BMW 633CSI 635CSI M6 Service Repair Manual 1983-1989
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🏷️ Basic Information Identification Make: BMW Model: 6 Series Model Variants: 633CSi, 635CSi, M6 (E24) Model Code: E24 Generation Generation: First Generation (E24) Codes Engine Codes: M30B32 (633CSi), M30B34 (635CSi), S38B35 (M6) 👋 Introduction Market Position Market Position: The BMW E24 6 Series was positioned as a luxury grand tourer, offering a blend of performance, comfort, and sophisticated styling, competing with models from Mercedes-Benz, Porsche, and Jaguar. Competitive Analysis Competitive Analysis: The 633CSi and 635CSi offered a more accessible entry into the luxury coupe segment compared to the outright performance of the Porsche 928, while providing superior handling and driver engagement than many American luxury coupes of the era. Key Features Key Features: Iconic Bertone-designed coupe body, powerful inline-six engines, rear-wheel drive, advanced (for its time) suspension, luxurious interior appointments, and a focus on driver involvement. 📋 Manual Details Coverage Areas Years Covered: 1983-1989 Page Count Page Count: Hundreds of pages (exact number not specified, but implies comprehensive) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, assembly, disassembly, cylinder head, pistons, crankshaft, camshaft, valve train Engine Management Fuel Injection: Bosch Motronic L-Jetronic/LH-Jetronic, fuel pumps, injectors, sensors, diagnostic procedures Cooling System: Radiator, fan, water pump, thermostat, coolant specifications Lubrication System: Oil pump, oil filter, oil pressure, lubrication points Exhaust System: Manifolds, catalytic converters (where applicable), mufflers, pipes Transmission Manual: Clutch, gearbox overhaul, gear selection, shifting mechanisms, fluid specifications Transmission Automatic: ZF 4HP22, torque converter, valve body, hydraulic systems, fluid specifications Drivetrain: Driveshaft, universal joints, differential, axle shafts, wheel bearings Suspension Front: MacPherson struts, control arms, bushings, ball joints, steering knuckles, spring replacement Suspension Rear: Independent trailing arm, shock absorbers, springs, control arms, bushings, sway bars Steering System: Power steering pump, steering rack, tie rods, steering column, steering fluid Brake System Front: Ventilated discs, calipers, brake pads, hydraulic lines, ABS (where applicable) Brake System Rear: Solid discs, calipers, brake pads, parking brake mechanism Wheels Tires: Bolt patterns, wheel torque specifications, tire pressure recommendations Electrical System Charging: Alternator, voltage regulator, battery maintenance Electrical System Ignition: Distributor, ignition coil, spark plugs, ignition timing, control modules Electrical System Lighting: Headlights, taillights, interior lights, bulb types Electrical System Accessories: Power windows, mirrors, locks, sunroof, wipers, horn, radio Body And Chassis: Frame, body panels, doors, hood, trunk, glass, seals HVAC System: Air conditioning compressor, refrigerant, heater core, blower motor, climate control unit Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs Troubleshooting Diagnostics: Fault finding, diagnostic codes, symptom-based repair guides Engine Repair Rebuild: Complete engine disassembly, inspection, repair, and reassembly procedures Transmission Repair: Overhaul and repair for both manual and automatic transmissions Brake System Repair: Pad and rotor replacement, caliper overhaul, bleeding procedures Electrical Component Testing: Testing of alternators, starters, ignition components, sensors, and actuators Suspension And Steering Repair: Replacement of worn suspension components and steering parts Bodywork And Trim Replacement: Guidelines for body panel alignment and trim piece installation/removal HVAC System Servicing: Refrigerant handling, component replacement, leak detection Technical Depth Depth Of Coverage: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans suitable for printing, preserving original manual clarity Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 633Csi: M30B32, 3.2L (3210cc) SOHC Inline-6 Engine 635Csi: M30B34, 3.4L (3430cc) SOHC Inline-6 Engine M6: S38B35, 3.5L (3453cc) DOHC Inline-6 (M88/3 derivative) Performance 633Csi Horsepower 633Csi: Approx. 197 hp (DIN) Torque 633Csi: Approx. 285 Nm (210 lb-ft) Performance 635Csi Horsepower 635Csi: Approx. 218 hp (DIN) Torque 635Csi: Approx. 310 Nm (229 lb-ft) Performance M6 Horsepower M6: Approx. 286 hp (DIN) Torque M6: Approx. 333 Nm (246 lb-ft) Fuel System Fuel System: Bosch Motronic fuel injection (L-Jetronic or LH-Jetronic variations across models/years) Fuel Type Fuel Type: Unleaded gasoline (Premium/Super Unleaded recommended) 🔧 Transmission Standard Transmission Standard: 4-speed manual (Getrag 265) on some models, 4-speed automatic (ZF 4HP22) common Optional Transmission Optional: 5-speed manual (Getrag 265) became more common on later 635CSi and standard on M6 Features Transmission Features: Dogleg first gear for manual transmission (on some models), smooth automatic shifts Fluid Type Transmission Fluid Auto: Dexron III (or equivalent ATF) Transmission Fluid Manual: GL-4 gear oil (e.g., Castrol TAF-X or equivalent) 📐 Dimensions Exterior Length Exterior Length: Approx. 4,750-4,800 mm (187.0-189.0 in) Exterior Width Exterior Width: Approx. 1,725 mm (67.9 in) Exterior Height Exterior Height: Approx. 1,370-1,380 mm (53.9-54.3 in) Wheelbase Wheelbase: Approx. 2,630 mm (103.5 in) Weights Curb Weight: Approx. 1,500-1,650 kg (3,307-3,638 lbs) 🛡️ Safety Features Ratings Safety Ratings: No formal NHTSA/Euro NCAP ratings available for this era, but built to high safety standards for its time. Era-appropriate safety features. Active...
