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BMW 5 Series E34 1991 Factory Service Repair Manual
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Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E34 Model Year: 1991 Codes Production Codes Covered: All E34 variants for 1991 model year Introduction Market Position Segment: Luxury...
Taper: Cars
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UGS: 433404
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| Basic Information | |
| Identification | |
| Make: | BMW |
| Model: | 5 Series |
| Chassis Code: | E34 |
| Model Year: | 1991 |
| Codes | |
| Production Codes Covered: | All E34 variants for 1991 model year |
| Introduction | |
| Market Position | |
| Segment: | Luxury mid-size executive sedan and wagon. |
| Bmw Positioning: | Known for performance, driving dynamics, build quality, and sophisticated engineering. |
| Competitive Analysis | |
| Key Competitors: | Mercedes-Benz E-Class (W124), Audi 100/200, Lexus LS 400 (introduced late in the E34's life). |
| Key Features | |
| Design Philosophy: | Evolved from the E28, featuring sharper lines and a more aerodynamic profile, iconic BMW kidney grille. |
| Engine Options 1991: | Range of inline-six and V8 engines (depending on specific market and model variants). |
| Drivetrain: | Primarily rear-wheel drive (RWD), with optional all-wheel drive (xDrive) available on select models (though less common in 1991 models targeted by this manual). |
| Manual Details | |
| Coverage Areas | |
| Coverage: | Comprehensive factory service and repair |
| Page Count | |
| Page Count: | Hundreds of pages (exact number not specified, but implies comprehensive) |
| Manual Type | |
| Type: | Factory Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | Downloadable PDF |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Detailed diagnosis, repair, and overhaul for all applicable gasoline engines (M20, M30, M50 variants). |
| Engine Management Electronic: | Bosch Motronic system diagnostics, sensor data, actuators, troubleshooting, wiring diagrams. |
| Fuel System: | Fuel injection systems, fuel pump, injectors, fuel pressure regulation, emissions control (catalytic converter, secondary air injection). |
| Cooling System: | Radiator, water pump, thermostat, hoses, fan operation, coolant specifications, bleeding procedures. |
| Exhaust System: | Exhaust manifold, catalytic converter, mufflers, oxygen sensors, exhaust leaks. |
| Transmission Manual: | Gearbox overhaul, clutch system, shift linkage, fluid specifications. |
| Transmission Automatic: | Transmission identification, hydraulic control, torque converter, electronic control unit (ECU) for transmission, fluid specifications, service procedures. |
| Drivetrain Rear Axle: | Differential service, axle shafts, wheel bearings, limited-slip differential (LSD) service if applicable. |
| Brakes System: | Front and rear disc brake service, ABS (Anti-lock Braking System) diagnostics and repair, brake fluid specifications, bleeding procedures. |
| Suspension System: | Front and rear suspension components, struts, shock absorbers, control arms, bushings, springs, alignment specifications. |
| Steering System: | Power steering system, steering rack/box, tie rods, steering wheel, alignment. |
| Electrical System Lighting: | Headlights, taillights, interior lighting, fog lights, bulb specifications. |
| Electrical System Charging: | Alternator, battery, voltage regulator, wiring. |
| Electrical System Starting: | Starter motor, ignition switch, ignition system (spark plugs, coils, distributor for applicable models). |
| Body Exterior: | Body panel removal/installation, door mechanisms, hood, trunk, bumpers, glass, seals. |
| Body Interior: | Dashboard, seats, trim panels, headliner, HVAC system controls. |
| HVAC System: | Heating, ventilation, and air conditioning (HVAC) components, blower motor, evaporator, condenser, refrigerant, climate control unit. |
| Instrumentation: | Instrument cluster, gauges, warning lights, diagnostics. |
| Safety Systems: | Seat belts, airbags (if equipped), structural integrity. |
| Wiring Diagrams: | Complete electrical system wiring diagrams for all major components. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake checks. |
| Troubleshooting: | Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. |
| Engine Repair: | Engine removal and installation, cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing chain/belt replacement. |
| Transmission Repair: | Transmission disassembly and reassembly, seal replacement, clutch replacement, torque converter replacement. |
| Brake Repair: | Brake pad and rotor replacement, caliper overhaul, master cylinder replacement, ABS component testing and replacement. |
| Suspension Repair: | Shock absorber and strut replacement, control arm bushing replacement, ball joint replacement. |
| Electrical Diagnosis: | Component testing, circuit diagnosis, connector repair, fuse and relay identification. |
| Body Panel Repair: | Door hinge adjustment, window regulator repair, lock mechanism servicing. |
| HVAC Service: | Refrigerant charging, leak detection, component replacement (compressor, expansion valve), blower motor replacement. |
| Special Tools: | Identification and usage instructions for specialized BMW tools required for certain procedures. |
| Technical Depth | |
| Depth: | In-depth, covering everything from basic maintenance to complete engine and transmission rebuilds. |
| Diagnostic Capability: | Advanced diagnostic procedures for engine management, ABS, and automatic transmission systems. |
