🏷️ Basic Information

Make:

BMW

Model:

535i

Model Variant:

535

Year:

1990

Chassis Code:

E34

👋 Introduction

Positioning:

The BMW 535i (E34) was positioned as a luxury sport sedan, offering a blend of performance, comfort, and advanced engineering for its era. It competed with other premium executive sedans.

Competitors:

Mercedes-Benz E-Class (W124), Audi 100/200, Lexus LS 400, Jaguar XJ.

Features:

Smooth and powerful M30 inline-six engine, refined E34 chassis, advanced suspension geometry, optional features like limited-slip differential, and a focus on driver engagement.

Value:

This comprehensive workshop manual is indispensable for any owner or technician looking to maintain, diagnose, and repair the BMW 535i (E34). It provides the manufacturer-specific technical knowledge required for proper service, ensuring the longevity and optimal performance of this classic BMW.

📋 Manual Details

Engine Variants Covered:

All 1990 535i Engine Variants

Transmission Types Covered:

All 1990 535i Transmission Types (Automatic and Manual)

Trim Levels Covered:

All 1990 535i Trim Levels

Estimated Pages:

Estimated 1500+ pages (typical for comprehensive workshop manuals of this era)

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed diagnosis, repair, and overhaul of the M30B35 inline-six engine, including cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel injection (Motronic), and exhaust system.

Transmission:

Comprehensive repair procedures for both the Getrag 260 5-speed manual transmission and the ZF 4HP-22 4-speed automatic transmission, including clutch, torque converter, valve body, seals, and fluid changes.

Drivetrain:

Service and repair of the rear-wheel-drive system, including driveshaft, universal joints, differential, and half-shafts.

Suspension:

Front and rear suspension system diagnosis and repair, including struts, control arms, ball joints, bushings, springs, shock absorbers, and steering linkage.

Brakes:

Detailed procedures for hydraulic brake system maintenance and repair, including brake fluid service, caliper overhaul, rotor replacement, brake booster, ABS system diagnosis (if equipped), and parking brake.

Electrical System:

Comprehensive wiring diagrams, component testing, troubleshooting for ignition, starting, charging, lighting, instruments, power accessories, and basic Motronic engine management system components.

Fuel System:

Diagnosis and repair of the fuel delivery system, including fuel pump, fuel injectors, fuel pressure regulator, fuel filter, and fuel tank.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, and fan clutch service and repair.

Exhaust System:

Catalytic converter, mufflers, pipes, and oxygen sensor service.

HVAC System:

Diagnosis and repair of the heating, ventilation, and air conditioning system, including refrigerant servicing, compressor, condenser, evaporator, and blower motor.

Body And Interior:

Body panel repair, door mechanisms, window regulators, interior trim, and seat adjustments.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, spark plug replacement, belt adjustments, fluid checks, and lubrication.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting charts.

Repair:

Step-by-step repair instructions for virtually every component of the vehicle, from minor adjustments to major overhauls.

Specifications Data:

Torque specifications, clearances, fluid capacities, resistance values, and other critical data for accurate assembly and repair.

Diagnostic Charts:

Flowcharts and tables to aid in identifying the root cause of problems.

Special Tools:

Identification and usage instructions for specialized BMW tools required for certain procedures.

Depth:

Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including advanced electrical system diagnostics.

📊 Manual Specifications

Format:

PDF

Searchable:

Likely searchable text within the PDF for quick access to information.

Quality:

High-resolution digital reproduction, ensuring clarity of text and diagrams.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

M30B35

Engine Type:

SOHC Inline 6-cylinder

Displacement:

3.430 cc (3.4 L)

Horsepower:

208 hp @ 5,700 rpm (approx.)

Torque:

225 lb-ft @ 4,000 rpm (approx.)

