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BMW 535 535i M535i 1985-1988 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variants: 535i, M535i Production Years Covered: 1985, 1986, 1987, 1988 Codes Chassis Code: E28 Engine Codes Common: M30B34 👋 Introduction Market Position Segment: Executive Sedan Reputation: Known for performance, luxury, and build quality. Competitive Analysis Competitors: Mercedes-Benz W124, Audi V8, Jaguar XJ. Key Features Powertrain: Inline-six M30 engine, rear-wheel drive. Design: Iconic E28 chassis, refined luxury interior. Performance Variant: M535i offered enhanced performance and sportier tuning. 📋 Manual Details Coverage Areas Manual Type: Complete Service and Repair Manual Language: English Format: Downloadable PDF Page Count: Hundreds of Pages (exact count not specified, but described as 'complete') 📖 Manual Coverage Systems Covered Engine: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, engine management (ECU), emissions control. Transmission: Manual and automatic transmission repair, overhaul, and adjustments. Drivetrain: Driveshaft, differential, axle shafts, wheel bearings. Suspension: Front and rear suspension components, alignment, shock absorbers, springs, bushings. Steering: Steering gear, power steering system, steering column, tie rods. Brakes: Hydraulic system, ABS (if equipped), brake calipers, master cylinder, brake pads, rotors, lines. Electrical System: Wiring diagrams, battery, alternator, starter, lighting, fuses, relays, electronic control units (ECUs), sensors. Body And Interior: Body panel repair, doors, windows, locks, interior trim, seats, HVAC system. Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications. Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel filter. Lubrication System: Oil pump, oil pan, oil filter, oil specifications. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes. Procedures Included Maintenance: Routine maintenance, scheduled service intervals, oil changes, fluid checks, filter replacements. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides, common problem identification. Repair: Step-by-step repair instructions for all major mechanical and electrical components. Overhaul: Engine and transmission overhaul procedures, rebuilding guides. Diagnostics: Component testing, diagnostic trouble codes (DTCs), electrical system diagnostics. Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and transmission rebuilds. User Level: Suitable for professional mechanics and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable due to PDF format. Print Quality Printable: Yes, designed for full or partial printing. Binding Type Digital: Not applicable (downloadable PDF). Paper Type Digital: Not applicable (digital document). ⚙️ Engine Specifications Primary Engine Engine Code: M30B34 Engine Type: 3.4L (3430 cc) Inline-6, SOHC, 12 Valves Bore X Stroke: 92 mm x 86 mm Compression Ratio: 8.0:1 or 9.0:1 (depending on market/variant) Performance Horsepower 535I: 182 hp @ 5500 rpm (approx.) Torque 535I: 220 lb-ft @ 3200 rpm (approx.) Horsepower M535I: 218 hp @ 5500 rpm (approx.) Torque M535I: 232 lb-ft @ 3200 rpm (approx.) Fuel System Fuel Delivery: Bosch L-Jetronic or Motronic fuel injection Fuel Type: Unleaded gasoline, premium octane recommended. Engine Management ECU: BMW Motronic 🔧 Transmission Standard Transmission Type 535I: Getrag 260 5-speed manual Optional Transmission Type Optional: ZF 4HP22 4-speed automatic Features Clutch: Hydraulically operated single dry plate clutch. Rear Axle Ratio: Typically 3.25:1 or 3.46:1, depending on transmission and market. 📐 Dimensions Exterior Length: Approx. 188.6 inches (4790 mm) Width: Approx. 69.3 inches (1760 mm) Height: Approx. 55.7 inches (1415 mm) Wheelbase: Approx. 104.3 inches (2650 mm) Weights Curb Weight: Approx. 3400-3600 lbs (1542-1633 kg) Gvw: Not specified, but typically around 4500 lbs. 🛡️ Safety Features Ratings Crash Test Data: No specific NHTSA/IIHS ratings available for this model year as standardized testing was less common. Active Features ABS: Optional on most models, standard on later M535i variants. Passive Features Seatbelts: 3-point inertia reel seatbelts with pre-tensioners available. Airbags: Not available on this model generation. Crumple Zones: Designed with front and rear crumple zones for energy absorption. 