BMW 5-Series (E28) M535i 1985-1988 Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 5-Series Model Code: E28 Variant: M535i Years Covered: 1985-1988 Codes Chassis Code: E28 Generation Generation Name: Second Generation BMW 5 Series (E28) 👋 Introduction Market Position Target Audience: BMW owners, independent repair shops, automotive technicians, DIY enthusiasts seeking detailed technical information for the E28 M535i. Competitive Analysis Value Proposition: Provides the exact same diagnostic and repair information used by dealership technicians, offering significant cost savings over professional servicing for complex repairs. Key Features Accuracy: Official factory documentation ensuring high accuracy and completeness. Visual Aids: Includes diagrams, illustrations, and pictures to aid in understanding procedures. Convenience: Digital PDF format allows for easy searching, printing of specific pages, and portability. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive A-Z service, repair, diagnosis, and maintenance for the BMW E28 M535i. Page Count Estimated Page Count: Detailed, but not explicitly stated. Assumed to be extensive based on 'COMPLETE official full service repair manual'. Manual Type Type: Official Factory Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, clutch, drivetrain, fuel system, exhaust system. Chassis: Suspension (front and rear), steering system, brakes (front and rear), wheels, tires. Electrical: Complete electrical system, wiring schematics, battery, charging system, ignition system, lighting, instrumentation, power accessories, fuses, relays. Body: Body panels, doors, windows, locks, interior trim, HVAC (heating, ventilation, and air conditioning), exterior trim. Procedures Included Maintenance: Routine maintenance schedules, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections. Repair: Engine overhaul, transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair, bodywork repairs. Diagnostics: Troubleshooting common issues, diagnostic procedures for various systems, fault code interpretation (where applicable). Technical Depth Depth: Factory-level technical detail, suitable for professional technicians and advanced DIY enthusiasts. Includes step-by-step instructions, diagrams, and specifications. Technical Areas Engine Mechanical: Detailed procedures for engine assembly, disassembly, valve adjustments, piston ring replacement, bearing replacement, cylinder head service. Fuel And Emission Control: In-depth coverage of the L-Jetronic fuel injection system, fuel pump, injectors, airflow meter, cold start valve, and emission control components. Ignition System: Diagnostic and repair procedures for the ignition coil, distributor, spark plug wires, and control module. Brake System: Complete overhaul procedures for calipers, master cylinder, brake lines, and ABS unit (if equipped). Suspension And Steering: Detailed instructions for replacing struts, shock absorbers, control arms, ball joints, tie rod ends, and power steering components. Wiring Schematics Electrical Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, crucial for accurate diagnosis. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Fully printable, allowing users to print specific pages or sections as needed. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type Recommendation: N/A (Digital PDF format), user printable on standard paper. Searchability Text Search: Likely searchable text within the PDF for quick information retrieval. Zoom Capabilities Zoom: Yes, zoom in/out functionality for detailed viewing of diagrams and images. Delivery Method Delivery: Instant Download Required Software Requirements: Adobe PDF Reader, WinZip (for extraction if compressed). Compatibility Operating Systems: Compatible with all versions of Windows and Mac. ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-6 Cylinder (M30B35) Performance Horsepower: Approximately 211 hp (157 kW) at 5700 rpm (DIN) Torque: Approximately 224 lb-ft (305 Nm) at 4000 rpm (DIN) Fuel System Fuel Delivery: Bosch L-Jetronic Fuel Injection Engine Details Displacement: 3.430 cc (3.4 Liters) Bore X Stroke: 92.0 mm x 86.0 mm Compression Ratio: 9.3:1 Cooling System Coolant Type: BMW Premium Coolant (G48 or equivalent) or a mix of ethylene glycol and distilled water. 