Positioning:
The BMW 5 Series (E34) was positioned as a luxury executive sedan, known for its sophisticated engineering, performance, and driver-focused dynamics. The 525i offered a potent inline-six engine, striking a balance between performance and efficiency for its class.
Competitors:
Key competitors included the Mercedes-Benz W124 E-Class, Audi V8 Quattro (later A8), Jaguar XJ, and Lexus LS (introduced mid-cycle).
Vehicle Features:
Rear-wheel drive or optional all-wheel drive (xDrive), sophisticated independent suspension, high-quality interior materials, precise steering feel, robust inline-six engines.
Benefit To Owner:
Empowers owners and technicians to perform all necessary maintenance, repairs, and diagnostics, extending the life and preserving the performance of this classic BMW.
Scope:
This is a professional-grade workshop manual, providing the depth of information typically found in factory service manuals, suitable for both DIY enthusiasts and professional mechanics.
Engine:
Complete engine overhaul, diagnosis, tuning, fuel system (EFI), ignition system, cooling system, lubrication system, emission controls
Transmission:
Manual and automatic transmission service, overhaul, diagnosis, fluid specifications
Drivetrain:
Driveshafts, differential, rear axle service, bearing specifications
Suspension:
Front and rear suspension component replacement, alignment specifications, shock absorber/strut service, bush replacement
Steering:
Power steering system diagnosis and repair, steering rack, tie rod ends, steering column service
Brakes:
Front and rear brake system overhaul (discs/pads/calipers), ABS system diagnosis and repair, brake fluid specifications, bleeding procedures
Electrical:
Complete wiring diagrams, starter, alternator, battery, lighting systems, fuses, relays, ECUs, dashboard instruments, diagnostic connectors
Bodywork:
Body panel removal/installation, door mechanisms, glass replacement, exterior trim, interior trim, body sealing, rust repair considerations
HVAC:
Air conditioning system service, climate control diagnosis, heater core replacement, blower motor service
Safety Systems:
Seat belt mechanisms, airbag system (if applicable for later models within range), chassis safety components
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, belt tensioning, fluid level checks
Troubleshooting:
Extensive diagnostic charts, symptom-based troubleshooting guides for all major systems
Repair:
Step-by-step repair instructions for all components and systems, including torque specifications
Rebuilds:
Engine and transmission rebuild procedures, including component clearances and specifications
Diagnostics:
OBD (On-Board Diagnostics) information, fault code interpretation, sensor testing, actuator testing
Installation:
Component installation procedures, accessory installation guidance
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine and transmission rebuilds, with detailed diagnostic strategies
Engine Type:
M50B25 Inline-6 Cylinder, DOHC
Displacement:
2.5 Liters (2494 cc)
Horsepower Hp:
189 hp @ 5900 rpm (approx. for M50B25)
Torque Lb Ft:
181 lb-ft @ 4200 rpm (approx. for M50B25)
Injection Type:
Bosch Motronic Electronic Fuel Injection (EFI)
Ignition System:
Distributorless Ignition System (DIS) or Coil-on-Plug depending on exact model year updates within E34 range, managed by Motronic ECU
Coolant Type:
BMW Blue Antifreeze/Coolant (Ethylene Glycol based)
Oil Type:
SAE 5W-30 or 5W-40 Synthetic Engine Oil (refer to manual for specific BMW approvals)
Block Material:
Aluminum Alloy
Head Material:
Aluminum Alloy
Type:
Getrag 260 5-Speed Manual Transmission
Type:
ZF 4HP22 4-Speed Automatic Transmission
Clutch Type:
Hydraulically actuated single dry plate clutch (Manual transmission)
Manual Transmission Fluid:
BMW approved gear oil (e.g., SAE 75W-90 GL-4/GL-5)
Automatic Transmission Fluid:
Dexron III or equivalent ATF
Crash Test Data:
While official NHTSA/IIHS ratings for this era are less comprehensive than modern standards, the E34 chassis was known for its solid construction. Specific detailed crash test data for this exact model may be limited.
ABS:
Anti-lock Braking System (ABS) typically standard on 525i models
Traction Control:
Automatic Stability Control (ASC) or ASC+T was an optional feature on later models.
Airbags:
Driver's side airbag became standard in later years of the E34 production; passenger airbag was typically optional or absent in early models.
Seatbelts:
3-point inertia-reel seatbelts with pretensioners (driver and front passenger)
Audio System:
Original systems often included AM/FM cassette players with optional CD changers. Speaker configurations varied by trim level. Aftermarket upgrades are common.
Cruise Control:
Standard on most 525i models, electronic cruise control system.
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control) with advanced features for its time.
Cellular:
N/A (no integrated cellular or Bluetooth connectivity)
Headlights:
Halogen headlights, with optional self-leveling Xenon headlights on later models (facelifted versions) as a premium feature.
Oil Change Interval:
Typically every 7,500 - 10,000 miles or 12 months, whichever comes first (depending on driving conditions and oil used).
Spark Plug Replacement:
At approximately 60,000 miles (check manual for exact type and interval).
Coolant Flush:
Every 2-3 years or as per manual recommendation.
Transmission Fluid Change:
Manual: Every 60,000 miles. Automatic: Every 30,000-60,000 miles (BMW often listed as 'lifetime' but periodic changes are recommended).
Power Steering Fluid:
BMW ATF Dexron III or Pentosin CHF 11S (verify for specific model year and system).
Coolant Capacity:
Approximately 8.5 Liters (total system capacity)
Common Problems:
Head gasket leaks, oil pan gasket leaks, valve cover gasket leaks, cooling system component failures (water pump, thermostat, hoses), ABS sensor failures, VANOS system issues (on later M50TU engines), window regulator failures, heater control valve leaks.
Recommendations:
Regular inspection and replacement of rubber hoses and seals, timely replacement of cooling system components, ensuring proper lubrication and oil changes.
Brand Legacy:
BMW, Bayerische Motoren Werke AG, has a long history of producing sporting luxury vehicles, renowned for engineering prowess and driving pleasure.
E34 Introduction:
The E34 generation of the 5 Series was introduced in 1987 (Europe) and 1989 (North America), succeeding the E28. It represented a significant leap in design, technology, and refinement.
E34 Facelift:
The E34 received a significant facelift in 1994, introducing updated styling, revised M50 engine variants (e.g., VANOS), and improved interior features. This manual covers both pre-facelift and facelifted models within the specified range.
Production Period:
1987-1996 (global), with 1989-1995 being the focus for this manual's applicable models.
Manufacturing Plants:
Primarily manufactured at BMW's Dingolfing plant in Germany, with some assembly also occurring in other global locations.
Car And Driver:
The E34 5 Series consistently appeared on Car and Driver's '10Best' lists during its production run, praising its balance of luxury, performance, and handling.
Motortrend:
Praised by various automotive publications for its engineering and driving dynamics, often competing favorably against its German and international rivals.
Safety Standards:
Designed to meet or exceed the safety regulations of its era in European and North American markets.
