Positioning Of Vehicle:
The BMW E28 5-series, particularly the 535i and M535i, represented the pinnacle of executive sports sedans in the mid-to-late 1980s, blending performance, luxury, and sophisticated engineering.
Competitors:
Competed against vehicles like the Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6, and Cadillac Seville.
Vehicle Highlights:
Renowned for its balanced chassis, powerful inline-six engine, driver-focused ergonomics, and solid build quality. The M535i offered enhanced performance tuning and sportier aesthetics.
Manual Value Proposition:
This manual serves as an indispensable resource for maintaining and repairing the classic BMW E28 535i and M535i. It provides the detailed, factory-level information necessary to keep these iconic vehicles in optimal condition.
Primary Coverage:
Service, Repair, Workshop
Estimated Page Count:
High volume (typically 1000+ pages for comprehensive manuals of this era)
Type:
Workshop Manual / Service Manual
Format:
Likely printed, but digital versions (PDF) are common for historical manuals.
Powertrain:
Engine (M30), Fuel System, Cooling System, Exhaust System, Ignition System
Drivetrain:
Transmission (Manual & Automatic), Driveshaft, Differential, Axles
Suspension Steering:
Front Suspension, Rear Suspension, Steering System, Power Steering
Brakes:
Front Brakes (Ventilated Discs), Rear Brakes (Discs), ABS (Anti-lock Braking System)
Electrical:
Battery, Charging System, Starting System, Lighting System, Instrumentation, Engine Management (ECU), Fuses and Relays, Wiring Diagrams
Body Chassis:
Body Panels, Doors, Hood, Trunk, Interior Trim, Glass, Chassis Components
Climate Control:
HVAC System, Air Conditioning, Heating
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Belt Adjustments, Fluid Checks and Replacements, Lubrication Points
Repair:
Engine Rebuilding, Transmission Overhaul, Brake System Repair, Suspension Component Replacement, Electrical System Diagnosis and Repair, Bodywork Repairs
Troubleshooting:
Diagnostic Procedures, Common Faults and Solutions, Symptom-based Troubleshooting Guides
Specifications:
Torque Specifications, Clearance Measurements, Timing Settings, Fluid Capacities and Types
Depth:
Comprehensive: Covers routine maintenance to full mechanical and electrical system overhauls. Suitable for professional mechanics and advanced DIY enthusiasts.
Digital Format:
PDF (if digital) - typically searchable, allowing easy access to specific topics. High-resolution scans ensure clarity of diagrams and text.
Print Quality:
Professional printing (if physical) with durable binding, clear text, and legible diagrams. Often includes fold-out diagrams for complex systems.
Binding:
Spiral-bound or perfect-bound to allow lay-flat viewing during repairs.
Paper Type:
Durable, often glossy paper to withstand workshop conditions and repeated use.
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Engine Displacement:
3.4 Liters (3430 cc)
Horsepower 535I:
Approx. 182 hp @ 5500 rpm
Torque 535I:
Approx. 214 lb-ft @ 3000 rpm
Horsepower M535I:
Approx. 192 hp @ 5500 rpm (European spec, US spec may vary)
Torque M535I:
Approx. 214 lb-ft @ 3000 rpm (European spec, US spec may vary)
Fuel Delivery:
Bosch L-Jetronic Fuel Injection
Fuel Type:
Unleaded Gasoline (Premium Recommended)
Ignition Type:
Distributor-based, electronic ignition
Transmission Type:
4-speed Automatic (ZF 4HP22)
Transmission Type:
5-speed Manual (Getrag 265)
Clutch Type:
Hydraulically Actuated (for manual transmission)
Automatic Transmission Fluid:
Dexron II (or equivalent specification)
Manual Transmission Fluid:
GL-4 SAE 75W-90 or GL-4 SAE 80W-90 Gear Oil
Length:
Approx. 188.2 in (4780 mm)
Width:
Approx. 68.7 in (1745 mm)
Height:
Approx. 55.0 in (1397 mm)
Wheelbase:
Approx. 103.5 in (2630 mm)
Curb Weight Approx:
3300-3500 lbs (1497-1588 kg) depending on transmission and equipment
Gross Vehicle Weight Rating Approx:
4300-4500 lbs (1950-2041 kg)
Trunk Volume Approx:
15.9 cu ft (450 L)
Crash Test Data:
Limited official crash test data from modern standards, but built with a robust unibody structure characteristic of BMW's engineering in the era.
ABS:
Standard on most models, featuring Bosch ABS II system.
Traction Control:
Not generally available on this model year.
Airbags:
Driver's airbag typically standard from 1987 onwards.
Seatbelts:
Three-point inertia-reel seatbelts in the front, two-point lap belts in the rear.
Body Structure:
Reinforced safety cage, crumple zones, and side impact beams.
Audio System:
Factory fitted AM/FM radio with cassette player, often with multiple speakers. Aftermarket upgrades common.
Climate Control Tech:
Manual or optional automatic climate control (ECC - Electronic Climate Control) with analog or digital displays.
ABS Implementation:
Early Bosch ABS system, providing anti-lock functionality for improved braking control in emergency situations.
Early Electronics:
Basic on-board computer (check control system) for system monitoring, not modern infotainment or smartphone integration.
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions. Consult manual for specific recommendations.
Transmission Fluid Change:
Automatic transmission fluid flush/change every 30,000-60,000 miles (48,000-96,000 km). Manual transmission fluid inspected periodically, change based on condition or mileage (e.g., 60,000-100,000 miles).
Coolant Replacement:
Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).
Spark Plug Replacement:
Bosch Super Plus (W8AC or equivalent) spark plugs typically replaced every 20,000-30,000 miles (32,000-48,000 km).
Engine Oil Type:
SAE 15W-40 or SAE 10W-40, API SG or higher (e.g., Castrol GTX, Valvoline Premium)
Coolant Type:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. BMW Blue Coolant (G48) or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF (Automatic Transmission Fluid), typically Dexron II or III compatible.
Common Problems:
Rust (especially wheel arches, rocker panels, jacking points), aging rubber components (bushings, hoses, seals), fuel distributor leaks, ABS sensor issues, headliner sagging, starter motor wear, coolant leaks from hoses and thermostat housing.
E28 Specific Wear:
Worn fuel injectors, brittle vacuum lines, failing fuel pump relay, differential seal leaks.
Bmw Legacy:
BMW, Bayerische Motoren Werke AG, has a long history of producing high-performance vehicles with a focus on driving dynamics and engineering excellence.
E28 Generation:
The E28 was the second generation of BMW's 5 Series executive sedan, produced from 1981 to 1988. It succeeded the E12 and was known for its significant engineering improvements, including a more advanced suspension and the introduction of ABS.
535I Introduction:
The 535i variant marked a return to a larger displacement engine in the 5 Series for many markets, offering enhanced performance over earlier models.
M535I Variant:
The M535i was a sportier, homologation special version based on the 535i, featuring M-tuned suspension, unique body styling (including the distinctive M spoiler package), sport seats, and sometimes a limited-slip differential. It was a precursor to the full M5 model.
Production Years:
E28 generation: 1981-1988. 1987 models are late production examples.
Manufacturing Location:
Germany (primarily Dingolfing plant)
