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Bmw M635CSI 1983-1989 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: M635CSi Model Code: E24 Production Years Covered: 1983-1989 Codes Engine Code: M88/3 (or S38B35 in later iterations) 👋 Introduction Market Position Classification: High-performance grand tourer coupe Era Context: Iconic model of the 1980s, representing BMW's engineering prowess in luxury performance Competitive Analysis Key Competitors: Porsche 911, Jaguar XJ-S, Ferrari 400i/412 Key Features Performance Orientation: M-tuned engine, advanced chassis dynamics, aerodynamic styling Luxury Appointments: Leather interior, advanced (for the era) features, comfortable ride for long distances 📋 Manual Details Coverage Areas Primary Coverage: Workshop Repair and Service Geographic Coverage: Global (primarily European and North American specifications) Page Count Estimated Page Count: 700-900 (typical for comprehensive workshop manuals of this era, actual may vary based on specific edition) Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: M88/3 (3.5L Inline-6), M30 (early 635CSi models before M6 designation) Fuel System: Bosch L-Jetronic fuel injection, fuel pump, injectors, pressure regulator, diagnosis Ignition System: Electronic ignition, coil, spark plugs, timing Transmission: Getrag 265 5-speed manual, ZF 4HP22 4-speed automatic (overhaul and service) Drivetrain: Rear-wheel drive, driveshaft, differential, axles Suspension: Front McPherson struts, rear semi-trailing arms, springs, dampers, bushings, alignment Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), hydraulic system, calipers, pads, rotors Steering: Power assisted steering system, steering rack, pump, fluid Electrical System: Wiring diagrams, battery, alternator, starter, fuses, relays, lighting, instrumentation, ECU diagnosis Bodywork: Exterior trim, bumpers, doors, hood, trunk, glass, chassis repair HVAC: Heating, ventilation, and air conditioning (if equipped) Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides Engine Repair: Top-end overhaul, bottom-end rebuild, component replacement (pistons, rings, bearings, valves) Transmission Repair: Clutch replacement (manual), torque converter service (automatic), internal component repair Brake System Repair: Brake pad/shoe replacement, rotor turning/replacement, caliper overhaul, brake line replacement, ABS bleeding Suspension And Steering Repair: Component replacement (shocks, struts, ball joints, tie rods), power steering pump and rack repair Electrical Troubleshooting: Use of wiring diagrams, testing components, diagnosing electrical faults Body And Interior Repair: Panel alignment, door mechanism repair, glass replacement Specifications And Data: Torque values, clearances, fluid capacities, electrical values Technical Depth Depth: Comprehensive (covers basic maintenance to complete engine and transmission overhauls) Diagnostics: Detailed diagnostic procedures for engine management, fuel, and ignition systems Rebuild Procedures: Step-by-step instructions for engine and transmission rebuilds 📊 Manual Specifications File Format File Type: PDF Searchable Text: Typically Yes (depending on the source scan quality) Printability: Printable (allows users to print specific sections or the entire manual) Print Quality Image Resolution: High-resolution scans for clarity of diagrams and text (variable based on original source) Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-6 Engine Displacement: 3453 cc (3.5 Liters) Engine Code M88: M88/3 Engine Code S38: S38B35 (later models, slight variations) Performance Horsepower: 286 PS (282 hp) at 6500 rpm (M88/3) Torque: 333 Nm (246 lb-ft) at 5000 rpm (M88/3) Redline: 7000 rpm Fuel System Fuel Injection Type: Bosch L-Jetronic Electronic Fuel Injection Fuel Type: Premium Unleaded Gasoline (91+ Octane) Compression Ratio: 10.5:1 🔧 Transmission Standard Standard Transmission: Getrag 265 5-speed Manual Transmission Optional Optional Transmission: ZF 4HP22 4-speed Automatic Transmission Features Manual Gear Ratios: 1st: 4.00, 2nd: 2.33, 3rd: 1.50, 4th: 1.17, 5th: 0.83 (Approximate, may vary by VIN) Automatic Features: Lock-up torque converter, Sport mode Final Drive Ratio: 3.25:1 (Standard, may vary with transmission and market) 📐 Dimensions Exterior Length: 4764 mm (187.6 in) Width: 1775 mm (69.9 in) Height: 1380 mm (54.3 in) Wheelbase: 2574 mm (101.3 in) Front Track: 1440 mm (56.7 in) Rear Track: 1470 mm (57.9 in) Weights Curb Weight: Approx. 1630-1700 kg (3594-3748 lbs) depending on transmission and options Gross Vehicle Weight Rating: Approx. 2080 kg (4586 lbs) 🛡️ Safety Features Ratings Safety Ratings Era: As per 1980s standards; detailed crash test data specific to modern standards is limited for this era. Active Features ABS: Anti-lock Braking System (ABS) - Standard on most M635CSi models Limited Slip Differential: Optional or standard depending on market and year (e.g., 25% LSD) Passive Features Seatbelts: Three-point inertia reel seatbelts (front), lap belts (rear) Body Construction: Reinforced safety cell, crumple zones Headrests: Front and rear headrests 💡 Technology Features Infotainment Audio System: Optional premium sound systems (e.g., Blaupunkt, Nakamichi) with cassette player Climate Control: Manual or optional automatic climate control Driver Assistance ABS System: Standard Anti-lock Braking System (ABS) Connectivity Connectivity Features: Limited by era; primarily analog systems. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, refer to manual for exact schedule Coolant Flush Interval: Every 2-3 years or as recommended Brake Fluid Flush Interval:...
