BMW 535 535i 1985-1988 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 535i Chassis Code: E28 Model Years: 1985, 1986, 1987, 1988 Codes Engine Code Primary: M30B34 👋 Introduction Market Position Segment: Luxury Mid-Size Sedan Target Audience: Performance-oriented luxury car buyers, enthusiasts, and professional mechanics. Competitive Analysis Key Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6. Key Features Performance Focus: Renowned for its potent inline-six engine and balanced chassis, offering a blend of luxury and sporty driving dynamics. Build Quality: Typical BMW build quality for the era, known for durability and driver engagement. 📋 Manual Details Coverage Areas Languages: English Manual Type: Workshop Service Repair Manual Coverage Scope: Complete Factory Service Information Page Count Estimated Pages: Hundreds (Specific count not provided, but described as comprehensive) Format Digital Format: Downloadable (likely PDF) Manual Type Manual Classification: Factory Service Manual (FSM) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, block assembly, crankshaft, pistons, connecting rods, valve train, timing, lubrication, cooling system. Engine Management: Fuel injection (Bosch L-Jetronic), ignition system, ECU diagnosis and troubleshooting, sensor operation. Transmission: Manual transmission (Getrag 265) and Automatic transmission (ZF 4HP22) removal, disassembly, inspection, repair, and installation. Clutch system. Drivetrain: Driveshaft, constant velocity joints, differential, rear axle assembly. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, bushings. Steering: Power steering system, steering rack, tie rods, steering column. Brakes: Front and rear disc brakes, brake calipers, rotors, pads, master cylinder, brake lines, ABS system (if equipped). Electrical System: Battery, alternator, starter motor, lighting system, power windows, mirrors, central locking, instrument cluster, wiring diagrams. HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, operation, and troubleshooting. Bodywork: Body panel removal/installation, doors, hood, trunk lid, bumpers, glass, seals, corrosion protection. Interior: Seats, dashboard, door panels, headliner, carpeting, trim components. Procedures Included Maintenance: Routine service, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement. Troubleshooting: Diagnostic procedures for common problems, fault codes, electrical system diagnostics. Repair: Detailed step-by-step repair instructions for all major components and systems. Overhaul: Engine and transmission overhaul procedures, including component specifications and clearances. Rebuild: Component rebuild instructions for specific parts like carburetors (if applicable, though likely FI), fuel pumps, alternators. Alignment: Wheel alignment specifications and procedures. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems. Technical Depth Diagnostic Capabilities: Advanced diagnostics for engine management, fuel injection, and ignition systems. Specification Detail: Torque specifications, clearances, fluid capacities, electrical resistance values, pressure readings. Special Tools: Identification and usage of BMW-specific special tools required for certain procedures. 📊 Manual Specifications File Format File Type: PDF (assumed for downloadable workshop manuals) Print Quality Printability: Printable in its entirety, suggesting high-resolution for clear reproduction. Binding Type Digital Binding: N/A (Digital download, user binds if printing) Paper Type Digital Paper Type: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline 6-Cylinder Engine Code: M30B34 Displacement: 3.4 Liters (3,430 cc) Performance Horsepower: Approx. 182-218 hp (depending on specific market and configuration) Torque: Approx. 220-240 lb-ft (depending on specific market and configuration) Fuel System Fuel Delivery: Bosch Motronic L-Jetronic Fuel Injection Fuel Type: Premium Unleaded Gasoline Cooling System Coolant Type: BMW Blue or equivalent ethylene glycol-based antifreeze Lubrication Oil Type: API SG or higher, SAE 15W-40 or 20W-50 (check manual for specific ambient temperature recommendations) 🔧 Transmission Standard Transmission Type Standard: Getrag 265 5-Speed Manual Transmission Optional Transmission Type Optional: ZF 4HP22 4-Speed Automatic Transmission Features Manual Transmission Features: Dogleg first gear pattern in some European versions, durable construction. Automatic Transmission Features: Smooth shifting, sport mode selection. Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil Automatic Transmission Fluid: Dexron II or equivalent ATF 📐 Dimensions Exterior Length: Approx. 191.9 inches (4874 mm) Width: Approx. 69.5 inches (1765 mm) Height: Approx. 55.5 inches (1410 mm) Wheelbase: Approx. 104.4 inches (2650 mm) Weights Curb Weight: Approx. 3,350 - 3,550 lbs (1520 - 1610 kg) Gross Vehicle Weight Rating: Refer to vehicle data plate Wheels Tires Wheel Bolt Pattern: 5 x 120 mm Tire Size Standard: 205/60VR15 or 225/55VR15 (depending on wheel size and options) 🛡️ Safety Features Ratings NHTSA Ratings: Not directly comparable to modern standards; vehicles of this era generally had less stringent testing. Focus on passive safety features of the design. Active Features ABS: Anti-lock Braking System (Optional on some models, standard on later ones) Passive Features Body Structure: Reinforced safety cage, crumple zones. Restraints: 3-point seatbelts (front and rear), driver's side airbag (optional/later models). Lighting: Halogen headlights, fog lights (optional). 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, often with amplifier and upgraded speaker options. Analog tuning and controls. Driver Assistance Cruise Control: Standard on most 535i models. Connectivity Early Automation: Power windows, power mirrors, central locking, optional heated seats, optional sunroof. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500...
