BMW E34 525I 535I M5 5 Series 1989 1990 Electronic TROUBLESHOOTING Manual
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🏷️ Basic Information Identification Make: BMW Model: 5 Series (E34) Model Variants: 525i, 535i, M5 Year: 1989, 1990 👋 Introduction Market Position Target Audience: Technicians, mechanics, DIY enthusiasts, and owners seeking detailed repair information. Key Features Comprehensiveness: Offers complete factory information for troubleshooting and repair. Accessibility: Instant download provides immediate access to crucial repair data. Value Proposition Cost Effectiveness: Provides a cost-effective alternative to expensive dealership service or multiple physical manuals. 📋 Manual Details Coverage Manual Type: Electronic Troubleshooting Manual Language: English File Format: PDF Delivery: Instant Download Requirements: Adobe PDF Reader, WinZip 📖 Manual Coverage Systems Engine Service Repair: Comprehensive coverage of engine service and repair procedures. Transmission Service Repair: Detailed information on transmission service and repair for both automatic and manual transmissions. Brake System: In-depth coverage of brake system components, maintenance, and troubleshooting. Wiring Diagrams: Complete electrical wiring diagrams for all vehicle systems. Electrical System: Detailed explanations of the electrical system, including component locations and functions. Suspension: Coverage of suspension components, alignment procedures, and repair. Steering: Information on steering system maintenance, repair, and troubleshooting. Cooling System: Detailed procedures for cooling system maintenance, including radiator, thermostat, and fan. Fuel Injection: In-depth troubleshooting and repair information for the fuel injection system. Fuel System: Coverage of the entire fuel system, including pump, lines, and tank. Emission System: Information related to emission control systems and troubleshooting. HVAC: Service and repair procedures for the heating, ventilation, and air conditioning (HVAC) system. Engine Control System: Detailed diagnostics and repair for the engine control unit (ECU) and related sensors. Chassis Body: Information on chassis and bodywork maintenance, repair, and diagnostics. Restraint System: Coverage of safety restraint systems, including airbags and seatbelts. Interior: Information pertaining to interior trim, components, and repair. Differential Drive: Detailed coverage of the differential and drive axle systems. Axle: Information on axle maintenance and repair. Procedures General Maintenance: Covers routine maintenance tasks and schedules. Troubleshooting: Extensive diagnostic procedures for identifying and resolving common and uncommon issues. Periodic Lubrication: Detailed lubrication points and schedules. Technical Depth Diagnostic Capabilities: Advanced diagnostic information, including fault codes and circuit analysis. Repair Instructions: Step-by-step repair instructions for most vehicle systems. 📊 Manual Specifications File Details File Type: PDF Print Quality: High Quality, Printable Searchability: Likely searchable PDF (dependent on original scan quality). Compression: May require WinZip for larger files. ⚙️ Engine Specifications 525I Engine Code: M20B25 (pre-facelift), M50B25 (facelift) Engine Type: Inline-6 Cylinder, DOHC Displacement: 2.5 Liters (2494 cc) Fuel System: Bosch Motronic Fuel Injection 535I Engine Code: M30B35 Engine Type: Inline-6 Cylinder, SOHC Displacement: 3.5 Liters (3430 cc) Fuel System: Bosch Motronic Fuel Injection M5 Engine Code: S38B36 Engine Type: Inline-6 Cylinder, DOHC Displacement: 3.6 Liters (3670 cc) Fuel System: Bosch Motronic Fuel Injection Performance General Horsepower 525I: Approx. 189 hp (M50B25) Horsepower 535I: Approx. 208 hp Horsepower M5: Approx. 