🏷️ Basic Information

Make:

BMW

Model:

525i

Chassis Code:

E34

Model Years:

1988-1991

Engine Code Range:

M20B25

👋 Introduction

Positioning:

Professional-grade DIY and shop reference for owners of the E34 generation 525i.

Comparison:

Offers superior detail and practical guidance compared to generic automotive repair guides, mirroring official BMW factory documentation.

Features:

Direct, actionable repair instructions, detailed schematics, and comprehensive troubleshooting sections for the DIY enthusiast and professional mechanic.

📋 Manual Details

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete overhaul, component testing, fuel injection, ignition system, lubrication, cooling system

Transmission:

Manual and automatic transmission repair, clutch service, driveshaft and differential overhaul

Brakes:

Hydraulic system, ABS diagnostics and repair, disc and drum brake service, parking brake

Electrical:

Wiring diagrams, component testing, starter, alternator, battery, lighting, instrument cluster, power accessories

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, alignment specifications

Steering:

Power steering system, steering column, tie rod ends, steering box/rack repair

Bodywork:

Body panel repair, rust prevention, door and window mechanisms, interior trim removal and installation

Climate Control:

HVAC system diagnosis and repair, refrigerant handling, blower motor, A/C compressor

Fuel System:

Fuel pump, fuel injectors, fuel lines, fuel tank service

Maintenance:

Oil change, filter replacements, spark plug service, coolant flush, brake fluid replacement, belt inspection/replacement

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting guides, common fault diagnosis

Repair:

Step-by-step repair instructions for all major components and systems

Diagnostics:

OBD-I (On-Board Diagnostics) code reading and interpretation, electrical testing procedures

Rebuilds:

Engine and transmission rebuild procedures with detailed torque specifications and clearances

Depth:

Comprehensive, covering basic maintenance to full mechanical and electrical overhauls

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text enabled

Printability:

Printable pages

Quality:

High resolution, factory-quality scans

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Inline 6-cylinder, SOHC

Engine Code:

M20B25

Displacement:

2.5 Liters (2494 cc)

Horsepower:

168 hp @ 5800 rpm (approx.)

Torque:

167 lb-ft @ 4300 rpm (approx.)

Induction:

Bosch Motronic fuel injection

Fuel Type:

Unleaded gasoline

Oil Capacity:

5.7 US quarts (5.4 Liters) with filter change

Coolant Capacity:

7.9 US quarts (7.5 Liters)

Spark Plugs:

NGK BKR6EK (or equivalent)

Valve Lash Adjustment Interval:

Recommended every 30,000 miles (may require feeler gauges and socket set)

🔧 Transmission

Type:

Getrag 260 5-speed manual transmission

Type:

ZF 4HP22 4-speed automatic transmission

Manual Fluid Type:

BMW MTF LT-2 (or equivalent, e.g., Red Line MTL)

Automatic Fluid Type:

BMW ATF LT 71141 (or equivalent, e.g., Pentosin ATF 1)

Clutch Kit Part Number Example:

SACHS 3000 164 201

📐 Dimensions

Length:

4719 mm (185.8 in)

Width:

1751 mm (68.9 in)

Height:

1410 mm (55.5 in)

Curb Weight:

1510 kg (3329 lbs) (approx. manual transmission)

Gross Vehicle Weight Rating:

2030 kg (4475 lbs) (approx.)

🛡️ Safety Features

Crash Test Results:

E34 models generally performed well in contemporary crash tests, though official ratings from modern standards are not directly applicable.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional ASC+T (Automatic Stability Control + Traction)

Airbags:

Driver's side airbag standard from ~1989/1990 models onwards. Passenger airbag optional.

Seatbelts:

3-point inertia-reel seatbelts front and rear

💡 Technology Features

Radio:

Standard AM/FM cassette player, optional CD player. Often features premium sound systems like HiFi or HiFi Professional.

Climate Control:

Manual or optional automatic climate control (ATC) with digital readouts.

Cruise Control:

Standard cruise control system.

Telematics:

Early models may have provisions for dealer-installed car phones. No integrated Bluetooth or smartphone connectivity.

🔧 Maintenance

Oil Change Interval:

BMW Service Indicator System (Conditional, typically 7,500-10,000 miles or annually)

Coolant Flush Interval:

Every 2-3 years or 30,000 miles

Brake Fluid Flush Interval:

Every 2 years

Engine Oil Spec:

BMW Longlife-98 (LL-98) or API SG/SH, ACEA A2/A3, SAE 5W-30 or 10W-40 depending on climate.

Power Steering Fluid:

Pentosin CHF 11S or BMW P/N 8329 0429 576

Brake Fluid Spec:

DOT 4

Common Problems:

Coolant hose failures (especially water pump outlet), heater core leaks, Vanos issues (later models, not on early M20), front control arm bushings, sagging headliner, window regulator failures, oil pan gasket leaks, vacuum hose deterioration.

📚 Vehicle History

Heritage:

BMW's reputation for engineering excellence, driver focus, and luxury sedans.

Generation:

Fifth generation of the BMW 5 Series. The E34 replaced the E28 and was succeeded by the E39.

Design Era:

Marked a transition to more aerodynamic and integrated styling, designed by Ercole Spada and Claus Luthe.

Production Years:

1987-1996 (global production for E34 range)

Manufacturing Locations:

Germany (Dingolfing, Munich), South Africa, Mexico, Thailand

🏆 Awards & Recognition

Awards:

The E34 generation was well-received for its driving dynamics and build quality, often appearing on 'best of' lists for executive sedans of its era, though specific awards for the '525i' variant are less commonly cited than the overall model line.