🏷️ Basic Information

Make:

BMW

Model:

5 Series (E34)

Product Name:

BMW 5 Series E34 1989-1995 Workshop Manual

Chassis Code:

E34

Production Years:

1989-1995

Covered Models:

525i (M20, M50, M50TU), 530i (M60), 535i (M30), 540i (M60)

👋 Introduction

Bmw E34 Era:

The E34 generation represented BMW's commitment to luxury, performance, and advanced engineering in the executive sedan segment during the late 1980s and 1990s.

Competitors:

Competed directly with luxury sedans from Mercedes-Benz (W124 E-Class), Audi (V8/A8), Jaguar (XJ), and Lexus (LS).

Engineering Philosophy:

Emphasized driver engagement, sophisticated suspension tuning, powerful inline-six and V8 engines, and a robust chassis.

Target Audience:

Discerning buyers prioritizing driving dynamics, build quality, and understated luxury.

📋 Manual Details

Engine Variants Covered:

M20 (2.0-2.5L I6), M50 (2.0-2.5L I6), M50TU VANOS (2.0-2.5L I6), M30 (3.0-3.4L I6), M60 (3.0L V8, 4.0L V8)

Transmission Variants Covered:

Automatic Transmission Unit, Automatic Transaxle, Manual Transmission

Chassis Systems Covered:

Brake, Cooling, Exhaust, Front Axle and Suspension, Lubrication, Rear Axle and Suspension, Steering, Body, Body Electrical

Electrical Systems Covered:

Electrical Wiring Diagrams, Charging, Ignition, Starting, Body Electrical

Specialty Systems Covered:

Air Conditioning, EFI (Electronic Fuel Injection), Emission Control, TurboCharger (if applicable to specific variants, though not explicitly listed as a primary engine feature)

Estimated Page Count:

High (typical comprehensive workshop manuals for this era and complexity often exceed 1000 pages)

Manual Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English

Format:

Digital (likely PDF, given industry trends; possibility of printed)

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for disassembly, inspection, repair, and reassembly of all covered engine types (M20, M50, M50TU, M30, M60), including valve train, crankshaft, pistons, connecting rods, oil pump, and cooling system components.

Fuel And Emission Control:

Comprehensive coverage of EFI systems (DME versions 1.3, 3.1, 3.3, 3.3.1), fuel injectors, fuel pump, fuel pressure regulator, and emission control systems including evaporative emission control (EVAP) and catalytic converter operation.

Ignition System:

Detailed diagnostics and repair procedures for ignition coils, spark plugs, crankshaft position sensors, camshaft position sensors, and ignition timing adjustments.

Transmission And Drivetrain:

Repair procedures for manual transmissions, automatic transmission units, and automatic transaxles, including gear selection, torque converter operation, hydraulic controls, and fluid service. Covers propeller shaft and driveshaft components.

Suspension And Steering:

Detailed repair and alignment procedures for front and rear suspension components (struts, shocks, control arms, bushings, ball joints, sway bars) and steering system components (power steering pump, steering rack, tie rods).

Braking System:

Procedures for brake pad and rotor replacement, caliper service, brake fluid flush and bleed, ABS system diagnostics and repair, and parking brake adjustments.

Electrical Body And Comfort:

Extensive coverage of body electrical systems, including lighting, power windows, central locking, instrument cluster, wipers, horn, and comfort systems like climate control (Air Conditioning).

Routine Maintenance:

Oil and filter changes, fluid checks and top-offs, spark plug replacement, air filter replacement, coolant flush and replacement, belt inspection and replacement.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common drivability issues, electrical faults, and mechanical failures, often including flowcharts and symptom-based troubleshooting.

Component Repair Overhaul:

Complete rebuild procedures for major components like engines, transmissions, differentials, and steering systems.

Collision Repair:

Specific guidance for body panel replacement, frame straightening, and structural integrity in the event of a collision.

Diagnostics Level:

Advanced: Includes diagnostic codes, testing procedures for sensors and actuators, and wiring diagrams for tracing electrical faults.

Repair Complexity:

Comprehensive: Covers everything from basic adjustments to complete engine and transmission overhauls.

Special Tools:

References Special Service Tools (SST) and Special Service Materials (SSM) required for specific repair operations, ensuring proper procedures are followed.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format) - commonly searchable and printable

Digital Resolution:

High-resolution scans or original digital source, ensuring clarity of text and diagrams.

Physical Format:

If printed: Likely perfect-bound or spiral-bound for ease of use on a workbench.

Physical Format:

If printed: Durable, semi-gloss paper to withstand workshop conditions and repeated handling.

Content Scope:

Comprehensive coverage, including not just mechanical and electrical repairs but also bodywork, collision repair, and specifications.

Troubleshooting Charts:

Includes detailed troubleshooting charts and diagrams to aid in diagnosing issues efficiently.

Torque Specifications:

Provides precise standard bolt torque specifications for critical engine, chassis, and drivetrain components.

