🏷️ Basic Information

Make:

BMW

Model:

5 Series

Model Variant:

535i, M535i

Production Years Covered:

1985, 1986, 1987, 1988

Chassis Code:

E28

👋 Introduction

Market Position:

The BMW 5 Series (E28) represented BMW's premium mid-size sedan offering, known for its blend of luxury, performance, and advanced engineering for its era. The 535i and M535i models were positioned as the sportier, higher-performance variants within the range.

Key Competitors:

Mercedes-Benz W124 E-Class, Audi 100/200, Volvo 700 Series, Jaguar XJ6.

Design Philosophy:

Elegance, sportiness, driver-focused cockpit, robust engineering, and refined handling characteristic of BMW.

Performance Emphasis:

The 535i and M535i models were specifically equipped with larger, more powerful engines to cater to enthusiasts seeking greater acceleration and driving dynamics.

📋 Manual Details

Regions Covered:

Global (European, North American specifications may vary slightly in detail)

Page Count:

227

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Management:

Detailed diagnostics, adjustments, and repair procedures for the M30 inline-six engine, including fuel injection (Motronic), ignition timing, and emission control systems.

Drivetrain:

Coverage of manual and automatic transmissions (Getrag 260, ZF 4HP22), differential, driveshafts, and clutch systems.

Suspension Steering:

Front and rear suspension components (MacPherson struts, independent trailing arms), shock absorbers, springs, sway bars, steering box, and power steering system.

Braking System:

Front and rear disc brake systems (ventilated front), ABS (Anti-lock Braking System) components, hydraulic lines, calipers, and master cylinder.

Electrical System:

Comprehensive wiring diagrams, battery, alternator, starter, lighting systems, instrumentation, power windows, mirrors, central locking, and onboard computer (if applicable).

Cooling Heating Ac:

Radiator, water pump, thermostat, cooling fan, heater core, blower motor, and air conditioning system service and repair.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, and fuel pressure regulator.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, and exhaust piping.

Body Chassis:

Body panel removal/installation, door mechanisms, interior trim, bumpers, and structural components.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, fluid level checks, belt inspections, and lubrication points.

Engine Repair:

Engine teardown, rebuild, head gasket replacement, piston and ring service, valve adjustments, and timing chain/belt (if applicable) replacement.

Transmission Repair:

Transmission removal, disassembly, inspection, reassembly, clutch replacement, and torque converter service.

Brake System Repair:

Brake pad and rotor replacement, brake caliper servicing, hydraulic system bleeding, and ABS component diagnostics.

Electrical Troubleshooting:

Diagnostic procedures for electrical faults, starter/alternator testing, wiring harness repair, and component testing using multimeters.

Suspension Steering Repair:

Replacement of ball joints, tie rod ends, control arms, shock absorbers, and steering components.

Emission Control Service:

Diagnosis and repair of emissions-related components, including catalytic converter testing and O2 sensor replacement.

Bodywork Restoration:

Guidelines for body panel alignment, rust repair considerations, and trim piece removal/installation.

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.

Diagnostic Capabilities:

Includes diagnostic charts, trouble codes (where applicable for the era), and step-by-step troubleshooting procedures for common and uncommon issues.

Specification Accuracy:

Provides detailed torque specifications, clearances, fluid capacities, and technical data critical for accurate repairs.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Likely searchable text, enhancing ease of use for locating specific information.

Print Quality:

Digital format allows for high-resolution viewing and printing.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code:

M30

Engine Type:

Naturally Aspirated Inline 6-Cylinder

Displacement:

3.430 cc (3.4 L)

Bore X Stroke:

92.0 mm x 86.0 mm

Compression Ratio:

8.0:1 (for 535i models)

Horsepower:

Approx. 211 hp @ 5,700 rpm (DIN) for 535i

Torque:

Approx. 224 lb-ft (305 Nm) @ 4,000 rpm (DIN) for 535i

M535I Performance Enhancements:

Slightly higher compression ratio, revised camshaft, and potentially different engine management tuning for increased output (details vary by market, typically around 218 hp).

Fuel Delivery:

Bosch L-Jetronic or Motronic fuel injection system (specific system depends on model year and market).

Fuel Type:

Unleaded Gasoline (RON 95/98 recommended)

Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

🔧 Transmission

Transmission Type 535I:

Getrag 260 5-speed Manual Transmission

Transmission Type Optional:

ZF 4HP22 4-speed Automatic Transmission

Manual Transmission Gear Ratios:

Specific ratios available in the manual for detailed analysis.

Automatic Transmission Modes:

Typically 'Economy' and 'Sport' modes selectable by the driver.

Manual Transmission Fluid Spec:

API GL-4 or GL-5, SAE 75W-90 (refer to manual for exact BMW specification).

