🏷️ Basic Information

Make:

BMW

Model:

535i / M535i

Year:

1988

Chassis Code:

E28

Engine Code 535I:

M30B34 (3.4L)

Engine Code M535I:

M30B34 (3.4L)

👋 Introduction

Positioning:

The BMW 535i and M535i were positioned as performance-oriented executive sedans, bridging the gap between the standard 5-series and the ultra-high-performance M5. The M535i, in particular, was a homologation special for motorsport, featuring enhanced chassis and engine tuning.

Competitors:

Mercedes-Benz W124 (260E, 300E), Audi V8 Quattro, Jaguar XJ6.

Vehicle Features:

Robust M30 inline-six engine, independent suspension, rear-wheel drive, refined interior, sophisticated German engineering. M535i added sport suspension, aerodynamic body kit, and often sport seats.

Value:

Essential resource for owners and independent mechanics to maintain and repair these classic, robust BMW sedans, preserving their performance and longevity.

📋 Manual Details

Primary Coverage:

Service, Repair, Workshop

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics

Estimated Page Count:

Estimated 1000+ pages (typical for comprehensive workshop manuals of this era)

Type:

Workshop Manual / Service Manual

Language:

English

Format:

Likely digital (PDF), given modern sales, but original may have been printed.

📖 Manual Coverage

Powertrain:

Engine mechanicals (M30B34), fuel injection (Bosch Motronic), cooling, exhaust, clutch, manual and automatic transmissions.

Drivetrain:

Driveshafts, differential, axles.

Suspension:

Front struts, rear semi-trailing arms, springs, shock absorbers, bushings, anti-roll bars.

Brakes:

Front and rear disc brakes (vented front), ABS (Antiblockiersystem) operation and repair, brake lines, master cylinder, calipers.

Steering:

Power steering system, steering gear, linkage.

Electrical:

Wiring diagrams, lighting, ignition system, starting system, charging system (alternator), battery, fuses, relays, instrument cluster, power windows, mirrors, central locking.

Bodywork:

Body panel removal/installation, interior trim, glass, seals, bumpers, body alignment.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, fluid checks and changes, belt inspections and replacement.

Major Repairs:

Engine overhaul, transmission rebuild, suspension component replacement, brake system overhauls.

Troubleshooting:

Diagnostic flowcharts, common problem identification and solutions.

Diagnostics:

Detailed procedures for diagnosing engine, electrical, and mechanical faults.

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics.

📊 Manual Specifications

Format Type:

Likely PDF (searchable text, printable pages).

Quality:

High resolution for clear diagrams and text.

Binding:

N/A for digital format. If printed, would be spiral or perfect bound.

Type:

N/A for digital format. If printed, would be durable paper suitable for workshop use.

⚙️ Engine Specifications

Engine Type:

Inline 6-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

3.4 Liters (3,430 cc)

Bore X Stroke Mm:

92.0 mm x 86.0 mm

Compression Ratio:

8.0:1 or 8.5:1 (depending on specific market/variant)

Valvetrain:

Single overhead camshaft (SOHC), 2 valves per cylinder

Horsepower 535I:

Approx. 208-218 hp @ 5,500 rpm (DIN)

Horsepower M535I:

Approx. 218 hp @ 5,500 rpm (DIN)

Torque 535I:

Approx. 290-300 Nm (214-221 lb-ft) @ 3,500 rpm

Torque M535I:

Approx. 305 Nm (225 lb-ft) @ 4,000 rpm

Fuel Delivery:

Bosch LE2-Jetronic or L-Jetronic fuel injection (sequential injection not typical for this era's M30)

Fuel Type:

Unleaded Premium Gasoline (91-98 RON)

Cooling System:

Pressurized water-cooled with engine-driven fan and viscous coupling or electric fan.

Ignition System:

Electronic Ignition (Motronic control)

🔧 Transmission

Transmission Type:

5-speed manual Getrag 265 (dogleg pattern in some M535i variants)

Transmission Type:

4-speed ZF automatic transmission

Clutch:

Single dry plate, hydraulically operated (manual)

Final Drive Ratio:

Various ratios available, typically 3.25 or 3.46 for performance models.

Differential:

Limited-slip differential (LSD) often optional or standard on M535i.

