BMW 535i M535i 1986 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: BMW Model: 535i / M535i Model Code: E28 Year: 1986 Codes Engine Codes: M30B34 👋 Introduction Market Position Segment: Luxury Sport Sedan Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6 Competitive Analysis Key Selling Points: Performance-oriented driving dynamics, luxurious interior, sophisticated engineering, powerful inline-six engine Key Features Manual Value Proposition: Essential resource for maintaining and repairing the iconic E28 platform, empowering owners and technicians with in-depth technical knowledge. 📋 Manual Details Coverage Areas Scope: All US, European, and other international market models Variant Coverage: 535i, M535i, various chassis configurations (standard, long-wheelbase where applicable) Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (M30B34), Fuel System (Bosch L-Jetronic), Ignition System, Exhaust System, Transmission (Getrag 5-speed manual, ZF 4-speed automatic), Drivetrain (Driveshaft, Differential, Axles) Chassis: Suspension (Front MacPherson strut, Rear semi-trailing arm), Steering (Power assisted rack and pinion), Brakes (Front vented discs, Rear discs, ABS), Wheels and Tires Electrical: Wiring Diagrams, Fuses and Relays, Lighting System, Instrumentation, Starter System, Charging System, Battery, Power Accessories (Windows, Locks, Mirrors) Body And Interior: Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Seats, Interior Trim, HVAC System (Heating, Ventilation, Air Conditioning) Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, fluid checks and changes, belt inspection and replacement, brake pad/rotor service Repair: Engine component overhaul, transmission repair/rebuild, suspension and steering component replacement, brake system repair, electrical component diagnosis and repair, body panel repair Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, starting problems, cooling system issues, fuel system malfunctions Diagnostics: Fault code interpretation (where applicable for the era), wiring diagram analysis, mechanical diagnostic procedures Technical Depth Depth: Comprehensive; suitable for professional technicians and advanced DIY enthusiasts Detail Level: Detailed step-by-step instructions, torque specifications, special tool requirements, diagnostic charts, wiring diagrams 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text (OCR enhanced where possible) Print Quality Resolution: High-resolution, suitable for printing specific sections or the entire manual Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-6 Cylinder Displacement: 3.430 cc (3.4 Liters) Bore X Stroke: 92.0 mm x 86.0 mm Compression Ratio: 8.0:1 (for M30B34) Performance Horsepower: 182 hp @ 5500 rpm (535i), 218 hp @ 5500 rpm (M535i) Torque: 220 lb-ft @ 3000 rpm (535i), 232 lb-ft @ 4000 rpm (M535i) Fuel System Injection System: Bosch L-Jetronic Electronic Fuel Injection Fuel Type: Premium Unleaded Gasoline (91+ octane) Ignition System Type: Electronic Ignition (Distributorless or Distributor-based depending on specific market/year detail) Cooling System Type: Pressurized Liquid Cooling Lubrication Oil Type Specification: BMW Longlife-98 or equivalent synthetic oil, SAE 15W-40 or 20W-50 depending on climate. Check manual for exact specification. 🔧 Transmission Standard Type: Getrag 265 5-Speed Manual Transmission Optional Type: ZF 4HP22 4-Speed Automatic Transmission Features Manual Clutch Type: Hydraulically Actuated Single Dry Plate Clutch Automatic Features: Lock-up torque converter, sport mode (in some variants) Fluid Specification Manual Transmission Fluid: GL-4 Gear Oil, SAE 75W-90 or 80W-90. Refer to manual for specific BMW fluid recommendation. Automatic Transmission Fluid: Dexron III/Mercon or equivalent. Consult manual for specific BMW approved fluid. 📐 Dimensions Exterior Length: Approx. 4620 mm (181.9 in) Width: Approx. 1700 mm (66.9 in) Height: Approx. 1380 mm (54.3 in) Wheelbase: Approx. 2770 mm (109.1 in) Weights Curb Weight: Approx. 1500-1600 kg (3300-3520 lbs), depending on transmission and options Gross Vehicle Weight Rating: Approx. 2000 kg (4400 lbs) Cargo Trunk Capacity: Approx. 470 Liters (16.6 cu ft) 🛡️ Safety Features Ratings Crash Test Information: NHTSA and IIHS data for this era is limited; emphasis on passive safety systems of the time. Active Features ABS: Anti-lock Braking System (ABS) available as an option or standard on M535i Traction Control: Not typically available on this model year Passive Features Airbags: Driver-side airbag became optional or standard late in E28 production, check specific vehicle build. Seat Belts: 3-point inertia-reel seat belts front and rear Crumple Zones: Engineered with front and rear crumple zones for energy absorption 💡 Technology Features Infotainment Head Unit: Original ETR AM/FM Stereo Cassette player. Optional 10-speaker Hi-Fi sound system. Dashboard Features: Analog gauges for speed, RPM, fuel, coolant temperature; warning lights for various systems; trip computer (optional). Driver Assistance Cruise Control: Available as an option. Parking Assistance: Rear-mounted parking sensors were not standard or common at this time. Connectivity Bluetooth: Not available in original configuration. Comfort Features Climate Control: Manual or optional automatic climate control (ECC - Electronic Climate Control). 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500 - 10,000 miles (12,000 - 16,000 km) with synthetic oil, or annually, whichever comes first. Refer to manual for exact recommendation. Transmission Fluid Change Interval: Manual: every 30,000 - 60,000 miles. Automatic: every 30,000 - 50,000 miles. Consult manual. Coolant...