Automatic Transmission Fluid Spec:

BMW ATF D2 or equivalent Dexron II (refer to manual for exact BMW specification).

📐 Dimensions

Length:

Approx. 4,725 mm (186.0 in)

Width:

Approx. 1,700 mm (66.9 in)

Height:

Approx. 1,415 mm (55.7 in)

Wheelbase:

Approx. 2,795 mm (110.0 in)

Curb Weight 535I Manual:

Approx. 1,540 kg (3,395 lbs)

Gross Vehicle Weight Rating:

Varies by market and specific configuration.

Trunk Capacity:

Approx. 480 liters (17.0 cu ft)

🛡️ Safety Features

Crash Test Data:

No standardized crash test ratings (like NHTSA/Euro NCAP) were prevalent in the same way as today. BMW's safety focus was on structural integrity and passive restraint systems for the era.

ABS:

Anti-lock Braking System (ABS) was a key optional or standard feature on higher trims like the 535i.

Seat Belts:

Three-point inertia-reel seat belts for front and rear occupants.

Headrests:

Adjustable front and rear headrests for improved whiplash protection.

Body Construction:

Reinforced passenger cell, crumple zones, and side-impact protection beams.

💡 Technology Features

Audio System:

Factory fitted radio/cassette player with amplifier, often with premium speaker options. Upgrades common in the aftermarket.

Instrumentation:

Comprehensive analog gauges including tachometer, speedometer, fuel level, and engine temperature. Onboard computer (check control) in some models.

Cruise Control:

Optional cruise control system available.

ABS:

As mentioned, ABS was a significant driver assistance technology for its time.

Connectivity Features:

Limited to basic electrical features like power windows, mirrors, and central locking. No digital connectivity in the modern sense.

🔧 Maintenance

Oil Change Interval:

Typically 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, depending on driving conditions. Refer to manual for specific BMW recommendation.

Spark Plug Replacement:

Approx. 30,000 miles (50,000 km) for standard ignition, potentially longer for platinum tip plugs if fitted later. Consult manual for original spec.

Coolant Flush:

Every 2 years or 40,000 miles (60,000 km).

Timing Belt Chain:

The M30 engine features a timing chain, which is designed for the life of the engine but may require tensioner or guide replacement at higher mileages (e.g., 150,000+ miles).

Engine Oil Capacity:

Approx. 6.0 liters (6.3 US quarts) with filter change. BMW recommends 20W-50 or 15W-50 synthetic blend for performance models, or 5W-30/10W-40 depending on climate and specific BMW approval.

Coolant Specification:

BMW Blue Antifreeze/Coolant concentrate (ethylene glycol based) mixed with distilled water in a 50/50 ratio.

Brake Fluid Specification:

DOT 3 or DOT 4 high-performance brake fluid.

Engine Oil Leaks:

Common areas include valve cover gasket, oil pan gasket, and oil filter housing seal due to age and material degradation.

Cooling System:

Plastic coolant expansion tank can become brittle and crack. Water pump and thermostat housings can also leak.

Electrical Connectors:

Corrosion or degradation of electrical connectors, especially in the engine bay and fuse box, can lead to intermittent faults.

Fuel Pump Reliability:

Early fuel pumps could be a point of failure; replacement with modern units is common.

Rust Corrosion:

Common rust areas include wheel arches, rocker panels, and the underside of the vehicle, typical for cars of this era, especially in regions with road salt.

Suspension Bushings:

Rubber suspension bushings (control arm, sway bar) wear out over time, leading to sloppy handling and clunking noises.

📚 Vehicle History

Brand Legacy:

BMW has a long-standing reputation for building sporty, driver-oriented luxury vehicles with superior engineering and performance.

E28 Generation:

The E28 was the second generation of the BMW 5 Series, produced from 1981 to 1988. It succeeded the E12 and introduced more advanced technology and refined styling.

E28 Updates:

The E28 received a significant facelift in 1985, introducing updated aerodynamics, improved interior ergonomics, and the availability of the M535i model with its characteristic M-Technic styling and performance enhancements.

Production Period:

1981-1988 (E28 generation), with 535i/M535i variants prominent in the later years of this period.

Manufacturing Locations:

Primarily Germany, with some assembly in other countries depending on market.

🏆 Awards & Recognition

Automotive Journalism Reviews:

The E28 generation of the 5 Series was widely praised by automotive journalists for its excellent handling, powerful engines, and build quality. The 535i and M535i models were often highlighted for their performance credentials.

Performance Awards:

While specific awards are hard to pinpoint for individual model variants from this era, the M535i was recognized as a high-performance sports sedan, a precursor to the iconic M5.

Reliability Reputation:

Generally considered reliable with proper maintenance, though like any classic car, requires ongoing attention to specific wear items.