BMW 5 Series E34 1989-1995 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Generation Chassis Code: E34 Production Years Covered: 1989-1995 👋 Introduction Market Position Segment: Executive Sedan/Luxury Mid-size Target Audience: Enthusiast owners, independent repair shops, DIY mechanics seeking in-depth repair knowledge. Competitive Analysis Competitors: Mercedes-Benz W124 E-Class, Audi V8 Quattro, Lexus LS400, Jaguar XJ Key Features Vehicle Strengths: Renowned driving dynamics, solid build quality, sophisticated engineering, available powerful inline-six and V8 engines. Manual Value Proposition: Empowers owners and technicians with the necessary knowledge to maintain and repair the complex systems of the E34 generation, preserving its performance and longevity. 📋 Manual Details Coverage Areas Main Coverage: Maintenance, Repair, Troubleshooting, Diagnostics, Wiring Diagrams Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (likely PDF, based on typical offerings) 📖 Manual Coverage Systems Covered Engine: M20, M30, M50, S38 (detailed overhaul, tuning, diagnostics) Fuel System: EFI, fuel pumps, injectors, pressure regulators, fuel tank service Ignition System: Distributorless ignition (DIS), coil-on-plug (COP), sensors, ECU control Transmission Manual: Getrag 260, Getrag 420G (clutch, gearbox overhaul, fluid changes) Transmission Automatic: ZF 4HP22, ZF 5HP18, ZF 5HP30 (shift solenoids, valve body, fluid service, torque converter) Drivetrain: Driveshaft, universal joints, differential service, limited-slip differential (LSD) options Suspension Front: MacPherson strut, control arms, sway bars, bushings, alignment specifications Suspension Rear: Multi-link independent suspension, trailing arms, shock absorbers, springs, alignment specifications Steering: Power steering system, steering rack, pump service, tie rods, steering column adjustments Brakes Front: Ventilated discs, ABS system (Bosch, Teves), brake pad/rotor replacement, caliper service Brakes Rear: Solid discs, ABS system, brake pad/rotor replacement, caliper service Electrical System: Alternator, starter motor, battery service, fuse box, relays, wiring harness repair Body And Chassis: Body panel removal/installation, door mechanisms, sunroof operation, chassis lubrication Climate Control: HVAC system, A/C refrigerant service, blower motor, heater core, climate control unit Interior Trim: Dashboard removal, seat mechanisms, interior paneling, headliner replacement Lighting: Headlights, taillights, interior lighting, bulb replacement, wiring Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections/replacements Engine Repair: Head gasket replacement, piston ring replacement, crankshaft/camshaft bearing replacement, timing chain/belt service Transmission Repair: Manual gearbox synchronization replacement, automatic transmission solenoid testing and replacement Brake System Repair: Brake fluid flush and bleeding, ABS sensor replacement, parking brake adjustment Electrical Diagnostics: Troubleshooting common electrical faults, component testing, wiring diagram interpretation Suspension And Steering Repair: Ball joint replacement, control arm bushing replacement, power steering fluid leak diagnosis Troubleshooting Guides: Step-by-step diagnostic procedures for common and uncommon issues Wiring Diagrams: Comprehensive, system-specific wiring schematics for all major electrical components Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system repair. 📊 Manual Specifications File Format Digital Quality: High-resolution scans, searchable text (if PDF), well-organized chapters Print Quality Paper Quality: Not applicable for digital format, but implies clear, legible text and diagrams. Binding Type Binding: Not applicable for digital format. ⚙️ Engine Specifications Primary Engine M50 Engine Code: M50B20, M50B25 Configuration: Inline 6-cylinder, DOHC, 24 valves Displacement 2.0L: 1990 cc (121.4 cu in) Displacement 2.5L: 2494 cc (152.2 cu in) Horsepower 2.0L: 150 hp @ 5900 rpm (approx.) Horsepower 2.5L: 192 hp @ 5900 rpm (approx.) Torque 2.0L: 137 lb-ft @ 4200 rpm (approx.) Torque 2.5L: 181 lb-ft @ 4200 rpm (approx.) Secondary Engine V8 Engine Code: M60B30, M60B40 Configuration: V8, DOHC, 32 valves Displacement 3.0L: 2997 cc (182.9 cu in) Displacement 4.0L: 3982 cc (243.0 cu in) Horsepower 3.0L: 215 hp @ 5800 rpm (approx.) Horsepower 4.0L: 282 hp @ 5800 rpm (approx.) Torque 3.0L: 214 lb-ft @ 4500 rpm (approx.) Torque 4.0L: 295 lb-ft @ 4500 rpm (approx.) Performance Engine Management: Bosch Motronic Electronic Engine Control (EEC) with OBD-I diagnostics. Fuel System Injection: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) 🔧 Transmission Standard Manual Gearbox Option: 5-speed Getrag 260 (for 6-cylinder models), 5-speed Getrag 420G (for M5 models) Optional Automatic Gearbox Option: 4-speed ZF 4HP22, 5-speed ZF 5HP18, 5-speed ZF 5HP30 (for V8 models) Features Drive System: Rear-wheel drive (RWD) Clutch: Hydraulically actuated single-plate dry clutch 📐 Dimensions Exterior Sedan Length: Approx. 4717-4784 mm (185.7-188.3 in) Width: Approx. 1751 mm (68.9 in) Height: Approx. 1410-1416 mm (55.5-55.7 in) Exterior Touring Length: Approx. 4754-4814 mm (187.2-189.5 in) Width: Approx. 1751 mm (68.9 in) Height: Approx. 1420-1445 mm (55.9-56.9 in) Weights Curb Weight: Approx. 1500-1750 kg (3300-3850 lbs), varies by model and equipment Wheelbase: Approx. 2760 mm (108.7 in) Wheels Tires Bolt Pattern: 5x120 mm Common Tire Sizes: 205/60 R15, 225/55 R15, 235/45 R17 (varies by trim) 🛡️ Safety Features Ratings Crash Test Data: Era-appropriate safety standards; no standardized global NCAP ratings as we know them today. Focus on passive safety features. Active Features ABS: Standard on most models, optional on early 6-cylinder models. (Bosch or Teves systems) Traction Control: Optional on...