Identification and usage of BMW-specific special tools required for certain procedures.
📊 Manual Specifications
File Format
File Type:
PDF (assumed for downloadable workshop manuals)
Print Quality
Printability:
Printable in its entirety, suggesting high-resolution for clear reproduction.
Binding Type
Digital Binding:
N/A (Digital download, user binds if printing)
Paper Type
Digital Paper Type:
N/A (Digital download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Engine Code:
M30B34
Displacement:
3.4 Liters (3,430 cc)
Performance
Horsepower:
Approx. 182-218 hp (depending on specific market and configuration)
Torque:
Approx. 220-240 lb-ft (depending on specific market and configuration)
Fuel System
Fuel Delivery:
Bosch Motronic L-Jetronic Fuel Injection
Fuel Type:
Premium Unleaded Gasoline
Cooling System
Coolant Type:
BMW Blue or equivalent ethylene glycol-based antifreeze
Lubrication
Oil Type:
API SG or higher, SAE 15W-40 or 20W-50 (check manual for specific ambient temperature recommendations)
🔧 Transmission
Standard
Transmission Type Standard:
Getrag 265 5-Speed Manual Transmission
Optional
Transmission Type Optional:
ZF 4HP22 4-Speed Automatic Transmission
Features
Manual Transmission Features:
Dogleg first gear pattern in some European versions, durable construction.
Automatic Transmission Features:
Smooth shifting, sport mode selection.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil
Automatic Transmission Fluid:
Dexron II or equivalent ATF
📐 Dimensions
Exterior
Length:
Approx. 191.9 inches (4874 mm)
Width:
Approx. 69.5 inches (1765 mm)
Height:
Approx. 55.5 inches (1410 mm)
Wheelbase:
Approx. 104.4 inches (2650 mm)
Weights
Curb Weight:
Approx. 3,350 - 3,550 lbs (1520 - 1610 kg)
Gross Vehicle Weight Rating:
Refer to vehicle data plate
Wheels Tires
Wheel Bolt Pattern:
5 x 120 mm
Tire Size Standard:
205/60VR15 or 225/55VR15 (depending on wheel size and options)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not directly comparable to modern standards; vehicles of this era generally had less stringent testing. Focus on passive safety features of the design.
Active Features
ABS:
Anti-lock Braking System (Optional on some models, standard on later ones)
Passive Features
Body Structure:
Reinforced safety cage, crumple zones.
Restraints:
3-point seatbelts (front and rear), driver's side airbag (optional/later models).
Lighting:
Halogen headlights, fog lights (optional).
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, often with amplifier and upgraded speaker options. Analog tuning and controls.
Driver Assistance
Cruise Control:
Standard on most 535i models.
Connectivity
Early Automation:
Power windows, power mirrors, central locking, optional heated seats, optional sunroof.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles or 6-12 months, whichever comes first (refer to manual for specific conditions).
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed (likely every 30,000 miles).
Spark Plug Replacement:
Refer to manual; typically around 30,000-60,000 miles depending on plug type.
Timing Belt Replacement:
N/A (M30 engine uses a timing chain)
Fluid Specifications
Coolant Capacity:
Approx. 9.5 Liters (refer to manual)
Engine Oil Capacity:
Approx. 6.5 Liters (6.9 US quarts) with filter (refer to manual)
Known Issues
Engine M30 Common:
Head gasket leaks (especially around rear coolant seal), oil leaks from front and rear main seals, valve cover gasket leaks, cooling system component failures (radiator, hoses, water pump).
Prone to rust in wheel wells, rocker panels, and around window seals, especially in areas with harsh winters.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's long-standing reputation for 'The Ultimate Driving Machine', emphasizing performance, engineering, and driver engagement.
Model Evolution
E28 Introduction:
The E28 generation succeeded the E12 and was produced from 1981 to 1988. It represented an evolution in BMW's mid-size luxury sedan offering, with improved aerodynamics, comfort, and technology.
535I Positioning:
The 535i was positioned as the top-tier model in the E28 lineup, offering a powerful six-cylinder engine and enhanced luxury features.
Production
Production Years:
1981-1988 (E28 generation)
Manufacturing Locations:
Germany (primarily Dingolfing)
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The E28 generation, including the 535i, was a frequent recipient of Car and Driver's '10Best' list for its exceptional driving dynamics and engineering.
Ratings
Contemporary Reviews:
Consistently praised by automotive journalists for its blend of performance, luxury, and handling.