BMW 5-Series E34 Service Repair Manual 1989-1995

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🏷️ Basic Information Identification Make: BMW Model: 5-Series Chassis Code: E34 Model Years Covered: 1989-1995 Codes Engine Codes Covered: M20B25, M30B35, M50B25, M50B30, M60B30, M60B40 Chassis Codes Detailed: E34 (Sedan/Saloon, Touring/Estate) 👋 Introduction Market Position Positioning: A highly sought-after resource for owners and independent mechanics looking to maintain and repair the BMW E34 5-Series, known for its build quality and driving dynamics. Competitive Analysis Advantage: Provides factory-level technical information and procedures typically only accessible to authorized BMW dealerships, offering significant cost savings for DIY repairs. Key Features User Friendliness: Designed for ease of use with step-by-step instructions and clear diagrams, catering to various skill levels. Completeness: Covers all major systems of the E34 generation, making it a singular reference point for comprehensive vehicle servicing. 📋 Manual Details Coverage Areas Regions Covered: Global (primarily North America and Europe, reflects common E34 specifications) Vehicle Variants Covered: Sedan (Saloon), Touring (Estate/Wagon) Page Count Estimated Page Count: Extremely Comprehensive (Exact count not specified, but implies thousands of pages typical for full workshop manuals) Manual Type Type: Complete Service / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Fuel Injection (Bosch Motronic variants), Ignition Systems, Engine Control Unit (ECU) diagnostics and repair. Engine Mechanical: Complete engine teardown and reassembly, cylinder head, piston, crankshaft, camshafts, timing, oil pump, lubrication system. Fuel System: Fuel pump, fuel injectors, fuel pressure regulator, fuel tank, fuel lines, emission control systems. Cooling System: Radiator, water pump, thermostat, cooling fans, hoses, expansion tank. Exhaust System: Exhaust manifolds, catalytic converters, mufflers, exhaust pipes, oxygen sensors. Transmission Manual: Clutch assembly, gearbox internals, shift linkage, driveshafts, clutch hydraulics. Transmission Automatic: Automatic transmission types (e.g., ZF 4HP22, 4HP24), valve body, torque converter, transmission control unit, cooler lines. Suspension Front: MacPherson struts, control arms, ball joints, sway bar, steering knuckles, springs, shock absorbers. Suspension Rear: Multi-link independent suspension, trailing arms, control arms, shock absorbers, springs, sway bar. Steering System: Power steering pump, steering rack/box, tie rods, steering column, steering wheel. Braking System: Front and rear disc brakes, calipers, rotors, master cylinder, ABS (Anti-lock Braking System) components, brake lines, parking brake. Wheels Tires: Wheel specifications, tire pressure recommendations, lug nut torque settings, wheel bearing replacement. Electrical System Power: Battery, alternator, starter motor, wiring diagrams for power distribution. Electrical System Lighting: Headlights, taillights, interior lighting, fog lights, bulb replacement, wiring. Electrical System Accessories: Power windows, power locks, sunroof, wipers, horn, seat adjustment, mirrors, central locking system. Bodywork Exterior: Body panel removal/installation, doors, hood, trunk, bumpers, fenders, glass replacement, seals. Bodywork Interior: Dashboard removal, trim panels, seats, carpeting, headliner, HVAC controls. Climate Control: Air conditioning system (compressor, refrigerant, evaporator, condenser), heating system, blower motor, climate control modules. Safety Systems: Seat belts, airbags (if equipped), ABS diagnostics. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid changes. Troubleshooting: Diagnostic procedures for common issues, fault codes, symptom-based troubleshooting guides. Repair Rebuilds: Engine rebuilds (detailed), transmission overhauls, differential repair, suspension component replacement, brake caliper rebuilding. Diagnostics: ECU diagnostics, sensor testing, actuator testing, electrical system tracing. Installation: Component installation procedures, accessory fitting. Technical Depth Depth: Extremely detailed, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical system schematics. Diagrams: Detailed step-by-step diagrams, exploded views, and electrical wiring schematics. Torque Specifications: Comprehensive list of torque settings for all critical fasteners. Fluid Capacities: Precise fluid capacities for all vehicle systems (engine oil, coolant, transmission fluid, brake fluid, etc.). 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Printability: All pages are printable, allowing users to print specific sections as needed. Binding Type Binding: Not Applicable (Digital PDF format) Paper Type Paper Type: Not Applicable (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Variants Listed: M20 (2.5L Inline-6), M30 (3.5L Inline-6), M50 (2.5L & 3.0L Inline-6, VANOS), M60 (3.0L & 4.0L V8). Performance Typical Horsepower Range: 150 hp (M20) to 310 hp (M60B40). Typical Torque Range: 170 lb-ft (M20) to 295 lb-ft (M60B40). Fuel System Injection Type: Electronic Fuel Injection (EFI) - Bosch Motronic variants (e.g., M1.3, M2.1, M2.3, M3.3). 🔧 Transmission Standard Common Manual: Getrag 260 (5-speed) Optional Common Automatic: ZF 4HP22 (4-speed), ZF 4HP24 (4-speed) Features Manual Gear Ratios: Specific gear ratios provided for Getrag 260 across different engine variants. Automatic Control: Includes details on automatic transmission control modules and modes (e.g., Economy/Sport). 📐 Dimensions Exterior Wheelbase: Approx. 111.5 inches (2835 mm) for Sedan, 110.4 inches (2804 mm) for Touring. Length: Approx. 188.5 inches (4790 mm) for Sedan, 189.9 inches (4826 mm) for Touring. Weights Curb Weight Range: Approx. 3400 - 4000 lbs (1540 - 1815 kg), depending on engine and configuration. 🛡️ Safety Features Ratings Crash Test Information: While specific ratings are not detailed in this manual description, it covers components like seatbelts and airbags, implying a...