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Bmw M635CSI 1983-1989 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
M635CSi
Model Code:
E24
Production Years Covered:
1983-1989
Codes
Engine Code:
M88/3 (or S38B35 in later iterations)
👋 Introduction
Market Position
Classification:
High-performance grand tourer coupe
Era Context:
Iconic model of the 1980s, representing BMW's engineering prowess in luxury performance
Competitive Analysis
Key Competitors:
Porsche 911, Jaguar XJ-S, Ferrari 400i/412
Key Features
Performance Orientation:
M-tuned engine, advanced chassis dynamics, aerodynamic styling
Luxury Appointments:
Leather interior, advanced (for the era) features, comfortable ride for long distances
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Repair and Service
Geographic Coverage:
Global (primarily European and North American specifications)
Page Count
Estimated Page Count:
700-900 (typical for comprehensive workshop manuals of this era, actual may vary based on specific edition)
Manual Type
Manual Type:
Workshop Service Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
M88/3 (3.5L Inline-6), M30 (early 635CSi models before M6 designation)
Fuel System:
Bosch L-Jetronic fuel injection, fuel pump, injectors, pressure regulator, diagnosis
Ignition System:
Electronic ignition, coil, spark plugs, timing
Transmission:
Getrag 265 5-speed manual, ZF 4HP22 4-speed automatic (overhaul and service)
Drivetrain:
Rear-wheel drive, driveshaft, differential, axles
Suspension:
Front McPherson struts, rear semi-trailing arms, springs, dampers, bushings, alignment
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), hydraulic system, calipers, pads, rotors
Steering:
Power assisted steering system, steering rack, pump, fluid
Electrical System:
Wiring diagrams, battery, alternator, starter, fuses, relays, lighting, instrumentation, ECU diagnosis
Bodywork:
Exterior trim, bumpers, doors, hood, trunk, glass, chassis repair
HVAC:
Heating, ventilation, and air conditioning (if equipped)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides
Engine Repair:
Top-end overhaul, bottom-end rebuild, component replacement (pistons, rings, bearings, valves)
Transmission Repair:
Clutch replacement (manual), torque converter service (automatic), internal component repair
Brake System Repair:
Brake pad/shoe replacement, rotor turning/replacement, caliper overhaul, brake line replacement, ABS bleeding
Suspension And Steering Repair:
Component replacement (shocks, struts, ball joints, tie rods), power steering pump and rack repair
Electrical Troubleshooting:
Use of wiring diagrams, testing components, diagnosing electrical faults
Body And Interior Repair:
Panel alignment, door mechanism repair, glass replacement
Specifications And Data:
Torque values, clearances, fluid capacities, electrical values
Technical Depth
Depth:
Comprehensive (covers basic maintenance to complete engine and transmission overhauls)
Diagnostics:
Detailed diagnostic procedures for engine management, fuel, and ignition systems
Rebuild Procedures:
Step-by-step instructions for engine and transmission rebuilds
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Typically Yes (depending on the source scan quality)
Printability:
Printable (allows users to print specific sections or the entire manual)
Print Quality
Image Resolution:
High-resolution scans for clarity of diagrams and text (variable based on original source)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline-6
Engine Displacement:
3453 cc (3.5 Liters)
Engine Code M88:
M88/3
Engine Code S38:
S38B35 (later models, slight variations)
Performance
Horsepower:
286 PS (282 hp) at 6500 rpm (M88/3)
Torque:
333 Nm (246 lb-ft) at 5000 rpm (M88/3)
