🏷️ Basic Information

Make:

BMW

Model:

5 Series

Chassis Code:

E34

Model Year:

1991

Product Name:

BMW E34 1991 Factory Service Repair Manual

👋 Introduction

Positioning:

The E34 represented BMW's entry into the mid-luxury sedan segment, emphasizing performance, comfort, and advanced technology for its era.

Competitors:

Competed with luxury sedans like the Mercedes-Benz W124 E-Class, Audi V8 Quattro, and Jaguar XJ.

Design Philosophy:

Continued BMW's 'ultimate driving machine' ethos with refined handling, powerful inline-six engines, and a driver-focused cockpit.

Innovation:

Introduced advanced features such as multi-link rear suspension, integrated aerodynamic design, and sophisticated electronic engine management.

📋 Manual Details

General Coverage:

Comprehensive repair and adjustment information for the 1991 BMW E34.

Target Audience:

Mechanics and DIY enthusiasts.

Estimated Pages:

Likely 1000+ pages, typical for a full factory service manual of this era.

Type:

Factory Service Repair Manual

Language:

English

Format:

Likely Print (original factory publication) or Digital (PDF scan).

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, repair, and overhaul procedures for various E34 engine variants of 1991, including M20, M30, and M50 families.

Engine Management:

Diagnosis and repair of Motronic fuel injection and ignition systems, sensors, actuators, and ECU troubleshooting.

Transmission Manual:

Removal, installation, and overhaul procedures for manual transmissions (e.g., Getrag 260).

Transmission Automatic:

Removal, installation, and overhaul procedures for automatic transmissions (e.g., ZF 4HP22).

Drivetrain:

Service and repair of driveshafts, differential, axle shafts, and related components.

Suspension:

Front and rear suspension component diagnosis, replacement, and alignment procedures.

Steering:

Power steering system diagnosis, repair, and component replacement.

Brakes:

Diagnosis and repair of hydraulic brake systems, including ABS (Anti-lock Braking System) components and procedures.

Electrical System:

Comprehensive wiring diagrams, component locations, and diagnostic procedures for all vehicle electrical systems.

Body And Chassis:

Body panel removal/installation, interior trim, glass replacement, and chassis repair procedures.

Heating And Air Conditioning:

Diagnosis and repair of HVAC systems, including refrigerant handling and component replacement.

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, and general inspections.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for various vehicle issues.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, repair, and reassembly.

Installation:

Procedures for installing new or replacement parts and accessories.

Diagnostics:

In-depth diagnostic routines for electrical, mechanical, and engine management systems.

Depth:

Complete factory-level detail, covering everything from basic adjustments to major overhauls and complex diagnostics.

📊 Manual Specifications

Digital Format:

If digital, typically PDF with searchable text for ease of use.

Print Quality:

High quality, professional printing with clear diagrams and text (for original print versions).

Binding:

Likely professional perfect binding or spiral binding for print versions, allowing the manual to lay flat.

Paper:

Durable, often glossy paper stock suitable for workshop environments (for original print versions).

⚙️ Engine Specifications

Engine Options 1991:

Common engines include the M20B25 (2.5L inline-6), M30B35 (3.5L inline-6), and the M50B25 (2.5L inline-6, introduced later in E34 production).

M20B25 Power:

Approx. 170 hp (125 kW) at 5,800 rpm

M20B25 Torque:

Approx. 225 Nm (166 lb-ft) at 4,300 rpm

M30B35 Power:

Approx. 208 hp (153 kW) at 5,700 rpm

M30B35 Torque:

Approx. 305 Nm (225 lb-ft) at 4,000 rpm

M50B25 Power:

Approx. 189 hp (141 kW) at 6,000 rpm

M50B25 Torque:

Approx. 245 Nm (181 lb-ft) at 4,700 rpm

Fuel Injection:

Bosch Motronic fuel injection and ignition systems (e.g., Motronic 1.3, 1.7, 3.1 depending on engine and market).

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended).

🔧 Transmission

Transmission Standard:

5-speed manual transmission was standard on many models.

