Segment:
Luxury Executive Sedan
Competitors:
Mercedes-Benz W124 E-Class, Audi V8, Lexus LS400 (later models)
Powertrain:
Smooth and powerful M60B40 4.0L V8 engine
Handling:
Renowned BMW 'Ultimate Driving Machine' handling characteristics for its class
Build Quality:
High levels of fit and finish, typical of BMW's German engineering
Technology:
Introduction of advanced technologies for the era, including early driver aids and sophisticated electronics
Primary Coverage:
Complete factory service and repair
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, wiring diagrams, specifications
Estimated Page Count:
800+
Type:
Factory Service Manual (FSM)
Engine:
M60B40 V8 engine (4.0L)
Transmission:
Manual (Getrag 260/5, 260/6) and Automatic (ZF 4HP22 EH) transmissions
Drivetrain:
Rear-wheel drive (RWD) system, differential, axles
Suspension:
Front MacPherson struts, rear multi-link suspension, shock absorbers, springs, bushings
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake hydraulics
Steering:
Power-assisted steering system, steering rack, pump
Electrical:
Complete wiring diagrams, ECU functions, starter, alternator, battery, lighting, ignition, fuel injection
Climate Control:
HVAC system, A/C, heater core, blower motor, controls
Body And Chassis:
Body panels, doors, windows, interior trim, chassis components
Maintenance:
Oil changes, filter replacements, fluid checks, belt adjustments, tune-ups
Troubleshooting:
Diagnostic procedures for common and complex issues, symptom-based troubleshooting charts
Repair:
Step-by-step repair instructions for all major mechanical and electrical components
Disassembly Reassembly:
Detailed instructions for component removal and installation
Diagnostics:
OBD-I (On-Board Diagnostics) system explanation and diagnostic codes
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Detail Level:
Includes torque specifications, clearances, timing procedures, and electrical schematics
Type:
5-speed manual transmission (Getrag 260/5)
Type:
4-speed automatic transmission (ZF 4HP22 EH)
Automatic Control:
Electronic control with multiple shift modes (e.g., Sport/Economy)
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent (API GL-4, SAE 75W-90)
Automatic Transmission Fluid:
Dexron III or equivalent
Length:
4,735 mm (186.4 in)
Width:
1,751 mm (68.9 in)
Height:
1,412 mm (55.6 in)
Wheelbase:
2,797 mm (110.1 in)
Curb Weight:
1,630 kg (3,594 lbs) approx.
Gross Vehicle Weight Rating:
2,100 kg (4,630 lbs) approx.
Crash Test Data:
NHTSA (US) and Euro NCAP (Europe) data for the E34 generation, generally considered robust for its time.
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional ASC+T (Automatic Stability Control and Traction) system available on some models.
Airbags:
Driver's side airbag standard for 1989 models in most markets; optional passenger airbag.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
Body Structure:
Reinforced passenger cell and crumple zones.
Audio System:
Premium Hi-Fi sound systems available, often with cassette tape players.
Navigation:
Early in-car navigation systems were optional on later E34 models, not typically on the 1989 model year.
Cruise Control:
Standard electronic cruise control.
Diagnostics:
OBD-I system accessible via a connector under the hood, requiring specific diagnostic tools or procedures.
Oil Change:
Every 5,000-7,500 miles or annually, depending on driving conditions (refer to manual for specific recommendations).
Spark Plugs:
Typically every 30,000 miles for platinum plugs, refer to manual for exact type and interval.
Coolant Flush:
Every 2 years or 30,000 miles.
Engine Oil:
BMW Longlife-98 (LL-98) or equivalent 5W-30 or 10W-40 synthetic oil. Check dipstick for capacity (approx. 7.5 liters).
Coolant:
BMW Blue Ethylene Glycol Coolant or equivalent (50/50 mix with distilled water).
Cooling System:
Plastic coolant expansion tank can become brittle and crack; plastic thermostat housing is also prone to cracking.
Oil Pan Gasket:
Leaking oil pan gaskets are common on the M60 V8.
Head Gaskets:
While generally robust, head gasket issues can occur, especially if the cooling system is neglected.
ABS Module:
ABS hydraulic unit failure is a known issue on E34 models equipped with ABS.
Window Regulators:
Power window regulators can be a source of failure.
Heater Core:
Heater core leaks can occur, often manifesting as a sweet smell inside the cabin or fogged windows.
Brand Focus:
BMW is synonymous with performance, luxury, and advanced engineering.
E34 Introduction:
The E34 generation, launched in 1987 (as a 1988 model in Europe, 1989 in North America), replaced the successful E28. It was a significant step forward in design, technology, and refinement.
E34 Positioning:
The 540i was introduced later in the E34 lifecycle (for model year 1994 in the US) with the M60 V8 engine, slotting above the 535i and offering a more potent and luxurious alternative.
1989 Model Year Updates:
For 1989, the E34 line was primarily comprised of the 525i and 535i. The 540i was not available in 1989. This manual *likely* covers early E34 chassis commonalities but the specific 540i (M60 engine) details would pertain to later model years (1994-1995 in the US).
Manufacturing Location:
Dingolfing, Germany
