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BMW 535 535i 1986 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 535i Model Designation: E28 Year: 1986 Codes Chassis Code: E28 Engine Code Primary: M30B34 👋 Introduction Market Position Segment: Executive Sedan / Luxury...
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BMW 535 535i 1986 Workshop Repair Service ManualBMW 535 535i 1986 Workshop Repair Service ManualBMW 535 535i 1986 Workshop Repair Service ManualBMW 535 535i 1986 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
535i
Model Designation:
E28
Year:
1986
Codes
Chassis Code:
E28
Engine Code Primary:
M30B34
👋 Introduction
Market Position
Segment:
Executive Sedan / Luxury Sports Sedan
Competitors 1986:
Mercedes-Benz W124 E-Class, Audi V8, Jaguar XJ6, Cadillac Seville
Competitive Analysis
Strengths Of E28 535I:
Sporting dynamics, refined inline-six engine, robust build quality, advanced (for the era) technology like ABS
Key Features
Powertrain:
Legendary M30 inline-six engine, sophisticated suspension, available ABS
Design Philosophy:
German engineering, driver-focused, understated luxury
📋 Manual Details
Coverage Areas
Markets Covered:
Global (all models/engines/trim/transmission types)
Regions Covered:
North America, Europe, Asia
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection (L-Jetronic), ignition system, cooling system, exhaust system, lubrication system, engine management system
Transmission Systems:
Manual transmission (Getrag 260), Automatic transmission (ZF 4HP22), clutch system, driveshafts, differentials
Chassis Systems:
Suspension (front struts, rear independent suspension, control arms, shock absorbers), steering system (power steering), braking system (ABS, front vented discs, rear discs), wheels and tires
Electrical Systems:
Wiring diagrams, battery, alternator, starter, lighting, instruments, power accessories, ECU, sensors, diagnostics
Body Systems:
Body construction, exterior panels, doors, windows, sunroof, interior trim, HVAC system, seats
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement
Repair Procedures:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation (where applicable)
Diagnostics:
On-board diagnostics (OBD), component testing, circuit diagnosis
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Detail Level:
Detailed step-by-step instructions with torque specifications, diagrams, and specifications
📊 Manual Specifications
File Format
PDF Quality:
High resolution, searchable text
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6 Cylinder, DOHC (Double Overhead Camshaft)
Engine Code:
M30B34
Displacement:
3.4 Liters (3,210 cc)
Bore X Stroke:
92.0 mm x 86.0 mm
Performance
Horsepower:
182 hp @ 5,500 rpm
Torque:
225 lb-ft @ 3,250 rpm
Fuel System
Fuel Delivery:
Bosch L-Jetronic Fuel Injection
Fuel Type:
Unleaded Gasoline (Premium Recommended)
Engine Management
ECM:
Bosch Motronic (likely combination fuel/ignition control)
🔧 Transmission
Standard
Type:
Getrag 260 5-Speed Manual
Optional
Type:
ZF 4HP22 4-Speed Automatic
Features
Manual Gear Ratios Final Drive:
Gear ratios vary by market/diff ratio. Common final drive: 3.25:1 or 3.46:1
Automatic Features:
Lock-up torque converter, Sport/Economy modes
📐 Dimensions
Exterior
Length:
186.4 inches (4,735 mm)
Width:
69.3 inches (1,760 mm)
Height:
55.1 inches (1,400 mm)
Wheelbase:
104.3 inches (2,650 mm)
Weights
Curb Weight Manual:
Approx. 3,450 lbs (1,565 kg)
Curb Weight Automatic:
Approx. 3,550 lbs (1,610 kg)
🛡️ Safety Features
Ratings
NHTSA Crash Test Rating:
Not rated under modern NHTSA standards
Active Features
ABS:
Standard (Bosch ABS II)
Passive Features
Airbags:
Driver-side airbag (optional, standard on late models)
Seat Belts:
Three-point front and rear seat belts
Crumple Zones:
Designed with energy-absorbing front and rear crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Cassette Player, optional premium sound system
Climate Control:
Manual or optional Automatic Climate Control (ACC) with digital display
Driver Assistance
Cruise Control:
Standard
Parking Assistance:
None (rear park sensors not available)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months, depending on driving conditions.
Major Tune Up Interval:
Approximately 30,000-50,000 miles (spark plugs, filters, ignition components)
Fluid Specifications
Engine Oil Type:
SAE 15W-40 or 10W-40 (API SG/SH) - Refer to manual for specific recommendations
Engine Oil Capacity:
6.5 US Quarts (6.2 Liters) with filter
Coolant Type:
BMW Coolant (Ethylene Glycol based) mixed 50/50 with distilled water
Transmission Fluid Manual:
GL-4 or GL-5 Gear Oil (e.g., 75W-90)
Transmission Fluid Automatic:
Dexron II or equivalent ATF
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Common Issues:
Oil leaks from valve cover and oil pan gaskets, timing chain wear (rare but possible), fuel distributor issues (L-Jetronic)
Cooling System Common Issues:
Radiator leaks, thermostat failures, heater core leaks (leading to interior water ingress)
Suspension Common Issues:
Worn control arm bushings, sagging springs, worn shock absorbers, strut mount failures
Electrical Common Issues:
Corroded wiring connectors, failing alternator, ignition coil issues, starter motor problems, dashboard warning light failures
ABS System Common Issues:
ABS sensor failures, ABS control unit issues, intermittent operation
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Bayerische Motoren Werke AG, founded 1916, known for performance, engineering, and luxury.
Model Evolution
E28 Generation:
Second generation of the BMW 5 Series (G28 platform), produced from 1981 to 1987. The 535i replaced the 533i.
E28 535I Introduction:
Introduced in 1985 for the 1985 model year, featuring the larger M30B34 engine.
Production
Manufacturing Location:
Dingolfing, Germany
Production Years:
1981-1987 (E28 generation), 535i specifically 1985-1987
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E28 chassis generally received positive reviews and was often a contender on Car and Driver's 10Best lists during its production run.
Ratings
Overall Performance Reputation:
Highly regarded for its driving dynamics, engine performance, and build quality for its era.
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