BMW 535i M535i 1986 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: 535i / M535i Year: 1986 Codes Chassis Code 535I: E28 Chassis Code M535I: E28 👋 Introduction Market Position Segment: Executive Sedan / Sports Sedan Target Audience: Performance-oriented luxury car buyers, enthusiasts Competitive Analysis Competitors 1986: Mercedes-Benz W124 E-Class, Audi 5000, Jaguar XJ6 Key Features Vehicle Philosophy: Sporty handling, powerful inline-six engine, refined luxury, advanced engineering for its time Manual Value Proposition: Enables owners and technicians to perform all necessary maintenance and repairs to factory specifications, ensuring longevity and performance. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair Page Count Estimated Page Count: 500-800 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Likely Printed (Original) or Digital PDF (reproduction) 📖 Manual Coverage Systems Covered Engine: 3.5L M30 inline-six, including L-Jetronic fuel injection, ignition system, cooling, lubrication, and exhaust Transmission: Manual (Getrag 265) and Automatic (ZF 4HP22) transmissions, including clutch, driveshafts, and differentials Suspension: Front MacPherson struts, rear semi-trailing arms, springs, shock absorbers, bushings, and wheel bearings Brakes: Front vented discs, rear solid discs (or drums on some specific variants), ABS system (Bosch ABS II), hydraulic lines, master cylinder, and parking brake Steering: Power-assisted recirculating ball steering system, hydraulic pump, steering gearbox, and linkages Electrical: Battery, charging system (alternator), starter, lighting, wipers, horn, instrument cluster, dashboard, central locking, power windows, and fuse/relay box schematics Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter, and L-Jetronic fuel injection components Bodywork: Body panel removal and installation, door mechanisms, window regulators, bumpers, trim, and underbody protection Climate Control: Heater core, blower motor, ventilation system, and HVAC controls Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, belt adjustments Troubleshooting: Diagnostic procedures for common faults, symptom-based troubleshooting guides, electrical system diagnostics Repair: Engine overhaul, transmission rebuild, suspension component replacement, brake system repairs, electrical component diagnosis and replacement Installation: Component removal and installation procedures for all major systems Specifications: Torque specifications, clearances, timing settings, and alignment data Technical Depth Depth: Highly detailed, suitable for professional mechanics and advanced DIY enthusiasts; covers full rebuilds and complex diagnostics 📊 Manual Specifications File Format Digital Format Details: Searchable text, high-resolution scans, bookmark functionality (if PDF) Print Quality Print Quality: Professional printing standards, clear diagrams and illustrations Binding Type Binding: Sturdy, lay-flat binding (if printed) for ease of use in workshop environments Paper Type Paper Quality: Durable paper stock resistant to shop grime and frequent use ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, SOHC Engine Code 535I: M30B34 Engine Displacement: 3430 cc (3.4 liters) Bore X Stroke: 92 mm x 86 mm Performance Horsepower 535I: 182 hp @ 5500 rpm (approx.) Torque 535I: 220 lb-ft @ 3000 rpm (approx.) Horsepower M535I: 211 hp @ 5500 rpm (approx., European spec often higher) Torque M535I: 232 lb-ft @ 3500 rpm (approx., European spec often higher) Fuel System Fuel Delivery: Bosch L-Jetronic electronic fuel injection Fuel Type: Unleaded gasoline (premium recommended) 🔧 Transmission Standard Standard Transmission: Getrag 265 5-speed manual Optional Optional Transmission: ZF 4HP22 4-speed automatic Features Manual Transmission Layout: Dogleg first gear pattern (on some manual transmissions) Automatic Transmission Features: Sport mode (on some variants) Fluid Specifications Manual Transmission Fluid: BMW ATF Dexron III (or equivalent specification) Automatic Transmission Fluid: BMW ATF Dexron III (or equivalent specification) 📐 Dimensions Exterior Length: 188.3 inches (4783 mm) Width: 69.4 inches (1763 mm) Height: 55.4 inches (1407 mm) Weights Curb Weight 535I: 3570 lbs (1620 kg) (approx.) Curb Weight M535I: 3590 lbs (1630 kg) (approx.) 