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Type: Car

Sku: 392157

Collections: ALL BMW

Availability: In stock

Tags: 1989 1990 1991 1992 1993 1994 1995 5 Series E34 BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Generation

Chassis Code:

Production Years Covered:

1989-1995

👋 Introduction

Market Position

Segment:

Executive Sedan/Luxury Mid-size

Target Audience:

Enthusiast owners, independent repair shops, DIY mechanics seeking in-depth repair knowledge.

Competitive Analysis

Competitors:

Mercedes-Benz W124 E-Class, Audi V8 Quattro, Lexus LS400, Jaguar XJ

Key Features

Vehicle Strengths:

Renowned driving dynamics, solid build quality, sophisticated engineering, available powerful inline-six and V8 engines.

Manual Value Proposition:

Empowers owners and technicians with the necessary knowledge to maintain and repair the complex systems of the E34 generation, preserving its performance and longevity.

📋 Manual Details

Coverage Areas

Main Coverage:

Maintenance, Repair, Troubleshooting, Diagnostics, Wiring Diagrams

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, based on typical offerings)

📖 Manual Coverage

Systems Covered

Engine:

M20, M30, M50, S38 (detailed overhaul, tuning, diagnostics)

Fuel System:

EFI, fuel pumps, injectors, pressure regulators, fuel tank service

Ignition System:

Distributorless ignition (DIS), coil-on-plug (COP), sensors, ECU control

Transmission Manual:

Getrag 260, Getrag 420G (clutch, gearbox overhaul, fluid changes)

Transmission Automatic:

ZF 4HP22, ZF 5HP18, ZF 5HP30 (shift solenoids, valve body, fluid service, torque converter)

Drivetrain:

Driveshaft, universal joints, differential service, limited-slip differential (LSD) options

Suspension Front:

MacPherson strut, control arms, sway bars, bushings, alignment specifications

Suspension Rear:

Multi-link independent suspension, trailing arms, shock absorbers, springs, alignment specifications

