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BMW 5 Series E34 1991 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E34 Model Year: 1991 Codes Production Codes Covered: All E34 variants for 1991 model year 👋 Introduction Market Position...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Chassis Code:
E34
Model Year:
1991
Codes
Production Codes Covered:
All E34 variants for 1991 model year
👋 Introduction
Market Position
Segment:
Luxury mid-size executive sedan and wagon.
Bmw Positioning:
Known for performance, driving dynamics, build quality, and sophisticated engineering.
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class (W124), Audi 100/200, Lexus LS 400 (introduced late in the E34's life).
Key Features
Design Philosophy:
Evolved from the E28, featuring sharper lines and a more aerodynamic profile, iconic BMW kidney grille.
Engine Options 1991:
Range of inline-six and V8 engines (depending on specific market and model variants).
Drivetrain:
Primarily rear-wheel drive (RWD), with optional all-wheel drive (xDrive) available on select models (though less common in 1991 models targeted by this manual).
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive factory service and repair
Page Count
Page Count:
Hundreds of pages (exact number not specified, but implies comprehensive)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed diagnosis, repair, and overhaul for all applicable gasoline engines (M20, M30, M50 variants).
Engine Management Electronic:
Bosch Motronic system diagnostics, sensor data, actuators, troubleshooting, wiring diagrams.
Fuel System:
Fuel injection systems, fuel pump, injectors, fuel pressure regulation, emissions control (catalytic converter, secondary air injection).
Cooling System:
Radiator, water pump, thermostat, hoses, fan operation, coolant specifications, bleeding procedures.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, oxygen sensors, exhaust leaks.
Transmission Manual:
Gearbox overhaul, clutch system, shift linkage, fluid specifications.
Transmission Automatic:
Transmission identification, hydraulic control, torque converter, electronic control unit (ECU) for transmission, fluid specifications, service procedures.
Drivetrain Rear Axle:
Differential service, axle shafts, wheel bearings, limited-slip differential (LSD) service if applicable.
Brakes System:
Front and rear disc brake service, ABS (Anti-lock Braking System) diagnostics and repair, brake fluid specifications, bleeding procedures.
Suspension System:
Front and rear suspension components, struts, shock absorbers, control arms, bushings, springs, alignment specifications.
Steering System:
Power steering system, steering rack/box, tie rods, steering wheel, alignment.
Electrical System Lighting:
Headlights, taillights, interior lighting, fog lights, bulb specifications.
Electrical System Charging:
Alternator, battery, voltage regulator, wiring.
Electrical System Starting:
Starter motor, ignition switch, ignition system (spark plugs, coils, distributor for applicable models).
Body Exterior:
Body panel removal/installation, door mechanisms, hood, trunk, bumpers, glass, seals.
Body Interior:
Dashboard, seats, trim panels, headliner, HVAC system controls.
HVAC System:
Heating, ventilation, and air conditioning (HVAC) components, blower motor, evaporator, condenser, refrigerant, climate control unit.
Instrumentation:
Instrument cluster, gauges, warning lights, diagnostics.
Safety Systems:
Seat belts, airbags (if equipped), structural integrity.
Wiring Diagrams:
Complete electrical system wiring diagrams for all major components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides.
Engine Repair:
Engine removal and installation, cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing chain/belt replacement.
Transmission Repair:
Transmission disassembly and reassembly, seal replacement, clutch replacement, torque converter replacement.
Brake Repair:
Brake pad and rotor replacement, caliper overhaul, master cylinder replacement, ABS component testing and replacement.
Suspension Repair:
Shock absorber and strut replacement, control arm bushing replacement, ball joint replacement.
Electrical Diagnosis:
Component testing, circuit diagnosis, connector repair, fuse and relay identification.
Body Panel Repair:
Door hinge adjustment, window regulator repair, lock mechanism servicing.
HVAC Service:
Refrigerant charging, leak detection, component replacement (compressor, expansion valve), blower motor replacement.
Special Tools:
Identification and usage instructions for specialized BMW tools required for certain procedures.
Technical Depth
Depth:
In-depth, covering everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures for engine management, ABS, and automatic transmission systems.
Specifications Accuracy:
Factory-level torque specifications, tolerances, and clearances for all major components.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Print Quality
Printability:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
Digital (Downloadable PDF)
Paper Type
Paper Recommendation:
Standard copier paper for printing.
Searchability
Text Search:
Likely text-searchable if created from digital source, allowing quick access to information.
