BMW 535i 1986 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 535i Year: 1986 Codes Chassis Code: E28 Engine Code: M30B34 👋 Introduction Market Position Segment: Executive Sedan Target Audience: Discerning drivers seeking performance,...

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Type: Car

Vendor:

Sku: 425333

Tags: 1986 535i BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code:

M30B34

👋 Introduction

Market Position

Segment:

Executive Sedan

Target Audience:

Discerning drivers seeking performance, luxury, and engineering excellence

Competitive Analysis

Key Competitors:

Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6

Key Features

Driving Dynamics:

Renowned for its balanced chassis, responsive steering, and comfortable ride

Engine Performance:

Powerful inline-six engine offering strong torque and smooth acceleration

Build Quality:

Typical BMW build quality with robust construction and durable materials

Design Philosophy:

Classic BMW 'kidney grille' design, aerodynamic profile, and functional interior

📋 Manual Details

Coverage Areas

Primary Focus:

Full Service and Repair

Diagnostic Coverage:

Comprehensive diagnostic procedures and troubleshooting guides

Rebuild Coverage:

Detailed instructions for engine, transmission, and differential rebuilds

Restoration Coverage:

Guidance for refurbishment and restoration of various vehicle components

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, timing, fuel injection, ignition, cooling, lubrication

Transmission:

Manual and Automatic transmission service, repair, and overhaul

Drivetrain:

Driveshaft, differential, axles, and CV joints

Suspension:

Front and rear suspension components, alignment, shock absorbers, bushings

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Hydraulic system, ABS (if equipped), brake calipers, rotors, pads, lines

Electrical:

Complete wiring diagrams, starter, alternator, battery, lighting, fuses, relays

Fuel System:

Fuel pump, injectors, fuel pressure regulator, fuel tank

Exhaust System:

Catalytic converter, mufflers, exhaust pipes, gaskets

Body And Frame:

Body panel removal and installation, chassis repair, door mechanisms, glass

HVAC:

Heating, Ventilation, and Air Conditioning system service and repair

Interior:

Dashboard, seating, trim panels, instrumentation

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug changes, fluid checks and top-offs

Tune Up:

Detailed tune-up procedures for optimal engine performance

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues

Component Replacement:

Removal and installation of major and minor components

Recalibration:

Procedures for recalibrating sensors and systems as needed

Specifications And Tolerances:

Detailed torque specifications, clearances, and measurements

Technical Depth

Depth Level:

Expert-level, suitable for professional technicians and experienced DIYers

Diagnostic Tools:

Reference to required diagnostic tools and equipment

Wiring Diagrams:

Comprehensive and detailed electrical wiring schematics

Rebuild Instructions:

Full engine and transmission rebuild procedures with diagrams

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

M30B34 Inline-6 (SOHC)

Displacement:

3.4 Liters (3430 cc)

Bore X Stroke:

92.0 mm x 86.0 mm

Compression Ratio:

8.0:1

Horsepower Net C.A.C.:

182 hp @ 5500 rpm

Torque Net C.A.C.:

220 lb-ft @ 3000 rpm

Performance

0-60 Mph:

Approx. 7.7 seconds

Fuel System

Fuel Delivery:

Bosch L-Jetronic Fuel Injection

Recommended Fuel:

Unleaded 89 Octane (AKI) / 95 RON

🔧 Transmission

Standard

Transmission Type:

Getrag 265 5-speed Manual

Optional

Transmission Type:

ZF 4HP22 4-speed Automatic

Features

Manual Gear Ratios:

1st: 4.00, 2nd: 2.10, 3rd: 1.37, 4th: 1.00, 5th: 0.81, Reverse: 3.55

Automatic Gear Ratios:

1st: 2.48, 2nd: 1.48, 3rd: 1.00, 4th: 0.74, Reverse: 3.14

Clutch Type:

Dry single-plate clutch (Manual)

📐 Dimensions

Exterior

Length:

190.4 inches (4836 mm)

Width:

69.3 inches (1760 mm)

Height:

55.0 inches (1397 mm)

Wheelbase:

104.3 inches (2649 mm)

Front Track:

57.5 inches (1460 mm)

Rear Track:

58.1 inches (1476 mm)

Weights

Curb Weight:

3450 - 3550 lbs (1565 - 1610 kg) approx.

Gross Vehicle Weight Rating:

4300 lbs (1950 kg) approx.

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

4/5 Stars (for period, simulated)

Active Features

Anti-lock Braking System (standard on 535i)

Traction Control:

Optional on some later E28 models, but not standard for 1986 535i

Passive Features

Airbags:

Driver airbag optional, passenger airbag not available

Seatbelts:

3-point front and rear seatbelts

Crumple Zones:

Front and rear energy-absorbing crumple zones

💡 Technology Features

Infotainment

Audio System:

Original BMW E28 audio systems were typically AM/FM radio and cassette player, often with optional premium sound packages.

Climate Control:

Manual or automatic climate control systems were available, featuring basic temperature and fan speed adjustments.

Driver Assistance

Cruise Control:

Standard feature on most 535i models.

Trip Computer:

Optional on some models, providing basic fuel consumption data.

Connectivity

Connectivity Features:

No modern connectivity features (Bluetooth, USB, etc.); designed for an era before these became standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually, depending on driving conditions.

Spark Plug Replacement:

Every 30,000 miles (48,000 km) or as recommended by plug manufacturer.

Timing Belt Replacement:

N/A (M30 engines use a timing chain)

Coolant Flush:

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

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 15W-40 or 20W-50 recommended for most climates. Check owner's manual for precise grade.

Engine Oil Capacity:

6.7 US quarts (6.3 liters) with filter change

Transmission Fluid Manual:

API GL-4, SAE 75W-90 or 80W-90 gear oil

Transmission Fluid Automatic:

Dexron III/Mercon ATF (or equivalent compatible fluid)

Coolant Type:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Engine Oil Leaks:

Valve cover gasket, oil pan gasket, front and rear main seals are common leak points.

Cooling System:

Plastic expansion tanks can become brittle and crack; water pumps and thermostats are also potential failure points.

Fuel Injection System:

Bosch L-Jetronic can develop issues with airflow meter, fuel pump, and injector seals.

Electrical System:

Corrosion in connectors, aging wiring harnesses, and failing relays can cause various electrical gremlins.

Suspension Bushings:

Rubber bushings in control arms, sway bars, and trailing arms degrade over time, affecting handling.

📚 Vehicle History

Brand Heritage

Brand Philosophy:

Bayerische Motoren Werke AG, known for engineering, performance, and luxury since 1916.

Model Evolution

E28 Generation:

The E28 was the second generation of the BMW 5 Series, produced from 1981 to 1988. It succeeded the E12 and was replaced by the E34.

535I Introduction:

The 535i designation typically indicated a larger, more powerful engine. For 1986, it featured the M30B34, a potent 3.4-liter inline-six, replacing the earlier 533i's 3.2-liter unit.

Production

Production Period E28:

1981-1988

Production Period 535I:

Included in E28 production, notably from 1985 onwards.

🏆 Awards & Recognition

Recognitions

Automotive Press Awards:

E28 generation generally received praise from automotive publications for its driving dynamics and refined engineering.

Contemporary Reviews:

Often cited as one of the best-handling sedans of its era, blending luxury and sport.