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BMW 535 535i M535i 1985-1988 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Specific Models Covered: 535i, M535i Codes Chassis Code: E28 👋 Introduction Market Position Segment: Executive Sedan Target Audience: Enthusiasts, owners seeking...
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BMW 535 535i M535i 1985-1988 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Specific Models Covered:
535i, M535i
Codes
Chassis Code:
E28
👋 Introduction
Market Position
Segment:
Executive Sedan
Target Audience:
Enthusiasts, owners seeking detailed repair information, independent repair shops specializing in BMW
Competitive Analysis
Competitors Era:
Mercedes-Benz W124, Audi 100/200, Volvo 700 Series, Jaguar XJ
Key Features
Vehicle Philosophy:
The E28 generation represents a mature expression of BMW's 'Ultimate Driving Machine' ethos, blending luxury with performance and refined engineering.
Manual Value Proposition:
Provides indispensable, factory-authentic information essential for maintaining, troubleshooting, and repairing these classic BMWs, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Years Covered:
1985, 1986, 1987, 1988
Page Count
Estimated Pages:
Hundreds of pages (exact count not specified, indicating a comprehensive volume)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable (implies digital format, likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing, valve train
Fuel System:
Fuel injection system (Bosch Motronic), fuel pump, injectors, pressure regulator, fuel tank
Ignition System:
Ignition coils, spark plugs, distributor (if applicable), ECU control
Cooling System:
Radiator, water pump, thermostat, hoses, fan, coolant specifications
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), mufflers, pipes, emissions control
Transmission Manual:
Manual transmission overhaul, clutch, shifter mechanism, fluid specifications
Transmission Automatic:
Automatic transmission overhaul, torque converter, hydraulic system, fluid specifications
Drivetrain:
Driveshafts, universal joints, differential, rear axle assembly
Suspension:
Front suspension (MacPherson struts), rear suspension (semi-trailing arms), springs, shock absorbers, bushings, alignment specifications
Steering:
Power steering system, steering rack, pump, hoses, tie rods, alignment
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake calipers, rotors, pads, master cylinder, brake lines, fluid specifications
Electrical System Engine:
Engine control unit (ECU), sensors, wiring diagrams for engine management
Electrical System Chassis:
Lighting, wipers, horn, power windows, power seats, central locking, wiring diagrams
Climate Control:
HVAC system, blower motor, heater core, A/C compressor, refrigerant, controls
Bodywork Exterior:
Body panel removal and installation, doors, hood, trunk, bumpers, glass, trim
Bodywork Interior:
Dashboard, interior trim panels, seating, carpet, headliner
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspections
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides
Repair Procedures:
Step-by-step instructions for component replacement and repair across all systems
Overhaul Rebuild:
Complete engine, transmission, and differential rebuild procedures
Electrical Diagnostics:
Wiring diagrams, component testing, troubleshooting electrical faults
Specifications Data:
Torque specifications, clearances, measurements, fluid capacities
Technical Depth
Depth:
Comprehensive factory-level detail for professional technicians and advanced DIY enthusiasts
Diagnostic Capability:
Detailed diagnostic strategies and specific test procedures for all major systems
Component Level:
Coverage extends to the level of individual component disassembly, inspection, and reassembly
📊 Manual Specifications
File Format
Digital Format:
PDF (assumed for download, enabling searchability and printing)
Print Quality
Printability:
Designed for printing (hundreds of pages implies ability to print a full manual)
Binding Type
Original Binding:
N/A (for downloadable format)
Paper Type
Original Paper:
N/A (for downloadable format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M30 (specifically M30B34)
Engine Type:
Inline 6-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
3.4 Liters (3430 cc)
Performance
Horsepower 535I:
Approx. 182 hp @ 5400 rpm (U.S. spec)
Torque 535I:
Approx. 225 lb-ft @ 3500 rpm (U.S. spec)
Horsepower M535I:
Approx. 192 hp @ 5400 rpm (European spec, U.S. M535i was less powerful and less common than the 535i)
Torque M535I:
Approx. 228 lb-ft @ 3500 rpm (European spec)
Fuel System
Injection System:
Bosch L-Jetronic or Motronic (depending on year and market)
Fuel Type:
Unleaded Gasoline (Premium Recommended)
🔧 Transmission
Standard
Transmission Type 535I:
Getrag 260 5-speed manual
Optional
Transmission Type Optional:
ZF 4HP22 4-speed automatic
Features
Rear Wheel Drive:
All models are RWD (Rear Wheel Drive)
Limited Slip Differential:
Optional on some models, standard on M535i
📐 Dimensions
Exterior
Length:
Approx. 191.1 inches (4854 mm)
Width:
Approx. 68.5 inches (1740 mm)
Height:
Approx. 55.3 inches (1405 mm)
Wheelbase:
Approx. 104.4 inches (2650 mm)
Weights
Curb Weight:
Approx. 3400-3600 lbs (1542-1633 kg), varies by transmission and options
🛡️ Safety Features
Ratings
Crash Testing Era:
NHTSA/IIHS crash testing was less standardized and detailed in this era compared to modern vehicles.
