BMW 5 Series (E34) 1989-1995 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Code: E34 Production Years: 1987-1996 Codes Covered Years: 1989-1995 👋 Introduction Market Position Positioning: The E34 5 Series was...

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Type: Car

Vendor:

Sku: 431904

Tags: 1989 1990 1991 1992 1993 1994 1995 5 Series 5 Series (E34) BMW Car Cars

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Generation

Chassis Code:

Production Years:

1987-1996

Codes

Covered Years:

1989-1995

👋 Introduction

Market Position

Positioning:

The E34 5 Series was BMW's executive sedan, positioned as a refined, sporty, and technologically advanced vehicle for its era, competing with rivals like the Mercedes-Benz E-Class and Audi 100/A6.

Target Audience:

Enthusiasts, DIY mechanics, and professional workshops seeking in-depth information for maintaining and repairing the E34 5 Series.

Competitive Analysis

Competition:

Key competitors included the Mercedes-Benz W124 E-Class, Audi C3/C4 (100/A6), Jaguar XJ, and Volvo 700/900 series. The E34 offered a balance of sporty handling, luxury, and robust engineering.

Key Features

Features:

Notable for its classic BMW design, rear-wheel drive (with optional xDrive for select models), sophisticated independent suspension, potent inline-six engines, and a driver-focused interior.

📋 Manual Details

Coverage Areas

Major Topics:

• General Data and Maintenance

• Engine

• Transmission

• Suspension, Steering and Brakes

• Body

• Body Equipment

• Electrical System

• Equipment and Accessories

• Electrical Wiring Diagrams

Specific Engine Coverage:

Covers the full range of E34 engines, including the inline-4 (in some markets), inline-6 (M20, M30, M50), and V8 (M60) variants, as well as the M5's S38 engine.

Page Count

Estimated Page Count:

Varies based on specific engine/transmission variants, but typically comprehensive for a full service manual.

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Covered Systems:

• Engine Mechanical (including specific variants like M20, M30, M50, S38, etc.)

• Engine Management (DME, ignition, fuel injection)

• Cooling System

• Exhaust System

• Manual and Automatic Transmissions

• Drivetrain and Axles

• Suspension Components (front and rear)

• Steering System

• Brake System (hydraulic, ABS)

• Chassis and Body

• Body Panels and Trim

• Interior Components and Upholstery

• HVAC System

• Fuel System

• Electrical System (lighting, power windows, central locking, etc.)

• Instrumentation and Gauges

• SRS Airbag System

• Diagnostics and Troubleshooting

• Wiring Diagrams (comprehensive electrical schematics)

Electrical System Detail:

Comprehensive coverage of all vehicle electrical systems, including lighting, power accessories (windows, locks, seats, mirrors), instrumentation, engine management sensors, body control modules, and diagnostic connectors. Detailed wiring diagrams are a key feature.

Suspension Steering Brakes Detail:

Detailed procedures for front and rear suspension components, including struts, shocks, control arms, ball joints, bushings, springs, steering rack, power steering pump, brake calipers, rotors, pads, and ABS components.

Procedures Included

Included Procedures:

• Routine Maintenance (oil changes, filter replacements, spark plugs)

• Engine Overhaul and Rebuild

• Transmission Service and Repair

• Brake Pad and Rotor Replacement

• Suspension Component Replacement (shocks, struts, bushings, control arms)

• Steering System Repair

• Cooling System Flushes and Component Replacement

• Fuel System Diagnosis and Repair

• Electrical Component Diagnosis and Repair

• Body Panel Alignment and Repair

• Interior Trim and Component Installation/Removal

• HVAC System Servicing

• Diagnostic Procedures using BMW-specific tools (e.g., DIS, GT1 principles)

• Troubleshooting common faults

• Wiring harness repair

• Component testing and replacement

Body Repair Procedures:

Includes procedures for removing and installing body panels, doors, hoods, trunk lids, bumpers, and interior trim. Also covers glass replacement and basic bodywork alignment.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Typically yes, PDF format allows for text searching of repair procedures and specifications.

Print Quality

Print Quality:

High-resolution, allowing for clear printing of diagrams and illustrations.

Illustration Quality:

Features detailed illustrations, diagrams, and sometimes photographs to guide repair procedures.

Binding Type

Binding:

Digital (PDF) - printable pages

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Variants:

• 2.0L M20B20 (520i)

• 2.5L M20B25 (525i, Europe)

• 2.5L M50B25 (525i, North America/Later Europe)

• 3.0L M30B30 (530i)

• 3.5L M30B35 (535i)

• 3.0L M60B30 (530i V8)

• 4.0L M60B40 (540i V8)

• 3.8L S38B38 (M5)

Engine Codes Examples:

M20B25, M50B25VANOS, M30B35, M60B40, S38B38.

