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BMW M6 633CS 635C Maintenance Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: M6 / 633CSi / 635CSi Chassis Code: E24 Body Style: Coupe Generation Generation Code: E24 Production Years Covered: 1976-1989 (Manual primarily covers later E24 M6, 633CSi, 635CSi variants) Codes Engine Codes Covered: M88/3, S38B35 (M6), M30B32 (633CSi), M30B34 (635CSi) 👋 Introduction Market Position Market Segment: Luxury Grand Tourer (GT), performance coupe Competitive Analysis Key Competitors Era: Porsche 928, Mercedes-Benz SEC coupes, Jaguar XJ-S Key Features Vehicle Highlights: Iconic 'shark nose' styling, powerful straight-six engines, sophisticated suspension, driver-focused interior, performance heritage Manual Value Proposition Manual Benefit: Essential resource for maintaining and repairing the complex systems of these classic BMWs, enabling owners to preserve their value and performance. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive workshop service and repair Page Count Estimated Page Count: Over 1500 pages (typical for comprehensive manuals of this era) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Compatibility Software Compatibility: Windows 95, 98, 2000, NT, XP, Vista, Windows 7 and later versions 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals (M88/3, S38B35, M30), cylinder head, valvetrain, lubrication, cooling, fuel injection (Bosch L-Jetronic/Motronic), ignition, exhaust Drivetrain Systems: Manual transmission (Getrag 265), automatic transmission (ZF 4HP22), clutch, driveshafts, differential Chassis Systems: Suspension (front strut, rear semi-trailing arm), steering, brakes (front discs, rear discs, ABS), wheels, tires Electrical Systems: Wiring diagrams, ignition system, charging system, starter motor, lighting, instrumentation, HVAC controls, power windows, central locking, airbag system Body Systems: Body construction, panels, doors, hood, trunk, glass, trim, bumpers Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, belt inspections Repair Procedures: Engine rebuilds, cylinder head removal/installation, valve adjustment, timing chain replacement, fuel injector service, radiator/cooling system repair, transmission overhaul, clutch replacement, brake caliper rebuild, suspension component replacement, electrical component diagnosis and repair Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, electrical fault tracing using wiring diagrams, engine performance checks Technical Depth Technical Depth: Extremely detailed, suitable for professional technicians and experienced DIY mechanics. Covers component disassembly, assembly, specifications, tolerances, and torque values. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality Recommendation: Printable on standard office printers. High-resolution scans for clear diagrams and text. Binding Type Binding Type For Print: Digital download (PDF) - no physical binding. Recommend printing and binding chapters as needed. Paper Type Paper Type For Print: Digital download (PDF) - no physical paper type. Searchability Text Searchability: Searchable text within the PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine M6 Engine Type: Naturally Aspirated Inline-6 (S38B35 for US M6, M88/3 for Euro M6) 635Csi Engine Type: Naturally Aspirated Inline-6 (M30B34) 633Csi Engine Type: Naturally Aspirated Inline-6 (M30B32) Performance M6 Horsepower Est: 256 hp (Euro M88/3) / 265 hp (US S38B35) M6 Torque Est: 243 lb-ft (Euro M88/3) / 243 lb-ft (US S38B35) 635Csi Horsepower Est: 218 hp (M30B34) 635Csi Torque Est: 224 lb-ft (M30B34) 633Csi Horsepower Est: 197 hp (M30B32) 633Csi Torque Est: 204 lb-ft (M30B32) Fuel System Fuel Injection System: Bosch L-Jetronic (early 633CSi), Bosch Motronic (later models including 635CSi, M6) Technical Details Bore Stroke M30: 84 mm x 90 mm (M30B34) Bore Stroke S38: 93.4 mm x 86 mm (S38B35) Compression Ratio M30B34: 9.3:1 Compression Ratio S38B35: 10.5:1 🔧 Transmission Standard Standard Transmission Type: 5-speed manual (Getrag 265) Optional Optional Transmission Type: 3-speed automatic (ZF 4HP22, later 4-speed automatic) Features Transmission Features: Close-ratio gearboxes (manual), torque converter lock-up (automatic) Fluid Specifications Manual Transmission Fluid: GL-4 gear oil (e.g., 75W-90 or 80W-90) Automatic Transmission Fluid: Dexron III / Mercon (ZF 4HP22) 📐 Dimensions Exterior Wheelbase Est: 2775 mm (109.3 in) Length Est: 4800 mm (189.0 in) Width Est: 1725 mm (67.9 in) Height Est: 1380 mm (54.3 in) Weights Curb Weight Est: 1600-1750 kg (3527-3858 lbs), varies by model and equipment Gross Vehicle Weight Rating Est: 2070 kg (4564 lbs) for 635CSi Wheels Tires Wheel Bolt Pattern: 5x120 mm Standard Tire Size 635Csi: 205/70VR14 or 220/55VR390 Standard Tire Size M6: 225/50VR16 (front), 245/45VR16 (rear) 🛡️ Safety Features Ratings Crash Test Data Availability: Limited official crash test data available for this era of vehicle, as testing standards were less rigorous. Active Features Active Safety Features: Optional Anti-lock Braking System (ABS), limited-slip differential (on some models) Passive Features Passive Safety Features: Reinforced chassis, collapsible steering column, front and rear crumple zones, optional airbags (late models) 💡 Technology Features Infotainment Infotainment Systems: Basic analog instrumentation, optional premium sound systems (e.g., Blaupunkt), cassette players. Driver Assistance Driver Assistance Features: Limited by modern standards; primarily focused on ABS (optional) and the handling dynamics of the chassis. Connectivity Connectivity Features: None by modern definition. Primarily mechanical and analog systems. 🔧 Maintenance Service Intervals Oil Change Interval Est: Every 7,500-10,000 miles or 12 months (depending on oil type and driving conditions) Spark Plug...