310 hp 🔧 Transmission 525I 535I Standard Transmission: 5-speed Manual (Getrag 260) Optional Transmission: 4-speed Automatic (ZF 4HP22) M5 Standard Transmission: 5-speed Manual (Getrag S5D 310Z) 📐 Dimensions Exterior General Wheelbase: Approximately 111.5 inches (2835 mm) Length: Approximately 191.0 inches (4850 mm) Width: Approximately 70.5 inches (1790 mm) Height: Approximately 56.2 inches (1427 mm) Weights Curb Weight 525I: Approx. 3500-3700 lbs (1590-1680 kg) Curb Weight 535I: Approx. 3600-3800 lbs (1630-1725 kg) Curb Weight M5: Approx. 3800-4000 lbs (1725-1815 kg) 🛡️ Safety Features Passive Features Airbags: Driver's side airbag standard on later models, optional on earlier ones. Passenger airbag not standard. Seatbelts: Three-point inertia-reel seatbelts front and rear. Chassis Structure: Reinforced safety cage and crumple zones. Active Features ABS: Anti-lock Braking System (ABS) available, often standard on M5 and higher trims. Traction Control: ASC (Automatic Stability Control) available on some models, particularly later E34s. 💡 Technology Features Infotainment Audio System: Factory cassette radio with optional CD changer. Upgradeable to modern infotainment systems. Climate Control: Manual or automatic climate control (ECC - Electronic Climate Control) depending on trim level. Driver Assistance Cruise Control: Standard cruise control on most models. On Board Computer: Optional OBC (On-Board Computer) providing basic vehicle status and trip information. Connectivity Telematics: No advanced telematics or smartphone integration from the factory. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 to 10,000 miles or 12 months, depending on driving conditions and oil used. Spark Plug Replacement: Refer to manual for specific interval; typically around 30,000-60,000 miles depending on plug type. Coolant Flush: Recommended every 2 years or 30,000 miles. Fluid Specifications Engine Oil Type: BMW recommends specific synthetic oils meeting BMW Longlife-98 or Longlife-01 specifications (e.g., 5W-30, 5W-40, 10W-40). Coolant Type: BMW Blue Coolant (G48) or equivalent ethylene glycol-based antifreeze mixed with distilled water (50/50). Transmission Fluid Auto: ZF Lifeguardfluid 5 (or equivalent Dexron III/Mercon for earlier models, consult manual). Transmission Fluid Manual: GL-4 or GL-5 gear oil, specific viscosity depends on ambient temperature. Known Issues Cooling System Failures: Plastic coolant expansion tanks, water...
GL-4 or GL-5 gear oil, specific viscosity depends on ambient temperature.
Known Issues
Cooling System Failures:
Plastic coolant expansion tanks, water pumps, and hose failures are common due to age and heat cycles.
Head Gasket:
The M30 engine can be prone to head gasket issues if overheated. M50 engines are generally more robust.
Oil Leaks:
Valve cover gaskets, oil pan gaskets, and rear main seals are common sources of oil leaks on older BMWs.
Electrical Gremlins:
Older wiring harnesses and connectors can degrade, leading to intermittent electrical issues.
Idle Control Valve:
Issues with the idle control valve (ICV) can cause rough idling or stalling.
Part Numbers
Oil Filter 525I M50:
Mann-Filter HU 833/1 or equivalent Mahle OX 121/2D
Oil Filter 535I M30:
Mann-Filter W930/21 or equivalent Mahle OX 108/1
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW has a long-standing reputation for building sporting sedans with excellent driving dynamics and engineering.
Model Evolution
E34 Introduction:
The E34 generation replaced the E28 5 Series and was produced from 1987 to 1996, with the 1989-1990 models representing the early part of this successful generation.
M5 Positioning:
The E34 M5 represented the pinnacle of performance in the 5 Series lineup during its era, offering a potent blend of luxury and raw power.
Production
Manufacturing Locations:
Primarily manufactured in Germany.
🏆 Awards & Recognition
Recognitions
E34 Reputation:
The E34 5 Series is widely acclaimed for its robust engineering, comfortable ride, and engaging driving experience, often cited as one of the best 5 Series generations.
M5 Performance:
The E34 M5 is a celebrated performance car, praised for its naturally aspirated inline-six engine and handling.