🏷️ Basic Information Identification Make: BMW Model: 5-series Chassis Code: E34 Model Year Covered: 1991 Codes Engine Codes Covered: M20, M30, M50, M52 (specific variants as per 1991 models) Transmission Codes Covered: Getrag 260, ZF 4HP22 (specific variants as per 1991 models) 👋 Introduction Market Position Positioning: Mid-size luxury sedan, known for its performance, handling, and build quality Competitive Analysis Competitors 1991: Mercedes-Benz E-Class (W124), Audi 100/200 (C3/C4), Lexus LS 400 (though often compared to larger sedans), Jaguar XJ Key Features Driving Dynamics: Renowned 'Ultimate Driving Machine' characteristics, balanced chassis, responsive steering, sophisticated suspension Powertrain: Smooth inline-six engines (M20, M50), torquey V8 (M60 introduced later in E34 lifespan, though 1991 primarily inline-six), efficient inline-four (M40 for some markets) Interior Quality: Driver-focused cockpit, high-quality materials, ergonomic design Design: Iconic 'Bangle butt' design cues (though more subtle than later generations), clean lines, aerodynamic profile 📋 Manual Details Coverage Areas Primary Coverage: All 1991 BMW 5-series (E34) models Repair Scope: A-Z (All repairs from routine maintenance to complete overhauls) Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Print (Likely spiral-bound or case-bound for dealership use) 📖 Manual Coverage Systems Covered Engine: Complete diagnosis, overhaul, timing, fuel injection (Bosch Motronic), emissions control, cooling system, lubrication system Transmission: Manual and automatic transmission diagnosis, repair, fluid changes, clutch replacement, torque converter service Drivetrain: Driveshaft, differential, axles, CV joints Suspension: Front and rear suspension, shock absorbers, springs, control arms, bushings, wheel alignment specifications Steering: Power steering system, steering rack, steering column, troubleshooting Brakes: Hydraulic system, ABS (Anti-lock Braking System), brake pads, rotors, calipers, master cylinder, bleeding procedures Electrical: Wiring diagrams for all systems, starter, alternator, battery, lighting, instrumentation, power windows, central locking, heated seats Bodywork: Body panel repair, door mechanisms, window regulators, seals, trim, rust prevention and repair techniques HVAC: Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling Procedures Included Maintenance: Oil change, filter replacement, spark plug service, fluid level checks, belt replacement, battery maintenance Troubleshooting: Diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting Repair: Component removal, installation, and adjustment procedures for all major systems Diagnostics: On-board diagnostics (OBD) interpretation (where applicable for the era), specific BMW diagnostic procedures Technical Depth Depth: Factory-level detail, including torque specifications, special tool requirements, and diagnostic fault codes Special Tools: Identification and usage of BMW-specific tools required for complex repairs 📊 Manual Specifications File Format Format Type: Physical Print Print Quality Quality: Professional dealership-grade printing, clear diagrams and text Binding Type Binding: Likely spiral-bound or case-bound for durability and lay-flat use Paper Type Paper Quality: Durable, high-quality paper stock suitable for workshop environments ⚙️ Engine Specifications Primary Engine Engine Family: M20 & M50 Inline-6 Common Engines 1991: M20B25 (2.5L), M50B25 (2.5L VANOS/non-VANOS) Displacement M20B25: 2494 cc (2.5 Liters) Bore Stroke M20B25: 84.0 mm x 75.0 mm Compression Ratio M20B25: 8.8:1 Horsepower M20B25: 170 hp @ 5800 rpm Torque M20B25: 225 Nm (166 lb-ft) @ 4300 rpm Displacement M50B25: 2494 cc (2.5 Liters) Bore Stroke M50B25: 84.0 mm x 75.0 mm Compression Ratio M50B25: 10.0:1 (non-VANOS) / 10.5:1 (VANOS) Horsepower M50B25: 189 hp @ 6000 rpm (non-VANOS) / 192 hp @ 5900 rpm (VANOS) Torque M50B25: 245 Nm (181 lb-ft) @ 4200 rpm (non-VANOS) / 245 Nm (181 lb-ft) @ 4700 rpm (VANOS) Performance 0 60 Mph Approx: 7.5 - 8.5 seconds (depending on engine and transmission) Fuel System Injection System: Bosch Motronic electronic fuel injection Fuel Type: Unleaded gasoline (premium unleaded recommended) Fuel Octane Rating: 91 AKI (95 RON) or higher 🔧 Transmission Standard Standard Transmission: 5-speed Getrag 260 manual transmission Optional Optional Transmission: ZF 4HP22 4-speed automatic transmission Features Automatic Features: Sport mode (on some models), lock-up torque converter for efficiency 📐 Dimensions Exterior Wheelbase: 2761 mm (108.7 in) Length: 4734 mm (186.4 in) Width: 1751 mm (68.9 in) Height: 1410 mm (55.5 in) Wheel Bolt Pattern: 5x120 Weights Curb Weight Approx: 1500-1650 kg (3300-3640 lbs) depending on model and equipment 🛡️ Safety Features Ratings NHTSA Rating Era: Ratings from this era are often less comprehensive than modern standards; focus on passive safety features Active Features ABS: Standard on most models, Bosch 2-channel ABS system Traction Control: Optional on some higher-spec models (ASC - Automatic Stability Control) Passive Features Airbags: Driver's side airbag standard on most 1991 models; passenger airbag optional/later addition for some markets Seatbelts: Pre-tensioned front seatbelts, three-point rear seatbelts Body Structure: Reinforced safety cage, crumple zones front and rear 💡 Technology Features Infotainment Audio System: Optional premium sound systems (e.g., Harmon Kardon), standard BMW cassette player with AM/FM radio Navigation: Early optional navigation systems available on some later E34 models, but not common or standard for 1991 Driver Assistance Cruise Control: Standard or optional depending on trim level Connectivity Connectivity Features: Limited by era; typically basic radio and phone prep (optional)...