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BMW M6 633CS 635C Maintenance Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
M6 / 633CSi / 635CSi
Chassis Code:
E24
Body Style:
Coupe
Generation
Generation Code:
E24
Production Years Covered:
1976-1989 (Manual primarily covers later E24 M6, 633CSi, 635CSi variants)
Codes
Engine Codes Covered:
M88/3, S38B35 (M6), M30B32 (633CSi), M30B34 (635CSi)
👋 Introduction
Market Position
Market Segment:
Luxury Grand Tourer (GT), performance coupe
Competitive Analysis
Key Competitors Era:
Porsche 928, Mercedes-Benz SEC coupes, Jaguar XJ-S
Key Features
Vehicle Highlights:
Iconic 'shark nose' styling, powerful straight-six engines, sophisticated suspension, driver-focused interior, performance heritage
Manual Value Proposition
Manual Benefit:
Essential resource for maintaining and repairing the complex systems of these classic BMWs, enabling owners to preserve their value and performance.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive workshop service and repair
Page Count
Estimated Page Count:
Over 1500 pages (typical for comprehensive manuals of this era)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Compatibility
Software Compatibility:
Windows 95, 98, 2000, NT, XP, Vista, Windows 7 and later versions
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanicals (M88/3, S38B35, M30), cylinder head, valvetrain, lubrication, cooling, fuel injection (Bosch L-Jetronic/Motronic), ignition, exhaust
Drivetrain Systems:
Manual transmission (Getrag 265), automatic transmission (ZF 4HP22), clutch, driveshafts, differential
Chassis Systems:
Suspension (front strut, rear semi-trailing arm), steering, brakes (front discs, rear discs, ABS), wheels, tires
Electrical Systems:
Wiring diagrams, ignition system, charging system, starter motor, lighting, instrumentation, HVAC controls, power windows, central locking, airbag system
Body Systems:
Body construction, panels, doors, hood, trunk, glass, trim, bumpers
Procedures Included
Maintenance Procedures:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, belt inspections
Repair Procedures:
Engine rebuilds, cylinder head removal/installation, valve adjustment, timing chain replacement, fuel injector service, radiator/cooling system repair, transmission overhaul, clutch replacement, brake caliper rebuild, suspension component replacement, electrical component diagnosis and repair
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, electrical fault tracing using wiring diagrams, engine performance checks
Technical Depth
Technical Depth:
Extremely detailed, suitable for professional technicians and experienced DIY mechanics. Covers component disassembly, assembly, specifications, tolerances, and torque values.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality Recommendation:
Printable on standard office printers. High-resolution scans for clear diagrams and text.
Binding Type
Binding Type For Print:
Digital download (PDF) - no physical binding. Recommend printing and binding chapters as needed.
Paper Type
Paper Type For Print:
Digital download (PDF) - no physical paper type.