🔧 Transmission Standard Transmission Type: Getrag 265 5-speed Manual Transmission Optional Transmission Type: ZF 4HP22 4-speed Automatic Transmission (Less common for M535i, but possible) Features Clutch Type: Hydraulically operated single dry plate clutch Fluid Specifications Manual Transmission Fluid: BMW approved transmission fluid (e.g., SAE 75W-90 GL-5) or equivalent. Automatic Transmission Fluid: BMW ATF LT-3 (Dexron III equivalent) or manufacturer-specified ATF. 📐 Dimensions Exterior Length: Approx. 4620 mm (181.9 in) Width: Approx. 1700 mm (66.9 in) Height: Approx. 1380 mm (54.3 in) Wheelbase Wheelbase: Approx. 2795 mm (110.0 in) Weights Curb Weight: Approx. 1500-1550 kg (3307-3417 lbs) 🛡️ Safety Features Ratings Crash Test Data: Specific crash test data for the E28 M535i is limited by modern standards; however, the E28 platform featured crumple zones and a reinforced passenger cell. Active Features Brakes: Front: Ventilated discs, Rear: Solid discs. ABS (Anti-lock Braking System) was standard or optional depending on market. Passive Features Seatbelts: Three-point inertia-reel seatbelts Headrests: Adjustable front headrests 💡 Technology Features Infotainment Audio System: Factory fitted premium sound system (e.g., Blaupunkt, Alpine) with cassette player and AM/FM radio. Driver Assistance ABS: Anti-lock Braking System (ABS) was available, enhancing braking control. Comfort Features Climate Control: Manual or optional automatic climate control system. Power Accessories: Power windows, power mirrors, central...
BMW owners, independent repair shops, automotive technicians, DIY enthusiasts seeking detailed technical information for the E28 M535i.
Competitive Analysis
Value Proposition:
Provides the exact same diagnostic and repair information used by dealership technicians, offering significant cost savings over professional servicing for complex repairs.
Key Features
Accuracy:
Official factory documentation ensuring high accuracy and completeness.
Visual Aids:
Includes diagrams, illustrations, and pictures to aid in understanding procedures.
Convenience:
Digital PDF format allows for easy searching, printing of specific pages, and portability.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive A-Z service, repair, diagnosis, and maintenance for the BMW E28 M535i.
Page Count
Estimated Page Count:
Detailed, but not explicitly stated. Assumed to be extensive based on 'COMPLETE official full service repair manual'.
Body panels, doors, windows, locks, interior trim, HVAC (heating, ventilation, and air conditioning), exterior trim.
Procedures Included
Maintenance:
Routine maintenance schedules, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections.
Repair:
Engine overhaul, transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair, bodywork repairs.
Diagnostics:
Troubleshooting common issues, diagnostic procedures for various systems, fault code interpretation (where applicable).
Technical Depth
Depth:
Factory-level technical detail, suitable for professional technicians and advanced DIY enthusiasts. Includes step-by-step instructions, diagrams, and specifications.
Technical Areas
Engine Mechanical:
Detailed procedures for engine assembly, disassembly, valve adjustments, piston ring replacement, bearing replacement, cylinder head service.
Fuel And Emission Control:
In-depth coverage of the L-Jetronic fuel injection system, fuel pump, injectors, airflow meter, cold start valve, and emission control components.
Ignition System:
Diagnostic and repair procedures for the ignition coil, distributor, spark plug wires, and control module.
Brake System:
Complete overhaul procedures for calipers, master cylinder, brake lines, and ABS unit (if equipped).
Suspension And Steering:
Detailed instructions for replacing struts, shock absorbers, control arms, ball joints, tie rod ends, and power steering components.
Wiring Schematics
Electrical Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, crucial for accurate diagnosis.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Fully printable, allowing users to print specific pages or sections as needed.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type Recommendation:
N/A (Digital PDF format), user printable on standard paper.
Searchability
Text Search:
Likely searchable text within the PDF for quick information retrieval.
Zoom Capabilities
Zoom:
Yes, zoom in/out functionality for detailed viewing of diagrams and images.
Delivery Method
Delivery:
Instant Download
Required Software
Requirements:
Adobe PDF Reader, WinZip (for extraction if compressed).