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Sku: 319992

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

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Description

🏷️ Basic Information

Identification

Make:

Model:

5-Series

Chassis Code:

Model Years Covered:

1989-1995

Codes

Engine Codes Covered:

M20B25, M30B35, M50B25, M50B30, M60B30, M60B40

Chassis Codes Detailed:

E34 (Sedan/Saloon, Touring/Estate)

👋 Introduction

Market Position

Positioning:

A highly sought-after resource for owners and independent mechanics looking to maintain and repair the BMW E34 5-Series, known for its build quality and driving dynamics.

Competitive Analysis

Advantage:

Provides factory-level technical information and procedures typically only accessible to authorized BMW dealerships, offering significant cost savings for DIY repairs.

Key Features

User Friendliness:

Designed for ease of use with step-by-step instructions and clear diagrams, catering to various skill levels.

Completeness:

Covers all major systems of the E34 generation, making it a singular reference point for comprehensive vehicle servicing.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (primarily North America and Europe, reflects common E34 specifications)

Vehicle Variants Covered:

Sedan (Saloon), Touring (Estate/Wagon)

Page Count

Estimated Page Count:

Extremely Comprehensive (Exact count not specified, but implies thousands of pages typical for full workshop manuals)

Manual Type

Type:

Complete Service / Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Management:

Fuel Injection (Bosch Motronic variants), Ignition Systems, Engine Control Unit (ECU) diagnostics and repair.

Engine Mechanical:

Complete engine teardown and reassembly, cylinder head, piston, crankshaft, camshafts, timing, oil pump, lubrication system.

Fuel System:

Fuel pump, fuel injectors, fuel pressure regulator, fuel tank, fuel lines, emission control systems.

Cooling System:

Radiator, water pump, thermostat, cooling fans, hoses, expansion tank.

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, exhaust pipes, oxygen sensors.

Transmission Manual:

Clutch assembly, gearbox internals, shift linkage, driveshafts, clutch hydraulics.

Transmission Automatic:

Automatic transmission types (e.g., ZF 4HP22, 4HP24), valve body, torque converter, transmission control unit, cooler lines.

Suspension Front:

MacPherson struts, control arms, ball joints, sway bar, steering knuckles, springs, shock absorbers.

Suspension Rear:

Multi-link independent suspension, trailing arms, control arms, shock absorbers, springs, sway bar.

Steering System:

Power steering pump, steering rack/box, tie rods, steering column, steering wheel.

Braking System:

Front and rear disc brakes, calipers, rotors, master cylinder, ABS (Anti-lock Braking System) components, brake lines, parking brake.

Wheels Tires:

Wheel specifications, tire pressure recommendations, lug nut torque settings, wheel bearing replacement.

Electrical System Power:

Battery, alternator, starter motor, wiring diagrams for power distribution.

Electrical System Lighting:

Headlights, taillights, interior lighting, fog lights, bulb replacement, wiring.

Electrical System Accessories:

Power windows, power locks, sunroof, wipers, horn, seat adjustment, mirrors, central locking system.

Bodywork Exterior:

Body panel removal/installation, doors, hood, trunk, bumpers, fenders, glass replacement, seals.

Bodywork Interior:

Dashboard removal, trim panels, seats, carpeting, headliner, HVAC controls.

Climate Control:

Air conditioning system (compressor, refrigerant, evaporator, condenser), heating system, blower motor, climate control modules.

Safety Systems:

Seat belts, airbags (if equipped), ABS diagnostics.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid changes.

Troubleshooting:

Diagnostic procedures for common issues, fault codes, symptom-based troubleshooting guides.