Searchability
Text Searchability:
Searchable text within the PDF for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
M6 Engine Type:
Naturally Aspirated Inline-6 (S38B35 for US M6, M88/3 for Euro M6)
635Csi Engine Type:
Naturally Aspirated Inline-6 (M30B34)
633Csi Engine Type:
Naturally Aspirated Inline-6 (M30B32)
Performance
M6 Horsepower Est:
256 hp (Euro M88/3) / 265 hp (US S38B35)
M6 Torque Est:
243 lb-ft (Euro M88/3) / 243 lb-ft (US S38B35)
635Csi Horsepower Est:
218 hp (M30B34)
635Csi Torque Est:
224 lb-ft (M30B34)
633Csi Horsepower Est:
197 hp (M30B32)
633Csi Torque Est:
204 lb-ft (M30B32)
Fuel System
Fuel Injection System:
Bosch L-Jetronic (early 633CSi), Bosch Motronic (later models including 635CSi, M6)
Technical Details
Bore Stroke M30:
84 mm x 90 mm (M30B34)
Bore Stroke S38:
93.4 mm x 86 mm (S38B35)
Compression Ratio M30B34:
9.3:1
Compression Ratio S38B35:
10.5:1
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual (Getrag 265)
Optional
Optional Transmission Type:
3-speed automatic (ZF 4HP22, later 4-speed automatic)
Features
Transmission Features:
Close-ratio gearboxes (manual), torque converter lock-up (automatic)
Fluid Specifications
Manual Transmission Fluid:
GL-4 gear oil (e.g., 75W-90 or 80W-90)
Automatic Transmission Fluid:
Dexron III / Mercon (ZF 4HP22)
📐 Dimensions
Exterior
Wheelbase Est:
2775 mm (109.3 in)
Length Est:
4800 mm (189.0 in)
Width Est:
1725 mm (67.9 in)
Height Est:
1380 mm (54.3 in)
Weights
Curb Weight Est:
1600-1750 kg (3527-3858 lbs), varies by model and equipment
Gross Vehicle Weight Rating Est:
2070 kg (4564 lbs) for 635CSi
Wheels Tires
Wheel Bolt Pattern:
5x120 mm
Standard Tire Size 635Csi:
205/70VR14 or 220/55VR390
Standard Tire Size M6:
225/50VR16 (front), 245/45VR16 (rear)
🛡️ Safety Features
Ratings
Crash Test Data Availability:
Limited official crash test data available for this era of vehicle, as testing standards were less rigorous.
Active Features
Active Safety Features:
Optional Anti-lock Braking System (ABS), limited-slip differential (on some models)
Passive Features
Passive Safety Features:
Reinforced chassis, collapsible steering column, front and rear crumple zones, optional airbags (late models)
💡 Technology Features
Infotainment
Infotainment Systems:
Basic analog instrumentation, optional premium sound systems (e.g., Blaupunkt), cassette players.
Driver Assistance
Driver Assistance Features:
Limited by modern standards; primarily focused on ABS (optional) and the handling dynamics of the chassis.
Connectivity
Connectivity Features:
None by modern definition. Primarily mechanical and analog systems.
🔧 Maintenance
Service Intervals
Oil Change Interval Est:
Every 7,500-10,000 miles or 12 months (depending on oil type and driving conditions)
Spark Plug Replacement Est:
Every 30,000-60,000 miles (depending on plug type - platinum recommended)
Timing Belt Chain Note:
These engines utilize a timing chain, which requires inspection for wear and tensioner issues, rather than a replacement interval like a belt.
Fluid Specifications
Engine Oil Spec:
API SG or higher, SAE 15W-40 or 10W-40 (check owner's manual for exact specs based on climate)
Coolant Spec:
BMW Blue Antifreeze/Coolant or equivalent ethylene glycol-based coolant
Brake Fluid Spec:
DOT 4
Known Issues
Common Engine Issues:
Head gasket leaks, oil pan leaks, valve cover gasket leaks, timing chain tensioner wear, fuel distributor issues (L-Jetronic), fuel pump failures, vacuum leaks
Common Transmission Issues:
Clutch wear, synchromesh wear (manual), torque converter shudder (automatic), automatic transmission cooler leaks
Common Chassis Issues:
Worn suspension bushings, worn ball joints, brake system component wear (rotors, pads, calipers), power steering leaks
Common Electrical Issues:
Corroded wiring connectors, failing relays, faulty fuel pump relays, instrument cluster issues, headlight switch failure
Parts Availability
Parts Availability Notes:
Some specialized parts may be scarce or expensive due to the age of the vehicles. The manual is crucial for identifying correct part numbers.
📚 Vehicle History
Brand Heritage
Brand History Context:
BMW's reputation for engineering excellence, sporty driving dynamics, and luxury vehicles.
Model Evolution
E24 Development:
E24 was the first generation of BMW's 6 Series, designed by Paul Bracq. It succeeded the E9 coupes. Known for its sleek, aerodynamic lines.
M6 Introduction:
The M635CSi (Euro) and M6 (US) variants were introduced to offer significantly enhanced performance, featuring the potent M88/M88/3 or S38 engines derived from motorsport.
Production
Production Period:
1976-1989
Manufacturing Location:
Dingolfing, Germany
🏆 Awards & Recognition
Recognitions
Automotive Press Acclaim:
The E24 chassis was highly regarded for its styling and driving experience, often praised by automotive journalists of its era as a premier grand tourer.
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