📐 Dimensions

Length Mm:

4620 mm (181.9 in)

Width Mm:

1700 mm (66.9 in)

Height Mm:

1410 mm (55.5 in)

Wheelbase Mm:

2700 mm (106.3 in)

Front Track Mm:

1430 mm (56.3 in)

Rear Track Mm:

1450 mm (57.1 in)

Curb Weight Kg:

Approx. 1500-1550 kg (3307-3417 lbs)

Gross Vehicle Weight Kg:

Approx. 2050 kg (4519 lbs)

Towing Capacity Kg:

Not officially specified for most markets, but generally discouraged for performance sedans.

Trunk Volume Liters:

Approx. 440 liters (15.5 cu ft)

🛡️ Safety Features

Crash Test Results:

No formal standardized crash test ratings (like NHTSA or Euro NCAP) existed in their current form during this era. BMW generally prioritized structural integrity and occupant protection.

ABS:

Standard on many later E28 models, including the 535i and M535i, featuring Bosch ABS.

Traction Control:

Not typically available on this generation.

Airbags:

Driver's side airbag optional, passenger airbag not available.

Seatbelts:

3-point inertia-reel seatbelts front and rear.

Crumple Zones:

Designed with front and rear crumple zones for impact energy absorption.

💡 Technology Features

Audio System:

Factory AM/FM stereo cassette player with optional amplifier and equalizer. Speaker configurations varied.

Navigation:

Not available.

Cruise Control:

Standard or optional, depending on market and trim.

Connectivity Features:

No modern connectivity features (Bluetooth, USB, etc.).

🔧 Maintenance

Oil Change Interval:

Every 10,000 - 15,000 km (6,000 - 9,000 miles) or 12 months, whichever comes first (recommendation based on era and engine type).

Spark Plug Replacement:

Typically every 30,000 - 50,000 km (20,000 - 30,000 miles).

Timing Belt Replacement:

N/A - M30 engines are chain-driven.

Coolant Flush:

Every 2-3 years or 60,000 km (37,000 miles).

Engine Oil Type:

API SG, ACEA A3/B3, SAE 10W-40 or 15W-50 (depending on climate). Check manual for specific BMW approval.

Engine Oil Capacity Liters:

Approx. 6.5 Liters (with filter change).

Coolant Type:

Ethylene glycol-based antifreeze, mixed 50/50 with distilled water.

Transmission Fluid Manual:

SAE 75W-90 or 80W-90 GL-4 gear oil.

Transmission Fluid Automatic:

Dexron III (or equivalent ATF compatible with ZF 4HP22).

Brake Fluid Type:

DOT 3 or DOT 4.

Engine Common Problems:

Oil leaks from valve cover gasket, oil pan gasket, and front timing cover seal. Fuel injector seal leaks. Potential for head gasket failure if overheated. Idling issues due to vacuum leaks or failing fuel pressure regulator/cold start injector.

Cooling System Common Problems:

Degradation of plastic coolant expansion tanks and hoses. Water pump failure. Thermostat sticking.

Electrical Common Problems:

Corroded grounds, faulty headlight relays, malfunctioning power window regulators, brittle wiring insulation, issues with the Motronic control unit or its related sensors.

Suspension Common Problems:

Worn control arm bushings, trailing arm bushings, and ball joints leading to poor handling and tire wear. Sagging rear springs.

Rust Prone Areas:

Wheel arches, rocker panels, jacking points, rear window seals, battery tray area.

📚 Vehicle History

Heritage:

BMW has a long history of producing sporting sedans with a focus on driving dynamics, performance, and luxury. The '5-series' designation represents BMW's executive sedan line.

E28 Introduction:

The E28 was the second generation of the BMW 5 Series, produced from 1981 to 1988. It succeeded the E12 and was replaced by the E34.

535I Introduction:

The 535i designation returned for the E28 generation, offering a significant performance upgrade over the previous 528i, utilizing the larger 3.4L M30 engine.

M535I Introduction:

The M535i (or 535i M-Technic in some markets) was a special performance model of the E28, developed by BMW Motorsport (now BMW M GmbH) as a precursor to the E28 M5. It featured M-tuned suspension, brakes, and styling.

Production Period E28:

1981-1988

Manufacturing Locations:

Germany (primarily Dingolfing plant)

🏆 Awards & Recognition

Performance Accolades:

The E28 chassis, particularly the M535i and M5, were highly regarded by automotive press for their balance of performance, handling, and luxury, establishing BMW's reputation in the sports sedan market.

Reliability Perception:

Generally considered reliable when properly maintained, but high mileage examples can present significant repair needs due to age and wear on components.

Manual Certification:

This is a professional workshop manual, not a certification. Its value lies in its technical accuracy and comprehensiveness.