Smooth inline-six engines (M20, M50), torquey V8 (M60 introduced later in E34 lifespan, though 1991 primarily inline-six), efficient inline-four (M40 for some markets)
7.5 - 8.5 seconds (depending on engine and transmission)
Fuel System
Injection System:
Bosch Motronic electronic fuel injection
Fuel Type:
Unleaded gasoline (premium unleaded recommended)
Fuel Octane Rating:
91 AKI (95 RON) or higher
🔧 Transmission
Standard
Standard Transmission:
5-speed Getrag 260 manual transmission
Optional
Optional Transmission:
ZF 4HP22 4-speed automatic transmission
Features
Automatic Features:
Sport mode (on some models), lock-up torque converter for efficiency
📐 Dimensions
Exterior
Wheelbase:
2761 mm (108.7 in)
Length:
4734 mm (186.4 in)
Width:
1751 mm (68.9 in)
Height:
1410 mm (55.5 in)
Wheel Bolt Pattern:
5x120
Weights
Curb Weight Approx:
1500-1650 kg (3300-3640 lbs) depending on model and equipment
🛡️ Safety Features
Ratings
NHTSA Rating Era:
Ratings from this era are often less comprehensive than modern standards; focus on passive safety features
Active Features
ABS:
Standard on most models, Bosch 2-channel ABS system
Traction Control:
Optional on some higher-spec models (ASC - Automatic Stability Control)
Passive Features
Airbags:
Driver's side airbag standard on most 1991 models; passenger airbag optional/later addition for some markets
Seatbelts:
Pre-tensioned front seatbelts, three-point rear seatbelts
Body Structure:
Reinforced safety cage, crumple zones front and rear
💡 Technology Features
Infotainment
Audio System:
Optional premium sound systems (e.g., Harmon Kardon), standard BMW cassette player with AM/FM radio
Navigation:
Early optional navigation systems available on some later E34 models, but not common or standard for 1991
Driver Assistance
Cruise Control:
Standard or optional depending on trim level
Connectivity
Connectivity Features:
Limited by era; typically basic radio and phone prep (optional)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 - 15,000 miles or 12-24 months (depending on driving conditions and oil used, consult manual)
Spark Plug Replacement:
Around 60,000 miles (may vary with plug type)
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles
Transmission Fluid Change:
Automatic: ~50,000-100,000 miles (BMW often cited as 'lifetime' but fluid replacement is recommended for longevity); Manual: Check for leaks, usually no specific interval unless issues arise
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30, 5W-40, or 10W-40 (refer to manual for specific viscosity based on climate)
Engine Oil Capacity:
Approx. 5.0 - 6.5 liters (5.3 - 6.9 US quarts), depending on engine
Coolant Type:
BMW Blue (G48) or equivalent ethylene glycol based coolant, mixed 50/50 with distilled water
Automatic Transmission Fluid:
Dexron II or III (check specific ZF transmission fill)
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent (e.g., Red Line MTL)
Brake Fluid Type:
DOT 4
Known Issues
Common Issues Engine:
Oil leaks from valve cover gasket and oil pan gasket, cooling system component failures (hoses, radiator, water pump), idle control valve issues (M50), distributor cap/rotor wear (M20)
Common Issues Suspension:
Worn control arm bushings, ball joints, tie rod ends, shock absorber fatigue, sagging rear springs
Common Issues Electrical:
Corroded wiring connectors (especially grounds), failing instrument cluster illumination, door lock actuator issues, HVAC blower motor resistor failure