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1989-1995 BMW All 5 Series Including Touring Sedan Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: Touring (Wagon), Sedan Codes Chassis Codes: E34 Engine Codes: M20, M30, M40, M42, M43, M50, M51 (Diesel), S38 (M5)...
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Type: Car
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Sku: 583795
1989-1995 BMW All 5 Series Including Touring Sedan Service Repair Manual1989-1995 BMW All 5 Series Including Touring Sedan Service Repair Manual1989-1995 BMW All 5 Series Including Touring Sedan Service Repair Manual1989-1995 BMW All 5 Series Including Touring Sedan Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Variant:
Touring (Wagon), Sedan
Codes
Chassis Codes:
E34
Engine Codes:
M20, M30, M40, M42, M43, M50, M51 (Diesel), S38 (M5)
👋 Introduction
Market Position
Segment:
Executive Sedan / Mid-size Luxury Sedan
Target Audience:
Affluent professionals and families
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class, Audi 100/A6, Lexus LS
Key Features
Driving Dynamics:
Renowned for balanced handling and driver engagement
Build Quality:
High-quality materials and robust construction
Powertrain Options:
Wide range of inline-6 petrol and diesel engines, including M-tuned performance variants
📋 Manual Details
Coverage Areas
Coverage Type:
Comprehensive Service and Repair
Page Count
Approximate Pages:
1500+
Manual Type
Type:
Factory Authorized Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, timing, valve adjustment, seals, gaskets, lubrication
Engine Management Electronic:
EFI, DME, sensor diagnostics, wiring diagrams, ECU troubleshooting
Fuel System:
Fuel pump, injectors, pressure regulator, tank servicing
Ignition System:
Coils, spark plugs, ignition timing, DME control
Cooling System:
Radiator, water pump, thermostat, hoses, fan clutch
Exhaust System:
Catalytic converter, mufflers, pipe replacement, O2 sensors
Transmission Manual:
Clutch, gearbox overhaul, gear selection
Transmission Automatic:
Fluid changes, valve body diagnostics, torque converter
Drivetrain:
Driveshafts, CV joints, differential service, limited-slip differentials
Suspension Front:
Struts, control arms, ball joints, bushings, alignment
Suspension Rear:
Shocks, trailing arms, bushings, sway bar
Steering System:
Power steering pump, rack and pinion, tie rods
Brake System:
Discs, pads, calipers, ABS, brake fluid flush
Wheels And Tires:
Bolt patterns, recommended sizes, torque specs
Body Structure:
Frame repair, body panel replacement, rust prevention
Exterior:
Bumpers, fenders, doors, hood, trunk, glass replacement
Interior:
Seats, trim panels, dashboard, headliner
HVAC System:
Blower motor, evaporator, heater core, A/C recharge
Electrical System General:
Battery, alternator, starter, wiring harnesses
Lighting System:
Headlights, taillights, interior lighting, bulb replacement
Instrumentation And Gauges:
Speedometer, tachometer, warning lights, cluster repair
Comfort And Convenience:
Power windows, locks, mirrors, sunroof, cruise control
Safety Systems:
Airbags (if equipped), seatbelt service
Diagnostics:
Troubleshooting charts, error codes, diagnostic procedures
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotation
Component Replacement:
Detailed step-by-step guides for all major components
Troubleshooting:
Systematic approaches to diagnosing common and complex faults
Rebuilding Procedures:
Engine, transmission, and differential rebuilds
Electrical Diagnostics:
Schematics, testing of circuits, component testing
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Specifications:
Torque values, clearances, fluid capacities, electrical specifications
Technical Depth
Depth:
Expert level, suitable for professional technicians and advanced DIYers
Detail Level:
Detailed diagrams, exploded views, and step-by-step instructions
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (OCR processed)
Print Quality
Image Resolution:
High resolution for clear diagrams and text
Binding Type
Binding:
Not Applicable (Digital)
Paper Type
Paper Quality:
Not Applicable (Digital)
⚙️ Engine Specifications
Primary Engine
Inline 4 Cylinder:
2.0L (M40/M43), 2.5L (M50/M52 - 24v variants) - approximate displacements
