🏷️ Basic Information

Make:

BMW

Model:

5 Series

Year:

1991

👋 Introduction

Market Segment:

Executive Luxury Sedan

Positioning Statement:

The BMW 5 Series of this era represented a benchmark in sporty luxury, combining performance, comfort, and advanced engineering.

Key Competitors:

Mercedes-Benz E-Class, Audi 100/200, Jaguar XJ, Lexus LS.

Driving Dynamics:

Renowned for its balanced chassis, rear-wheel-drive dynamics, and engaging driving experience.

Quality And Refinement:

High build quality, luxurious interior appointments, and a quiet, comfortable ride.

Purpose Statement:

To provide comprehensive, accurate, and actionable information for the diagnosis, repair, and maintenance of the 1991 BMW 5 Series.

📋 Manual Details

Engine Options Covered:

All gasoline engines offered in 1991 BMW 5 Series models

Transmission Options Covered:

Automatic and Manual transmissions

Chassis Variants Covered:

Sedan (E34)

Estimated Page Count:

Over 1500 pages (typical for a comprehensive service manual of this era)

Type:

Full Service Repair Manual

Language:

English

Format:

Print (likely spiral-bound or perfect-bound for durability)

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, including cylinder head, pistons, crankshaft, timing systems, lubrication system.

Engine Management:

Fuel injection systems (e.g., Bosch Motronic), ignition systems, sensor diagnostics, ECU (Electronic Control Unit) functions.

Transmission Manual:

Clutch, gearbox internal components, shift mechanisms, linkages, maintenance.

Transmission Automatic:

Hydraulic systems, valve bodies, torque converter, planetary gear sets, electronic controls, maintenance.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System) components, brake pads, rotors, calipers, lines, bleeding procedures.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.

Steering:

Power steering system, steering rack/box, tie rods, steering column, alignment.

Electrical System:

Wiring diagrams, component locations, fuses, relays, battery, charging system (alternator), starting system (starter).

HVAC:

Heating, Ventilation, and Air Conditioning system, refrigerant, controls, blower motor, evaporator, condenser.

Body And Frame:

Body panel removal/installation, structural components, doors, windows, trim, rust prevention and repair.

Interior Trim:

Dashboard, seats, headliner, door panels, carpeting, repair and replacement.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, coolant flushes, drive belt inspection/replacement.

Troubleshooting:

Diagnostic flowcharts, symptom analysis, common problems and their solutions.

Component Removal Installation:

Detailed step-by-step instructions for removing and reinstalling virtually every component.

Rebuilding Procedures:

Comprehensive instructions for rebuilding major components like engines, transmissions, and differentials.

Electrical Diagnostics:

Testing of electrical circuits, component testing, use of multimeters and oscilloscopes.

Specifications And Tolerances:

Detailed torque specifications, clearances, and other critical measurements for engine and chassis components.

Depth:

Expert level, covering everything from basic fluid changes to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostic procedures for engine management, ABS, and other electronic systems.

📊 Manual Specifications

Digital Format:

N/A (stated as a print manual)

Print Quality:

High quality, with clear diagrams and legible text (typical for OEM or reputable aftermarket manuals)

Binding Type:

Likely perfect-bound or spiral-bound for lay-flat usability in a workshop environment.

Paper Type:

Durable, possibly coated paper stock to withstand workshop conditions and repeated use.

⚙️ Engine Specifications

Engine Code Examples:

M20B25 (for 525i), M30B35 (for 535i), M60B30/B40 (later in E34 lifecycle, but may have overlap in manual coverage).

525I:

2.5 Liters (2494 cc)

535I:

3.5 Liters (3430 cc)

Configuration:

Inline-6 cylinder, DOHC (Double Overhead Camshaft) for M20/M30, DOHC V8 for M60.

525I Horsepower:

Approx. 168-189 hp (depending on market and specific engine variant)

525I Torque:

Approx. 222-245 Nm (164-181 lb-ft)

535I Horsepower:

Approx. 208-211 hp

535I Torque:

Approx. 305-310 Nm (225-229 lb-ft)

System Type:

Electronic Fuel Injection (EFI), typically Bosch Motronic system.

Type:

Distributorless Ignition System (DIS) or distributor-based ignition depending on exact engine and market.

Type:

Pressurized, liquid-cooled, with thermostatically controlled fan.

Type:

Pressurized wet-sump system.