Repair Rebuilds:

Engine rebuilds (detailed), transmission overhauls, differential repair, suspension component replacement, brake caliper rebuilding.

Diagnostics:

ECU diagnostics, sensor testing, actuator testing, electrical system tracing.

Installation:

Component installation procedures, accessory fitting.

Technical Depth

Depth:

Extremely detailed, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical system schematics.

Diagrams:

Detailed step-by-step diagrams, exploded views, and electrical wiring schematics.

Torque Specifications:

Comprehensive list of torque settings for all critical fasteners.

Fluid Capacities:

Precise fluid capacities for all vehicle systems (engine oil, coolant, transmission fluid, brake fluid, etc.).

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Printability:

All pages are printable, allowing users to print specific sections as needed.

Binding Type

Binding:

Not Applicable (Digital PDF format)

Paper Type

Paper Type:

Not Applicable (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Variants Listed:

M20 (2.5L Inline-6), M30 (3.5L Inline-6), M50 (2.5L & 3.0L Inline-6, VANOS), M60 (3.0L & 4.0L V8).

Performance

Typical Horsepower Range:

150 hp (M20) to 310 hp (M60B40).

Typical Torque Range:

170 lb-ft (M20) to 295 lb-ft (M60B40).

Fuel System

Injection Type:

Electronic Fuel Injection (EFI) - Bosch Motronic variants (e.g., M1.3, M2.1, M2.3, M3.3).

🔧 Transmission

Standard

Common Manual:

Getrag 260 (5-speed)

Optional

Common Automatic:

ZF 4HP22 (4-speed), ZF 4HP24 (4-speed)

Features

Manual Gear Ratios:

Specific gear ratios provided for Getrag 260 across different engine variants.

Automatic Control:

Includes details on automatic transmission control modules and modes (e.g., Economy/Sport).

📐 Dimensions

Exterior

Wheelbase:

Approx. 111.5 inches (2835 mm) for Sedan, 110.4 inches (2804 mm) for Touring.

Length:

Approx. 188.5 inches (4790 mm) for Sedan, 189.9 inches (4826 mm) for Touring.

Weights

Curb Weight Range:

Approx. 3400 - 4000 lbs (1540 - 1815 kg), depending on engine and configuration.

🛡️ Safety Features

Ratings

Crash Test Information:

While specific ratings are not detailed in this manual description, it covers components like seatbelts and airbags, implying a focus on vehicle safety systems.

Active Features

Detailed diagnostic and repair procedures for the Bosch ABS system.

Passive Features

Airbag System:

Procedures for airbag system inspection and components (though replacement procedures require extreme caution).

💡 Technology Features

Infotainment

Audio Systems:

Factory radio/cassette or CD player options, with speaker system details and replacement guidelines.

Driver Assistance

Traction Control:

ASC (Automatic Stability Control) or ASC+T (with Traction control) available on some models.

Connectivity

Remote Locking:

Central locking system and remote keyless entry features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 to 10,000 miles (12,000 to 16,000 km) or 12 months, depending on driving conditions (refer to manual for exact recommendations).

Spark Plug Replacement:

Varies by engine type; e.g., approximately 30,000 miles for standard plugs, potentially longer for platinum/iridium.

Coolant Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil:

Refer to manual for specific grades based on engine and climate; commonly synthetic SAE 0W-40, 5W-30, 5W-40, 10W-40, 10W-60.

Coolant:

BMW Blue or Green antifreeze (ethylene glycol based) mixed with distilled water (50/50 ratio).

Brake Fluid:

DOT 4

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, specific viscosity as per manual (e.g., 75W-90, 80W-90).

Transmission Fluid Automatic:

Dexron II or III (ZF specifications).

Known Issues

Common Wear Items:

Cracked dashboards, headliner sag, sagging door cards, aging rubber hoses and seals, valve cover gasket leaks, coolant leaks (water pump, thermostat housing), rear subframe mounting points, blower motor resistor, ABS sensor failures.

E34 Specific Concerns:

VANOS unit issues on M50 engines, potential head gasket failure on M60 V8s due to overheating, EGS (transmission control) module failures.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

The E34 embodied BMW's 'Ultimate Driving Machine' philosophy, blending luxury, performance, and advanced engineering.

Model Evolution

E34 Development:

The E34 was the third generation of the BMW 5-Series, succeeding the E28 and preceding the E39. It introduced significant aerodynamic improvements and new engine technologies.

Production

Production Years:

1987-1996 (globally), with the covered range being 1989-1995 models.

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The E34 5-Series was a frequent recipient of Car and Driver's '10Best' list during its production years, highlighting its exceptional driving dynamics and overall quality.