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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类型: Car

斯库: 433404

标签: 1991 5 Series E34 BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Year:

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

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.