BMW 5 Series E34 Service Repair Manual 89-96

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E34 Model Years Covered: 1989-1996 Codes Body Styles: Sedan (4-door), Touring (Wagon/Estate) 👋 Introduction Market Position E34 Market Segment: Executive/Luxury Sedan and Wagon, known for its blend of performance, comfort, and build quality. Competitive Analysis Contemporary Competitors: Mercedes-Benz W124 E-Class, Audi V8/A8, Lexus LS400, Volvo 700/900 Series, Jaguar XJ. Key Features E34 Engineering Highlights: Rear-wheel drive dynamics, advanced inline-six and V8 engine options, sophisticated independent suspension, robust construction, and driver-focused ergonomics. Manual Utility Target Audience: BMW enthusiasts, DIY mechanics, independent repair shops, and owners seeking to maintain or restore their E34. 📋 Manual Details Coverage Areas Documentation Type: Comprehensive Service and Repair Manual Primary Regions Of Applicability: Global (with potential regional variations noted for specific emissions or equipment) Page Count Estimated Page Count: Hundreds of Pages (exact count not specified, but indicative of extensive detail) Manual Type Manual Format: PDF Language Language: English 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of all E34 engine variants (e.g., M20, M30, M50, M52, S38, M60, M62, etc.) including cylinder head, block, crankshaft, pistons, connecting rods, valve train, timing components. Engine Management: Detailed information on fuel injection systems (Bosch Motronic variations), ignition systems, sensors, actuators, ECU diagnostics, and troubleshooting. Transmission Manual: Repair and overhaul procedures for manual transmissions (e.g., Getrag variants), including clutch operation, gearbox internal components, and shift linkage. Transmission Automatic: Repair and overhaul procedures for automatic transmissions (e.g., ZF 4HP variants), including torque converter, valve body, planetary gears, and electronic control. Drivetrain: Driveshaft, CV joints, differential (rear axle) inspection, repair, and fluid specifications. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, anti-roll bars, and alignment procedures. Steering: Power steering system, steering rack/gearbox, tie rods, and troubleshooting. Brakes: Hydraulic braking system, ABS (Anti-lock Braking System) diagnostics and repair, brake discs, pads, calipers, lines, master cylinder, and parking brake. Electrical System: Comprehensive wiring diagrams, component locations, fuse/relay assignments, battery, charging system (alternator, starter), lighting, instrumentation, and accessory circuits. HVAC: Heating, ventilation, and air conditioning system diagnosis, repair, refrigerant handling, and component replacement. Body And Chassis: Body panel removal/installation, interior trim, glass, doors, locks, hinges, and corrosion prevention. Fuel System: Fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulation, and evaporative emissions control (EVAP). Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, and general inspections. Troubleshooting: Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, and fault code interpretation (where applicable). Repair And Rebuild: Step-by-step instructions for component removal, repair, overhaul, and reinstallation for all major systems. Adjustments: Detailed procedures for adjustments such as idle speed, valve clearance (if applicable), parking brake, and headlight aim. Component Replacement: Instructions for replacing wear items and failure-prone components like water pumps, alternators, starter motors, fuel pumps, O2 sensors, etc. Technical Depth Depth Of Information: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed torque specifications and diagnostic procedures. Diagnostic Capabilities: Includes diagnostic flowcharts, sensor data interpretation, and troubleshooting based on system symptoms, catering to both DIYers and professional technicians. Rebuild Procedures: Detailed instructions for engine and transmission overhauls, including machining specifications and assembly sequences. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Readability: High-resolution scans of original documentation ensuring clear text and diagrams. Binding Type Digital Format Features: Searchable text for quick information retrieval, bookmarking capabilities, zoom functionality for diagrams. Paper Type Original Document Medium: Originally printed on durable paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Options Engine Variants: Wide range including M20 (2.0L-2.7L I6), M30 (3.0L-3.5L I6), M50 (2.0L-3.0L I6, Vanos), M52 (2.0L-2.8L I6, Vanos), M60 (3.0L-4.0L V8), M62 (3.5L-4.4L V8), S38 (3.6L-3.8L I6 M-Power). Performance Examples Horsepower Range: Approximately 129 hp (520i M20) to 340 hp (M50 M5 3.8L). Torque Range: Approximately 174 Nm (520i M20) to 400 Nm (M50 M5 3.8L). Fuel System Injection Type: Bosch Motronic electronic fuel injection (EFI) across most variants. Early models may feature K-Jetronic (E34 520i M20). Engine Management Ignition Type: Electronic ignition systems, often integrated with Motronic ECU. Timing System Valve Timing: Belt drive for M20/M30, Chain drive for M50/M52/M60/M62/S38. VANOS (Variable Valve Timing) introduced on M50/M52 engines. 🔧 Transmission Standard Transmission Manual Gearboxes: Getrag 260 (5-speed) commonly found on inline-six engines. Other Getrag and ZF units may be present. Optional Transmission Automatic Gearboxes: ZF 4HP22 (4-speed) common on most models, ZF 4HP24 on higher-performance variants. Later models may feature ZF 5HP (5-speed) automatic transmissions. Features Clutch Type: Hydraulically actuated single-plate dry clutch for manual transmissions. 📐 Dimensions Exterior Sedan Length Sedan: Approx. 4710-4780 mm (185.4-188.6 in), varies by model/year. Exterior Touring Length Touring: Approx. 4755-4820 mm (187.2-189.8 in), varies by model/year. Exterior Wheelbase: Approx. 2760 mm (108.7 in) Weights Curb Weight: Approximately 1450-1750...