The BMW E24 6 Series was positioned as a luxury grand tourer, offering a blend of performance, comfort, and sophisticated styling, competing with models from Mercedes-Benz, Porsche, and Jaguar.
Competitive Analysis
Competitive Analysis:
The 633CSi and 635CSi offered a more accessible entry into the luxury coupe segment compared to the outright performance of the Porsche 928, while providing superior handling and driver engagement than many American luxury coupes of the era.
Key Features
Key Features:
Iconic Bertone-designed coupe body, powerful inline-six engines, rear-wheel drive, advanced (for its time) suspension, luxurious interior appointments, and a focus on driver involvement.
📋 Manual Details
Coverage Areas
Years Covered:
1983-1989
Page Count
Page Count:
Hundreds of pages (exact number not specified, but implies comprehensive)
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans suitable for printing, preserving original manual clarity
Original systems typically included AM/FM radio, cassette player. Later models may have offered more advanced stereo systems. No complex infotainment systems like modern vehicles.
Driver Assistance
Driver Assistance:
ABS (Anti-lock Braking System) became available and standard on later models. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity
Connectivity Options:
Basic telecommunication features in some luxury trims, but no Bluetooth or smartphone integration in original form.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 10,000-15,000 km (6,000-10,000 miles) or annually, depending on driving conditions.
Service Intervals Filters
Filter Replacement Interval:
Oil filter with every oil change; Air filter every 20,000-30,000 km (12,000-18,000 miles); Fuel filter every 40,000-60,000 km (24,000-36,000 miles).
Service Intervals Spark Plugs
Spark Plug Replacement Interval:
Approx. 30,000-50,000 km (18,000-30,000 miles) depending on plug type.
Fluid Specifications Engine Oil
Engine Oil Specification:
SAE 15W-40 or 20W-50 (depending on climate and specific engine variant). API SF/SG or higher.
Fluid Specifications Coolant
Coolant Specification:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio). BMW recommends specific coolants.
Fluid Specifications Brake Fluid
Brake Fluid Specification:
DOT 4
Known Issues
Common Issues:
Rust (wheel arches, sills, strut towers), aging rubber components (bushings, hoses), fuel injection system (pump, injectors, airflow meter), electrical issues (wiring harness degradation, relay failures), climate control system failures, headliner sag, transmission seal leaks, differential whine.
📚 Vehicle History
Brand Heritage
Brand Heritage:
BMW, Bayerische Motoren Werke AG, is renowned for its 'Ultimate Driving Machine' philosophy, emphasizing performance, engineering excellence, and driver engagement in its vehicles.
Model Evolution
Model Evolution E24:
The E24 6 Series replaced the E9 coupe and was produced from 1976 to 1989. It received a significant facelift in 1982, which included revised styling and updated mechanicals. The M6 (or M635CSi in Europe) was the high-performance variant.
Production
Production Period:
1976-1989 (E24 generation)
Production Locations
Production Locations:
Germany (Dingolfing plant)
🏆 Awards & Recognition
Recognitions
Recognitions:
The E24 6 Series is widely recognized by automotive enthusiasts and critics for its timeless design, dynamic driving capabilities, and status as a classic luxury GT.
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