Positioning:
The BMW 5 Series (E34) represented BMW's commitment to combining luxury, performance, and advanced engineering in the executive sedan segment.
Competitors:
Competed against vehicles like the Mercedes-Benz E-Class (W124), Audi 100/200, and Jaguar XJ.
Design Philosophy:
Elegance, driver-centric cockpit, balanced chassis, and inline-6 engine refinement.
Target Audience:
Discerning drivers valuing driving dynamics, build quality, and understated luxury.
Value:
Essential resource for owners and independent workshops to maintain, diagnose, and repair the 1990 BMW 525i, saving on dealership labor costs.
Primary Coverage:
All service, repair, and maintenance procedures for the 1990 BMW 525i (E34 chassis).
Engine Coverage:
M20B25 inline-6 engine.
Transmission Coverage:
4-speed automatic and 5-speed manual transmissions.
Electrical Coverage:
Complete wiring diagrams, component locations, and diagnostic procedures.
Body Coverage:
Body and chassis repair, interior trim, exterior panels, glass replacement.
Suspension Coverage:
Front and rear suspension, steering system, wheel alignment.
Brake Coverage:
Front and rear brake systems, including ABS (if equipped).
Type:
Factory Service Repair Manual (FSM)
Purpose:
Comprehensive guide for diagnosis, repair, and maintenance.
Printability:
Printable (entire manual or selected pages)
Searchability:
Searchable text content
Engine Management:
Engine mechanical, fuel injection (Motronic), ignition, emissions control.
Cooling System:
Radiator, thermostat, water pump, coolant specifications.
Exhaust System:
Catalytic converter, mufflers, exhaust manifold.
Climate Control:
HVAC system, refrigerant, diagnosis.
Lighting System:
Headlights, taillights, interior lighting, wiring.
Instrumentation:
Gauges, warning lights, onboard diagnostics.
Chassis Components:
Frame, subframes, body mounts.
Maintenance:
Oil changes, filter replacements, spark plug service, belt inspection/replacement.
Troubleshooting:
Diagnostic flowcharts for common drivability and system issues.
Repair Rebuild:
Engine overhaul, transmission rebuild, suspension component replacement.
Installation:
Component installation, accessory fitting.
Specifications:
Torque values, clearances, fluid capacities, pressure specifications.
Depth:
Comprehensive, from basic adjustments to complete engine and transmission overhauls.
Diagnostic Level:
Advanced, including troubleshooting guides and diagnostic trouble codes (DTCs) where applicable for the era.
Wiring Detail:
Detailed wiring diagrams for all electrical systems.
Configuration:
Inline 6-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
2.5 Liters (2494 cc)
Bore X Stroke:
84.0 mm x 75.0 mm
Horsepower:
168 hp @ 5800 rpm (approx.)
Torque:
164 lb-ft @ 4300 rpm (approx.)
Fuel Delivery:
Bosch Motronic M1.3 Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher)
Coolant Type:
BMW Blue Antifreeze (or equivalent silicate-free ethylene glycol-based)
Recommended Oil Viscosity:
15W-40 or 20W-50 (depending on climate/usage), check manual for exact specs.
Capacity W Filter:
6.5 Liters (6.9 US quarts)
Transmission Type:
5-speed manual transmission (Getrag 260/5)
Transmission Type:
4-speed automatic transmission (ZF 4HP22)
Manual Clutch:
Hydraulic clutch actuation.
Fluid Type:
MTF LT-2 (BMW Manual Transmission Fluid) or equivalent GL-4 gear oil.
Fluid Type:
Dexron III (or equivalent ATF - Automatic Transmission Fluid).
Capacity:
1.3 Liters (1.4 US quarts)
Capacity:
1.5 Liters (1.6 US quarts) for pan drop refill.
NHTSA Front Impact:
Not rated by modern standards, but designed with robust safety cage and energy-absorbing crumple zones.
Airbags:
Driver's side airbag (standard on 1990 models).
Seatbelts:
3-point inertia-reel seatbelts front and rear.
Body Structure:
Integrated safety cage, energy-absorbing steering column, reinforced doors.
ABS:
Anti-lock Braking System (ABS) standard on 525i.
Traction Control:
Optional ASC (Automatic Stability Control) available on some models.
Radio:
BMW Bavaria C Business Cassette or Professional RDS system (optional).
Speakers:
Typically 6 or 8 speaker system.
Cruise Control:
Standard on 525i.
Onboard Computer:
Optional OBC (On-Board Computer) displaying fuel economy, range, and diagnostics.
Phone Integration:
N/A for modern standards; optional dealer-installed car phones were available.
Oil Change Interval:
Every 7,500-10,000 miles or annually, consult manual for exact mileage and oil type.
Spark Plug Replacement:
Recommended every 30,000 miles (Bosch W8AC or equivalent).
Drive Belt Inspection:
Inspect serpentine belt (if applicable) or V-belts for wear and tension at every oil change, replace as needed.
Coolant Flush:
Recommended every 2 years or 30,000 miles.
Power Steering Fluid:
Pentosin CHF 11 S or BMW PSF (Power Steering Fluid)
Engine M20:
Cracked cylinder head (less common on 2.5L than 2.7L), fuel pump failure, coolant leaks from metal thermostat housing and water pump.
Electrical:
Corrosion on grounds, faulty door lock actuators, dashboard illumination issues, ABS sensor failures.
Suspension:
Worn control arm bushings, worn ball joints, shock absorber failure.
Interior:
Sagging headliner, failing pixels in instrument cluster OBC.
Oil Filter:
Mann-Filter W 940/1, Mahle OC 205, or equivalent.
Air Filter:
Mann-Filter C 2421, Mahle LX 282, or equivalent.
Fuel Filter:
Mann-Filter WK 57/3, Bosch 0 450 905 271, or equivalent.
Bmw Philosophy:
BMW's reputation for 'The Ultimate Driving Machine' was solidified in this era.
E34 Introduction:
The E34 generation of the 5 Series debuted in 1987 (Europe) and 1988 (North America), succeeding the E28.
E34 Key Innovations:
Significant aerodynamic improvements over the E28, integrated safety features, and advanced engine management.
Production Period:
1987-1996
Plant:
Dingolfing, Germany