Steering:

Power steering system, steering rack, pump service, tie rods, steering column adjustments

Brakes Front:

Ventilated discs, ABS system (Bosch, Teves), brake pad/rotor replacement, caliper service

Brakes Rear:

Solid discs, ABS system, brake pad/rotor replacement, caliper service

Electrical System:

Alternator, starter motor, battery service, fuse box, relays, wiring harness repair

Body And Chassis:

Body panel removal/installation, door mechanisms, sunroof operation, chassis lubrication

Climate Control:

HVAC system, A/C refrigerant service, blower motor, heater core, climate control unit

Interior Trim:

Dashboard removal, seat mechanisms, interior paneling, headliner replacement

Lighting:

Headlights, taillights, interior lighting, bulb replacement, wiring

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections/replacements

Engine Repair:

Head gasket replacement, piston ring replacement, crankshaft/camshaft bearing replacement, timing chain/belt service

Transmission Repair:

Manual gearbox synchronization replacement, automatic transmission solenoid testing and replacement

Brake System Repair:

Brake fluid flush and bleeding, ABS sensor replacement, parking brake adjustment

Electrical Diagnostics:

Troubleshooting common electrical faults, component testing, wiring diagram interpretation

Suspension And Steering Repair:

Ball joint replacement, control arm bushing replacement, power steering fluid leak diagnosis

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon issues

Wiring Diagrams:

Comprehensive, system-specific wiring schematics for all major electrical components

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system repair.

📊 Manual Specifications

File Format

Digital Quality:

High-resolution scans, searchable text (if PDF), well-organized chapters

Print Quality

Paper Quality:

Not applicable for digital format, but implies clear, legible text and diagrams.

Binding Type

Binding:

Not applicable for digital format.

⚙️ Engine Specifications

Primary Engine M50

Engine Code:

M50B20, M50B25

Configuration:

Inline 6-cylinder, DOHC, 24 valves

Displacement 2.0L:

1990 cc (121.4 cu in)

Displacement 2.5L:

2494 cc (152.2 cu in)

Horsepower 2.0L:

150 hp @ 5900 rpm (approx.)

Horsepower 2.5L:

192 hp @ 5900 rpm (approx.)

Torque 2.0L:

137 lb-ft @ 4200 rpm (approx.)

Torque 2.5L:

181 lb-ft @ 4200 rpm (approx.)

Secondary Engine V8

Engine Code:

M60B30, M60B40

Configuration:

V8, DOHC, 32 valves

Displacement 3.0L:

2997 cc (182.9 cu in)

Displacement 4.0L:

3982 cc (243.0 cu in)

Horsepower 3.0L:

215 hp @ 5800 rpm (approx.)

Horsepower 4.0L:

282 hp @ 5800 rpm (approx.)

Torque 3.0L:

214 lb-ft @ 4500 rpm (approx.)

Torque 4.0L:

295 lb-ft @ 4500 rpm (approx.)

Performance

Engine Management:

Bosch Motronic Electronic Engine Control (EEC) with OBD-I diagnostics.

Fuel System

Injection:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

🔧 Transmission

Standard Manual

Gearbox Option:

5-speed Getrag 260 (for 6-cylinder models), 5-speed Getrag 420G (for M5 models)

Optional Automatic

Gearbox Option:

4-speed ZF 4HP22, 5-speed ZF 5HP18, 5-speed ZF 5HP30 (for V8 models)

Features

Drive System:

Rear-wheel drive (RWD)

Clutch:

Hydraulically actuated single-plate dry clutch

📐 Dimensions

Exterior Sedan

Length:

Approx. 4717-4784 mm (185.7-188.3 in)

Width:

Approx. 1751 mm (68.9 in)

Height:

Approx. 1410-1416 mm (55.5-55.7 in)

Exterior Touring

Length:

Approx. 4754-4814 mm (187.2-189.5 in)

Width:

Approx. 1751 mm (68.9 in)

Height:

Approx. 1420-1445 mm (55.9-56.9 in)

Weights

Curb Weight:

Approx. 1500-1750 kg (3300-3850 lbs), varies by model and equipment

Wheelbase:

Approx. 2760 mm (108.7 in)

Wheels Tires

Bolt Pattern:

5x120 mm

Common Tire Sizes:

205/60 R15, 225/55 R15, 235/45 R17 (varies by trim)

🛡️ Safety Features

Ratings

Crash Test Data:

Era-appropriate safety standards; no standardized global NCAP ratings as we know them today. Focus on passive safety features.

