BMW 535 535i 1990 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 535i Year: 1990 Codes Chassis Code: E34 Engine Code: M30B35 👋 Introduction Market Position Segment: Executive Sedan Brand Perception: Luxury, performance, engineering excellence...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code:

M30B35

👋 Introduction

Market Position

Segment:

Executive Sedan

Brand Perception:

Luxury, performance, engineering excellence

Competitive Analysis

Competitors:

Mercedes-Benz W124 E-Class, Audi V8, Lexus LS 400

Key Features

Design Philosophy:

Understated elegance, driver-focused cockpit, robust build quality

Driving Dynamics:

Renowned for sophisticated suspension tuning and engaging handling for its class

📋 Manual Details

Coverage Areas

Coverage Continents:

Global (primarily North American market focus)

Coverage Regions:

North America

Page Count

Estimated Pages:

Hundreds (exact count not specified, but implies comprehensive)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (M30B35), Fuel System, Ignition System, Exhaust System, Transmission (Automatic & Manual)

Chassis:

Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Wheels & Tires

Electrical:

Engine Management, Lighting, Instrumentation, Audio System, Power Accessories, Fuse & Relay Locations, Wiring Diagrams

Bodywork:

Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System, Exterior Trim

Procedures Included

Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements, spark plug replacement

Troubleshooting:

Diagnostic procedures, fault code interpretation, symptom-based troubleshooting for all major systems

Repair:

Engine rebuild, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair

Installation:

Component replacement and installation procedures

Technical Depth

Depth:

Comprehensive (from basic adjustments to complete overhauls, including detailed diagnostic information)

📊 Manual Specifications

File Format

File Type:

Print Quality

Quality:

Printable (user can print entire manual or select pages)

Binding Type

Binding Options:

N/A (Digital PDF - user dependent)

Paper Type

Paper Recommendation:

N/A (Digital PDF - user dependent)

⚙️ Engine Specifications

Primary Engine

Engine Name:

M30B35

Configuration:

Inline-6 Cylinder

Displacement:

3.430 cc (3.4 Liters)

Bore X Stroke:

92 mm x 86 mm

Compression Ratio:

8.0:1

Valvetrain:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Performance

Horsepower Net:

208 hp @ 5700 rpm

Torque Net:

225 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Bosch Motronic M1.3 Fuel Injection

Fuel Type:

Unleaded Gasoline (Premium)

Cooling System

Coolant Type:

BMW Blue Antifreeze (or equivalent)

Lubrication System

Oil Capacity W Filter:

6.5 Liters (6.9 US Quarts)

🔧 Transmission

Standard

Type:

Getrag 260/5 5-speed Manual Transmission

Optional

Type:

ZF 4HP22 EVO 4-speed Automatic Transmission

Features

Automatic Features:

Electronic control, sport mode

Fluid Specifications

Manual Fluid Type:

BMW MTF LT-2 or equivalent (e.g., Red Line MT-90)

Automatic Fluid Type:

Dexron III (or equivalent)

📐 Dimensions

Exterior

Length:

4,720 mm (185.8 inches)

Width:

1,750 mm (68.9 inches)

Height:

1,410 mm (55.5 inches)

Wheelbase:

2,760 mm (108.7 inches)

Weights

Curb Weight Manual:

1,570 kg (3,461 lbs)

Curb Weight Automatic:

1,590 kg (3,505 lbs)

Gross Vehicle Weight Rating:

2,050 kg (4,519 lbs)

Wheels Tires

Wheel Bolt Pattern:

5 x 120 mm

Standard Tire Size:

205/65 R15

Optional Tire Size:

225/55 R15

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

Not rated (era specific, likely to have performed poorly by modern standards)

NHTSA Frontal Impact Passenger:

Not rated (era specific)

Active Features

Standard (Bosch ABS II)

Passive Features

Airbags:

Driver's side airbag standard

Seatbelts:

Front 3-point inertia-reel seat belts, rear 3-point seat belts

Chassis Design:

Monocoque chassis with integral safety cage

💡 Technology Features

Infotainment

Audio System:

Factory BMW E34 radio/cassette system, optional CD changer.

Climate Control:

Manual or optional automatic climate control (ECC - Electronic Climate Control).

Driver Assistance

Cruise Control:

Standard or optional, electronic

Traction Control:

Optional ASC (Automatic Stability Control) system available on some models.

Connectivity

Connectivity Features:

Limited by era; primarily focused on internal vehicle systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

10,000-15,000 km (6,000-10,000 miles) or as indicated by the vehicle's Condition Based Service (CBS) system (if equipped), or annually.

Air Filter Replacement:

Every 20,000-30,000 km (12,000-18,000 miles)

Spark Plug Replacement:

Every 40,000-60,000 km (24,000-36,000 miles) for standard plugs, longer for platinum/iridium.

Coolant Flush:

Every 2-3 years or 50,000 km (30,000 miles)

Fluid Specifications

Brake Fluid:

DOT 4

Power Steering Fluid:

ATF Dexron II/III or Pentosin CHF 11S (verify specific model variant)

Known Issues

Engine:

Head gasket leaks (especially on higher mileage M30 engines), oil leaks from valve cover and oil pan gaskets, timing chain tensioner wear.

Cooling System:

Plastic coolant expansion tank can become brittle and crack, water pump leaks, radiator leaks.

Electrical:

ABS control module failures, instrument cluster illumination issues, sunroof motor failure, door lock actuator problems.

Suspension:

Front control arm bushings wear, rear trailing arm bushings wear, shock absorber degradation.

Interior:

Cracked dashboard (especially in hot climates), headliner sag, worn seat leather.

📚 Vehicle History

Brand Heritage

Heritage:

BMW, Bayerische Motoren Werke AG, known for precision engineering and sporting sedans.

Model Evolution

Generation:

E34 (Second generation 5 Series)

Introduction Year:

1987 (Europe), 1989 (North America)

Design Influence:

E34 design by Boyke Boyer, influenced by BMW's iconic 'Hofmeister kink'.

Production

Production Years E34:

1987-1996

Manufacturing Locations:

Germany (Dingolfing, Munich)

🏆 Awards & Recognition

Recognitions

Automotive Press Awards:

The E34 generation of the 5 Series consistently received praise from automotive journalists for its driving dynamics and build quality.

Design Awards:

While specific design awards for the 1990 model are not readily cited, the E34's styling is considered a benchmark of classic BMW design.