1991 BMW 535i Service and Repair Manual

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Factory-Grade Data

1991 BMW 535i service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Sedan 4-Door

Engines covered

  • 3.5L 3430CC l6 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 BMW 535i Recalls & Complaints

NHTSA #98V17800004/08/1998Component: ENGINE AND ENGINE COOLING:COOLING SYSTEM

VEHICLE DESCRIPTION: PASSENGER VEHICLES. A MALFUNCTION OR FAILURE OF A COOLANT SYSTEM COMPONENT, SUCH AS A THERMOSTAT, WATER PUMP, OR FAN BELT, CAN RESULT IN SIGNIFICANTLY INCREASED COOLANT TEMPERAT

Consequence

IF A CRACK WERE TO FORM OR A SEAM WERE TO SEPARATE IN THE HEATER CORE END PIECE, HOT COOLANT COULD S

Remedy

DEALERS WILL INSTALL A NEW DESIGN RADIATOR CAP TO CONTROL PRESSURE AND PROVIDE GREATER COOLANT OVERF

TSB #10249437

The basic conditions for initializing the power windows are not met.

TSB #50896

RECALL 96V110 - BMW OF NORTH AMERICA HAS INITIATED A RECALL CAMPAIGN WHICH INVOLVES THE AIRBAG CONTACT RING LOCKING TAB. *TW

TSB #50898

ANNOUNCEMENT THAT OWNERS OF VEHICLES INVOLVED IN RECALLS 96V110 AND 96V111 WILL BE COMBINED INTO ONE MAILING. *TW

20010322Component: ENGINE AND ENGINE COOLING:COOLING SYSTEM

CONSUMER HAD REPLACED MOST OF ENGINE COOLING SYSTEM PARTS. EACH TIME THAT TAKES VEHICLE TO DEALER THEY WILL REPLACE A PART, AND PRESENTLY, VEHICLE NEEDS TO BE FIXED AGAIN.*AK

20000516Component: ELECTRICAL SYSTEM:IGNITION:SWITCH

FAULTY IGNITION SWITCH CAUSED THE STARTER TO BURN UP, RESULTING IN THE VEHICLE LOOSING ALL POWER WHILE DRIVING ON THE HIGHWAY. NLM

20000426Component: ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

WHILE DRIVING ABOUT 55 MPH VEHICLE STALLED WITHOUT PRIOR WARNING. CONSUMER HAD TAKEN VEHICLE TO DEALER A FEW TIMES FOR THE SAME PROBLEM. BUT PROBLEM IS STILL THERE. *AK

20000115Component: POWER TRAIN:AUTOMATIC TRANSMISSION

NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK

19990817Component: AIR BAGS

AIRBAG WARNING LIGHT CAME ON BECAUSE OF A WIRE BURNING OUT. DEALER SAYS IT NEEDED TO BE REPLACED. SHORTLY AFTER WIRE WAS REPLACED, THE WARNING LIGHT CAME BACK ON. DEALER SAID IT WAS THE CONTACT RING

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