BMW 535I E28 Service Repair Manual 1985-1988

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🏷️ Basic Information Identification Make: BMW Model: 535i Chassis Code: E28 Production Years: 1985-1988 Codes Engine Code Primary: M30B34 👋 Introduction Market Position Market Segment: Executive Sedan, Luxury Sports Sedan...

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Type: Car

Vendor:

Sku: 274194

Tags: 1985 1986 1987 1988 5 Series 535I BMW Car Cars E28

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Production Years:

1985-1988

Codes

Engine Code Primary:

M30B34

👋 Introduction

Market Position

Market Segment:

Executive Sedan, Luxury Sports Sedan

Competitive Analysis

Competitors:

Mercedes-Benz W124 E-Class, Audi V8 (Type 44), Jaguar XJ (XJ40), Volvo 700 Series

Key Features Vehicle

Performance Orientation:

Known for its engaging driving dynamics, powerful straight-six engine, and refined luxury.

Key Features Manual

Manual Utility:

Indispensable resource for owners and technicians seeking to maintain or repair the E28 535i, offering comprehensive detail unmatched by basic owner's manuals.

Manual Value Proposition

Value For Owner:

Empowers owners to perform complex maintenance and repairs, potentially saving significant costs and preserving the vehicle's value and performance.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Fuel System, Cooling System, Exhaust System, Bodywork, Interior, Diagnostics

Page Count

Page Count:

Hundreds of Pages (Specific count not provided in product info, but implied to be extensive)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine rebuild procedures, component removal and installation, cylinder head, pistons, crankshaft, camshaft, timing, lubrication system

Fuel System:

Bosch L-Jetronic fuel injection system diagnosis and repair, fuel pump, injectors, fuel lines, pressure regulator

Ignition System:

Ignition timing, coil, distributor, spark plugs, control module diagnostics

Cooling System:

Radiator, fan, water pump, thermostat, coolant hoses, flush and refill procedures

Exhaust System:

Catalytic converter, muffler, exhaust manifold, oxygen sensor replacement and diagnosis

Transmission Manual:

Getrag 260 gearbox, clutch assembly, shift linkage, fluid replacement, rebuild procedures

Transmission Automatic:

ZF 4HP22 automatic transmission, torque converter, valve body, clutch packs, fluid change and diagnosis

Driveshafts Axles:

Driveshaft U-joints, differential, axle shafts, seals, wheel bearings

Suspension Front:

MacPherson struts, control arms, sway bar, ball joints, bushings, shock absorber replacement

Suspension Rear:

Semi-trailing arms, independent suspension, shock absorbers, bushings, wheel bearings

Steering System:

Power steering pump, steering rack, tie rods, steering column, alignment procedures

Brake System Front:

Ventilated disc brakes, calipers, pads, rotors, brake lines, ABS system (if equipped)

Brake System Rear:

Solid disc brakes, calipers, pads, rotors, brake lines

Electrical System Overview:

Wiring diagrams, fuse box locations, relay functions, component identification

Battery Charging:

Alternator, starter motor, battery maintenance and testing

Lighting System:

Headlights, taillights, interior lights, bulb replacement, wiring

Instrument Cluster:

Gauge removal and repair, warning lights, speedometer, tachometer diagnosis

HVAC System:

Heater core, A/C system, blower motor, climate controls, refrigerant charging

Body Exterior:

Door panel removal, window regulators, sunroof operation, trim piece replacement, panel alignment

Body Interior:

Seat removal, dashboard disassembly, carpet replacement, headliner repair

Glass Replacement:

Windshield, side windows, rear window removal and installation

Procedures Included

Maintenance Schedule:

Detailed recommended service intervals for all major components and fluids

Troubleshooting Guide:

Systematic diagnostic procedures for common and uncommon problems

Repair Procedures:

Step-by-step instructions for virtually all repair and replacement tasks

Rebuild Procedures:

Comprehensive instructions for rebuilding engines, transmissions, and other major components

Refurbishment Guidance:

Tips and techniques for restoring worn or aged components

Restoration Techniques:

Detailed guidance for comprehensive vehicle restoration projects

Technical Specifications Tables:

Torque specifications, clearances, measurements, fluid capacities, wear limits

Wiring Diagrams:

High-quality, detailed wiring schematics for all vehicle systems

Diagnostic Charts:

Flowcharts for diagnosing electrical and mechanical issues

Technical Depth

Depth Level:

Extensive: Covers everything from basic fluid changes to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Assumed high quality for digital reproduction of original documentation, enabling clear printing of diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-cylinder, SOHC

Engine Code:

M30B34

Displacement:

3.4 liters (3430 cc)

Performance

Horsepower:

Approx. 182-211 hp (depending on market and specific configuration)

Torque:

Approx. 224-243 lb-ft (depending on market and specific configuration)

Fuel System

Fuel Delivery:

Bosch L-Jetronic (or Motronic in later models/markets) fuel injection

Fuel Type

Fuel Type:

Premium Unleaded Gasoline

Engine Management

ECU Type:

Bosch Motronic (likely ML or M-based variants)

🔧 Transmission

Standard

Transmission Type Standard:

Getrag 260 5-speed Manual

Optional

Transmission Type Optional:

ZF 4HP22 4-speed Automatic

Features

Clutch Type:

Hydraulically actuated single dry plate clutch

Fluid Specifications

Manual Transmission Fluid:

BMW ATF Dexron II or equivalent (check specific manual for exact spec/capacity)

Automatic Transmission Fluid:

BMW ATF Dexron II or equivalent (check specific manual for exact spec/capacity)

📐 Dimensions

Exterior

Length:

Approx. 4,715 mm (185.6 in)

Width:

Approx. 1,700 mm (66.9 in)

Height:

Approx. 1,420 mm (55.9 in)

Wheelbase

Wheelbase:

Approx. 2,794 mm (110.0 in)

Weights

Curb Weight:

Approx. 1,500-1,650 kg (3,300-3,640 lbs) depending on transmission and options

🛡️ Safety Features

Ratings

Safety Ratings:

NHTSA and IIHS ratings from the era are generally not directly comparable to modern standards. Known for robust build quality.

Active Features

Optional Anti-lock Braking System (ABS) available on some models.

Passive Features

Seat Belts:

3-point front seat belts with pretensioners (likely standard or common option), 3-point rear seat belts.

Driver Airbag:

Driver's side airbag became an option during this generation's lifecycle, standard on later E28s.

Crumple Zones:

Designed with front and rear crumple zones for improved occupant protection.

💡 Technology Features

Infotainment

Audio System:

Typically an analog radio with cassette player; aftermarket upgrades common. Sound system quality varied by option package.

Driver Assistance

Cruise Control:

Standard or optional electronic cruise control.

Trip Computer:

Basic trip computer functions may have been available on higher trims.

Connectivity

Connectivity Features:

Limited by era; primarily focused on basic vehicle functions. No modern smartphone integration or Bluetooth.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 - 10,000 miles or 12 months, depending on driving conditions and oil type.

Spark Plug Replacement:

Refer to manual, but generally around 30,000 - 60,000 miles for standard plugs.

Timing Belt Chain:

The M30B34 engine uses a timing chain, which is designed to last the life of the engine but requires periodic inspection for stretch or tensioner wear.

Fluid Specifications

Engine Oil Spec:

Refer to manual for specific viscosity (e.g., 15W-40, 20W-50 synthetic) and API service classification. Capacity approx. 6.5 liters (7 quarts).

Coolant Spec:

Ethylene glycol-based coolant (e.g., BMW Blue or compatible) mixed with distilled water. Capacity approx. 10-12 liters.

Brake Fluid Spec:

DOT 3 or DOT 4 (check manual for specific recommendation)

Known Issues

Common Wear Items:

Bushings (control arm, sway bar, trailing arm), fuel injectors, fuel pump, power steering hoses, heater core leaks, O2 sensor failure, ABS sensor failure.

Engine Specific Concerns:

Head gasket leaks (due to age/heat cycles), oil pan gasket leaks, exhaust manifold cracks.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's long-standing reputation for engineering excellence, sportiness, and luxury driving experience.

Model Evolution

E28 Development:

The E28 was a significant evolution from the E12, featuring more modern styling, improved aerodynamics, enhanced safety, and a more sophisticated chassis.

535I Positioning:

The 535i represented the higher-performance, more luxurious variant of the E28 lineup, offering a potent engine and upscale features.

Production

Production Period:

1981-1988 (E28 generation)

Production Locations

Manufacturing Sites:

Primarily Dingolfing, Germany, with potential assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Automotive Press:

The E28 generation, including the 535i, was widely praised by automotive journalists for its performance, handling, and build quality, often cited as a benchmark for sports sedans of its time.