Transmission Optional:

4-speed automatic transmission (e.g., ZF 4HP22) was a common option.

Automatic Features:

Some automatic transmissions featured Sport and Economy modes.

📐 Dimensions

Wheelbase:

Approx. 2763 mm (108.8 inches)

Length:

Approx. 4734 mm (186.4 inches)

Width:

Approx. 1751 mm (68.9 inches)

Height:

Approx. 1410 mm (55.5 inches)

Curb Weight:

Varies by model and equipment, typically 1500-1650 kg (3300-3650 lbs).

Gross Vehicle Weight Rating:

Typically around 2000-2150 kg (4400-4750 lbs).

🛡️ Safety Features

Crash Test Data:

While official NHTSA/IIHS ratings for this specific year are less common, E34s were known for robust chassis construction. Data is limited for this period.

ABS:

Anti-lock Braking System (ABS) was standard on most models or a frequently optioned feature.

Airbags:

Driver's side airbag became increasingly common, though not always standard on all 1991 models. Passenger airbag became available later.

Seatbelts:

Three-point inertia-reel seatbelts for all occupants.

Body Structure:

Reinforced safety cell with crumple zones designed for impact absorption.

💡 Technology Features

Audio System:

Factory premium audio systems often featured cassette decks with optional CD changers and amplifier upgrades.

Climate Control:

Optional automatic climate control (ECC - Electronic Climate Control) offered more precise temperature management.

Cruise Control:

Standard on most models, providing a more relaxed driving experience on highways.

Onboard Computer:

Optional onboard computer provided fuel economy data, trip information, and fault warnings.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 - 10,000 miles (12,000 - 15,000 km) or annually, depending on driving conditions and oil type used. Consult manual for specific recommendations.

Spark Plug Replacement:

Varies by spark plug type (copper, platinum, long-life). Consult manual, typically 30,000 - 60,000 miles.

Coolant Flush:

Recommended every 2-3 years or approximately 30,000 miles.

Engine Oil:

API SJ or SL rated, viscosity typically 0W-40, 5W-30, or 5W-40 depending on climate. (e.g., Castrol, Mobil 1). Refer to manual for exact specification.

Coolant:

BMW Blue Antifreeze (G48 specification) or equivalent silicate-free ethylene glycol coolant. Mix 50/50 with distilled water.

Brake Fluid:

DOT 4 brake fluid.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90.

Transmission Fluid Automatic:

ZF LifeguardFluid5 or equivalent Dexron III / Mercon compatible fluid. Consult manual for exact type.

Common Problems:

Head gasket leaks, cooling system component failure (water pump, thermostat, hoses), VANOS issues (on later M50 engines), fuel pump and injector issues, E32/E38 specific electrical gremlins can sometimes carry over, O2 sensor failure, ignition coil/distributor failure, rust in common areas (wheel arches, rocker panels, battery tray).

Maintenance Tip E34:

Regular inspection and replacement of cooling system components is critical due to the potential for catastrophic engine damage from overheating.

📚 Vehicle History

Bmw Legacy:

BMW has a long-standing reputation for building performance-oriented luxury vehicles with exceptional engineering.

E34 Introduction:

The E34 generation succeeded the E28 and was produced from 1988 to 1996, representing a significant modernization in design and technology.

E34 Design:

Designed by Claus Luthe, the E34 featured a more aerodynamic and sophisticated design compared to its predecessor.

Production Period:

1988-1996 (global production)

Manufacturing Locations:

Primarily Dingolfing, Germany; also assembled in various locations worldwide including South Africa and Mexico.

🏆 Awards & Recognition

Automotive Press Acclaim:

The E34 was consistently praised by automotive journalists for its driving dynamics, build quality, and sophisticated engineering.

Car And Driver Five Best:

The 5 Series (E34) was a frequent recipient of Car and Driver's '10Best' list during its production run.

Iso 9001 Certification:

While not a vehicle award, BMW's manufacturing facilities adhered to stringent quality standards like ISO 9001 during this period, ensuring high production quality.