🏷️ Basic Information

Make:

BMW

Model:

5-series

Chassis Code:

E34

Model Year Covered:

1991

Engine Codes Covered:

M20, M30, M50, M52 (specific variants as per 1991 models)

Transmission Codes Covered:

Getrag 260, ZF 4HP22 (specific variants as per 1991 models)

👋 Introduction

Positioning:

Mid-size luxury sedan, known for its performance, handling, and build quality

Competitors 1991:

Mercedes-Benz E-Class (W124), Audi 100/200 (C3/C4), Lexus LS 400 (though often compared to larger sedans), Jaguar XJ

Driving Dynamics:

Renowned 'Ultimate Driving Machine' characteristics, balanced chassis, responsive steering, sophisticated suspension

Powertrain:

Smooth inline-six engines (M20, M50), torquey V8 (M60 introduced later in E34 lifespan, though 1991 primarily inline-six), efficient inline-four (M40 for some markets)

Interior Quality:

Driver-focused cockpit, high-quality materials, ergonomic design

Design:

Iconic 'Bangle butt' design cues (though more subtle than later generations), clean lines, aerodynamic profile

📋 Manual Details

Primary Coverage:

All 1991 BMW 5-series (E34) models

Repair Scope:

A-Z (All repairs from routine maintenance to complete overhauls)

Estimated Page Count:

1000+

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Print (Likely spiral-bound or case-bound for dealership use)

📖 Manual Coverage

Engine:

Complete diagnosis, overhaul, timing, fuel injection (Bosch Motronic), emissions control, cooling system, lubrication system

Transmission:

Manual and automatic transmission diagnosis, repair, fluid changes, clutch replacement, torque converter service

Drivetrain:

Driveshaft, differential, axles, CV joints

Suspension:

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

Steering:

Power steering system, steering rack, steering column, troubleshooting

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), brake pads, rotors, calipers, master cylinder, bleeding procedures

Electrical:

Wiring diagrams for all systems, starter, alternator, battery, lighting, instrumentation, power windows, central locking, heated seats

Bodywork:

Body panel repair, door mechanisms, window regulators, seals, trim, rust prevention and repair techniques

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling

Maintenance:

Oil change, filter replacement, spark plug service, fluid level checks, belt replacement, battery maintenance

Troubleshooting:

Diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting

Repair:

Component removal, installation, and adjustment procedures for all major systems

Diagnostics:

On-board diagnostics (OBD) interpretation (where applicable for the era), specific BMW diagnostic procedures

Depth:

Factory-level detail, including torque specifications, special tool requirements, and diagnostic fault codes

Special Tools:

Identification and usage of BMW-specific tools required for complex repairs

📊 Manual Specifications

Format Type:

Physical Print

Quality:

Professional dealership-grade printing, clear diagrams and text

Binding:

Likely spiral-bound or case-bound for durability and lay-flat use

Paper Quality:

Durable, high-quality paper stock suitable for workshop environments

⚙️ Engine Specifications

Engine Family:

M20 & M50 Inline-6

Common Engines 1991:

M20B25 (2.5L), M50B25 (2.5L VANOS/non-VANOS)

Displacement M20B25:

2494 cc (2.5 Liters)

Bore Stroke M20B25:

84.0 mm x 75.0 mm

Compression Ratio M20B25:

8.8:1

Horsepower M20B25:

170 hp @ 5800 rpm

Torque M20B25:

225 Nm (166 lb-ft) @ 4300 rpm

Displacement M50B25:

2494 cc (2.5 Liters)

Bore Stroke M50B25:

84.0 mm x 75.0 mm

Compression Ratio M50B25:

10.0:1 (non-VANOS) / 10.5:1 (VANOS)

Horsepower M50B25:

189 hp @ 6000 rpm (non-VANOS) / 192 hp @ 5900 rpm (VANOS)

Torque M50B25:

245 Nm (181 lb-ft) @ 4200 rpm (non-VANOS) / 245 Nm (181 lb-ft) @ 4700 rpm (VANOS)

0 60 Mph Approx:

7.5 - 8.5 seconds (depending on engine and transmission)

Injection System:

Bosch Motronic electronic fuel injection

Fuel Type:

Unleaded gasoline (premium unleaded recommended)

