Positioning:
The BMW M535i E28 was a high-performance variant of the executive E28 sedan, bridging the gap between the standard 5 Series and the legendary M5. It offered enhanced power and handling for discerning drivers.
Competitors:
Mercedes-Benz 300E, Audi 100 Quattro, Jaguar XJ6, Volvo 760.
Performance Enhancements:
Sport-tuned suspension, limited-slip differential, larger wheels, aerodynamic aids, upgraded braking system.
Quality Assurance:
Guaranteed complete, no missing pages, superior to cheaper, incomplete alternatives. Focus on accuracy and thoroughness for correct first-time repairs.
Primary Focus:
Service, Repair, Maintenance, Diagnostics
Secondary Focus:
Troubleshooting, Specifications, Wiring Diagrams
Estimated Pages:
Over 1000 (typical for comprehensive workshop manuals of this era)
Type:
Workshop Manual / Service Repair Manual
Format:
Digital (likely PDF, common for modern reprints)
Engine:
M30B34 (3.4L Inline-6), including fuel injection (L-Jetronic), ignition, cooling, lubrication, emissions control.
Transmission:
Getrag 265 (5-speed manual), ZF 4HP22 (4-speed automatic), clutch, driveshaft, differential.
Chassis And Suspension:
Front MacPherson struts, rear semi-trailing arms, shock absorbers, springs, anti-roll bars, power steering system.
Brakes:
Front and rear disc brakes (solid or ventilated depending on spec), ABS system (if equipped), brake hydraulics, parking brake.
Electrical System:
Battery, alternator, starter, lighting, ignition system, fuel injection control unit (ECU), dashboard instruments, power windows, central locking, radio.
Bodywork And Interior:
Body panel removal and installation, door mechanisms, trim, seats, climate control system (HVAC), sound insulation.
Wiring Diagrams:
Comprehensive color-coded wiring diagrams for all major electrical systems.
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and top-offs, brake inspections, tire rotation.
Engine Repair:
Top-end overhaul (cylinder head), bottom-end overhaul (crankshaft, bearings), piston and ring replacement, valve adjustment (if applicable), timing belt/chain replacement (if applicable).
Transmission Service:
Fluid and filter changes (automatic), clutch replacement (manual), transmission overhaul.
Brake System Repair:
Pad and rotor replacement, caliper rebuild, master cylinder replacement, bleeding the brake system, ABS component diagnosis and replacement.
Suspension And Steering Repair:
Shock absorber replacement, ball joint replacement, tie rod end replacement, steering rack repair or replacement.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, component testing, ECU diagnosis.
Climate Control Service:
Refrigerant recharge, component replacement (compressor, condenser, evaporator), blower motor diagnosis.
Body And Trim Repair:
Panel alignment, rust repair techniques, interior component installation and removal.
Troubleshooting Guides:
Systematic approaches to diagnosing common and uncommon problems with symptom-based fault finding.
Depth:
Comprehensive. Covers everything from basic fluid changes to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.
Transmission Type:
Getrag 265 5-Speed Manual
Transmission Type:
ZF 4HP22 4-Speed Automatic
Differential:
Standard Limited-Slip Differential (LSD)
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or SAE 80W-90 (refer to manual for specific BMW PN)
Automatic Transmission Fluid:
Dexron II (or equivalent specification ATF)
Wheelbase:
Approx. 104.1 inches (2644 mm)
Length:
Approx. 191.2 inches (4856 mm)
Width:
Approx. 68.5 inches (1740 mm)
Height:
Approx. 55.1 inches (1400 mm)
Curb Weight:
Approx. 3500-3700 lbs (1588-1678 kg), depending on options.
Standard Wheel Size:
15-inch alloy wheels (e.g., BBS Mahle)
Optional Wheel Size:
16-inch alloy wheels
Tire Size:
Typically 205/55VR15 or 225/50VR15
Crash Testing Era:
Pre-modern safety rating era; focused on passive safety features of the time.
Braking Enhancement:
Anti-lock Braking System (ABS) - available on some models/years.
Handling Stability:
Sport-tuned suspension, limited-slip differential for enhanced traction.
Occupant Protection:
Reinforced safety cage, crumple zones, three-point seat belts, padded dashboard, optional driver's side airbag (late production).
Lighting:
Halogen headlights, fog lights.
Audio System:
Factory AM/FM radio with cassette player, upgraded speaker systems available.
ABS:
Anti-lock Braking System (ABS) - Optional on some models, crucial system to maintain.
Connectivity Features:
Limited to factory radio, no modern connectivity options like Bluetooth or USB from the factory. Aftermarket solutions are common.
Climate Control:
Manual or automatic climate control (optional), air conditioning.
Convenience:
Power windows, power locks, central locking system, cruise control (optional).
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. High-performance driving may necessitate more frequent changes.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.
Fuel Filter Replacement:
Every 20,000-30,000 miles (32,000-48,000 km).
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (e.g., standard vs. platinum).
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).
Engine Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change. Refer to manual for specific oil type (e.g., BMW High Performance SAE 15W-40 or 10W-40).
Coolant Type:
Ethylene glycol-based antifreeze with water (50/50 mix recommended). BMW Blue coolant (G48) compatible for refills if needed.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
BMW Power Steering Fluid (or equivalent approved fluid, e.g., Pentosin CHF 11 S is NOT correct for this model. Refer to manual for correct specification).
Common Engine Problems:
Oil leaks (valve cover gasket, oil pan gasket), cooling system component failure (radiator, hoses, water pump), fuel distributor issues, ignition component failure (rotor, cap).
Common Transmission Problems:
Clutch wear (manual), transmission mount failure, automatic transmission valve body issues.
Common Chassis Problems:
Worn suspension bushings (control arm, sway bar), shock absorber degradation, power steering leaks.
Common Electrical Problems:
Corroded wiring harness connectors, failing alternators, starter motor issues, dashboard warning light failures.