Active Features
ABS:
Optional ABS (Anti-lock Braking System) available on most models.
Traction Control:
Not typically available on E28 models.
Passive Features
Airbags:
Driver's side airbag introduced later in the E28's life, not standard on all models or early years.
Seatbelts:
3-point front seatbelts, rear seatbelts
💡 Technology Features
Infotainment
Audio System:
Typically an AM/FM radio with cassette player, often with optional premium sound systems (e.g., Bavaria C) and multi-speaker configurations.
Climate Control Tech:
Manual or optional automatic climate control (ECC - Electronic Climate Control) offering precise temperature regulation.
Driver Assistance
Cruise Control:
Standard or optional cruise control for highway driving.
Onboard Computer:
Some models featured an early form of onboard computer for basic trip data and diagnostics.
Connectivity
Connectivity Era:
Limited to basic audio input; no modern Bluetooth or smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles or annually, depending on driving conditions and oil type used.
Coolant Flush:
Every 2 years or 24,000 miles.
Spark Plug Replacement:
Around 30,000 miles for standard plugs; refer to manual for specific types.
Timing Belt Chain:
M30 engines use a timing chain, which is designed to last the life of the engine but requires inspection for wear and tensioner condition.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 15W-40 or 10W-40 (check specific viscosity for climate).
Coolant Type:
BMW Blue or G48 equivalent antifreeze (ethylene glycol based), mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Transmission Fluid Manual:
GL-4 75W-90 or 80W-90 gear oil (check specific manual for recommendations).
Transmission Fluid Automatic:
ZF TE-ML 11A or TE-ML 11B (often referred to as Dexron II/III in later specifications, but original spec is critical).
Known Issues
Cooling System Leaks:
Common radiator leaks, hose failures, and water pump seal deterioration. Check for white residue around connections.
Rubber Component Degradation:
Age-related failure of suspension bushings, engine mounts, vacuum hoses, and fuel lines.
Electrical Gremlins:
Corrosion on connectors, failing relays, and wear in wiring harnesses can lead to intermittent electrical issues.
Fuel Injector Clogging:
Can affect performance and fuel economy, often resolved with cleaning or replacement.
Clutch Wear:
Wear and tear on the clutch components (disc, pressure plate, release bearing) is a common maintenance item for manual transmissions.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's established reputation for building driver-focused luxury sedans with superior handling and engineering.
Model Evolution
E12 Predecessor:
The E28 succeeded the E12 5 Series, refining its platform and introducing more advanced technology and performance.
E34 Successor:
The E28 was replaced by the E34 5 Series in 1988/1989, representing a significant generational leap in design and technology.
Production
Production Years:
E28 Series produced from 1981 to 1988.
Key Variants:
520i, 524d, 525e, 528i, 535i, M535i, M5 (E28S38).
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The 535i (and its predecessors) frequently appeared on Car and Driver's 10Best list during this era, recognizing its superior driving dynamics and performance.
Automotive Journalism Acclaim:
Consistently praised by automotive press for its blend of luxury, performance, and build quality, setting benchmarks for the executive sedan class.
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