🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E34

Product Name:

BMW 5 Series (E34) (525i 525iX 530i 535i 535i Sport & 525i Sport, 540i, 540i M-sport, M5) Service Repair Guide

Generation Code:

E34

Production Years:

1988-1995

Engine Codes Covered:

M20B25, M30B35, M60B30, M60B40, S38B36

👋 Introduction

Class:

Executive Sedan / Sports Sedan

Target Audience:

Discerning drivers seeking a blend of luxury, performance, and engineering excellence. Owners and independent mechanics.

Key Competitors:

Mercedes-Benz W124 E-Class, Audi V8 / A8, Lexus LS400, Jaguar XJ.

Design Philosophy:

The E34 represented a more modern and aerodynamic design compared to its predecessor (E28), while retaining BMW's signature driving dynamics and build quality. Known for its solid construction and driver-focused cockpit.

Performance Variants:

The E34 lineup culminated in the legendary M5, powered by the S38 inline-6 engine, offering supercar-level performance for its era. The V8 models (530i, 540i) provided a different flavor of potent performance.

📋 Manual Details

Vehicle Models Covered:

525i, 525iX, 530i, 535i, 535i Sport, 525i Sport, 540i, 540i M-sport, M5

Body Styles Covered:

Sedan, Touring (Wagon), Convertible (E34 convertible was not a factory option, but aftermarket conversions exist and manual may cover related systems if applicable to common conversion components)

Total Pages:

>1500

Type:

Workshop Service and Repair Manual

Language:

English (assumed, based on product description typical for this market)

File Format:

PDF

📖 Manual Coverage

Engine:

Detailed coverage of 6-cylinder (M20/M50 variants) and V8 (M60) engines, including M5 (S38) specific components. Includes engine mechanical, cooling, lubrication, fuel injection (Bosch Motronic), ignition, exhaust, and emissions control.

Transmission:

Manual (Getrag 260, ZF) and automatic (ZF 4HP22, 4HP24, 5HP18, 5HP30) transmissions. Covers removal, installation, internal components, fluid service, and troubleshooting.

Drivetrain:

Rear-wheel drive (RWD) and All-wheel drive (525iX). Covers driveshafts, universal joints, differentials (including limited-slip options), and axle shafts.

Brakes:

Hydraulic brake system, including ABS (Anti-lock Braking System) variants. Covers master cylinder, brake booster, calipers, pads, rotors, lines, and bleeding procedures. Includes parking brake system.

Suspension Steering:

Front and rear suspension (MacPherson struts front, multi-link rear). Covers springs, shock absorbers, control arms, bushings, sway bars, and wheel bearings. Steering system includes rack-and-pinion, power steering pump, hoses, and steering column.

Electrical:

Comprehensive coverage of the electrical system, including battery, charging system (alternator), starting system (starter), lighting (headlights, taillights, interior), instrumentation, power accessories (windows, locks, mirrors), climate control, and audio systems. Includes detailed wiring diagrams.

Body Chassis:

Body structure, doors, hood, trunk, bumpers, glass, trim, and interior components. Covers body repair procedures, rust prevention, and panel replacement.

Climate Control:

HVAC system, including blower motor, evaporator, condenser, refrigerant, heating core, and control modules. Covers diagnosis and repair of both manual and automatic climate control systems.

Safety Restraint System:

Supplemental Restraint System (SRS) including airbags and seatbelt pre-tensioners. Covers sensor locations, diagnostic procedures, and replacement guidelines. Note: specific coverage for side airbags may be limited in early E34 models.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, belt inspections and replacements, spark plug replacement, brake fluid flush, coolant flush, and general inspections.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues across all vehicle systems. Includes symptom-based troubleshooting and diagnostic trouble codes (DTCs) if applicable to the vehicle's era.

Repair:

Detailed repair procedures for virtually every component of the vehicle, from minor adjustments to complete engine and transmission overhauls. Includes removal, disassembly, inspection, repair, assembly, and reinstallation.

Wiring Diagrams:

Comprehensive and detailed wiring diagrams for all electrical circuits, color-coded and keyed for easy identification. Crucial for diagnosing electrical faults.

Specifications Data:

Torque specifications, fluid capacities, fluid types, part numbers (where applicable), tolerances, clearances, and diagnostic parameters for all major components.

Depth:

Full workshop level. Covers everything from basic fluid changes and inspections to complete engine rebuilds, transmission overhauls, suspension component replacement, and in-depth electrical diagnostics.

📊 Manual Specifications

File Format:

PDF

Compatibility:

Windows, Mac, Linux

Printability:

All pages printable without restriction.

Image Quality:

High-resolution scans with clear illustrations, drawings, and photos.

Binding Type:

Digital Download (PDF)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Options:

Inline-6 (2.5L M20/M50, 3.0L M50, 3.5L M30), V8 (4.0L M60), 3.8L Inline-6 (S38B38 for M5)

Typical Horsepower Range:

170 hp (525i M20) to 310 hp (M5 3.8L)

Typical Torque Range:

220 Nm (525i M20) to 400 Nm (M5 3.8L)

Fuel Delivery:

Bosch Motronic electronic fuel injection (EFI) across most variants. M30 variants may use earlier KE-Jetronic or similar systems, though Motronic was phased in.

