1991 BMW M5 E34 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: M5 Generation Code: E34 Year: 1991 Codes Chassis Code: E34 Engine Code Primary: S38B36 👋 Introduction Market Position Positioning: High-performance executive sedan targeting...

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Type: Car

Vendor:

Sku: 455002

Tags: 1991 5 Series BMW Car Cars M5 E34

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Generation Code:

Year:

Codes

Chassis Code:

Engine Code Primary:

S38B36

👋 Introduction

Market Position

Positioning:

High-performance executive sedan targeting enthusiasts and discerning drivers.

Manual Value Proposition:

Provides detailed, specific information enabling owners and technicians to maintain and repair the vehicle to factory standards.

Competitive Analysis

Competitors Era:

Competed with other high-performance sedans like the Mercedes-Benz 500E, Jaguar XJ-S, and high-spec versions of Audi and Lexus sedans.

Key Features

Vehicle Key Features:

Powerful inline-six engine, sophisticated chassis, luxurious interior, exceptional driving dynamics.

Manual Key Features:

Vehicle-specific, factory-level detail, comprehensive system coverage, digital format flexibility.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair for all 1991 BMW M5 E34 models.

Repair Scope:

A-Z repairs, maintenance, diagnostics, and servicing.

Page Count

Estimated Page Count:

Likely 1000+ pages (typical for full factory service manuals of this era, exact count not provided).

Manual Type

Type:

Factory Service and Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, rebuild, lubrication, cooling system, fuel system, intake and exhaust systems.

Engine Control:

Engine management, ignition system, starting and charging systems, emission control systems.

Transmission:

Manual transmission (Getrag 280/6) service, overhaul, clutch service, automatic transmission (optional, though E34 M5 was manual-only, manual is covered extensively).

Drivetrain:

Driveshaft, differential, axle, suspension components, wheel bearings.

Brakes:

Brake system diagnosis and repair, hydraulic systems, ABS (Anti-lock Braking System), parking brake.

Steering:

Steering column, power steering system diagnosis and repair.

Suspension:

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

Wheels Tires:

Tire and wheel specifications, mounting, balancing.

Electrical General:

General electrical system troubleshooting, wiring harnesses, fuses, relays.

Lighting:

Headlights, taillights, interior lighting, auxiliary lighting.

Instrumentation:

Instrument panel components, gauges, warning lights.

Climate Control:

Air conditioning system service, diagnosis, and repair.

Safety Restraints:

Supplementary Restraint System (SRS) airbags, seat belt systems.

Body Exterior:

Engine hood, doors, body panels, glass, mirrors, exterior trim.

Body Interior:

Interior trim, seats, door panels, console components.

Multiplex Communication:

Multiplex wiring systems, CAN communication (early forms if applicable).

Procedures Included

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, fluid checks, brake inspections, tune-ups.

Diagnostic Procedures:

Troubleshooting guides for various systems, fault code interpretation (if applicable), component testing.

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, and overhaul.

Installation Procedures:

Installation of new components, accessories, and replacement parts.

Adjustment Procedures:

Adjustments for engine timing, idle speed, clutch linkage, etc.

Wiring Schematics:

Complete electrical wiring diagrams for all vehicle systems.

Special Tool Usage:

Identification and usage of special tools required for specific repairs.

Technical Depth

Depth:

Factory-level detail, covering basic maintenance to complete engine and transmission rebuilds, advanced diagnostics.

Illustrations:

Abundant diagrams, line drawings, and illustrations for clarity.

Step By Step:

Complete step-by-step instructions for all procedures.

📊 Manual Specifications

File Format

Compatibility:

Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac compatible.

Requirements:

Adobe PDF Reader and Winzip (free online).

Print Quality

Printability:

All pages are printable, allows for enlarged copies of diagrams.

Searchability:

Implied searchable text within the PDF format.

Binding Type

Binding:

Digital (PDF) - no physical binding.