Fuel Octane Rating:

91 AKI (95 RON) or higher

🔧 Transmission

Standard Transmission:

5-speed Getrag 260 manual transmission

Optional Transmission:

ZF 4HP22 4-speed automatic transmission

Automatic Features:

Sport mode (on some models), lock-up torque converter for efficiency

📐 Dimensions

Wheelbase:

2761 mm (108.7 in)

Length:

4734 mm (186.4 in)

Width:

1751 mm (68.9 in)

Height:

1410 mm (55.5 in)

Wheel Bolt Pattern:

5x120

Curb Weight Approx:

1500-1650 kg (3300-3640 lbs) depending on model and equipment

🛡️ Safety Features

NHTSA Rating Era:

Ratings from this era are often less comprehensive than modern standards; focus on passive safety features

ABS:

Standard on most models, Bosch 2-channel ABS system

Traction Control:

Optional on some higher-spec models (ASC - Automatic Stability Control)

Airbags:

Driver's side airbag standard on most 1991 models; passenger airbag optional/later addition for some markets

Seatbelts:

Pre-tensioned front seatbelts, three-point rear seatbelts

Body Structure:

Reinforced safety cage, crumple zones front and rear

💡 Technology Features

Audio System:

Optional premium sound systems (e.g., Harmon Kardon), standard BMW cassette player with AM/FM radio

Navigation:

Early optional navigation systems available on some later E34 models, but not common or standard for 1991

Cruise Control:

Standard or optional depending on trim level

Connectivity Features:

Limited by era; typically basic radio and phone prep (optional)

🔧 Maintenance

Oil Change Interval:

Typically 10,000 - 15,000 miles or 12-24 months (depending on driving conditions and oil used, consult manual)

Spark Plug Replacement:

Around 60,000 miles (may vary with plug type)

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles

Transmission Fluid Change:

Automatic: ~50,000-100,000 miles (BMW often cited as 'lifetime' but fluid replacement is recommended for longevity); Manual: Check for leaks, usually no specific interval unless issues arise

Engine Oil Type:

API SG or higher, SAE 5W-30, 5W-40, or 10W-40 (refer to manual for specific viscosity based on climate)

Engine Oil Capacity:

Approx. 5.0 - 6.5 liters (5.3 - 6.9 US quarts), depending on engine

Coolant Type:

BMW Blue (G48) or equivalent ethylene glycol based coolant, mixed 50/50 with distilled water

Automatic Transmission Fluid:

Dexron II or III (check specific ZF transmission fill)

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent (e.g., Red Line MTL)

Brake Fluid Type:

DOT 4

Common Issues Engine:

Oil leaks from valve cover gasket and oil pan gasket, cooling system component failures (hoses, radiator, water pump), idle control valve issues (M50), distributor cap/rotor wear (M20)

Common Issues Suspension:

Worn control arm bushings, ball joints, tie rod ends, shock absorber fatigue, sagging rear springs

Common Issues Electrical:

Corroded wiring connectors (especially grounds), failing instrument cluster illumination, door lock actuator issues, HVAC blower motor resistor failure

Common Issues Interior:

Cracked dashboard (sun damage), sagging headliner, worn seat bolsters

Common Issues Body:

Rust around wheel arches, rocker panels, sunroof drains, and battery tray area

📚 Vehicle History

Heritage:

BMW, Bayerische Motoren Werke AG, founded in 1916, renowned for sporty sedans and luxury vehicles

E34 Generation Start:

Introduced in 1987 (Europe) / 1988 (North America)

E34 Generation End:

Produced until 1995 (sedan) / 1996 (touring)

E34 Positioning:

Successor to the E28 5-series, predecessor to the E39 5-series

E34 Variants Covered By Manual:

520i, 525i, 530i, 535i, 540i (and their respective Touring variants if applicable to the 1991 model year service data)

Production Locations:

Mainly Dingolfing, Germany; also assembled in other plants globally

🏆 Awards & Recognition

Automotive Journal Awards:

Consistently ranked highly by automotive publications for handling, build quality, and performance during its production run.

Driving Experience Rating:

Considered a benchmark for driver engagement in its class

Manual Endorsement:

Explicitly stated as the manual used by dealership technicians, implying factory-approved procedures and accuracy.