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BMW 535 535i 1985-1988 Service Repair Manual
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Basic Information Identification Make: BMW Model: 535i Model Code: E28 Years Covered: 1985, 1986, 1987, 1988 Codes Engine Code: M30B34 Introduction Market Position Positioning: The BMW 535i (E28) was positioned...
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| Basic Information | |
| Identification | |
| Make: | BMW |
| Model: | 535i |
| Model Code: | E28 |
| Years Covered: | 1985, 1986, 1987, 1988 |
| Codes | |
| Engine Code: | M30B34 |
| Introduction | |
| Market Position | |
| Positioning: | The BMW 535i (E28) was positioned as a luxury sports sedan, offering a blend of performance, comfort, and advanced engineering for its time. It competed with other European luxury sedans and performance-oriented models. |
| Competitive Analysis | |
| Competitors: | Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6, Volvo 740/760 |
| Key Features | |
| Performance Emphasis: | Strong inline-six engine, sophisticated suspension, rear-wheel drive bias, driver-focused interior |
| Luxury Appointments: | High-quality interior materials, advanced features for the era (e.g., optional ABS, power amenities) |
| Manual Details | |
| Coverage Areas | |
| Manual Type: | Service and Repair Manual |
| Language: | English |
| Format: | PDF Download |
| Page Count | |
| Estimated Page Count: | Approx. 1000+ pages (typical for comprehensive manuals of this era) |
| Manual Coverage | |
| Systems Covered | |
| Engine: | 3.4L M30 Inline-6, fuel injection (L-Jetronic), ignition system, cooling system, lubrication system, exhaust system |
| Transmission: | Getrag 260 5-speed manual, ZF 4HP22 4-speed automatic, clutch, driveline, driveshaft, differential |
| Suspension: | Front MacPherson struts, rear semi-trailing arms, springs, shock absorbers, bushings, alignment specifications |
| Brakes: | Front and rear disc brakes, ABS (Anti-lock Braking System), hydraulic system, parking brake |
| Steering: | Power-assisted rack and pinion steering system, steering column, steering linkage |
| Electrical: | Battery, alternator, starter, lighting system, wiring diagrams, fuse box layout, ignition switch, instrument cluster, power windows, mirrors, central locking |
| Fuel System: | Fuel tank, fuel pump, fuel filter, fuel lines, injectors, L-Jetronic fuel injection control unit |
| HVAC: | Heating, ventilation, air conditioning system, components, operation, service |
| Body: | Body panels, doors, hood, trunk, bumpers, glass, seals, interior trim |
| Chassis: | Frame construction, subframes, mounting points |
| Procedures Included | |
| Maintenance: | Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid flush, belt inspection and replacement, lubrication points |
| Troubleshooting: | Diagnostic procedures for engine performance, electrical faults, cooling system issues, transmission problems, brake system malfunctions |
| Repair: | Engine overhaul, transmission rebuild, suspension component replacement, brake caliper repair, electrical component repair, body panel repair, HVAC system repair |
| Diagnostics: | Fault code retrieval (where applicable for era), sensor testing, actuator testing, L-Jetronic system diagnostics |
| Adjustments: | Valve clearance adjustment, ignition timing adjustment, idle speed adjustment, brake adjustment |
| Technical Depth | |
| Depth: | Comprehensive - Covers basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams. |
| Manual Specifications | |
| File Format | |
| File Format: | |
| Searchability: | Likely text-searchable if scanned from a high-quality source |
| Print Quality | |
| Print Quality: | High resolution scans suitable for printing |
| Binding Type | |
| Binding Type: | N/A (Digital PDF) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Naturally Aspirated Inline-6 Cylinder |
| Displacement: | 3.4 Liters (3430 cc) |
| Bore X Stroke: | 92.0 mm x 86.0 mm |
| Compression Ratio: | 8.0:1 or 8.5:1 (depending on market/year) |
| Performance | |
| Horsepower: | 182-191 hp @ 5000-5400 rpm (depending on market/year) |
| Torque: | 220-230 lb-ft @ 3300-3500 rpm (depending on market/year) |
| Fuel System | |
| Fuel Delivery: | Bosch L-Jetronic Electronic Fuel Injection |
| Fuel Type: | Unleaded Gasoline (Premium Recommended) |
| Ignition System | |
| Ignition Type: | Electronic Ignition (breakerless) |
| Cooling System | |
| Cooling Type: | Liquid Cooled |
| Lubrication System | |
| Oil Capacity: | Approx. 6.5 quarts (6.2 Liters) with filter |
| Engine Management | |
| ECM Type: | L-Jetronic control unit |
| Transmission | |
| Standard | |
| Transmission Type Standard: | Getrag 260 5-Speed Manual |
| Optional | |
| Transmission Type Optional: | ZF 4HP22 4-Speed Automatic |
| Features | |
| Clutch Type: | Hydraulic Actuated Single Dry Plate Clutch (Manual) |
