Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Diagnostic, Maintenance, Troubleshooting
Estimated Page Count:
1000+
Type:
Professional Workshop Manual
Format:
Downloadable (likely PDF)
Engine:
Detailed overhaul, diagnostics, performance tuning
Transmission:
Manual and Automatic: overhaul, fluid service, diagnostics
Drivetrain:
Driveshafts, differentials, axle components
Suspension:
Front and rear suspension components, alignment, troubleshooting
Brakes:
ABS, hydraulic system, pad/rotor replacement, caliper overhaul
Steering:
Power steering system, steering rack, linkages
Electrical System:
Full wiring diagrams, component testing, diagnostic procedures
Fuel System:
Fuel injection, pumps, injectors, diagnostics
Cooling System:
Radiator, water pump, thermostat, fan, troubleshooting
Exhaust System:
Components, troubleshooting
HVAC:
Air conditioning system, heater core, climate control
Bodywork:
Panel removal/installation, trim, glass
Interior:
Trim removal, seat mechanisms, dashboard components
Routine Maintenance:
Oil changes, filter replacements, spark plugs, fluids
Major Repairs:
Engine rebuilds, transmission overhaul, suspension replacement
Troubleshooting:
Diagnostic flowcharts, common fault finding
Diagnostics:
Component testing, error code interpretation (where applicable)
Special Tools:
Identification and usage of specialized BMW tools
Depth:
Comprehensive, from basic maintenance to full rebuilds
Diagrams:
Step-by-step diagrams and illustrations for procedures
Torque Specifications:
Detailed torque values for all critical fasteners
Clearances:
Engine component clearances, bearing clearances
Engine Code:
M20B25 (primarily)
Engine Type:
Inline 6-cylinder, 24-valve (DOHC for later E34 models, SOHC for earlier M20 based)
Displacement:
2.5 Liters (2494 cc)
Horsepower:
Approx. 168-170 hp (varies slightly by market and year)
Torque:
Approx. 220-225 Nm (162-166 lb-ft) (varies slightly)
Fuel Delivery:
Bosch Motronic electronic fuel injection (EFI)
Fuel Type:
Unleaded gasoline (Premium recommended)
Bore X Stroke:
84 mm x 75 mm
Compression Ratio:
8.8:1 (typical for M20B25)
Type:
5-speed manual transmission
Type:
4-speed automatic transmission (e.g., ZF 4HP22)
Clutch:
Hydraulically actuated single dry plate clutch
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or SAE 80W-90 (verify specific BMW spec)
Automatic Transmission Fluid:
BMW LT 71141 or equivalent Dexron III/Mercon (verify specific BMW spec)
Length:
Approx. 4714 mm (185.6 in)
Width:
Approx. 1751 mm (68.9 in)
Height:
Approx. 1412 mm (55.6 in)
Wheelbase:
Approx. 2799 mm (110.2 in)
Curb Weight:
Approx. 1550-1650 kg (3417-3638 lbs)
Gross Weight:
Approx. 2000-2100 kg (4409-4630 lbs)
Historical Ratings:
No standardized crash test ratings like modern NCAP/IIHS available for this era, but designed to high BMW safety standards of the time.
ABS:
Anti-lock Braking System (ABS) standard on most E34 525i models
Airbags:
Driver's side airbag introduced during the E34's lifecycle (check specific year/market for availability)
Seatbelts:
3-point inertia-reel seatbelts with pre-tensioners available
Chassis Design:
Reinforced safety cell, crumple zones
Audio System:
Factory BMW radio/cassette player with optional CD changer. Speaker system details and replacement procedures will be in the manual.
Climate Control:
Manual or automatic climate control (ECC - Electronic Climate Control) depending on trim. System operation and troubleshooting are covered.
Cruise Control:
Standard on many models, operation and diagnosis are included.
OBD Ii:
OBD-I is standard for this era. The manual will explain diagnostic connector locations and early diagnostic procedures.
Oil Change:
Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, depending on driving conditions. The manual will detail the condition-based service (CBS) system or recommended intervals.
Spark Plugs:
Intervals vary by plug type (e.g., 30,000 miles for standard, 60,000+ for long-life). The manual will specify the exact type and interval.
Coolant Flush:
Every 2-3 years or as recommended by BMW coolant specifications.
Timing Belt Chain:
The M20 engine uses a timing belt. Replacement is critical, typically every 60,000 miles or 5 years. The manual will provide the exact interval and procedure. Later E34 models might have the M50 engine with a timing chain.
Engine Oil:
Typically BMW High Performance SAE 5W-30 or 5W-40 synthetic. Refer to manual for precise BMW Longlife-XX specification.
Coolant:
BMW Blue Ethylene Glycol coolant (50/50 mix with distilled water). Verify specific BMW antifreeze specification.
Brake Fluid:
DOT 4 hydraulic fluid. BMW recommends DOT 4 LV (Low Viscosity) for ABS systems.
Cooling System Leaks:
Common issues include cracked plastic coolant expansion tanks, failing water pumps, and hose degradation.
Head Gasket:
While not as prevalent as some other BMWs, head gasket issues can occur, especially with age and overheating. The manual details testing and replacement.
Ignition System:
Coil packs, spark plug wires, and distributor (on older M20) can degrade over time, affecting performance.
Window Regulators:
Electric window regulators can be prone to failure. Manuals detail their removal and repair.
ABS Sensors:
ABS wheel speed sensors can fail, leading to ABS warning lights. The manual covers diagnosis.
Bmw Philosophy:
BMW's commitment to 'Ultimate Driving Machine' is evident in the E34's balance of performance, luxury, and engineering.
E34 Generation:
The E34 (produced 1987-1996) replaced the E28 and introduced more aerodynamic styling and advanced technology. The 525i was a core model, offering a balance of performance and efficiency.
Manufacturing Locations:
Primarily Germany (Dingolfing, Munich)
Key Variants:
Sedan (4-door) and Touring (wagon) body styles were available. This manual focuses on the 525i Sedan.
