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BMW 5-series (E34) 1991 Service and Repair Manual

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🏷️ 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)...
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BMW 5-series (E34) 1991 Service and Repair Manual
🏷️ 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)
🔧 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
Common Issues Interior:
Cracked dashboard (sun damage), sagging headliner, worn seat bolsters
Common Issues Body:
Rust around wheel arches, rocker panels, sunroof drains, and battery tray area
📚 Vehicle History
Brand Heritage
Heritage:
BMW, Bayerische Motoren Werke AG, founded in 1916, renowned for sporty sedans and luxury vehicles
Model Evolution
E34 Generation Start:
Introduced in 1987 (Europe) / 1988 (North America)
E34 Generation End:
Produced until 1995 (sedan) / 1996 (touring)
E34 Positioning:
Successor to the E28 5-series, predecessor to the E39 5-series
E34 Variants Covered By Manual:
520i, 525i, 530i, 535i, 540i (and their respective Touring variants if applicable to the 1991 model year service data)
Production
Production Locations:
Mainly Dingolfing, Germany; also assembled in other plants globally
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
Consistently ranked highly by automotive publications for handling, build quality, and performance during its production run.
Ratings
Driving Experience Rating:
Considered a benchmark for driver engagement in its class
Certifications
Manual Endorsement:
Explicitly stated as the manual used by dealership technicians, implying factory-approved procedures and accuracy.
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