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BMW 5 Series 1989-1995 Workshop Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation: E34 Codes Chassis Code: E34 👋 Introduction Market Position Market Position: Luxury Executive Sedan - Competed against Mercedes-Benz E-Class, Audi...
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BMW 5 Series 1989-1995 Workshop Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Generation:
E34
Codes
Chassis Code:
E34
👋 Introduction
Market Position
Market Position:
Luxury Executive Sedan - Competed against Mercedes-Benz E-Class, Audi V8/A8, Lexus LS, Cadillac DeVille. Positioned as a performance-oriented, technologically advanced, and driver-focused luxury vehicle.
Competitive Analysis
Key Competitors:
Mercedes-Benz W124 E-Class, Audi Typ 44 (200/V8), Lexus LS400, Jaguar XJ6. The E34 offered a balance of performance, luxury, and build quality that differentiated it.
Key Features
Defining Characteristics:
Iconic BMW handling and driving dynamics, sophisticated inline-six engines, optional V8 engines, spacious and driver-oriented interior, robust build quality, advanced (for its time) electronics and safety features.
📋 Manual Details
Coverage Areas
Covered Years:
1989, 1990, 1991, 1992, 1993, 1994, 1995
Page Count
Page Count:
450
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (M20, M30, M50, M60, M62 engines), fuel injection, ignition, cooling, lubrication, exhaust, emissions control
Transmission Systems:
Manual transmission (Getrag 260, Getrag 420G), Automatic transmission (ZF 4HP22, ZF 5HP18, ZF 5HP30), clutch, driveshaft, differential
Chassis Systems:
Suspension (front strut, rear multi-link), steering (power steering), brakes (ABS, vented discs), wheels and tires
Electrical Systems:
Engine control unit (ECU), body control module (BCM), lighting, instrumentation, power accessories, wiring diagrams, diagnostic procedures
Body Systems:
Body panels, doors, windows, mirrors, interior trim, HVAC system, security system
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, coolant flush, brake fluid service, belt inspections and replacements, general inspections
Repair Procedures:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper and rotor replacement, electrical component diagnosis and repair, body panel repair
Troubleshooting Procedures:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical circuit testing, fuel system diagnosis
Technical Depth
Technical Depth:
Comprehensive - from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic flowcharts and wiring diagrams
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans, suitable for printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Variants Covered:
Inline-4 (M40 - less common in North America), Inline-6 (M20B25 - 2.5L, M50B25/B25TU - 2.5L, M50B30 - 3.0L), V8 (M60B30 - 3.0L, M60B40 - 4.0L, M62B44 - 4.4L for later models/specific markets)
Performance
Horsepower Range:
150 hp (M40) to 322 hp (M60B40, M50B30 in M5)
Torque Range:
180 lb-ft (M40) to 317 lb-ft (M60B40)
Fuel System
Fuel Delivery:
Bosch Motronic electronic fuel injection (EFI) across most variants
🔧 Transmission
Standard
Standard Transmission:
5-speed manual (Getrag 260 for most 6-cyl, Getrag 420G for M5 variants)
Optional
Optional Transmission:
4-speed automatic (ZF 4HP22), 5-speed automatic (ZF 5HP18, ZF 5HP30 for V8 models)
Features
Rear Wheel Drive:
All models are RWD
Limited Slip Differential:
Optional on many models, standard on M5 and some high-performance variants
📐 Dimensions
Exterior
Wheelbase:
Approx. 111.5 inches (2832 mm)
Length:
Approx. 191.1 inches (4854 mm)
Width:
Approx. 70.5 inches (1791 mm)
Height:
Approx. 56.1 inches (1425 mm)
Weights
Curb Weight Range:
Approx. 3400 - 4000 lbs (1542 - 1814 kg) depending on engine and equipment
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not consistently tested under modern NHTSA standards, but generally considered a safe vehicle for its era due to robust construction.
Active Features
ABS:
Standard on most models from 1990 onwards, optional on earlier models.
Traction Control:
Optional on higher-end models, often referred to as ASC (Automatic Stability Control) or ASC+T (with throttle control).
Passive Features
Airbags:
Driver's side airbag standard from early 90s; passenger airbag optional/standard on later models.
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners (front)
Crumple Zones:
Designed with front and rear crumple zones for impact energy absorption.
💡 Technology Features
Infotainment
Audio System:
BMW Bavaria C series radios (various configurations), optional CD changers, premium sound systems (e.g., HiFi system).
Climate Control:
Manual or automatic climate control (ECC - Electronic Climate Control) with independent driver/passenger temperature control on higher trims.
Driver Assistance
Cruise Control:
Standard on most models, electronic cruise control.
Connectivity
Onboard Computer:
Optional OBC (On-Board Computer) providing fuel consumption, range, average speed, etc.
Phone Integration:
Optional early cellular phone integration systems were available on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or 12 months, depending on driving conditions and oil used. Check specific model year recommendations.
Coolant Flush Interval:
Every 2-3 years or as recommended by BMW, often using BMW coolant concentrate.
Spark Plug Replacement:
Varies by engine: Platinum/Iridium plugs can last 60,000-100,000 miles. Older copper plugs may require 20,000-30,000 mile replacement.
Fluid Specifications
Engine Oil Type:
API SJ or SL, SAE 5W-30 or 5W-40 synthetic recommended by BMW. Check manual for specific viscosity based on climate.
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) or equivalent.
Brake Fluid Type:
DOT 4.
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 synthetic gear oil (for Getrag transmissions). Check specific fill quantities.
Transmission Fluid Automatic:
ZF LifeguardFluid5 (or equivalent) for ZF 5HP transmissions; Dexron III (or equivalent) for ZF 4HP transmissions. Check specific fill quantities and procedures.
Known Issues
Common Failures:
Cooling system component degradation (hoses, water pump, plastic expansion tank), front sway bar links and bushings, vacuum leaks (especially on M50 engines), fuel pump failure, OVP relay issues (for some models), VANOS seal degradation (on M50TU/M52 engines), window regulator failures, door panel clips breaking.
E34 Specific Concerns:
The E34 is known for its robust construction but requires diligent maintenance to prevent costly issues. Electrical gremlins can sometimes arise due to age and moisture ingress. Timing chain guides on M60/M62 engines are a known wear item.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for producing driver-focused, well-engineered vehicles with a strong emphasis on performance and quality.
Model Evolution
E34 Development:
The E34 succeeded the E28 5 Series and was designed by Claus Luthe. It introduced a more aerodynamic and refined styling, improved chassis dynamics, and a wider range of engine options, including the first V8 in a 5 Series.
Production
Production Years:
1987-1996 (globally), covering model years 1989-1995 for North American market inclusion.
Manufacturing Locations:
Germany (Dingolfing plant), South Africa, and assembly kits for other markets.
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Frequently appeared on Car and Driver's '10Best' lists during its production run, particularly the 535i and M5 models.
European Awards:
Received numerous accolades across Europe for its driving dynamics, luxury, and engineering.
Ratings
Owner Satisfaction:
Generally high owner satisfaction, particularly for vehicles that have been well-maintained. Recognized for longevity when properly cared for.
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