| Manual Gear Ratios: | Typical ratios: 1st: 4.00, 2nd: 2.13, 3rd: 1.30, 4th: 1.00, 5th: 0.81 (Subject to specific gearbox version) |
| Automatic Features: | Lock-up torque converter, sport/economy modes (on some variants) |
| Fluid Specifications | |
| Manual Transmission Fluid: | BMW recommends ATF Dexron II or equivalent (API GL-4 specification often cited) |
| Automatic Transmission Fluid: | ATF Dexron II or III equivalent |
| Dimensions | |
| Exterior | |
| Length: | 4,700 mm (185.0 in) |
| Width: | 1,700 mm (66.9 in) |
| Height: | 1,415 mm (55.7 in) |
| Wheelbase: | 2,795 mm (110.0 in) |
| Weights | |
| Curb Weight: | Approx. 1,450 - 1,550 kg (3,197 - 3,417 lbs) depending on transmission and options |
| Wheels Tires | |
| Wheel Size: | 14-inch or 15-inch alloy wheels standard, optional 16-inch |
| Tire Size: | Standard: 195/70VR14, Optional: 205/55VR15, 225/50VR16 |
| Bolt Pattern: | 5 x 120 mm |
| Safety Features | |
| Ratings | |
| NHTSA Rating: | Not rated under modern standards; designed with occupant safety as a priority for its era. |
| Active Features | |
| ABS: | Optional Anti-lock Braking System (ABS) |
| Traction Control: | Not typically available |
| Passive Features | |
| Airbags: | Driver's airbag became standard in later E28 production (post-1987/88), not standard on all models. |
| Seatbelts: | Three-point inertia-reel seatbelts front and rear |
| Crumple Zones: | Designed with front and rear crumple zones for energy absorption |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory fitted AM/FM stereo cassette player, optional premium sound systems (e.g., Blaupunkt, Bavaria C) |
| Driver Assistance | |
| ABS: | Availability of optional ABS system. |
| Connectivity | |
| Connectivity Features: | Limited by era; primarily focused on vehicle systems. No Bluetooth or USB connectivity. |
| Comfort Features | |
| Comfort Features List: | Power windows, power mirrors, central locking, cruise control (optional), air conditioning, heated seats (optional), power adjustable seats (optional) |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 7,500 - 10,000 miles or 12 months (refer to manual for exact recommendation based on driving conditions) |
| Spark Plug Replacement: | Every 30,000 - 60,000 miles (depending on plug type - copper vs. platinum) |
| Coolant Flush Interval: | Every 2-3 years or 30,000-50,000 miles |
| Timing Belt Replacement: | N/A - The M30 engine uses a timing chain, which is designed to last the life of the engine but may require tensioner adjustment/replacement. |
| Fluid Specifications | |
| Engine Oil Specification: | API SG/SH or higher, SAE 15W-40 or 20W-50 recommended (consult manual for specific viscosity based on climate). |
| Coolant Specification: | Ethylene glycol based antifreeze, typically 50/50 mix with distilled water. BMW blue coolant or equivalent. |
| Brake Fluid Specification: | DOT 3 or DOT 4 brake fluid |
| Known Issues | |
| Engine: | Head gasket leaks (especially on early M30s), oil leaks from valve cover and oil pan gaskets, aging fuel injection components, vacuum leaks. |
| Electrical: | Corroded grounds, failing voltage regulators, aging wiring harnesses, intermittent instrument cluster issues, trunk wiring harness fatigue. |
| Suspension: | Worn control arm bushings, worn ball joints, failing rear subframe mounts, strut mount wear. |
| Cooling System: | Leaking coolant hoses, failing water pump, radiator leaks, viscous fan clutch failure. |
| Part Numbers | |
| Oil Filter Example: | Mann Filter W940/1 or Mahle OX103 (verify for specific engine variant) |
| Air Filter Example: | Mann Filter C33130/2 (verify for specific engine variant) |
| Vehicle History | |
| Brand Heritage | |
| Bmw Philosophy: | BMW's reputation for building driver-focused, technologically advanced automobiles with superior handling characteristics. |
| Model Evolution | |
| E28 Introduction: | The E28 chassis replaced the E12 5 Series in 1981 and was produced until 1988. The 535i variant, introduced later in the E28's lifecycle, offered the potent M30 engine. |
| 535I Significance: | The 535i represented a significant performance upgrade within the E28 range, bridging the gap between the 528e and the limited M535i/M5 models. It featured the largest engine in the standard 5 Series lineup. |
| Production | |
| Production Years: | 1981-1988 (E28 chassis); 535i specific production around 1984-1988 |
| Manufacturing Locations: | Germany (Dingolfing) |
| Awards & Recognition | |
| Recognitions | |
| Period Reputation: | Consistently praised for its driving dynamics, build quality, and performance by automotive journalists of the era. |
| Ratings | |
| Performance Awards: | Often cited in 'best driver's car' discussions from its era, though specific named awards might be difficult to pinpoint without extensive historical research. |
| Certifications | |
| Certification Standards: | Built to German and international automotive safety and emissions standards of the mid-to-late 1980s. |