💡 Technology Features Infotainment Audio System: Factory premium sound system, cassette player common. Driver Assistance Cruise Control: Standard on most models. Climate Control: Manual or automatic climate control available. Connectivity Bluetooth Usb: Not available from factory; aftermarket solutions required. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or annually, depending on driving conditions. Spark Plug Replacement: Refer to manual, typically around 30,000 miles for M30 engines. Timing Belt Replacement: Not applicable, M30 engine uses a timing chain. Fluid Specifications Engine Oil: SAE 15W-40 or 20W-50 API SG, or BMW High Performance engine oil (check manual for exact grade). Coolant: Ethylene glycol based antifreeze, 50/50 mix with distilled water. BMW Coolant. Brake Fluid: DOT 3 or DOT 4 brake fluid. Transmission Fluid Manual: API GL-4 or GL-5 gear oil (e.g., SAE 75W-90 or 80W-90). Transmission Fluid Automatic: Dexron II or equivalent automatic transmission fluid. Power Steering Fluid: BMW Power Steering Fluid or Dexron II/III ATF. Known Issues Common Problems: Oil leaks (valve cover gasket, oil pan gasket), cooling system leaks (hoses, water pump, radiator), seized alternator pulleys, aging wiring harnesses, fuel distributor issues (L-Jetronic), differential seal leaks, front control arm bushings wear. Common Issues M30...
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BMW 535 535i M535i 1985-1988 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Variants:
535i, M535i
Production Years Covered:
1985, 1986, 1987, 1988
Codes
Chassis Code:
E28
Engine Codes Common:
M30B34
👋 Introduction
Market Position
Segment:
Executive Sedan
Reputation:
Known for performance, luxury, and build quality.
Competitive Analysis
Competitors:
Mercedes-Benz W124, Audi V8, Jaguar XJ.
Key Features
Powertrain:
Inline-six M30 engine, rear-wheel drive.
Design:
Iconic E28 chassis, refined luxury interior.
Performance Variant:
M535i offered enhanced performance and sportier tuning.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Service and Repair Manual
Language:
English
Format:
Downloadable PDF
Page Count:
Hundreds of Pages (exact count not specified, but described as 'complete')
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, engine management (ECU), emissions control.
Transmission:
Manual and automatic transmission repair, overhaul, and adjustments.
Drivetrain:
Driveshaft, differential, axle shafts, wheel bearings.
Suspension:
Front and rear suspension components, alignment, shock absorbers, springs, bushings.
Steering:
Steering gear, power steering system, steering column, tie rods.
Brakes:
Hydraulic system, ABS (if equipped), brake calipers, master cylinder, brake pads, rotors, lines.
Electrical System:
Wiring diagrams, battery, alternator, starter, lighting, fuses, relays, electronic control units (ECUs), sensors.
Body And Interior:
Body panel repair, doors, windows, locks, interior trim, seats, HVAC system.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant specifications.
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel filter.
Lubrication System:
Oil pump, oil pan, oil filter, oil specifications.
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes.
Procedures Included
Maintenance:
Routine maintenance, scheduled service intervals, oil changes, fluid checks, filter replacements.
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, common problem identification.
Repair:
Step-by-step repair instructions for all major mechanical and electrical components.
Overhaul:
Engine and transmission overhaul procedures, rebuilding guides.
Diagnostics:
Component testing, diagnostic trouble codes (DTCs), electrical system diagnostics.
Wiring Diagrams:
Detailed electrical wiring schematics for all vehicle systems.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds.
User Level:
Suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable due to PDF format.
Print Quality
Printable:
Yes, designed for full or partial printing.
Binding Type
Digital:
Not applicable (downloadable PDF).