⚙️ Engine Specifications
Primary Engine
Engine Variants Covered 1991:
Likely includes 4-cylinder (M40), inline-6 (M20, M30, M50) gasoline engines and potentially early V8 (M60) in some markets for the 1991 model year.
Performance
Horsepower Range Typical:
Approximately 138 hp (318i) to 211 hp (535i) for inline-6 models, potentially higher for M-versions or early V8s.
Torque Range Typical:
Corresponds to horsepower figures, e.g., around 170 lb-ft to 230 lb-ft for inline-6.
Fuel System
Injection Type:
Bosch Motronic electronic fuel injection (EFI) across all variants.
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher).
Engine Codes
Common Engines 1991:
M20B25 (525i), M30B35 (535i), M50B25 (525i, 525ix).
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission (Getrag 260/5 or similar).
Optional
Optional Transmission:
4-speed ZF automatic transmission (e.g., ZF 4HP22).
Features
Transmission Control:
Electronic or hydraulic control for automatic transmissions, clutch operation for manual.
Fluid Specifications
Automatic Transmission Fluid:
Typically Dexron-III or equivalent (e.g., BMW ATF LT-3).
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, specific viscosity dependent on ambient temperature (e.g., 75W-90).
📐 Dimensions
Exterior
Body Styles:
4-door Sedan (Saloon), 5-door Touring (Wagon).
Wheelbase:
Approx. 111.5 inches (2835 mm)
Length:
Approx. 191.1 inches (4854 mm) for Sedan
Weights
Curb Weight Range:
Approx. 3400 - 3800 lbs (1542 - 1724 kg) depending on engine and equipment.
🛡️ Safety Features
Ratings
Crash Test Data:
While official NHTSA/IIHS ratings from the era are less comprehensive than today, the E34 was designed with advanced safety structures for its time, including crumple zones and a robust passenger cell.
Active Features
ABS:
Standard or optional Anti-lock Braking System (ABS) on most models.
Passive Features
Seatbelts:
Three-point inertia-reel seatbelts for front and rear occupants.
Airbags:
Driver's side airbag became standard on many models by 1991, passenger airbag optional or unavailable depending on market.
💡 Technology Features
Infotainment
Audio System:
Factory cassette player with AM/FM radio, optional CD player or changer, various speaker configurations (e.g., Hi-Fi system).
Driver Assistance
Cruise Control:
Standard or optional electronic cruise control.
Traction Control:
Optional ASC (Automatic Stability Control) on some models.
Connectivity
Diagnostic Port:
Early OBD-I diagnostic connector, typically a 14-pin round connector under the hood, requiring specialized BMW diagnostic tools (e.g., GT1, INPA).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, depending on driving conditions and oil used.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for standard plugs, longer for platinum/iridium.
Coolant Flush Interval:
Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).
Brake Fluid Flush Interval:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Viscosity:
BMW recommends synthetic 5W-30, 5W-40, or 10W-40 depending on climate (refer to owner's manual for exact specification).
Coolant Type:
BMW blue antifreeze or equivalent silicate-free coolant (typically 50/50 mix with distilled water).
Power Steering Fluid:
BMW Power Steering Fluid (P/N 81 22 9 407 763) or Pentosin CHF 11S.
Known Issues
Common Wear Items:
Vibrations from driveshaft center support bearing, coolant leaks from plastic water pump impellers or hose connectors, aging rubber bushings, ABS sensor failures, fuel pump failures.
Electrical Gremlins:
Can develop due to aging wiring insulation, corroded connectors, or failing grounds, particularly in the engine bay and fuse box.
Engine Specific Issues:
M20: Oil pan gasket leaks. M30: Head gasket issues, oil leaks. M50: VANOS unit (on later models, not typically an issue for early M50s), thermostat housing leaks.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for performance, engineering excellence, and driver engagement.
Model Evolution
E34 Introduction:
Introduced in 1988 as the successor to the E28 5 Series.
E34 Updates 1991:
Early production phase for E34, representing the refined but less updated versions compared to later facelifts.
Production
Production Years:
1988–1996
Manufacturing Locations:
Dingolfing, Germany; Rosslyn, South Africa; various CKD assembly plants worldwide.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Consistently praised by automotive publications for its driving dynamics, build quality, and engineering. Often featured in 'best of' lists for its era.
Ratings
Reliability Perception:
Generally considered reliable when properly maintained, with a robust mechanical design.