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Bmw 633csi 635csi M6 1983-1989 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 6 Series (E24) Variant: 633CSi, 635CSi, M6 Years Covered: 1983-1989 Codes Chassis Code: E24 👋 Introduction Market Position Positioning: The BMW E24 6...
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Sku: 420732
Bmw 633csi 635csi M6 1983-1989 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
6 Series (E24)
Variant:
633CSi, 635CSi, M6
Years Covered:
1983-1989
Codes
Chassis Code:
E24
👋 Introduction
Market Position
Positioning:
The BMW E24 6 Series represented BMW's flagship grand tourer, blending performance, luxury, and sophisticated styling. The M6 variant, in particular, was a high-performance halo model.
Competitive Analysis
Competitors:
Competed with other luxury grand tourers of its era, such as the Mercedes-Benz SEC coupes, Jaguar XJ-S, and Porsche 928.
Key Features
Design:
Iconic Paul Bracq design, long hood, low profile, shark-nose front fascia, pillarless hardtop coupe body style.
Performance:
Powerful inline-six engines, rear-wheel drive, refined handling, offering a comfortable yet engaging driving experience.
📋 Manual Details
Coverage Areas
General Maintenance:
Comprehensive
Troubleshooting:
Comprehensive
Engine Service Repair:
Comprehensive
Transmission Service Repair:
Comprehensive
Brake System:
Comprehensive
Wiring Diagrams:
Comprehensive
Electrical System:
Comprehensive
Suspension:
Comprehensive
Periodic Lubrication:
Comprehensive
Steering:
Comprehensive
Cooling System:
Comprehensive
Fuel Injection Fuel System:
Comprehensive
Emission System:
Comprehensive
Heater Air Conditioning:
Comprehensive
Engine Control System:
Comprehensive
Chassis Body:
Comprehensive
Restraint System:
Comprehensive
Interior:
Comprehensive
Differential Drive:
Comprehensive
Axle:
Comprehensive
Page Count
Estimated Pages:
Hundreds (exact count not specified, but implies extensive detail)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, fuel injection, cooling, exhaust, transmission, differential, driveshafts.
Chassis:
Suspension (front and rear), steering system, brake system (including ABS if equipped), wheels, tires.
Electrical:
Complete wiring diagrams, starter system, charging system, ignition system, lighting, instrumentation, power accessories, engine control unit (ECU) diagnostics.
Body Interior:
Body repair, chassis, doors, windows, sunroof, interior trim, seats, restraint systems (seatbelts), HVAC system.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, belt inspections, spark plug replacement, lubrication points.
Diagnostics Troubleshooting:
System-specific troubleshooting guides, common fault identification, diagnostic procedures for engine, transmission, and electrical systems.
Engine Repair:
Engine disassembly and reassembly, cylinder head service, piston and connecting rod installation, crankshaft service, timing belt/chain service, fuel injector testing and replacement, emissions system repair.
Transmission Repair:
Manual and automatic transmission disassembly, inspection, repair, and reassembly. Clutch service, driveshaft and universal joint repair.
Brake System Repair:
Brake pad and rotor replacement, brake caliper service, brake line and hose replacement, bleeding the brake system, ABS system diagnostics and repair.
Electrical Repair:
Component testing, wiring harness repair, sensor replacement, starter motor and alternator service, fuse and relay diagnosis.
Suspension Steering Repair:
Component replacement (shocks, struts, ball joints, tie rod ends, bushings), steering rack service, wheel alignment specifications.
Technical Depth
Depth:
Complete factory-level repair and maintenance information, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic adjustments to full component rebuilds.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High Resolution, fully printable (individual pages or entire manual).
Binding Type
Type:
Digital Download (printable).
Paper Type
Type:
N/A (Digital format).