🔧 Transmission

525I Transmission:

5-speed Manual (Getrag 260/5)

535I Transmission:

5-speed Manual (Getrag 280/5)

525I Automatic:

4-speed Automatic (ZF 4HP22)

535I Automatic:

4-speed Automatic (ZF 4HP22)

Manual Features:

Dual-mass flywheel, hydraulic clutch actuation.

Automatic Features:

Lock-up torque converter, electronic control unit (ECU) for shift logic, Sport/Economy modes (on some variants).

Manual Transmission Fluid:

API GL-4 or GL-5, viscosity typically SAE 75W-90 or 75W-80 (check manual for exact spec).

Automatic Transmission Fluid:

BMW LT-3 or equivalent Dexron III/Mercon specification (check manual for exact spec).

📐 Dimensions

Length:

Approx. 4700-4730 mm (185-186 inches)

Width:

Approx. 1750 mm (69 inches)

Height:

Approx. 1410 mm (55.5 inches)

Wheelbase:

Approx. 2760 mm (108.7 inches)

Curb Weight Examples:

Approx. 1550-1700 kg (3417-3748 lbs) depending on engine and equipment.

Gross Vehicle Weight Rating Gvwr:

Consult manual for specific model and options (typically around 2000-2100 kg).

Trunk Capacity:

Approx. 510 Liters (18 cu ft)

Wheel Bolt Pattern:

5x120 mm

Tire Sizes Examples:

205/65R15, 225/55R15, 225/50VR16 (depending on trim and options)

🛡️ Safety Features

Crash Test Results:

NHTSA ratings for this era are generally positive for its class but would require specific lookup for 1991 models.

ABS:

Standard on most models, Anti-lock Braking System.

Traction Control:

Optional on some models (ASR - Automatic Stability Control).

Airbags:

Driver's side airbag standard on most 1991 models; passenger airbag optional or standard on higher trims.

Seat Belts:

Three-point inertia-reel seat belts front and rear.

Crumple Zones:

Designed with front and rear crumple zones for energy absorption in impacts.

💡 Technology Features

Audio System:

Factory premium sound systems, cassette player, optional CD changer.

Climate Control:

Manual or automatic climate control (ECC - Electronic Climate Control) on higher trims.

Cruise Control:

Standard on most models.

Onboard Computer:

Optional 'Check Control' system for monitoring vehicle status.

Phone Integration:

Optional dealer-installed car phone systems.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 - 10,000 miles or 12 months (check manual for specific recommendation and oil type).

Spark Plug Replacement:

Approx. 30,000 - 60,000 miles depending on spark plug type (standard copper vs. platinum).

Coolant Flush Interval:

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

Engine Oil Type Examples:

BMW High Performance Synthetic SAE 5W-30 or 5W-40 (check owner's manual or manual for exact API/ACEA specs).

Brake Fluid Type:

DOT 3 or DOT 4 (consult manual for specific recommendation).

Power Steering Fluid:

ATF Dexron II or III (check manual for exact specification).

Engine Oil Capacity 525I:

Approx. 6.5 Liters (6.9 US Quarts)

Engine Oil Capacity 535I:

Approx. 7.5 Liters (7.9 US Quarts)

Coolant Capacity:

Approx. 9-10 Liters (9.5-10.6 US Quarts)

Cooling System Leaks:

Common for plastic coolant expansion tanks, hoses, and water pumps to degrade over time.

Oil Pan Gasket Leaks:

Can develop leaks due to age and heat cycles, especially on the M30 engines.

Vibration Issues:

Driveshaft center support bearing, flex disc (guibos), and differential mounts can wear, causing vibrations.

Heater Core Failure:

Heater core can fail, leading to coolant leaks inside the cabin.

ABS Sensor Failure:

ABS wheel speed sensors can become faulty, leading to ABS warning lights.

📚 Vehicle History

Bmw Legacy:

BMW has a long-standing reputation for engineering excellence, performance, and luxury vehicles since its inception.

E34 Introduction:

The E34 generation of the 5 Series was introduced in 1987 (Europe) and 1988 (North America), succeeding the E28. The 1991 model year falls into the early to mid-production cycle of the E34.

E34 Updates:

The E34 received updates throughout its lifecycle, including the introduction of V8 engines (M60) and revised interior/exterior styling in later years.

Manufacturing Locations:

Primarily manufactured in Dingolfing, Germany.

🏆 Awards & Recognition

Car And Driver 10Best:

The E34 generation was frequently named to Car and Driver's 10Best list during its production run.

European Car Of The Year Contender:

While not winning, the E34 was a strong contender in its segment and highly regarded by automotive press.

Reliability Ratings:

Generally considered reliable with proper maintenance, though specific component wear is common with age.