Compatibility
Operating Systems:
Compatible with all versions of Windows and Mac.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-6 Cylinder (M30B35)
Performance
Horsepower:
Approximately 211 hp (157 kW) at 5700 rpm (DIN)
Torque:
Approximately 224 lb-ft (305 Nm) at 4000 rpm (DIN)
Fuel System
Fuel Delivery:
Bosch L-Jetronic Fuel Injection
Engine Details
Displacement:
3.430 cc (3.4 Liters)
Bore X Stroke:
92.0 mm x 86.0 mm
Compression Ratio:
9.3:1
Cooling System
Coolant Type:
BMW Premium Coolant (G48 or equivalent) or a mix of ethylene glycol and distilled water.
🔧 Transmission
Standard
Transmission Type:
Getrag 265 5-speed Manual Transmission
Optional
Transmission Type:
ZF 4HP22 4-speed Automatic Transmission (Less common for M535i, but possible)
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Fluid Specifications
Manual Transmission Fluid:
BMW approved transmission fluid (e.g., SAE 75W-90 GL-5) or equivalent.
Automatic Transmission Fluid:
BMW ATF LT-3 (Dexron III equivalent) or manufacturer-specified ATF.
📐 Dimensions
Exterior
Length:
Approx. 4620 mm (181.9 in)
Width:
Approx. 1700 mm (66.9 in)
Height:
Approx. 1380 mm (54.3 in)
Wheelbase
Wheelbase:
Approx. 2795 mm (110.0 in)
Weights
Curb Weight:
Approx. 1500-1550 kg (3307-3417 lbs)
🛡️ Safety Features
Ratings
Crash Test Data:
Specific crash test data for the E28 M535i is limited by modern standards; however, the E28 platform featured crumple zones and a reinforced passenger cell.
Active Features
Brakes:
Front: Ventilated discs, Rear: Solid discs. ABS (Anti-lock Braking System) was standard or optional depending on market.
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts
Headrests:
Adjustable front headrests
💡 Technology Features
Infotainment
Audio System:
Factory fitted premium sound system (e.g., Blaupunkt, Alpine) with cassette player and AM/FM radio.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was available, enhancing braking control.
Comfort Features
Climate Control:
Manual or optional automatic climate control system.
Power Accessories:
Power windows, power mirrors, central locking were common features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000-15,000 km (6,000-10,000 miles) or annually, depending on driving conditions.
Spark Plug Replacement:
Refer to manual for specific interval, typically around 30,000-40,000 km (20,000-25,000 miles).
Timing Belt Replacement:
Not applicable, M30 engine uses a timing chain.
Fluid Specifications
Engine Oil Capacity:
Approximately 6.5 liters (6.9 US quarts) with filter change.
Engine Oil Specification:
API SG or higher, SAE 15W-40 or 10W-40 depending on climate (refer to manual for exact recommendations).
Overheating due to aged radiator, water pump, or thermostat.
Electrical Gremlins:
Degrading wire insulation, corroded grounds, and failing relays can cause intermittent issues.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for building driver-focused, performance-oriented luxury sedans.
Model Evolution
E28 Development:
The E28 was an evolution of the E12, introducing significant updates in chassis, aerodynamics, and engine technology, solidifying BMW's position in the executive sedan market.
Production
Production Period:
1981-1988 (E28 generation). M535i variants produced within this timeframe.
Manufacturing Location:
Germany
Model Specific
M535I Positioning:
The M535i was positioned as a sportier, more powerful version of the standard 5-Series, bridging the gap to the iconic E28 M5.
🏆 Awards & Recognition
Recognitions
Automotive Press:
The E28 generation, including sportier variants like the M535i, was consistently praised by automotive press for its excellent handling, powerful engines, and build quality.
Ratings
Performance Benchmarks:
Often benchmarked against contemporary luxury sports sedans from Mercedes-Benz and Audi, typically holding its own in performance and driving dynamics.