Fuel Delivery:

Bosch Motronic ML-1.3 Fuel Injection

Fuel Type:

Unleaded Gasoline (premium recommended)

Ignition System:

Electronic Ignition (Distributor)

🔧 Transmission

Transmission Type:

Getrag 260 5-speed Manual Transmission

Transmission Type:

ZF 4HP-22 4-speed Automatic Transmission

Clutch Type:

Hydraulically operated single dry plate clutch (manual)

Differential:

Standard open differential; Optional Limited-Slip Differential (LSD)

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (or specified BMW fluid)

Automatic Transmission Fluid:

Dexron III (or specified BMW ATF fluid)

📐 Dimensions

Length:

Approx. 4,730 mm (186.2 in)

Width:

Approx. 1,750 mm (68.9 in)

Height:

Approx. 1,410 mm (55.5 in)

Wheelbase:

Approx. 2,760 mm (108.7 in)

Curb Weight:

Approx. 1,560-1,650 kg (3,439-3,638 lbs)

🛡️ Safety Features

Crash Test Data:

While official NHTSA/IIHS ratings for this specific year and model are limited, the E34 chassis was known for its robust construction and safety features for the era, including a strong safety cell and crumple zones.

Braking System:

Standard 4-wheel disc brakes; Optional Anti-lock Braking System (ABS)

Steering:

Power-assisted recirculating ball steering

Airbags:

Driver's side airbag optional or standard depending on market and specific build date.

Seatbelts:

3-point inertia reel seatbelts front and rear.

Chassis Design:

Reinforced passenger cell, crumple zones front and rear.

💡 Technology Features

Audio System:

Factory-provided AM/FM stereo cassette player, often with amplifier and premium speaker options (e.g., HiFi system).

ABS:

Anti-lock Braking System (ABS) was an optional feature, providing enhanced braking control.

Original Connectivity:

Basic vehicle diagnostics via OBD-I port (BMW proprietary connector, not universal OBD-II).

HVAC Features:

Manual or automatic climate control with A/C, recirculate function, and cabin air filtration (depending on options).

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, depending on driving conditions and oil used. Refer to manual for specific conditions.

Spark Plug Replacement:

Refer to manual; generally around 30,000 miles for standard plugs, potentially longer for platinum/iridium.

Coolant Flush:

Every 2-3 years or 30,000 miles.

Brake Fluid Flush:

Every 2 years.

Engine Oil Type:

API SG or higher, SAE 5W-30 or 5W-40 synthetic recommended (check manual for exact viscosity and specifications).

Engine Oil Capacity:

Approx. 6.5 liters (6.9 US quarts) with filter change.

Coolant Type:

Ethylene glycol-based antifreeze (BMW blue or equivalent, mixed 50/50 with distilled water).

Power Steering Fluid:

BMW CHF 11 S or compatible hydraulic fluid.

Common Wear Items:

Valve cover gasket leaks, oil pan gasket leaks, front suspension bushings (control arms, sway bar), rear trailing arm bushings, driveshaft flex disc (guibo), water pump, fuel pump, idle control valve (ICV), ABS sensor failure.

Electrical Issues:

Corrosion in fuse box and wiring harnesses, faulty SRS control module (if equipped), headlight switch failure.

Engine Specific:

M30 engine is generally robust but can suffer from oil leaks due to aging seals and gaskets. Timing chain guides and tensioners should be inspected.

📚 Vehicle History

Bmw Legacy:

BMW has a long-standing reputation for producing driver-focused, well-engineered automobiles with a strong emphasis on performance and luxury.

E34 Generation:

The E34 generation of the BMW 5 Series, produced from 1987 to 1996, represented a significant evolution in design and technology from its E28 predecessor. It featured a more aerodynamic and refined body, improved suspension, and advanced electronics for its time.

Manufacturing Location:

Primarily Dingolfing, Germany.

Production Period:

The 1990 model year falls within the early to mid-production phase of the E34 generation.

🏆 Awards & Recognition

General Reputation:

The E34 generation, including the 535i, is widely regarded as a benchmark for sports sedan handling and build quality, earning praise from automotive journalists for its dynamic capabilities and comfortable ride.

Consumer Reports Era:

While specific ratings for the 1990 535i are historical, the E34 series generally performed well in reliability and owner satisfaction surveys of its time, though some common BMW wear items were noted.