Paper Type
Digital:
Not applicable (digital document).
⚙️ Engine Specifications
Primary Engine
Engine Code:
M30B34
Engine Type:
3.4L (3430 cc) Inline-6, SOHC, 12 Valves
Bore X Stroke:
92 mm x 86 mm
Compression Ratio:
8.0:1 or 9.0:1 (depending on market/variant)
Performance
Horsepower 535I:
182 hp @ 5500 rpm (approx.)
Torque 535I:
220 lb-ft @ 3200 rpm (approx.)
Horsepower M535I:
218 hp @ 5500 rpm (approx.)
Torque M535I:
232 lb-ft @ 3200 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch L-Jetronic or Motronic fuel injection
Fuel Type:
Unleaded gasoline, premium octane recommended.
Engine Management
ECU:
BMW Motronic
🔧 Transmission
Standard
Transmission Type 535I:
Getrag 260 5-speed manual
Optional
Transmission Type Optional:
ZF 4HP22 4-speed automatic
Features
Clutch:
Hydraulically operated single dry plate clutch.
Rear Axle Ratio:
Typically 3.25:1 or 3.46:1, depending on transmission and market.
📐 Dimensions
Exterior
Length:
Approx. 188.6 inches (4790 mm)
Width:
Approx. 69.3 inches (1760 mm)
Height:
Approx. 55.7 inches (1415 mm)
Wheelbase:
Approx. 104.3 inches (2650 mm)
Weights
Curb Weight:
Approx. 3400-3600 lbs (1542-1633 kg)
Gvw:
Not specified, but typically around 4500 lbs.
🛡️ Safety Features
Ratings
Crash Test Data:
No specific NHTSA/IIHS ratings available for this model year as standardized testing was less common.
Active Features
ABS:
Optional on most models, standard on later M535i variants.
Passive Features
Seatbelts:
3-point inertia reel seatbelts with pre-tensioners available.
Airbags:
Not available on this model generation.
Crumple Zones:
Designed with front and rear crumple zones for energy absorption.
💡 Technology Features
Infotainment
Audio System:
Factory premium sound system, cassette player common.
Driver Assistance
Cruise Control:
Standard on most models.
Climate Control:
Manual or automatic climate control available.
Connectivity
Bluetooth Usb:
Not available from factory; aftermarket solutions required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or annually, depending on driving conditions.
Spark Plug Replacement:
Refer to manual, typically around 30,000 miles for M30 engines.
Timing Belt Replacement:
Not applicable, M30 engine uses a timing chain.
Fluid Specifications
Engine Oil:
SAE 15W-40 or 20W-50 API SG, or BMW High Performance engine oil (check manual for exact grade).
Coolant:
Ethylene glycol based antifreeze, 50/50 mix with distilled water. BMW Coolant.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil (e.g., SAE 75W-90 or 80W-90).
Transmission Fluid Automatic:
Dexron II or equivalent automatic transmission fluid.
Power Steering Fluid:
BMW Power Steering Fluid or Dexron II/III ATF.
Known Issues
Common Problems:
Oil leaks (valve cover gasket, oil pan gasket), cooling system leaks (hoses, water pump, radiator), seized alternator pulleys, aging wiring harnesses, fuel distributor issues (L-Jetronic), differential seal leaks, front control arm bushings wear.
Common Issues
M30 Engine Notes:
M30 engine is robust but requires diligent maintenance; timing chain tensioner can fail if not serviced.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW), a German automaker renowned for luxury vehicles and performance.
Model Evolution
Predecessor:
BMW E12 5 Series.
Successor:
BMW E34 5 Series.
Production
Production Period:
1981-1988
Manufacturing Locations:
Germany (primarily Dingolfing), South Africa, Mexico, Thailand.
M535I Specifics
M535I Introduction:
Introduced in 1984, it was the first M-Sport version of the E28.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive journalists for its handling, comfort, and performance, often considered a benchmark for the era.
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