Paper Type

Paper Type Analogy:

Digital format eliminates the need for paper, preventing grease and tears.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Inline-6

Engine Code:

S38B36

Displacement:

3.6 Liters (3535 cc)

Bore X Stroke:

94.4 mm x 86.0 mm

Compression Ratio:

10.0:1

Valvetrain:

DOHC, 24 Valves (4 per cylinder), Double VANOS (later models, check for specific 1991 model year implementation)

Performance

Horsepower Hp:

315 hp @ 6,900 rpm

Torque Lb Ft:

266 lb-ft @ 4,750 rpm

Fuel System

Fuel Delivery:

Bosch Motronic M3.1 Fuel Injection (Sequential)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

Cooling

Cooling System:

Liquid-Cooled, Thermostatically Controlled Fan, Expansion Tank

🔧 Transmission

Standard

Type:

Getrag 280/6 Manual Transmission

Gears:

6-Speed Manual

Clutch Type:

Hydraulically Actuated Single Dry Plate Clutch

Optional

Type:

N/A for 1991 M5 E34 (exclusively manual)

Features

Rear Differential:

Limited-Slip Differential (LSD)

📐 Dimensions

Exterior

Length:

Approx. 4,710 mm (185.4 in)

Width:

Approx. 1,750 mm (68.9 in)

Height:

Approx. 1,420 mm (55.9 in)

Wheelbase:

Approx. 2,760 mm (108.7 in)

Front Track:

Approx. 1,475 mm (58.1 in)

Rear Track:

Approx. 1,495 mm (58.9 in)

Weights

Curb Weight:

Approx. 1,700 kg (3,748 lbs)

Gross Vehicle Weight Rating:

Approx. 2,150 kg (4,740 lbs)

Wheel Bolt Pattern:

5 x 120 mm

Wheel Size:

17 x 7.5J (standard)

Tire Size:

235/45ZR17 (standard)

🛡️ Safety Features

Ratings

Crash Test Data:

No specific official ratings for 1991 available from modern agencies, but built to high standards for its era.

Active Features

Yes (Bosch ABS III)

Traction Control:

No (ASC+T was introduced later on BMW models)

Passive Features

Airbags:

Driver's side airbag standard.

Seat Belts:

Front and rear seat belts, pretensioners for front seats.

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory premium sound system, likely Nakamichi or Blaupunkt with amplifier, optional CD changer.

Display:

Analog gauges, OBC (On-Board Computer) display in instrument cluster.

Driver Assistance

Cruise Control:

Yes, electronic cruise control.

Parking Assistance:

Rear parking sensors were not standard or widely available for this model year.

Connectivity

Connectivity Features:

Limited to analog systems; no Bluetooth or modern smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles or 12-15,000 km (refer to manual for precise recommendation).

Air Filter Replacement:

Every 30,000 miles or as needed based on inspection.

Spark Plug Replacement:

Typically every 60,000 miles (check specific plug type).

Brake Fluid Flush:

Every 2 years.

Coolant Flush:

Every 2-3 years or 40,000-60,000 miles.

Fluid Specifications

Engine Oil Type:

Synthetic 5W-30 or 5W-40 (refer to manual for specific BMW approval).

Engine Oil Capacity:

Approx. 6.5 liters (6.9 US quarts) with filter change.

Transmission Fluid Type:

BMW MTF LT-2 or equivalent (manual transmission).

Differential Fluid Type:

Hypoid gear oil SAE 75W-90, API GL-5.

Coolant Type:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) or equivalent.

Known Issues

Common Issues:

Eccentric shaft sensor failure, oil pan gasket leaks, VANOS seal wear (if applicable), cooling system component failures (hoses, water pump), subframe bushings, rear main seal leaks.

Maintenance Importance:

Proactive maintenance and adherence to service intervals are critical for the longevity and performance of the S38 engine and its complex systems.

📚 Vehicle History

Brand Heritage

Heritage:

BMW has a long-standing reputation for building driver-focused, performance-oriented luxury vehicles.

Model Evolution

E34 M5 Generation:

The E34 M5 was the third generation of the M5, succeeding the E28 M5 and preceding the E39 M5.

E34 M5 Development:

Developed by BMW Motorsport GmbH, it featured a hand-built engine and a chassis tuned for track-like performance.

Production

Production Years:

1988–1995

Manufacturing Location:

Dingolfing, Germany

Production Volume E34 M5:

Approximately 12,000 units worldwide.

🏆 Awards & Recognition

Recognitions

Performance Accolades:

Widely praised by automotive journalists for its performance, handling, and driver engagement, often cited as one of the best sports sedans of its era.