Inline 6 Cylinder:
2.5L (M20B25, M50B25), 2.7L (M20B27 '325e/330e'), 3.0L (M30B30, M50B30), 3.4L (M30B34/B34A), 3.5L (M30B35), 3.6L (M50B36 'M5'), 3.8L (S38B38 'M5')
Inline 6 Diesel:
2.4L (M21D24 - Turbo Diesel), 2.5L (M51D25 - Turbo Diesel)
Performance
Horsepower Range:
Approx. 120 HP (base diesel) to 315 HP (S38B38 M5)
Torque Range:
Approx. 140 lb-ft to 265 lb-ft
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic variants commonly used
Fuel Type:
Unleaded gasoline (Octane rating varies by engine), Diesel fuel
🔧 Transmission
Standard
Manual:
Getrag 260 (4-speed on early models, 5-speed standard on most)
Optional
Automatic:
ZF 4HP22 (4-speed automatic, common on larger engines)
Features
Transmission Fluid Manual:
BMW MTF LT-2 or equivalent (e.g., Red Line MT-90)
Transmission Fluid Automatic:
Dexron III or equivalent
📐 Dimensions
Exterior
Length Sedan:
Approx. 191.0 inches
Length Touring:
Approx. 192.0 inches
Wheelbase:
Approx. 111.5 inches
Weights
Curb Weight:
Approx. 3,500 - 4,000 lbs (varies by model and options)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not rated under modern comprehensive testing protocols; designed to robust German safety standards of the era.
Active Features
ABS:
Standard on most models from mid-production onwards, optional on earlier variants
Traction Control:
Optional on some higher-performance models (ASC)
Passive Features
Airbags:
Driver-side airbag became standard during the model run; passenger airbag optional on later models.
Seat Belts:
3-point inertia-reel seatbelts front and rear
💡 Technology Features
Infotainment
Audio System:
Factory cassette player with AM/FM radio, optional CD changer. Brands like Blaupunkt, Becker, and BMW's own units were common.
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control) with diagnostic capabilities.
Driver Assistance
Cruise Control:
Standard feature on most models
Connectivity
Vehicle Communication:
Basic diagnostic port (OBD-I style), limited data transmission compared to modern vehicles.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles or annually, depending on driving conditions and oil type.
Coolant Flush Interval:
Every 2 years or 30,000 miles
Spark Plug Replacement:
Varies by plug type: ~30,000 miles for standard, ~60,000 miles for platinum/iridium
Transmission Fluid Change Auto:
Recommended every 50,000-60,000 miles
Fluid Specifications
Engine Oil Type Gasoline:
API SJ/SL or ACEA A3/B4, SAE 0W-30, 0W-40, 5W-30, 5W-40, 10W-40 depending on climate and engine. Consult manual for specific engine recommendations.
Engine Oil Capacity:
Varies by engine: approx. 5.5 - 7.5 quarts
Brake Fluid Type:
DOT 4
Known Issues
Cooling System:
Plastic coolant expansion tanks prone to cracking, water pump failures, thermostat housing leaks.
Electrical:
Sensor failures (MAF, O2, coolant temp), blower motor resistor failure, wiring harness degradation, DME capacitor failures.
Suspension:
Wear on control arm bushings, ball joints, and shock mounts leading to vibration and poor handling.
Fuel System:
Fuel pump failures, injector seal leaks, fuel pressure regulator issues.
Engine Oil Leaks:
Valve cover gaskets, oil pan gaskets, rear main seals are common leak points.
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW has a long-standing reputation for performance, luxury, and driver-focused vehicles.
Model Evolution
Generation Introduction:
The E34 generation replaced the E28 5 Series and was produced from late 1987 to 1996. It represented a significant step forward in design and technology.
Touring Introduction:
The Touring (wagon) variant was introduced in 1991.
Performance Variants:
Included the potent M5 models (E34 M5) featuring the S38 engine.
Production
Production Years:
1989-1995 (Model years covered by this manual)
🏆 Awards & Recognition
Recognitions
Automotive Journalism Awards:
Consistently lauded by automotive press for its engineering, performance, and comfort. Often featured in 'best of' lists for its era.
Ratings
Reliability Perception:
While complex, generally considered reliable when properly maintained. Some components require periodic attention.
Certifications
Manufacturing Standards:
Built to stringent BMW quality and safety standards.
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