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BMW 525 525i 1988 1989 1990 1991 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 525i Model Generation: E34 Codes Chassis Code: E34 Engine Code Prefix: M50 👋 Introduction Market Position Positioning: The BMW...
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BMW 525 525i 1988 1989 1990 1991 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Variant:
525i
Model Generation:
E34
Codes
Chassis Code:
E34
Engine Code Prefix:
M50
👋 Introduction
Market Position
Positioning:
The BMW 5 Series E34 represented the executive sedan segment, known for its blend of luxury, performance, and advanced engineering for its era.
Competitive Analysis
Competitors:
Competed with vehicles like the Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, and certain models from Lexus and Volvo.
Key Features
Design:
Penned by legendary designer Ercole Spada, the E34 featured a more angular and aerodynamic design compared to its E28 predecessor, while retaining BMW's signature kidney grille.
Engineering:
Renowned for its sophisticated suspension, balanced chassis, and driver-focused ergonomics.
Target Audience
Audience:
Professionals, enthusiasts, and those seeking a reliable and engaging luxury sedan.
📋 Manual Details
Coverage Areas
Covered Years:
1988, 1989, 1990, 1991
Page Count
Page Count:
227
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, cooling.
Engine Management:
Fuel injection (Bosch Motronic), ignition system, sensors, actuators, diagnostic procedures.
Transmission Manual:
Clutch, gearbox overhaul, shift mechanism, driveshafts.
Transmission Automatic:
Automatic transmission overhaul, hydraulic control, electronic control unit (if applicable for model years covered).
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment procedures.
Steering:
Power steering system, steering rack, pump, linkages, troubleshooting.
Brakes:
Brake system components (discs, pads, calipers, master cylinder), ABS system (if equipped), hydraulic lines, bleeding procedures.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting, fuses, relays, wiring diagrams.
Body And Chassis:
Body panels, doors, hinges, latches, bumpers, interior trim, structural components.
HVAC:
Heating, ventilation, and air conditioning system components, refrigerant handling, troubleshooting.
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter replacement.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes.
Wheels And Tires:
Wheel torque specifications, tire pressure recommendations.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement.
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, fault codes interpretation.
Repair:
Step-by-step repair instructions for all major mechanical and electrical systems.
Overhaul:
Complete disassembly, inspection, and reassembly procedures for engine and transmission.
Diagnostics:
Testing procedures for sensors, actuators, and control modules, use of diagnostic equipment.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to in-depth component overhaul and diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans for clear text and diagrams, suitable for printing.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-6 Cylinder, DOHC
Engine Displacement:
2.5 Liters (2494 cc)
Engine Code:
M50B25
Performance
Horsepower:
189 hp @ 6000 rpm (approximate, may vary slightly by market/year)
Torque:
245 Nm (181 lb-ft) @ 4200 rpm (approximate, may vary slightly by market/year)
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection
Fuel Type:
Unleaded Premium Gasoline (91+ Octane)
Engine Features
Valvetrain:
Double Overhead Camshafts (DOHC), 4 valves per cylinder.
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (ZF 4HP22)
Features
Drivetrain:
Rear-Wheel Drive (RWD)
📐 Dimensions
Exterior
Length:
4710 mm (185.4 in)
Width:
1751 mm (68.9 in)
Height:
1410 mm (55.5 in)
Weights
Curb Weight:
1500-1600 kg (3307-3527 lbs) (approximate, depending on options)
🛡️ Safety Features
Ratings
Crash Testing:
As per 1980s/1990s standards; modern ratings not directly comparable.
Active Features
ABS:
Anti-lock Braking System (ABS) was available, often standard on later models or as an option.
Traction Control:
Optional ASC (Automatic Stability Control) or ASC+T (with Traction Control) became available later in the E34's lifecycle.
Passive Features
Airbags:
Driver's side airbag became standard in later years of the E34 production, often optional initially.
Seatbelts:
Front and rear seat belts.
💡 Technology Features
Infotainment
Radio System:
Factory AM/FM cassette player, optional CD changer.
Onboard Computer:
On-Board Computer (OBC) provided trip data, fuel economy, and system checks, often with a rudimentary display.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Exterior Features:
Optional power sunroof, power mirrors, headlamp washers.
🔧 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 type.
Major Service Interval:
Major services often recommended around 30,000, 60,000, and 100,000 miles, including checks of belts, hoses, fluid flushes, and component inspections.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 Synthetic or Semi-Synthetic Oil meeting BMW Longlife-98 specifications (or equivalent API SG/SH).
Coolant Type:
BMW Blue Antifreeze/Coolant (ethylene glycol-based) mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
API GL-4 or GL-5 Gear Oil (e.g., 75W-90)
Transmission Fluid Automatic:
BMW ATF LT-3 or equivalent (check specific transmission filter kit for exact spec)
Power Steering Fluid:
BMW Power Steering Fluid or ATF Dexron III
Known Issues
Cooling System:
Water pump failure, thermostat issues, radiator leaks, cracking coolant expansion tanks.
Engine Management:
Mass Air Flow (MAF) sensor failures, idle control valve issues, VANOS (variable valve timing) solenoid/seal issues on later M50 engines (though less common on early 2.5L).
Suspension:
Wear in control arm bushings (BMW specific part numbers like 31121136531), ball joints, and tie rod ends.
Electrical:
Fuse box corrosion, alternator regulator issues, OBC (On-Board Computer) pixel degradation.
Interior:
Headliner sagging, driver's seat bolster wear, instrument cluster warning light bulb failures.
Fuel System:
Fuel pump failures, leaky fuel injectors.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long history of producing high-quality, performance-oriented luxury vehicles, dating back to the early 20th century.
Model Evolution
E34 Introduction:
The E34 generation of the 5 Series was introduced in 1987 (as a 1988 model in North America) and replaced the E28.
E34 Updates:
The E34 received a significant facelift in 1994 (affecting 1994-1995 models), but this manual covers the pre-facelift versions.
Production
Production Years E34:
1987-1996 (global)
Manufacturing Locations:
Primarily Germany (Dingolfing plant), with some assembly in other locations.
🏆 Awards & Recognition
Recognitions
Editorial Reviews:
The E34 5 Series was widely praised by automotive journalists for its driving dynamics, build quality, and refined interior.
Automotive Journalism Accolades:
Frequently appeared on 'Ten Best Cars' lists from publications like Car and Driver during its production run.
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