Electronic Ignition (Distributorless or Distributor-based depending on specific market/year detail)
Cooling System
Type:
Pressurized Liquid Cooling
Lubrication
Oil Type Specification:
BMW Longlife-98 or equivalent synthetic oil, SAE 15W-40 or 20W-50 depending on climate. Check manual for exact specification.
🔧 Transmission
Standard
Type:
Getrag 265 5-Speed Manual Transmission
Optional
Type:
ZF 4HP22 4-Speed Automatic Transmission
Features
Manual Clutch Type:
Hydraulically Actuated Single Dry Plate Clutch
Automatic Features:
Lock-up torque converter, sport mode (in some variants)
Fluid Specification
Manual Transmission Fluid:
GL-4 Gear Oil, SAE 75W-90 or 80W-90. Refer to manual for specific BMW fluid recommendation.
Automatic Transmission Fluid:
Dexron III/Mercon or equivalent. Consult manual for specific BMW approved fluid.
📐 Dimensions
Exterior
Length:
Approx. 4620 mm (181.9 in)
Width:
Approx. 1700 mm (66.9 in)
Height:
Approx. 1380 mm (54.3 in)
Wheelbase:
Approx. 2770 mm (109.1 in)
Weights
Curb Weight:
Approx. 1500-1600 kg (3300-3520 lbs), depending on transmission and options
Gross Vehicle Weight Rating:
Approx. 2000 kg (4400 lbs)
Cargo
Trunk Capacity:
Approx. 470 Liters (16.6 cu ft)
🛡️ Safety Features
Ratings
Crash Test Information:
NHTSA and IIHS data for this era is limited; emphasis on passive safety systems of the time.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option or standard on M535i
Traction Control:
Not typically available on this model year
Passive Features
Airbags:
Driver-side airbag became optional or standard late in E28 production, check specific vehicle build.
Seat Belts:
3-point inertia-reel seat belts front and rear
Crumple Zones:
Engineered with front and rear crumple zones for energy absorption
💡 Technology Features
Infotainment
Head Unit:
Original ETR AM/FM Stereo Cassette player. Optional 10-speaker Hi-Fi sound system.
Dashboard Features:
Analog gauges for speed, RPM, fuel, coolant temperature; warning lights for various systems; trip computer (optional).
Driver Assistance
Cruise Control:
Available as an option.
Parking Assistance:
Rear-mounted parking sensors were not standard or common at this time.
Connectivity
Bluetooth:
Not available in original configuration.
Comfort Features
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 - 10,000 miles (12,000 - 16,000 km) with synthetic oil, or annually, whichever comes first. Refer to manual for exact recommendation.
Transmission Fluid Change Interval:
Manual: every 30,000 - 60,000 miles. Automatic: every 30,000 - 50,000 miles. Consult manual.
Coolant Flush Interval:
Every 2 years or 30,000 miles.
Fluid Specifications
Coolant:
BMW Blue Coolant or equivalent ethylene glycol based antifreeze (50/50 mix with distilled water). Check manual for specific OEM part number.
Brake Fluid:
DOT 4 specification. Flush and replace every 2 years.
Power Steering Fluid:
BMW approved power steering fluid or Dexron III. Refer to manual for specific type.
Known Issues
Engine Common Issues:
Head gasket leaks (especially if overheated), oil leaks from valve cover gasket and oil pan gasket, fuel distributor diaphragm issues, vacuum leaks, idle control valve issues.
Suspension Common Issues:
Worn control arm bushings, worn ball joints, sagging front springs, rear shock absorber leaks.