⚙️ Engine Specifications

Engine Lineup Overview:

A diverse range of inline-six and V8 engines catering to different performance and refinement needs.

525I M20:

Approx. 170 hp (DIN), 220 Nm torque, 2.5L M20B25 inline-6.

525I M50:

Approx. 192 hp (DIN), 245 Nm torque, 2.5L M50B25 inline-6 (dual VANOS on M50TU).

530I M60:

Approx. 218 hp (DIN), 290 Nm torque, 3.0L M60B30 V8.

535I M30:

Approx. 211 hp (DIN), 305 Nm torque, 3.5L M30B35 inline-6.

540I M60:

Approx. 286 hp (DIN), 400 Nm torque, 4.0L M60B40 V8.

Efi System:

Bosch Motronic DME (Digital Motor Electronics) variants: DME 1.3, 3.1, 3.3, and 3.3.1. These are sophisticated multi-point injection systems.

🔧 Transmission

Transmission Options:

Primarily available with 5-speed manual transmissions (e.g., Getrag 260) or 4-speed automatic transmissions (e.g., ZF 4HP22).

Performance Transmission:

The 540i often featured a 5-speed automatic (e.g., ZF 5HP30) for enhanced performance and smoother shifts.

Automatic Features:

Automatic transmissions often included Sport/Economy modes and limp-home functions.

📐 Dimensions

Overall Length:

Approx. 4710-4790 mm (depending on model variant)

Overall Width:

Approx. 1750-1770 mm

Overall Height:

Approx. 1410-1420 mm

Wheelbase:

Approx. 2760-2830 mm (standard and long wheelbase variants)

Curb Weight:

Ranges from approx. 1500 kg for 525i to over 1750 kg for 540i

🛡️ Safety Features

Crash Test Performance:

Generally good for its era, with a strong safety cage and crumple zones. Specific NHTSA/Euro NCAP ratings may vary by year and region.

ABS:

Anti-lock Braking System (ABS) was standard on most models, with later models featuring more advanced DSC (Dynamic Stability Control) options.

Airbags:

Driver's airbag was standard from the early 1990s. Passenger airbags became optional or standard on later models.

Seatbelts:

Pyrotechnic seatbelt tensioners for front occupants.

💡 Technology Features

Audio System:

Premium sound systems available, often with cassette players and optional CD changers. Basic radio units were also common.

Cruise Control:

Standard cruise control on most models.

Parking Assistance:

Optional rear park distance control (PDC) became available on later models.

Telephone:

Optional integrated car phones were available in some markets.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000-15,000 km (6,000-10,000 miles) or annually, depending on driving conditions and oil type used.

Coolant Flush:

Recommended every 2-3 years or as per BMW specifications for the coolant type.

Spark Plug Replacement:

Varies by plug type; typically 50,000-100,000 km for high-quality platinum or iridium plugs.

Engine Oil:

Depends on engine and climate. Typically BMW Longlife-01 or Longlife-98 approved synthetic oils, viscosity grades like 5W-30, 5W-40, or 10W-40.

Coolant:

BMW Blue Antifreeze/Coolant (G48) or equivalent silicate-free ethylene glycol-based coolant. Mix ratio 50/50 with distilled water.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, typically SAE 75W-90 synthetic.

Transmission Fluid Automatic:

Dexron III or equivalent ATF fluid. Check specific transmission type for exact specification.

Brake Fluid:

DOT 4 Low Viscosity (LV) or DOT 4 Plus brake fluid.

Cooling System:

Plastic coolant expansion tanks can become brittle and crack. Water pumps and thermostats are also common wear items.

Head Gasket M60:

Early M60 V8 engines had issues with the head gasket sealant, leading to coolant leaks. Later revisions addressed this.

Oil Pan Gasket M60:

The oil pan gasket on the M60 V8 is also a known leak source and can be labor-intensive to replace.

Fuel Pump Relay:

The stock fuel pump relay is a common failure point, leading to no-start conditions.

Window Regulators:

Power window regulators can fail due to plastic wear or motor issues.

📚 Vehicle History

Bmw Performance Sedan:

The 5 Series has long been BMW's flagship executive sports sedan, building on a legacy of sporty yet comfortable vehicles.

E34 Introduction:

Introduced in 1987 (Europe) and 1988 (North America), the E34 was a significant design and engineering evolution from the E28 predecessor, featuring a sleeker aerodynamic profile and more advanced technology.

E34 Updates:

Received updates throughout its lifecycle, including the introduction of the VANOS system on M50 engines, V8 options (M60), and chassis refinements.

Manufacturing Locations:

Primarily produced at BMW's Dingolfing plant in Germany. CKD (Completely Knocked Down) kits were also assembled in various international locations.

🏆 Awards & Recognition

Car And Driver 10Best:

The E34 5 Series was a frequent recipient of Car and Driver's '10Best' list during its production years, recognized for its handling, performance, and value.

Consumer Reports Reliability:

While specific ratings varied, BMWs of this era were generally praised for build quality, though complex electronics could present challenges.