🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E34 Model Year: 1991 Product Name: BMW E34 1991 Factory Service Repair Manual 👋 Introduction Market Position Positioning: The E34 represented BMW's entry into the mid-luxury sedan segment, emphasizing performance, comfort, and advanced technology for its era. Competitive Analysis Competitors: Competed with luxury sedans like the Mercedes-Benz W124 E-Class, Audi V8 Quattro, and Jaguar XJ. Key Features Design Philosophy: Continued BMW's 'ultimate driving machine' ethos with refined handling, powerful inline-six engines, and a driver-focused cockpit. Innovation: Introduced advanced features such as multi-link rear suspension, integrated aerodynamic design, and sophisticated electronic engine management. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair and adjustment information for the 1991 BMW E34. Target Audience: Mechanics and DIY enthusiasts. Page Count Estimated Pages: Likely 1000+ pages, typical for a full factory service manual of this era. Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Likely Print (original factory publication) or Digital (PDF scan). 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, repair, and overhaul procedures for various E34 engine variants of 1991, including M20, M30, and M50 families. Engine Management: Diagnosis and repair of Motronic fuel injection and ignition systems, sensors, actuators, and ECU troubleshooting. Transmission Manual: Removal, installation, and overhaul procedures for manual transmissions (e.g., Getrag 260). Transmission Automatic: Removal, installation, and overhaul procedures for automatic transmissions (e.g., ZF 4HP22). Drivetrain: Service and repair of driveshafts, differential, axle shafts, and related components. Suspension: Front and rear suspension component diagnosis, replacement, and alignment procedures. Steering: Power steering system diagnosis, repair, and component replacement. Brakes: Diagnosis and repair of hydraulic brake systems, including ABS (Anti-lock Braking System) components and procedures. Electrical System: Comprehensive wiring diagrams, component locations, and diagnostic procedures for all vehicle electrical systems. Body And Chassis: Body panel removal/installation, interior trim, glass replacement, and chassis repair procedures. Heating And Air Conditioning: Diagnosis and repair of HVAC systems, including refrigerant handling and component replacement. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, and general inspections. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for various vehicle issues. Repair Procedures: Step-by-step instructions for component removal, disassembly, repair, and reassembly. Installation: Procedures for installing new or replacement parts and accessories. Diagnostics: In-depth diagnostic routines for electrical, mechanical, and engine management systems. Technical Depth Depth: Complete factory-level detail, covering everything from basic adjustments to major overhauls and complex diagnostics. 📊 Manual Specifications File Format Digital Format: If digital, typically PDF with searchable text for ease of use. Print Quality Print Quality: High quality, professional printing with clear diagrams and text (for original print versions). Binding Type Binding: Likely professional perfect binding or spiral binding for print versions, allowing the manual to lay flat. Paper Type Paper: Durable, often glossy paper stock suitable for workshop environments (for original print versions). ⚙️ Engine Specifications Primary Engine Engine Options 1991: Common engines include the M20B25 (2.5L inline-6), M30B35 (3.5L inline-6), and the M50B25 (2.5L inline-6, introduced later in E34 production). Performance M20B25 Power: Approx. 170 hp (125 kW) at 5,800 rpm M20B25 Torque: Approx. 225 Nm (166 lb-ft) at 4,300 rpm M30B35 Power: Approx. 208 hp (153 kW) at 5,700 rpm M30B35 Torque: Approx. 305 Nm (225 lb-ft) at 4,000 rpm M50B25 Power: Approx. 189 hp (141 kW) at 6,000 rpm M50B25 Torque: Approx. 245 Nm (181 lb-ft) at 4,700 rpm Fuel System Fuel Injection: Bosch Motronic fuel injection and ignition systems (e.g., Motronic 1.3, 1.7, 3.1 depending on engine and market). Fuel Type: Premium Unleaded Gasoline (91+ octane recommended). 🔧 Transmission Standard Transmission Standard: 5-speed manual transmission was standard on many models. Optional Transmission Optional: 4-speed automatic transmission (e.g., ZF 4HP22) was a common option. Features Automatic Features: Some automatic transmissions featured Sport and Economy modes. 📐 Dimensions Exterior Wheelbase: Approx. 2763 mm (108.8 inches) Length: Approx. 4734 mm (186.4 inches) Width: Approx. 1751 mm (68.9 inches) Height: Approx. 1410 mm (55.5 inches) Weights Curb Weight: Varies by model and equipment, typically 1500-1650 kg (3300-3650 lbs). Gross Vehicle Weight Rating: Typically around 2000-2150 kg (4400-4750 lbs). 🛡️ Safety Features Ratings Crash Test Data: While official NHTSA/IIHS ratings for this specific year are less common, E34s were known for robust chassis construction. Data is limited for this period. Active Features ABS: Anti-lock Braking System (ABS) was standard on most models or a frequently optioned feature. Passive Features Airbags: Driver's side airbag became increasingly common, though not always standard on all 1991 models. Passenger airbag became available later. Seatbelts: Three-point inertia-reel seatbelts for all occupants. Body Structure: Reinforced safety cell with crumple zones designed for impact absorption. 💡 Technology Features Infotainment Audio System: Factory premium audio systems often featured cassette decks with optional CD changers and amplifier upgrades. Climate Control: Optional automatic climate control (ECC - Electronic Climate Control) offered more precise temperature...