BMW 5-series (E34) 1995 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5-series Chassis Code: E34 Model Year: 1995 Codes Internal Product Code: 5E3495SRM 👋 Introduction Market Position Positioning: Premium executive sedan offering a blend...

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Description

🏷️ Basic Information

Identification

Make:

Model:

5-series

Chassis Code:

Model Year:

Codes

Internal Product Code:

5E3495SRM

👋 Introduction

Market Position

Positioning:

Premium executive sedan offering a blend of luxury, performance, and durability.

Competitive Analysis

Competitors:

Mercedes-Benz W124 E-Class, Audi V8/A8, Lexus LS 400, Cadillac DeVille.

Key Features

Design Philosophy:

Chris Bangle's design influence, elegant lines, driver-centric interior.

Platform:

E34 platform, renowned for its robust engineering and dynamic handling.

📋 Manual Details

Coverage Areas

All Models Covered:

Repair Scope:

A-Z (All Repairs)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Service and Repair Manual

Origin:

Dealership Technician Level

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul, component testing, timing, lubrication, cooling

Engine Management:

Fuel injection (Bosch Motronic), ignition systems, sensor diagnostics, DME

Transmission Manual:

Disassembly, assembly, clutch system, shifting mechanisms

Transmission Automatic:

Torque converter, hydraulic controls, valve body, electronic transmission control (EGS)

Drivetrain:

Driveshafts, differential, axles, wheel bearings

Suspension:

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

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), brake pads, rotors, calipers, parking brake

Electrical System:

Battery, charging system, starter, lighting, horns, wipers, washers

Body Electrical:

Power windows, mirrors, central locking, interior lighting, dashboard instrumentation

HVAC:

Heating, ventilation, air conditioning (A/C) system, climate control

Bodywork Exterior:

Bumpers, fenders, doors, hood, trunk, glass, seals

Bodywork Interior:

Seats, dashboard, trim panels, headliner

Procedures Included

Preventive Maintenance:

Scheduled services, inspections, fluid changes, filter replacements

Routine Repairs:

Brake pad replacement, fluid flush, spark plug changes, belt replacement

Diagnostic Troubleshooting:

Step-by-step troubleshooting flowcharts for common and uncommon issues, DTC interpretation

Major Overhauls:

Engine rebuild, transmission overhaul, suspension component replacement

Component Replacement:

Detailed instructions for replacing virtually any part on the vehicle

Special Tools:

Identification and usage of specialized tools required for specific procedures

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete rebuilds and diagnostics)

Diagnostic Information:

Detailed diagnostic procedures, wiring diagrams, component testing specifications

Torque Specifications:

Exact torque values for all critical fasteners

Schematics:

Complete electrical schematics and vacuum routing diagrams

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content

Print Quality

Image Resolution:

High-resolution scans for clarity

Readability:

Optimized for easy reading on screen and printout

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Options 1995:

M50B25 (2.5L Inline-6), M60B30 (3.0L V8), M60B40 (4.0L V8)

Performance M50B25

Displacement M50B25:

2.5 Liters (2494 cc)

Horsepower M50B25:

189 hp @ 6000 rpm (Euro spec, US spec slightly lower)

Torque M50B25:

245 Nm (181 lb-ft) @ 4200 rpm (Euro spec)

Performance M60B40

Displacement M60B40:

4.0 Liters (3982 cc)

Horsepower M60B40:

282 hp @ 5800 rpm (US spec)

Torque M60B40:

400 Nm (295 lb-ft) @ 4500 rpm (US spec)

Fuel System

Fuel Injection:

Bosch Motronic Electronic Fuel Injection (EFI)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

Engine Layout

Configuration:

Inline-6 (M50 series), V8 (M60 series)

Engine Features

Valvetrain M50:

Dual Overhead Camshafts (DOHC), 4 valves per cylinder, VANOS (Variable Valve Timing) on later M50s

Valvetrain M60:

Dual Overhead Camshafts (DOHC), 4 valves per cylinder

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Getrag S5D 250G (on most 6-cylinder models)

Optional

Optional Transmission:

4-speed Automatic (ZF 4HP22 or 4HP24)

Features Automatic

Automatic Modes:

Standard, Sport, and often Economy modes

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent (e.g., Pentosin MTL 75W-80)

Automatic Transmission Fluid:

Dexron III or Pentosin ATF 134

📐 Dimensions

Exterior Sedan

Length Sedan:

4734 mm (186.4 in)

Width Sedan:

1751 mm (68.9 in)

Height Sedan:

1410 mm (55.5 in)

Exterior Touring

Length Touring:

4755 mm (187.2 in)

Width Touring:

1751 mm (68.9 in)

Height Touring:

1443 mm (56.8 in)

Wheelbase

Wheelbase:

2760 mm (108.7 in)

Weights

Curb Weight Est Sedan:

1500-1700 kg (3300-3750 lbs) depending on engine/options

Gross Vehicle Weight Rating Est:

1900-2100 kg (4190-4630 lbs)

Wheel Bolt Pattern:

5x120

Wheel Size Standard:

15x7 inches (commonly)

Wheel Size Optional:

16-17 inches (e.g., Style 32, BBS RS)

🛡️ Safety Features

Ratings

Crash Test Data Availability:

Limited official NHTSA/IIHS data for this specific era and model, but E34 generally considered well-built.

Active Features

Standard on most models, Bosch ABS III

Traction Control:

ASR (Anti-Slip Regulation) available on some models, particularly V8 and later 6-cylinder

Passive Features

Airbags:

Driver's side airbag standard, passenger airbag optional/standard on later models.

Seatbelts:

Front seatbelt pretensioners

Chassis Construction:

Reinforced safety cell, crumple zones

💡 Technology Features

Infotainment

Audio System:

BMW Business CD, BMW Professional RDS radio/cassette, optional CD changer.

Navigation:

Optional BMW on-board computer and navigation system (early generation).

Driver Assistance

Cruise Control:

Standard on most models.

Parking Sensors:

Rear parking sensors (Park Distance Control) available as an option on later models.

Connectivity

Early Telematics:

Limited by modern standards, primarily focused on vehicle systems and audio.

🔧 Maintenance

Service Intervals General

Oil Change Interval:

Typically 7,500 - 15,000 miles (12,000 - 24,000 km) or annually, depending on driving conditions and oil type.

Major Service Interval:

Around 30,000 - 60,000 miles (50,000 - 100,000 km) for spark plugs, coolant, brake fluid, etc.

Fluid Specifications

Engine Oil Type:

BMW Longlife-98 (LL-98) or equivalent synthetic, typically 5W-30 or 5W-40.

Coolant Type:

BMW Blue Antifreeze/Coolant or equivalent (ethylene glycol based), typically 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4

Known Issues

Cooling System:

Plastic coolant expansion tanks can become brittle and crack. Water pump seals and thermostat housing leaks.

Suspension Bushings:

Front control arm bushings (RTABs), subframe bushings, and rear trailing arm bushings are common wear items.

Vibration Issues:

Driveshaft flex disc (guibo) failure, center support bearing wear, driveshaft imbalance.

Electrical Gremlins:

Corrosion in connectors, aging wiring harnesses, ABS module failures, faulty OVP relays (Over Voltage Protection).

M60 V8 Issues:

Head gasket leaks, timing chain guide wear (Nikasil coating in early M60s can wear if poor fuel quality is used, leading to a recall/replacement with Alusil).

Heater Core:

Leaking heater cores are a common issue, leading to coolant smell inside the cabin.

Fluid Capacities

Engine Oil Capacity M50:

Approx. 6.5 Liters (6.9 US Quarts)

Engine Oil Capacity M60:

Approx. 7.5 Liters (7.9 US Quarts)

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW's established reputation for engineering excellence, sporty driving dynamics, and luxury.

Model Evolution

E34 Introduction:

Introduced in 1987 (Europe), 1988 (North America), replacing the E28 5-Series.

E34 Facelift:

Facelift in 1994 (model year 1995 update for some markets) brought revised bumpers, mirrors, and interior trim.

Production

Production Years:

1987-1996

Manufacturing Locations:

Germany (Dingolfing), South Africa, Thailand, Venezuela.

Model Variants

Key Variants:

520i, 525i, 530i, 535i, 540i, M5 (S38B36/S38B38), Touring (wagon) variants.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E34 5-series was a frequent recipient of Car and Driver's '10Best' list during its production run, celebrated for its driving dynamics and engineering.

Ratings

General Reputation:

Widely regarded as one of the best driving sedans of its era, praised for build quality and refined performance.