| Specifications Accuracy: | Factory-level torque specifications, tolerances, and clearances for all major components. |
| Manual Specifications | |
| File Format | |
| Format: | PDF (Portable Document Format) |
| Print Quality | |
| Printability: | High-resolution, suitable for printing individual pages or the entire manual. |
| Binding Type | |
| Binding: | Digital (Downloadable PDF) |
| Paper Type | |
| Paper Recommendation: | Standard copier paper for printing. |
| Searchability | |
| Text Search: | Likely text-searchable if created from digital source, allowing quick access to information. |
| Engine Specifications | |
| Primary Engine | |
| Engine Variants Covered 1991: | Likely includes 4-cylinder (M40), inline-6 (M20, M30, M50) gasoline engines and potentially early V8 (M60) in some markets for the 1991 model year. |
| Performance | |
| Horsepower Range Typical: | Approximately 138 hp (318i) to 211 hp (535i) for inline-6 models, potentially higher for M-versions or early V8s. |
| Torque Range Typical: | Corresponds to horsepower figures, e.g., around 170 lb-ft to 230 lb-ft for inline-6. |
| Fuel System | |
| Injection Type: | Bosch Motronic electronic fuel injection (EFI) across all variants. |
| Recommended Fuel: | Premium Unleaded Gasoline (91 octane or higher). |
| Engine Codes | |
| Common Engines 1991: | M20B25 (525i), M30B35 (535i), M50B25 (525i, 525ix). |
| Transmission | |
| Standard | |
| Standard Transmission: | 5-speed manual transmission (Getrag 260/5 or similar). |
| Optional | |
| Optional Transmission: | 4-speed ZF automatic transmission (e.g., ZF 4HP22). |
| Features | |
| Transmission Control: | Electronic or hydraulic control for automatic transmissions, clutch operation for manual. |
| Fluid Specifications | |
| Automatic Transmission Fluid: | Typically Dexron-III or equivalent (e.g., BMW ATF LT-3). |
| Manual Transmission Fluid: | GL-4 or GL-5 gear oil, specific viscosity dependent on ambient temperature (e.g., 75W-90). |
| Dimensions | |
| Exterior | |
| Body Styles: | 4-door Sedan (Saloon), 5-door Touring (Wagon). |
| Wheelbase: | Approx. 111.5 inches (2835 mm) |
| Length: | Approx. 191.1 inches (4854 mm) for Sedan |
| Weights | |
| Curb Weight Range: | Approx. 3400 - 3800 lbs (1542 - 1724 kg) depending on engine and equipment. |
| Safety Features | |
| Ratings | |
| Crash Test Data: | While official NHTSA/IIHS ratings from the era are less comprehensive than today, the E34 was designed with advanced safety structures for its time, including crumple zones and a robust passenger cell. |
| Active Features | |
| ABS: | Standard or optional Anti-lock Braking System (ABS) on most models. |
| Passive Features | |
| Seatbelts: | Three-point inertia-reel seatbelts for front and rear occupants. |
| Airbags: | Driver's side airbag became standard on many models by 1991, passenger airbag optional or unavailable depending on market. |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory cassette player with AM/FM radio, optional CD player or changer, various speaker configurations (e.g., Hi-Fi system). |
| Driver Assistance | |
| Cruise Control: | Standard or optional electronic cruise control. |
| Traction Control: | Optional ASC (Automatic Stability Control) on some models. |
| Connectivity | |
| Diagnostic Port: | Early OBD-I diagnostic connector, typically a 14-pin round connector under the hood, requiring specialized BMW diagnostic tools (e.g., GT1, INPA). |
| 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 used. |
| Spark Plug Replacement: | Every 30,000 miles (48,000 km) for standard plugs, longer for platinum/iridium. |
| Coolant Flush Interval: | Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km). |
| Brake Fluid Flush Interval: | Every 2 years, regardless of mileage. |
| Fluid Specifications | |
| Engine Oil Viscosity: | BMW recommends synthetic 5W-30, 5W-40, or 10W-40 depending on climate (refer to owner's manual for exact specification). |
| Coolant Type: | BMW blue antifreeze or equivalent silicate-free coolant (typically 50/50 mix with distilled water). |
| Power Steering Fluid: | BMW Power Steering Fluid (P/N 81 22 9 407 763) or Pentosin CHF 11S. |
| Known Issues | |
| Common Wear Items: | Vibrations from driveshaft center support bearing, coolant leaks from plastic water pump impellers or hose connectors, aging rubber bushings, ABS sensor failures, fuel pump failures. |
| Electrical Gremlins: | Can develop due to aging wiring insulation, corroded connectors, or failing grounds, particularly in the engine bay and fuse box. |
| Engine Specific Issues: | M20: Oil pan gasket leaks. M30: Head gasket issues, oil leaks. M50: VANOS unit (on later models, not typically an issue for early M50s), thermostat housing leaks. |
| Vehicle History | |
| Brand Heritage | |
| Bmw Legacy: | BMW's reputation for performance, engineering excellence, and driver engagement. |
| Model Evolution | |
| E34 Introduction: | Introduced in 1988 as the successor to the E28 5 Series. |
| E34 Updates 1991: | Early production phase for E34, representing the refined but less updated versions compared to later facelifts. |
| Production | |
| Production Years: | 1988–1996 |
| Manufacturing Locations: | Dingolfing, Germany; Rosslyn, South Africa; various CKD assembly plants worldwide. |
| Awards & Recognition | |
| Recognitions | |
| Automotive Press: | Consistently praised by automotive publications for its driving dynamics, build quality, and engineering. Often featured in 'best of' lists for its era. |
| Ratings | |
| Reliability Perception: | Generally considered reliable when properly maintained, with a robust mechanical design. |