Fuel Type:

Premium Unleaded Gasoline

Bore Stroke Examples:

M50B25: 84 mm x 75 mm; M60B40: 94 mm x 90 mm; S38B38: 94.4 mm x 90 mm

Compression Ratio Examples:

M50B25: 10.0:1; M60B40: 10.0:1; S38B38: 10.5:1

🔧 Transmission

Standard Transmission Example:

5-speed Manual (Getrag 260)

Optional Transmission Example:

4-speed Automatic (ZF 4HP22), 5-speed Automatic (ZF 5HP18/5HP30)

All Wheel Drive Option:

Available on the 525iX model, utilizing a viscous coupling center differential.

📐 Dimensions

Length Example:

~4717 mm (Sedan)

Width Example:

~1751 mm

Height Example:

~1412 mm (Sedan)

Curb Weight Range:

~1500 kg - 1800 kg (depending on model and equipment)

Gross Vehicle Weight Rating Example:

~2050 kg

🛡️ Safety Features

Crash Test Results:

Generally considered safe for its era. Specific ratings vary by testing body and year, but the E34 offered advanced safety features for its time, including a robust safety cage and improved crumple zones compared to previous generations.

Active Safety Features:

Anti-lock Braking System (ABS) standard on most models, optional on earlier ones. Optional traction control (ASC/ASC+T) on some later models. Power-assisted steering.

Passive Safety Features:

Driver and front passenger airbags (standard later in the E34's life, optional earlier). Front and rear crumple zones. Seatbelt pre-tensioners. Reinforced door beams.

💡 Technology Features

Audio System:

BMW Bavaria C or Professional RDS cassette players, optional CD changers. High-fidelity sound systems available with amplifier upgrades.

Navigation:

Optional early GPS navigation systems were available on some models, though generally rudimentary by modern standards.

Traction Control:

Automatic Stability Control (ASC) and ASC+T (with throttle control) became available on later models, particularly on V8 and M5 variants.

Cruise Control:

Standard on most models, electronically controlled.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 to 15,000 miles (12,000 to 24,000 km) or annually, depending on driving conditions and oil used. Consult the manual for specific recommendations for your model and year.

Spark Plug Replacement Interval:

15,000-30,000 miles for conventional plugs, up to 100,000 miles for some premium or platinum/iridium plugs (check specific type).

Coolant Flush Interval:

Every 2-3 years or 30,000-50,000 miles.

Engine Oil Spec:

API SG or higher, SAE 5W-30, 5W-40, or 10W-40 recommended depending on climate. BMW approved synthetic oils are highly recommended. Consult manual for precise viscosity based on region and temperature.

Coolant Spec:

Ethylene glycol based antifreeze, typically BMW P/N 83 19 9 407 776 (blue) or equivalent. A 50/50 mix with distilled water is standard.

Brake Fluid Spec:

DOT 4 (low viscosity). BMW recommends P/N 81 22 9 407 796 or equivalent.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil. Specific viscosity varies by transmission (e.g., 75W-90, 75W-85). Consult manual.

Transmission Fluid Automatic:

ZF LifeguardFluid 5 (for 5HP models) or equivalent Dexron III/Mercon type fluids for older 4HP models. Always use BMW-specified fluid for optimal performance and longevity.

Common E34 Issues:

Cooling system failures (cracked plastic expansion tanks, failed water pumps, thermostat housing leaks), Vanos system on later M50 engines (though less problematic than M52/E39), fuel pump issues, ignition coil failures, E32/E38 shared ABS/ASC module failures, rear subframe mounting points cracking, headliner sagging, sunroof drains clogging, oil pan gasket leaks, valve cover gasket leaks.

📚 Vehicle History

Bmw Legacy:

The 5 Series has been BMW's core executive sedan offering since the mid-1970s, renowned for its sporting character, advanced engineering, and driver engagement. The E34 built upon this legacy.

E34 Development:

The E34 succeeded the E28 and was produced from late 1987 to mid-1995. It featured a more aerodynamic design by Claus Luthe and introduced significant technological advancements for BMW, including the sophisticated M60 V8 engine and the availability of all-wheel drive.

Facelift Updates:

A significant facelift occurred in 1994, introducing revised front and rear styling, updated interior trim, and the introduction of the M50-based 525i (from the previous M20-based 525i) and the new 540i V8.

Production Period:

1988-1995

Manufacturing Locations:

Germany (Dingolfing plant is primary)

🏆 Awards & Recognition

Car And Driver 5Best:

The E34 5 Series was a frequent recipient of Car and Driver's '10Best' list during its production run, particularly the 535i and M5 variants, lauded for its driving dynamics and engineering.

Road And Track Editors Choice:

Consistently praised by automotive journalists for its performance, handling, and build quality.