Positioning:
The 1991 BMW 535i (E34) represented the pinnacle of BMW's mid-size luxury sports sedan offering, known for its sophisticated engineering, powerful inline-six engine, and engaging driving dynamics. This manual caters to owners and technicians seeking to maintain and repair this esteemed vehicle.
Competitors:
Competed against luxury sedans like the Mercedes-Benz W124 E-Class, Audi V8 Quattro, and Cadillac Seville.
Vehicle Highlights:
Smooth and potent M30 inline-six engine, refined ride and handling balance, luxurious interior, and robust build quality.
Systems Covered:
Engine mechanical, engine electrical, fuel system, exhaust system, cooling system, lubrication system, transmission (manual and automatic), drivetrain, suspension, steering, brakes, body, interior, HVAC, electrical system, troubleshooting, diagnostics.
Type:
Service and Repair Manual Software
Format:
Digital Software (likely PDF or proprietary viewer)
Engine Mechanical:
Detailed overhaul procedures for the M30B35 engine, including cylinder head, camshaft, timing chain, pistons, connecting rods, crankshaft, valve train, and oil pan.
Engine Electrical:
Ignition system (ECU, coils, spark plugs), starter, alternator, battery, wiring diagrams, sensor identification and testing.
Fuel System:
Fuel injection system (Bosch Motronic), fuel pump, fuel injectors, fuel pressure regulator, fuel tank, and lines.
Transmission:
Service and overhaul for both the Getrag 260 5-speed manual and the ZF 4HP22 4-speed automatic transmission, including fluid changes, clutch replacement (manual), and torque converter (automatic).
Suspension And Steering:
Front and rear suspension components (struts, shocks, control arms, bushings), power steering system (pump, rack, lines), wheel alignment specifications.
Brakes:
Front and rear disc brake systems, ABS (Anti-lock Braking System) components, brake fluid specifications, hydraulic system bleeding, pad and rotor replacement.
Electrical System:
Comprehensive wiring diagrams for all major systems, lighting, power windows, mirrors, central locking, interior electronics, fuses, and relays.
Maintenance:
Oil change intervals and specifications, filter replacements (oil, fuel, air), spark plug replacement, coolant flush and replacement, brake fluid flush.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common issues related to engine performance, electrical systems, and drivability.
Repair:
Step-by-step repair instructions for all major vehicle components, including engine rebuild, transmission overhaul, suspension replacement, and body panel repair.
Diagnostics:
Information on diagnostic trouble codes (DTCs) relevant to the Motronic engine management system and other electronic modules.
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications and diagnostic procedures.
Engine Type:
Naturally aspirated inline-6 cylinder
Displacement:
3.430 cc (3.4 L)
Horsepower:
208 hp @ 5,700 rpm
Torque:
225 lb-ft @ 4,000 rpm
Fuel Delivery:
Bosch Motronic M3.3 electronic fuel injection
Fuel Type:
Unleaded gasoline
Coolant Type:
BMW Blue Coolant (or equivalent silicate-free antifreeze)
Oil Type:
SAE 15W-40 or 15W-50 (check specific climate recommendations in manual)
Oil Capacity:
Approx. 6.5 liters (6.9 US quarts) with filter change
Length:
4,710 mm (185.4 in)
Width:
1,750 mm (68.9 in)
Height:
1,410 mm (55.5 in)
Curb Weight:
Approx. 1,500-1,600 kg (3,300-3,500 lbs) depending on transmission and options
Gross Vehicle Weight Rating:
Approx. 2,000 kg (4,400 lbs)
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months (refer to manual for specific conditions)
Spark Plug Replacement:
Approx. 30,000 miles (Bosch Super Plus WR 7 DC or equivalent)
Timing Belt Chain:
M30B35 uses a timing chain, which requires inspection for stretch and tensioner wear but typically does not have a fixed replacement interval like a belt.
Coolant Capacity:
Approx. 10.5 liters (11.1 US quarts)
Brake Fluid Spec:
DOT 3 or DOT 4
Common Complaints:
Coolant leaks (hose clamps, radiator, water pump), ABS sensor failure, power steering leaks, sagging headliner, seized door seals.
Engine Specific Issues:
M30 oil pan gasket leaks, valve cover gasket leaks, thermostat housing leaks, idle control valve issues.
Bmw Legacy:
BMW has a long-standing reputation for building driver-focused, sporty luxury sedans known as the 'Ultimate Driving Machine'.
E34 Generation:
The E34 generation (1987-1996) was a significant redesign for the BMW 5 Series, introducing improved aerodynamics, chassis dynamics, and a more upscale interior compared to its E28 predecessor.
Production Years:
1987-1996 (E34 generation); 1987-1993 for 535i variant
Manufacturing Locations:
Germany