Active Features

Standard on most models, optional on early 6-cylinder models. (Bosch or Teves systems)

Traction Control:

Optional on some models (ASC+T)

Passive Features

Airbags:

Driver's airbag standard from 1993 onwards; optional passenger airbag on later models.

Seatbelts:

Three-point inertia-reel seatbelts front and rear.

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Optional BMW Bavaria C Business/Professional cassette radios, with CD changer preparation. Analog tuning, pre-amplified outputs.

Navigation:

Early generation (optional) GPS navigation systems were available on later E34 models, often with separate CRT screens and CD-ROM maps.

Driver Assistance

Cruise Control:

Standard on most models, electronically controlled.

Parking Sensors:

Not available on E34 generation.

Connectivity

Phone Integration:

Optional integrated car phone systems were available on very late models, but no modern Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 - 10,000 miles or 12 months (depending on driving conditions and oil used). The manual will provide specific recommendations.

Spark Plugs:

Typically 30,000 - 60,000 miles, depending on plug type (copper, platinum, iridium).

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles. The manual will specify BMW's coolant type.

Fluid Specifications

Engine Oil:

BMW recommends specific viscosity grades (e.g., 5W-30, 10W-40) and API service classifications. The manual will detail exact specifications and capacities for each engine. Example: M50B25 requires ~6.5 liters.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, viscosity dependent on temperature. Manual will specify Getrag's recommendations. Approx. 1.5-2.0 liters for Getrag 260.

Transmission Fluid Automatic:

ZF LifeguardFluid (or equivalent ATF spec like Dexron III for older models, check manual for exact spec). Approx. 3-4 liters for a pan drain/refill. ZF recommends specific fluid for longevity.

Brake Fluid:

DOT 4 or DOT 4 Plus. Capacities are low, manual will specify.

Coolant:

BMW Blue or BMW Green antifreeze concentrate mixed with distilled water (50/50 ratio). Approx. 9-11 liters.

Known Issues

Cooling System:

Plastic coolant expansion tanks can become brittle and crack. Water pump impellers can degrade.

Engine M50:

VANOS (Variable Valve Timing) solenoid or sealing rings can fail, leading to rough idle and performance loss. Eccentric shaft sensor failure (ESS) can cause no-start conditions.

Engine M60:

Head gasket leaks are less common, but coolant leaks from the front timing cover are known. Nikasil cylinder liner degradation on early M60B30/B40 engines (replaced with Alusil later) can be an issue if poor fuel quality or overheating occurred.

Suspension:

Worn control arm bushings, shock mounts, and rear subframe bushings can affect ride and handling. Sway bar links often wear out.

Electrical:

Corroded ground points, failing EWS (immobilizer) on later models, dashboard warning lights (e.g., ABS, check engine) due to sensor failures or wiring issues.

Fuel System:

Fuel pump failure, clogged fuel injectors, leaking fuel lines.

📚 Vehicle History

Brand Heritage

Brand Identity:

BMW's reputation for 'The Ultimate Driving Machine,' synonymous with performance, engineering, and driver engagement.

Model Evolution

Predecessor:

BMW E28 5 Series

Successor:

BMW E39 5 Series

Key Developments E34:

Introduction of V8 engines, aerodynamic improvements over E28, increased chassis rigidity, development of Touring (wagon) variant.

Production

Production Period:

1987-1996 (globally), with E34 variant production ending in 1995/1996.

Manufacturing Locations:

Germany (Dingolfing plant), South Africa, Austria, Thailand.

🏆 Awards & Recognition

Recognitions

Automotive Press Acclaim:

Consistently praised by automotive journalists for its driving dynamics, build quality, and sophisticated engineering. Often cited as one of the best sedans of its era.