Positioning:
The E28 generation represented a significant evolution for BMW's executive sedan, blending performance, luxury, and advanced engineering. The 535i and M535i were positioned as the performance-oriented variants within this esteemed lineup.
Competitors:
Competed against other high-performance luxury sedans of its era, such as Mercedes-Benz W124 models (e.g., 300E), Audi 100/200, and Jaguar XJ-S, offering a compelling blend of German engineering and driving dynamics.
Features:
Renowned for its robust inline-six engines, sophisticated suspension, driver-focused interior, and classic BMW styling. The E28 was the first 5 Series to offer a diesel engine and an M version (M535i).
Coverage:
Complete workshop service and repair for BMW 535i and M535i E28 models.
Estimated Page Count:
Approximately 1000+ pages (typical for comprehensive workshop manuals of this era).
Type:
Workshop Service Repair Manual
Format:
Downloadable Digital Format (PDF, likely with searchable text)
Engine:
Engine mechanical (M30B34/B35), fuel injection (L-Jetronic/Motronic), ignition system, cooling system, lubrication system, exhaust system.
Transmission:
Manual and automatic transmission service, repair, and overhaul.
Drivetrain:
Driveshaft, differential, axle shafts, wheel bearings.
Suspension:
Front and rear suspension components, steering system, alignment specifications.
Brakes:
Front and rear brake systems (disc brakes), ABS (if equipped), hydraulic system.
Electrical:
Wiring diagrams, electrical components, lighting, instrumentation, power accessories, battery, alternator, starter.
Body:
Body panel removal and installation, doors, windows, sunroof, interior trim, HVAC system.
Maintenance:
Scheduled maintenance, oil changes, fluid checks and replacements, filter changes, spark plug replacement.
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component repair, electrical component diagnosis and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault codes (where applicable).
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical values.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
Engine Code 535I:
M30B34 (3.4-liter inline-six)
Engine Code M535I:
M30B35 (3.5-liter inline-six)
Horsepower:
Approximately 182-218 hp (depending on market and specific tune).
Torque:
Approximately 214-228 lb-ft.
Horsepower:
Approximately 211-252 hp (depending on market and specific tune, often higher for Euro-spec).
Torque:
Approximately 232-265 lb-ft.
System:
Bosch L-Jetronic or Motronic fuel injection systems.
Configuration:
SOHC (Single Overhead Camshaft), 2 valves per cylinder
Type:
4-speed or 5-speed manual transmission (Getrag).
Type:
ZF 4HP22 automatic transmission.
Clutch:
Hydraulically actuated single dry plate clutch.
Manual:
BMW ATF Dexron II or equivalent.
Automatic:
BMW ATF Dexron II or equivalent.
Length:
Approx. 188.5 inches (4790 mm)
Width:
Approx. 68.1 inches (1730 mm)
Height:
Approx. 55.1 inches (1400 mm)
Wheelbase:
Approx. 103.7 inches (2630 mm)
Curb Weight:
Approx. 3200-3400 lbs (1450-1540 kg), varies by model and equipment.
Crash Testing:
E28 models predate modern standardized crash testing. Safety features focused on structural integrity, crumple zones, and occupant restraint.
ABS:
Anti-lock Braking System (ABS) was an available option on later models.
Seatbelts:
3-point seat belts with pretensioners (early models may have manual adjustment).
Airbags:
Driver airbag was not standard on early E28s; became available on later models.
Steering Column:
Collapsible steering column for improved impact protection.
Audio System:
Factory cassette player with AM/FM radio, often with upgraded speaker systems (e.g., Blaupunkt or Harman Kardon).
Cruise Control:
Standard cruise control system.
Climate Control:
Manual or optional automatic climate control ('ECC').
Connectivity Options:
Limited by era; primarily analog systems. Later models offered optional power windows, locks, mirrors, and sunroof.
Oil Change:
Every 7,500-10,000 miles or annually, whichever comes first (using high-quality synthetic oil is recommended).
Spark Plugs:
Replace every 30,000-50,000 miles depending on plug type (e.g., copper vs. platinum). Consult manual for specific recommendations.
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Engine Oil:
API SG or higher, SAE 5W-30 or 10W-40 (check manual for specific viscosity based on temperature).
Coolant:
BMW Blue or Green coolant concentrate mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4.
Fuel System:
Fuel accumulator failure, leaking fuel injectors, worn fuel pump relays, cracked fuel lines.
Engine:
Head gasket leaks (especially on higher mileage engines), worn valve stem seals leading to oil consumption, timing chain tensioner wear.
Suspension:
Worn control arm bushings, shock absorber degradation, rear trailing arm bushings ('RTABs').
Electrical:
Corroded grounds, failing alternator voltage regulators, instrument cluster pixel degradation, fuse box corrosion.
Interior:
Sagging headliner, crumbling dashboard materials, worn seat bolsters.
Heritage:
BMW has a long-standing reputation for producing driver-focused, high-performance sedans with excellent engineering and build quality, dating back to its origins in aircraft engines and motorcycles.
E28 Introduction:
The E28 was introduced in 1981 as the successor to the E12 5 Series, building upon its predecessor's strengths with improved aerodynamics, updated styling, and more powerful engine options.
E28 Development:
Evolved through various engine upgrades and facelifts. The 535i (replacing the 528i) and the M535i (a precursor to the E34 M5) were key performance variants that defined the model's sporting credentials.
Production Years:
1981-1988
Manufacturing Locations:
Primarily Dingolfing, Germany.
Contemporary Reviews:
Consistently praised by automotive journalists of the time for its driving dynamics, build quality, and blend of sportiness and luxury. Often cited as a benchmark in its class.
Driver Engagement:
Highly regarded for driver engagement and handling characteristics.
Bmw Quality Standard:
Built to BMW's rigorous quality standards of the era, emphasizing durability and long-term reliability when properly maintained.
