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BMW 535 E28 Service Repair Workshop Manual 1985-1988

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🏷️ Basic Information Identification Make: BMW Model: 535i Model Code: E28 Generation Generation Name: Second Generation 5 Series Generation Years: 1981-1988 (E28 chassis) Codes Chassis Code: E28 👋 Introduction Market...
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BMW 535 E28 Service Repair Workshop Manual 1985-1988
🏷️ Basic Information
Identification
Make:
BMW
Model:
535i
Model Code:
E28
Generation
Generation Name:
Second Generation 5 Series
Generation Years:
1981-1988 (E28 chassis)
Codes
Chassis Code:
E28
👋 Introduction
Market Position
Segment:
Luxury Executive Sedan
Era:
Mid-to-late 1980s
Competitive Analysis
Competitors:
Mercedes-Benz W124, Audi 100/200, Volvo 700 Series, Jaguar XJ
Key Features
Design Philosophy:
German engineering, driver-focused ergonomics, robust build quality, refined performance
Target Audience:
Affluent professionals, driving enthusiasts
📋 Manual Details
Coverage Areas
Years Covered:
1985, 1986, 1987, 1988
Page Count
Estimated Page Count:
Detailed (typical for BMW factory manuals of this era, likely 1000+ pages)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF), searchable
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (M30 inline-six, including fuel injection, ignition, cooling, lubrication), Transmission (manual and automatic), Drivetrain (driveshaft, differential, axles)
Chassis:
Suspension (front strut, rear semi-trailing arm), Steering (power assisted), Brakes (ABS, disc brakes front and rear), Wheels and Tires
Electrical:
Wiring diagrams, fuse box layout, lighting, instrumentation, starting and charging system, power windows, mirrors, locks, climate control electronics
Bodywork:
Body panels, doors, hood, trunk, glass, interior trim, bumpers, seals
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, belt replacement
Troubleshooting:
Diagnostic procedures, common faults and their remedies, symptom-based troubleshooting guides
Repair:
Component removal and installation, overhaul procedures, adjustments, torque specifications
Diagnostics:
Engine management system diagnosis, ABS system diagnosis, electrical system fault finding
Technical Depth
Depth:
Comprehensive from basic checks to major overhauls and diagnostics, suitable for professional technicians and advanced DIY enthusiasts
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams
Binding Type
Binding:
Not Applicable (Digital)
Paper Type
Paper:
Not Applicable (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
M30B34: 3.4-liter (3277 cc) inline-six SOHC
Performance
Horsepower:
182 hp @ 5500 rpm (US Spec)
Torque:
214 lb-ft @ 3000 rpm (US Spec)
Fuel System
Injection System:
Bosch L-Jetronic (later models may have Motronic)
Fuel Type:
Unleaded gasoline (premium recommended)
Cooling System
Coolant Type:
BMW Blue or equivalent ethylene glycol-based coolant
Lubrication
Oil Type:
API SG, SAE 15W-40 or 10W-40 (check manual for specific viscosity based on climate)
Engine Management
Ignition System:
Electronic Ignition (CDI)
🔧 Transmission
Standard
Transmission Type:
4-speed Getrag 260 manual transmission
Optional
Transmission Type:
4-speed ZF 4HP22 automatic transmission
Features
Clutch:
Hydraulically operated single dry plate clutch
Automatic Transmission Features:
Electronic control for shifting, lock-up torque converter
Fluid Specifications
Manual Transmission Fluid:
BMW Gear Oil G2 or equivalent SAE 75W-90 synthetic
Automatic Transmission Fluid:
Dexron III or equivalent ATF
📐 Dimensions
Exterior
Length:
4716 mm (185.7 in)
Width:
1700 mm (66.9 in)
Height:
1415 mm (55.7 in)
Wheelbase:
2794 mm (110.0 in)
Weights
Curb Weight:
Approx. 1560 kg (3439 lbs)
Gross Vehicle Weight:
Approx. 2010 kg (4431 lbs)
Cargo
Trunk Volume:
Approx. 0.46 m³ (16.2 cu ft)
🛡️ Safety Features
Ratings
Era Safety Standards:
Designed to meet 1980s safety regulations, including energy-absorbing bumpers and safety cage construction
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option or standard on later models
Passive Features
Seat Belts:
3-point inertia-reel seat belts front and rear
Steering Column:
Collapsible steering column
Headrests:
Adjustable front and rear headrests
💡 Technology Features
Infotainment
Radio System:
Factory AM/FM cassette stereo systems, often with upgraded aftermarket head units in modern usage
Speakers:
Typically 4-6 speaker configuration
Driver Assistance
Cruise Control:
Standard or optional electronic cruise control
Climate Control:
Manual or optional automatic climate control (HCC - Hydro-Electro-Climatronic)
Connectivity
Connectivity Era:
Limited to factory radio and speaker systems; modern upgrades focus on Bluetooth and aux inputs
🔧 Maintenance
Service Intervals
Oil Change Interval:
10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first (with synthetic oil)
Spark Plug Replacement:
Refer to manual, typically every 30,000-50,000 km (18,000-30,000 miles)
Timing Belt Replacement:
N/A (M30 engine uses a timing chain)
Fluid Specifications
Coolant Capacity:
Approx. 8.0 Liters (8.5 US Quarts)
Brake Fluid:
DOT 4
Known Issues
Common Wear Items:
Fuel pump, AFM (Air Flow Meter), suspension bushings, heater core, sunroof drains
Electrical Gremlins:
Can occur due to age and wiring degradation, particularly with older alarm systems or aftermarket additions
Maintenance Tips
Engine Cooling:
Regular coolant flushes and inspection of hoses are critical for preventing overheating in the M30 engine.
Fuel Delivery:
Clean or replace fuel filter periodically; consider upgrading fuel pump if experiencing lean conditions.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure, focus on performance and driver engagement
Model Evolution
Predecessor:
BMW E12 5 Series
Successor:
BMW E34 5 Series
Production
Production Years E28:
1981-1988
Manufacturing Locations:
Germany (Dingolfing), South Africa, Mexico
Production Volume:
Significant volume, establishing BMW as a major player in the executive sedan market
🏆 Awards & Recognition
Recognitions
Performance Recognition:
Consistently ranked as a top driver's car in its class by automotive publications of the era (e.g., Car and Driver, Road & Track)
Ratings
Build Quality Rating:
Highly regarded for its solid construction and longevity
Certifications
Certification Type:
While specific awards might be difficult to pinpoint from decades ago, the E28 series was integral to BMW's global reputation for engineering excellence.
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