🛡️ Safety Features Ratings Safety Ratings Era: NHTSA/IIHS ratings from this era are less comprehensive than modern standards. Active Features ABS: Bosch Anti-lock Braking System (ABS II) on 535i/M535i models Chassis Design: Advanced E28 chassis with independent suspension for predictable handling Passive Features Seatbelts: 3-point front seatbelts, 2-point rear seatbelts (standard; optional 3-point rear belts on some) Body Structure: Reinforced safety cage, crumple zones 💡 Technology Features Infotainment Audio System: Factory BMW/Blaupunkt cassette player with AM/FM radio, optional CD changer interface. Driver Assistance ABS System: Bosch ABS II system, providing enhanced braking control. Connectivity Connectivity Features: Limited by era; primarily focused on vehicle systems. No modern connectivity like Bluetooth or USB. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500-10,000 miles or annually, depending on driving conditions (consult manual for specifics). Spark Plug Replacement: Approximately every 30,000 miles for standard plugs (check manual for specific type and gap). Coolant Flush: Every 2-3 years or as recommended by BMW (typically BMW coolant specified). Fluid Specifications Engine Oil Type: 15W-40 or 20W-50 API SG or higher (refer to manual for exact BMW specification, often a synthetic blend is beneficial) Engine Oil Capacity: 6.5 liters (approx. 6.9 US quarts) with filter change Coolant Type: BMW Blue Coolant (G48 ethylene glycol based) or equivalent...
Performance-oriented luxury car buyers, enthusiasts
Competitive Analysis
Competitors 1986:
Mercedes-Benz W124 E-Class, Audi 5000, Jaguar XJ6
Key Features
Vehicle Philosophy:
Sporty handling, powerful inline-six engine, refined luxury, advanced engineering for its time
Manual Value Proposition:
Enables owners and technicians to perform all necessary maintenance and repairs to factory specifications, ensuring longevity and performance.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair
Page Count
Estimated Page Count:
500-800 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Likely Printed (Original) or Digital PDF (reproduction)
📖 Manual Coverage
Systems Covered
Engine:
3.5L M30 inline-six, including L-Jetronic fuel injection, ignition system, cooling, lubrication, and exhaust
Transmission:
Manual (Getrag 265) and Automatic (ZF 4HP22) transmissions, including clutch, driveshafts, and differentials
Suspension:
Front MacPherson struts, rear semi-trailing arms, springs, shock absorbers, bushings, and wheel bearings
Brakes:
Front vented discs, rear solid discs (or drums on some specific variants), ABS system (Bosch ABS II), hydraulic lines, master cylinder, and parking brake
Battery, charging system (alternator), starter, lighting, wipers, horn, instrument cluster, dashboard, central locking, power windows, and fuse/relay box schematics
Rust (especially around wheel arches, rocker panels, jacking points), door seal deterioration.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
The Ultimate Driving Machine, focus on performance, engineering, and driver engagement.
Model Evolution
E28 Generation:
Second generation of the BMW 5 Series, produced from 1981 to 1988. Known for its sharper styling and improved dynamics over the E12.
535I Positioning:
Replaced the 528e and 533i, offering a more potent engine option in the 5 Series lineup.
M535I Positioning:
A homologation special and performance variant of the E28, bridging the gap to the M5. Featured sportier suspension, aero kits, and often more powerful engines (especially in European markets).
Production
Production Location:
Dingolfing, Germany
Production Years E28:
1981-1988
🏆 Awards & Recognition
Recognitions
E28 Reputation:
Widely regarded as a benchmark for sporty handling and build quality in the executive sedan class of its time.
Performance Reviews:
Contemporary automotive reviews often praised the M30 engine's smooth power delivery and the chassis's balance.
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