Performance

Horsepower Torque:

Varies significantly by engine. For example, the M50B25 produced around 189 hp and 181 lb-ft of torque, while the M60B40 produced around 282 hp and 295 lb-ft of torque.

Fuel System

Injection Type:

Bosch Motronic electronic fuel injection (EFI) across most variants.

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission.

Optional

Optional Transmission:

4-speed or 5-speed automatic transmission (ZF 4HP22, ZF 5HP18, ZF 5HP30 depending on engine).

Features

Transmission Features:

Rear-wheel drive, with some models offering optional all-wheel drive (xDrive).

📐 Dimensions

Exterior

Wheelbase:

111.4 inches (2830 mm)

Length:

190.4 inches (4836 mm)

Width:

70.2 inches (1783 mm)

Height:

56.1 inches (1425 mm)

Weights

Curb Weight:

Ranges from approximately 3400 lbs (1542 kg) for base models to over 4000 lbs (1814 kg) for V8 and M5 variants.

🛡️ Safety Features

Ratings

Crash Test Results:

As tested by NHTSA in its era, the E34 generally performed well for its time, though specific ratings are not as detailed as modern standards.

Active Features

Active Safety:

• Anti-lock Braking System (ABS) - standard on most models

• Traction Control System (ASC/ASC+T) - optional or standard on higher trims/later models

Passive Features

Passive Safety:

• Reinforced safety cage

• Front and side impact beams

• Driver and passenger airbags (standard on later models)

• Height-adjustable seatbelts

💡 Technology Features

Infotainment

Infotainment Systems:

Factory radio/cassette players, optional CD changers, basic climate control, and early navigation systems on premium models.

Driver Assistance

Assistance Features:

Limited by modern standards; primary features included ABS and optional Traction Control (ASC/ASC+T).

Connectivity

Connectivity Options:

No direct smartphone integration; limited to aftermarket solutions for auxiliary input or Bluetooth.

🔧 Maintenance

Service Intervals

Recommended Intervals:

Oil changes: 7,500-10,000 miles (or annually). Spark plugs: 30,000-100,000 miles depending on type. Coolant: 2-4 years or 30,000-60,000 miles. Transmission fluid: Often considered 'lifetime', but recommended 60,000-100,000 miles for automatics. Differential fluid: 30,000-50,000 miles.

Fluid Specifications

Engine Oil:

Typically SAE 5W-30 or 5W-40 synthetic oil meeting BMW Longlife-98 or Longlife-01 specifications (check specific engine recommendations).

Coolant:

BMW Blue or equivalent G48 ethylene glycol coolant, mixed 50/50 with distilled water.

Brake Fluid:

DOT 4.

Transmission Fluid Manual:

Typically SAE 75W-90 or 80W-90 GL-4 or GL-5 gear oil (check specific transmission variant for precise specification).

Transmission Fluid Automatic:

Dexron III (or equivalent) for earlier automatic transmissions, potentially ZF LifeguardFluid 5 for later 5-speed units.

Known Issues

Common Problems:

• Cooling system leaks (radiator, hoses, water pump)

• Oil leaks (valve cover gasket, oil pan gasket, oil filter housing)

• Head gasket failure (especially on older M30 engines)

• ABS/ASC sensor failures

• Window regulator failures

• HVAC blower motor resistor failure

• Subframe mounting points wear

• Ignition coil failures

• Fuel pump and injector issues

• Suspension bushing deterioration

Common Problems Electrical:

• Fuse box corrosion

• Door lock actuator failure

• Sunroof motor issues

• Check Control Module (CCM) malfunctions

📚 Vehicle History

Brand Heritage

Bmw Heritage:

BMW has a long-standing reputation for producing driver-focused luxury sedans with a focus on performance, handling, and build quality.

Model Evolution

E34 Evolution:

The E34 was the third generation of the 5 Series, succeeding the E28 and preceding the E39. It introduced significant styling updates, improved aerodynamics, and the availability of V8 engines and all-wheel drive for the first time in the 5 Series line.

E34 Facelift:

Received a facelift in 1994, introducing updated bumpers, side skirts, mirrors, and some interior refinements.

Production

Production Details:

Produced at BMW's Dingolfing plant in Germany and through CKD (Completely Knocked Down) kits in various countries. Total production exceeded 1.3 million units.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Consistently praised by automotive journalists for its driving dynamics, build quality, and refined ride. Often cited as a benchmark for executive sedans of its era.