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BMW E24 633 635 M6 1983-1989 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 6 Series E24 Chassis Code: E24 Body Styles Covered: Coupe (also known as Gran Turismo Coupe) Production Years Covered: 1983-1989 Codes Covered Models...
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BMW E24 633 635 M6 1983-1989 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
6 Series E24
Chassis Code:
E24
Body Styles Covered:
Coupe (also known as Gran Turismo Coupe)
Production Years Covered:
1983-1989
Codes
Covered Models Variants:
633CSi, 635CSi, M6
👋 Introduction
Market Position
Vehicle Class:
Luxury Grand Tourer (GT)
Target Audience:
Enthusiasts and owners of classic BMW E24 models seeking in-depth technical information for maintenance and repair.
Competitive Analysis
Key Competitors:
Mercedes-Benz SEC Coupe, Porsche 928, Jaguar XJ-S.
Key Features
Design Philosophy:
Iconic 'Bangle Butt' design, powerful straight-six engines, rear-wheel drive, and superior driving dynamics.
Manual Value Proposition:
Provides factory-level repair information, crucial for preserving the value and performance of these collectible BMWs.
📋 Manual Details
Coverage Areas
Overall Coverage:
Comprehensive factory service and repair for BMW E24 6 Series.
Page Count
Page Count:
800+
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed repair, diagnostics, and specifications for engine systems, including cooling, lubrication, fuel, and ignition.
Transmission:
Repair and maintenance procedures for manual and automatic transmissions, including clutch, gearbox, and drivetrain components.
Suspension:
Complete coverage of front and rear suspension systems, including shock absorbers, springs, bushings, and alignment.
Steering:
Service and repair of the steering system, including power steering, steering rack, and tie rods.
Brakes:
In-depth information on brake system maintenance and repair, including disc brakes, ABS (if equipped), hydraulic systems, and parking brake.
Electrical System:
Comprehensive electrical system diagnostics, including wiring diagrams, component testing, starter, alternator, and lighting.
Body:
Bodywork repair, chassis, doors, windows, sunroof, and exterior trim.
Body Equipment:
Coverage of interior trim, seats, dashboard, and accessories.
Equipment And Accessories:
Details on climate control, power windows, power seats, and other optional equipment.
Wiring Diagrams:
Detailed and clearly laid out wiring schematics for all electrical systems.
Procedures Included
General Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, and basic inspections.
Engine Overhaul:
Procedures for engine disassembly, inspection, reassembly, and rebuild.
Transmission Repair:
Step-by-step repair guides for transmission components and assemblies.
Brake System Repair:
Detailed instructions for brake pad replacement, caliper service, fluid bleeding, and rotor resurfacing/replacement.
Suspension Component Replacement:
Guidance on replacing control arms, ball joints, tie rod ends, and shock absorbers.
Electrical Troubleshooting:
Systematic diagnostic steps for resolving electrical faults.
Body Panel Repair:
Techniques for repairing dents, rust, and replacing body panels.
Component Installation:
Instructions for installing various vehicle components and accessories.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures and troubleshooting charts for identifying and resolving complex issues.
Rebuild Procedures:
Complete rebuild instructions for major mechanical components like engines and transmissions.
Specifications Accuracy:
Precise technical data, torque values, clearances, and tolerances essential for correct repairs.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Resolution:
High-resolution scans ensuring clarity of text and diagrams.
Searchability:
Searchable text allows for quick information retrieval.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type 633Csi:
M30B32 inline-six (3.2L)
Engine Type 635Csi:
M30B34 inline-six (3.4L)
Engine Type M6:
S38B35 inline-six (3.5L)
Performance
Horsepower 633Csi:
Approx. 197 hp
Torque 633Csi:
Approx. 210 lb-ft
Horsepower 635Csi:
Approx. 218 hp (Euro spec) / 182 hp (US spec)
Torque 635Csi:
Approx. 225 lb-ft (Euro spec) / 210 lb-ft (US spec)
Horsepower M6:
Approx. 256 hp (Euro spec) / 210 hp (US spec)
Torque M6:
Approx. 243 lb-ft (Euro spec) / 245 lb-ft (US spec)
Fuel System
Fuel Delivery:
Bosch L-Jetronic or Motronic fuel injection
Engine Management
Ignition System:
Electronic ignition with distributor
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Getrag manual (early models) / 5-speed Getrag manual (later models)
Optional
Transmission Type Optional:
ZF 4HP22 4-speed automatic
Features
Drivetrain:
Rear-wheel drive
📐 Dimensions
Exterior
Wheelbase:
Approx. 103.7 inches (2634 mm)
Length:
Approx. 191.1 inches (4854 mm)
Width:
Approx. 70.9 inches (1801 mm)
Height:
Approx. 53.5 inches (1359 mm)
Weights
Curb Weight:
Approx. 3,600 - 3,900 lbs (1630 - 1770 kg), varies by model and equipment
🛡️ Safety Features
Ratings
Crash Safety Era:
Designed to 1980s safety standards; no modern crash test ratings available.
Active Features
ABS:
Anti-lock Braking System (ABS) available on some models, particularly later ones and M6.
Passive Features
Seatbelts:
3-point inertia-reel seatbelts
Driver Airbag:
Driver airbag not standard during this production period; later models may have it.
💡 Technology Features
Infotainment
Audio System:
Factory-installed Blaupunkt or BMW branded AM/FM cassette stereo systems, often with optional CD changers in later models.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Connectivity Features:
Limited to basic audio inputs; no modern Bluetooth or USB connectivity from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions. Check manual for specific recommendation.
Major Service Interval:
Varies, but often includes spark plug replacement, timing belt inspection (if applicable, though these are chain-driven), and comprehensive fluid checks around 30,000-60,000 miles (48,000-96,000 km).
Fluid Specifications
Engine Oil:
SAE 15W-40 or 20W-50 API SG or higher (consult manual for exact specification based on temperature and model).
Coolant:
BMW-approved ethylene glycol coolant with corrosion inhibitors (typically a 50/50 mix with distilled water).
Transmission Fluid Auto:
Dexron III or equivalent (check manual for specific BMW part number/type).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine M30:
Head gasket leaks, oil pan gasket leaks, valve stem seals, timing chain wear, fuel injector issues.
Suspension And Steering:
Worn control arm bushings, ball joints, tie rod ends, power steering leaks.
Electrical System:
Corroded wiring harnesses, failing fuel pump relays, alternator issues, dashboard warning light problems.
Body Corrosion:
Rust prone areas include wheel arches, rocker panels, and sunroof drains.
📚 Vehicle History
Brand Heritage
Bmw Heritage:
BMW's legacy of performance, luxury, and engineering excellence.
Model Evolution
E24 Introduction:
Introduced in 1976 as a replacement for the E9 coupe, the E24 established BMW's presence in the luxury coupe segment.
E24 Facelift:
Received significant updates in 1982, including revised bodywork, updated interior, and improved aerodynamics.
M6 Introduction:
The high-performance M6 (also known as M635CSi in Europe) was introduced in 1983, featuring the potent M88/3 engine from the M1 supercar.
Production
Production Period:
1976-1989
Major Markets:
North America, Europe, Japan
🏆 Awards & Recognition
Recognitions
Collectible Status:
Widely recognized as a modern classic and a benchmark for luxury GT cars of its era.
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