc brakes, ABS (Anti-lock Braking System), brake fluid type, bleeding procedures, caliper and rotor replacement, parking brake.

Electrical System:

Battery, alternator, starter motor, ignition system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, diagnostic connector.

Engine Management:

Bosch Motronic DME, sensors (crankshaft position, camshaft position, throttle position, coolant temp, air flow meter), actuators (idle control, fuel injectors), troubleshooting and diagnostics.

Bodywork:

Body panel removal and installation, door mechanisms, window regulators, seals, bumpers, corrosion protection.

Interior:

Seating, dashboard, trim panels, HVAC controls, instrument cluster, sound system.

Heating Ventilation Air Conditioning:

HVAC system operation, blower motor, heater core, A/C compressor, refrigerant, climate control panel, troubleshooting.

Procedures Included

Routine Maintenance:

Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, wiring diagram interpretation.

Repair Overhaul:

Step-by-step instructions for major component repairs and full overhauls (engine, transmission, suspension, brakes).

Diagnostic Procedures:

ECU fault codes (if applicable via diagnostic connector), sensor testing, component testing using multimeters and oscilloscopes.

Specifications Data:

Torque specifications for all fasteners, clearances, tolerances, electrical system voltages and resistances.

Special Tools:

Identification of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including detailed diagnostics and electrical schematics.

📊 Manual Specifications

File Format

File Type:

PDF (assumed for digital sales)

Searchability:

Searchable text (expected for professional digital manuals)

Printability:

Printable (likely, allowing users to print specific sections)

Print Quality

Image Resolution:

High-resolution (for clarity of diagrams and illustrations)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B34

Engine Type:

3.4L Naturally Aspirated Inline-6 (I6)

Displacement:

3430 cc (3.4 Liters)

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:

182 hp @ 5500 rpm (approximate, Euro spec higher)

Torque:

220 lb-ft @ 3000 rpm (approximate)

Fuel System

Fuel Injection:

Bosch Motronic Electronic Fuel Injection

Fuel Type:

Unleaded Gasoline (Premium)

Engine Management

ECU Type:

Bosch Motronic (e.g., DME 1.3)

🔧 Transmission

Standard

Type:

5-Speed Manual (Getrag 260/5)

Optional

Type:

4-Speed Automatic (ZF 4HP22)

Features

Clutch:

Hydraulic actuation, single dry plate

Final Drive Ratio:

3.25:1 (typical, can vary)

📐 Dimensions

Exterior

Length:

185.2 inches (4704 mm)

Width:

69.1 inches (1755 mm)

Height:

55.9 inches (1420 mm)

Wheelbase:

108.7 inches (2761 mm)

Weights

Curb Weight:

3,400 - 3,600 lbs (1542 - 1633 kg) approx.

Gross Vehicle Weight Rating:

4,500 lbs (2041 kg) approx.

Cargo

Trunk Volume:

15.7 cubic feet (445 liters) approx.

🛡️ Safety Features

Ratings

Crash Test Data:

Limited standardized data from this era, but generally robust chassis construction.

Active Features

Standard Anti-lock Braking System (ABS) on all models

Traction Control:

Optional (ASC - Automatic Stability Control) on some later models

Passive Features

Airbags:

Driver's side airbag became standard later in the E28 production run, check specific vehicle.

Seatbelts:

3-point inertia-reel seatbelts with pretensioners

Body Structure:

Reinforced passenger cell, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory premium sound system (e.g., Nakamichi, Blaupunkt) with cassette player.

Climate Control:

Manual or automatic climate control with A/C.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Connectivity

Diagnostic Port:

BMW's early diagnostic connector for engine management troubleshooting.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or annually, whichever comes first.

Spark Plug Replacement:

Every 30,000 miles (48,000 km)

Coolant Flush:

Every 2-3 years

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil:

API SG or SH, SAE 10W-40 or 5W-40 synthetic blend (refer to manual for exact BMW approval)

Engine Oil Capacity:

6.5 US quarts (6.2 liters) with filter

Coolant:

BMW Blue Antifreeze/Coolant or equivalent silicate-free ethylene glycol-based coolant

Coolant Capacity:

2.5 US gallons (9.5 liters) approx.

Brake Fluid:

DOT 4

Manual Transmission Fluid:

ATF Dexron III or equivalent (e.g., Pentosin ATF1100)

Automatic Transmission Fluid:

ATF Dexron III or equivalent (e.g., Pentosin ATF1100)

Differential Fluid:

SAE 75W-90 synthetic gear oil

Power Steering Fluid:

BMW CHF 11S or equivalent Pentosin hydraulic fluid

Known Issues

Engine Oil Leaks:

Common due to aging seals and gaskets (e.g., valve cover gasket, oil pan gasket, front/rear main seals).

Cooling System:

Plastic expansion tank cracks, water pump failure, thermostat issues, fan clutch failure.

Suspension Bushings:

Wear and tear on control arm bushings, trailing arm bushings, and sway bar links, leading to poor handling and noise.

Electrical Gremlins:

Corrosion in wiring harnesses, failing relays, instrument cluster issues, door lock actuators.

Fuel System:

Clogged fuel injectors, failing fuel pumps, DME issues.

ABS System:

ABS sensor failures, ABS control unit issues.

📚 Vehicle History

Brand Heritage

Bmw Heritage:

BMW, known for 'The Ultimate Driving Machine,' with a long history in performance and luxury automotive engineering.

Model Evolution

E28 Generation:

The E28 was an evolution of the E12, featuring cleaner styling, improved aerodynamics, and significant technological advancements, including the introduction of ABS and onboard engine management.

535I Introduction:

The 535i variant was introduced to offer a more potent performance option within the 5 Series lineup, slotting above the 528i and preceding the M5.

Production

Production Years E28:

1981-1988

Manufacturing Locations:

Dingolfing, Germany; South Africa; Rosslyn, South Africa (CKD assembly).

🏆 Awards & Recognition

Recognitions

Model Reputation:

The E28 5 Series, including the 535i, is widely regarded as a benchmark for its era in terms of driving dynamics, build quality, and engineering sophistication.