⚙️ Engine Specifications
Primary Engine 633Csi
Engine Code:
M30B32
Displacement:
3.2 liters (3210 cc)
Configuration:
Inline-6, SOHC
Horsepower:
Approx. 197 hp (147 kW) @ 5500 rpm (Euro spec), lower for US spec
Torque:
Approx. 285 Nm (210 lb-ft) @ 3500 rpm (Euro spec), lower for US spec
Primary Engine 635Csi
Engine Code:
M30B34
Displacement:
3.4 liters (3430 cc)
Configuration:
Inline-6, SOHC
Horsepower:
Approx. 218 hp (163 kW) @ 5800 rpm (Euro spec), 182 hp (136 kW) for US spec
Torque:
Approx. 304 Nm (224 lb-ft) @ 4000 rpm (Euro spec), 275 Nm (203 lb-ft) for US spec
Primary Engine M6
Engine Code:
S38B35
Displacement:
3.5 liters (3453 cc)
Configuration:
Inline-6, DOHC, 24 valves
Horsepower:
Approx. 256 hp (191 kW) @ 6500 rpm (Euro spec), 260 hp (194 kW) for US spec (early) / 282 hp (210 kW) for US spec (late)
Torque:
Approx. 333 Nm (246 lb-ft) @ 5000 rpm (Euro spec), 340 Nm (251 lb-ft) for US spec
Fuel System
Type:
Bosch L-Jetronic or Motronic fuel injection (model dependent)
🔧 Transmission
Standard
Type:
Getrag 4-speed automatic (early models) or 5-speed manual (standard on most 635CSi and M6).
Optional
Type:
Getrag 4-speed automatic (optional on manual models), Getrag 5-speed manual (optional on some automatic models).
Features
Overdrive:
Fifth gear on manual transmissions serves as an overdrive gear for improved fuel economy at highway speeds.
Clutch:
Single dry plate clutch (manual transmissions).
📐 Dimensions
Exterior
Length:
Approx. 197.2 in (5009 mm)
Width:
Approx. 70.5 in (1791 mm)
Height:
Approx. 53.7 in (1364 mm)
Weights
Curb Weight:
Approx. 3600-3900 lbs (1633-1769 kg) depending on model and options.
🛡️ Safety Features
Ratings
Crash Test Data:
No formal NHTSA or IIHS crash test data publicly available for this specific generation and model year range.
Active Features
ABS:
Anti-lock Braking System (ABS) was available as an option on later models.
Passive Features
Airbags:
Driver's side airbag became standard during the latter part of this production run. Passenger airbags were not typically offered.
Seatbelts:
Three-point inertia-reel seatbelts in the front, lap belts in the rear.
💡 Technology Features
Infotainment
Audio System:
Factory fitted cassette tape players with AM/FM radio, often with upgraded speaker systems. Later models may feature more advanced sound systems.
Driver Assistance
Cruise Control:
Available as an option on most models.
Connectivity
OBD:
No modern OBD-II port. Diagnostics often rely on specialized BMW diagnostic tools or manual interpretation of fault codes via specific procedures outlined in the manual.
🔧 Maintenance
Service Intervals
Oil Change:
Recommended every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions. Consult manual for specific intervals.
Transmission Fluid Change:
Automatic: Recommended every 30,000-50,000 miles (48,000-80,000 km). Manual: Typically lifetime fluid, but periodic inspection is advised.
Coolant Flush:
Recommended every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).
Fluid Specifications
Engine Oil:
SAE 15W-40 or 10W-40 API SG rated oil (check manual for exact specification based on climate).
Transmission Fluid Automatic:
Dexron III (or equivalent).
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Rust:
Common in wheel wells, rocker panels, door bottoms, and sunroof areas due to age and material susceptibility. Thorough inspection is crucial.
Electrical Gremlins:
Aging wiring harnesses, corroded connectors, and failing relays can lead to various electrical faults. The manual's comprehensive wiring diagrams are invaluable here.
Fuel Delivery:
Fuel pump failures, clogged injectors, and fuel pressure regulator issues can impact performance. Bosch L-Jetronic and Motronic systems require specific diagnostic approaches.
Cooling System:
Radiator leaks, failing water pumps, and aging hoses are common. Overheating can lead to severe engine damage.
Suspension Wear:
Bushings, ball joints, and tie rod ends are prone to wear, affecting handling and ride quality. The manual details replacement procedures.
📚 Vehicle History
Brand Heritage
Heritage:
BMW's reputation for producing driver-focused luxury vehicles with exceptional engineering and performance.
Model Evolution
E24 Development:
The E24 6 Series was introduced in 1976 as the successor to the E9 coupes. It featured a new chassis and updated styling, evolving significantly throughout its production.
Facelifts Updates:
Received minor updates and facelifts during its lifespan, including revised bumpers, grilles, and interior appointments. The M6 (initially branded M635CSi in Europe) was introduced as the high-performance variant.
Production
Production Years:
1976-1989 (E24 generation).
Manufacturing Locations:
Germany.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive journalists of the era for its performance, styling, and luxury. Recognized as a benchmark grand tourer.
Collectible Status:
Highly collectible classic BMW, particularly the M6 variant, appreciated for its engineering and driving dynamics.
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