Redline:
7000 rpm
Fuel System
Fuel Injection Type:
Bosch L-Jetronic Electronic Fuel Injection
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Compression Ratio:
10.5:1
🔧 Transmission
Standard
Standard Transmission:
Getrag 265 5-speed Manual Transmission
Optional
Optional Transmission:
ZF 4HP22 4-speed Automatic Transmission
Features
Manual Gear Ratios:
1st: 4.00, 2nd: 2.33, 3rd: 1.50, 4th: 1.17, 5th: 0.83 (Approximate, may vary by VIN)
Automatic Features:
Lock-up torque converter, Sport mode
Final Drive Ratio:
3.25:1 (Standard, may vary with transmission and market)
📐 Dimensions
Exterior
Length:
4764 mm (187.6 in)
Width:
1775 mm (69.9 in)
Height:
1380 mm (54.3 in)
Wheelbase:
2574 mm (101.3 in)
Front Track:
1440 mm (56.7 in)
Rear Track:
1470 mm (57.9 in)
Weights
Curb Weight:
Approx. 1630-1700 kg (3594-3748 lbs) depending on transmission and options
Gross Vehicle Weight Rating:
Approx. 2080 kg (4586 lbs)
🛡️ Safety Features
Ratings
Safety Ratings Era:
As per 1980s standards; detailed crash test data specific to modern standards is limited for this era.
Active Features
ABS:
Anti-lock Braking System (ABS) - Standard on most M635CSi models
Limited Slip Differential:
Optional or standard depending on market and year (e.g., 25% LSD)
Passive Features
Seatbelts:
Three-point inertia reel seatbelts (front), lap belts (rear)
Body Construction:
Reinforced safety cell, crumple zones
Headrests:
Front and rear headrests
💡 Technology Features
Infotainment
Audio System:
Optional premium sound systems (e.g., Blaupunkt, Nakamichi) with cassette player
Climate Control:
Manual or optional automatic climate control
Driver Assistance
ABS System:
Standard Anti-lock Braking System (ABS)
Connectivity
Connectivity Features:
Limited by era; primarily analog systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, refer to manual for exact schedule
Coolant Flush Interval:
Every 2-3 years or as recommended
Brake Fluid Flush Interval:
Every 2 years
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 20W-50 or 15W-50 recommended (refer to manual for specific viscosity based on temperature)
Engine Oil Capacity:
6.5 liters (6.9 US quarts) with filter
Coolant Type:
BMW Blue or Green ethylene glycol based coolant
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90
Transmission Fluid Automatic:
Dexron II or equivalent ATF
Differential Fluid:
API GL-5 gear oil, SAE 75W-90 or 80W-90 (check for Limited Slip Differential requirements)
Brake Fluid Type:
DOT 4
Known Issues
Engine M88 M30 Notes:
Head gasket sealing, valve stem seals, timing chain guides, oil pump drive
Electrical Common Problems:
Fraying wire looms (especially engine harness), aging fuel pump relays, dashboard illumination issues
Suspension Wear Items:
Bushings (control arm, sway bar), ball joints, tie rod ends
Rust Prone Areas:
Fender arches, rocker panels, around windshield and rear window seals
📚 Vehicle History
Brand Heritage
Bmw Motorsport Division:
Developed by BMW M GmbH, leveraging motorsport expertise for road-going performance
Model Evolution
Basis Model:
Based on the BMW 6 Series Coupe (E24 platform)
Evolution From 635Csi:
The M635CSi was a high-performance variant, often distinguished by its M-tuned engine and chassis upgrades
Production
Production Period:
1983-1989
Manufacturing Location:
Dingolfing, Germany
Production Volume:
Relatively limited compared to standard 6 Series, estimated around 4,500 units worldwide
🏆 Awards & Recognition
Recognitions
Period Acclaim:
Consistently praised by automotive journalists for its performance, handling, and distinctive styling.
Legacy Status:
Considered a modern classic and one of the most desirable BMW models of its time.
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