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Tipo: Car

Fabricante:

Sku: 267531

Coleções: ALL BMW

Disponibilidade: Em estoque

Tag: 1989 1990 1991 1992 1993 1994 1995 1996 5 Series E34 BMW Car Cars Misc

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Model Years Covered:

1989-1996

Codes

Body Styles:

Sedan (4-door), Touring (Wagon/Estate)

👋 Introduction

Market Position

E34 Market Segment:

Executive/Luxury Sedan and Wagon, known for its blend of performance, comfort, and build quality.

Competitive Analysis

Contemporary Competitors:

Mercedes-Benz W124 E-Class, Audi V8/A8, Lexus LS400, Volvo 700/900 Series, Jaguar XJ.

Key Features

E34 Engineering Highlights:

Rear-wheel drive dynamics, advanced inline-six and V8 engine options, sophisticated independent suspension, robust construction, and driver-focused ergonomics.

Manual Utility

Target Audience:

BMW enthusiasts, DIY mechanics, independent repair shops, and owners seeking to maintain or restore their E34.

📋 Manual Details

Coverage Areas

Documentation Type:

Comprehensive Service and Repair Manual

Primary Regions Of Applicability:

Global (with potential regional variations noted for specific emissions or equipment)

Page Count

Estimated Page Count:

Hundreds of Pages (exact count not specified, but indicative of extensive detail)

Manual Type

Manual Format:

Language

Language:

English

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of all E34 engine variants (e.g., M20, M30, M50, M52, S38, M60, M62, etc.) including cylinder head, block, crankshaft, pistons, connecting rods, valve train, timing components.

Engine Management:

Detailed information on fuel injection systems (Bosch Motronic variations), ignition systems, sensors, actuators, ECU diagnostics, and troubleshooting.

Transmission Manual:

Repair and overhaul procedures for manual transmissions (e.g., Getrag variants), including clutch operation, gearbox internal components, and shift linkage.

Transmission Automatic:

Repair and overhaul procedures for automatic transmissions (e.g., ZF 4HP variants), including torque converter, valve body, planetary gears, and electronic control.

Drivetrain:

Driveshaft, CV joints, differential (rear axle) inspection, repair, and fluid specifications.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, anti-roll bars, and alignment procedures.

Steering:

Power steering system, steering rack/gearbox, tie rods, and troubleshooting.

Brakes:

Hydraulic braking system, ABS (Anti-lock Braking System) diagnostics and repair, brake discs, pads, calipers, lines, master cylinder, and parking brake.

Electrical System:

Comprehensive wiring diagrams, component locations, fuse/relay assignments, battery, charging system (alternator, starter), lighting, instrumentation, and accessory circuits.

HVAC:

Heating, ventilation, and air conditioning system diagnosis, repair, refrigerant handling, and component replacement.

Body And Chassis:

Body panel removal/installation, interior trim, glass, doors, locks, hinges, and corrosion prevention.

Fuel System:

Fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulation, and evaporative emissions control (EVAP).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, and general inspections.

Troubleshooting:

Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, and fault code interpretation (where applicable).

Repair And Rebuild:

Step-by-step instructions for component removal, repair, overhaul, and reinstallation for all major systems.

Adjustments:

Detailed procedures for adjustments such as idle speed, valve clearance (if applicable), parking brake, and headlight aim.

Component Replacement:

Instructions for replacing wear items and failure-prone components like water pumps, alternators, starter motors, fuel pumps, O2 sensors, etc.

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed torque specifications and diagnostic procedures.

Diagnostic Capabilities:

Includes diagnostic flowcharts, sensor data interpretation, and troubleshooting based on system symptoms, catering to both DIYers and professional technicians.

Rebuild Procedures:

Detailed instructions for engine and transmission overhauls, including machining specifications and assembly sequences.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Readability:

High-resolution scans of original documentation ensuring clear text and diagrams.

Binding Type

Digital Format Features:

Searchable text for quick information retrieval, bookmarking capabilities, zoom functionality for diagrams.

Paper Type

Original Document Medium:

Originally printed on durable paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine Options

Engine Variants:

Wide range including M20 (2.0L-2.7L I6), M30 (3.0L-3.5L I6), M50 (2.0L-3.0L I6, Vanos), M52 (2.0L-2.8L I6, Vanos), M60 (3.0L-4.0L V8), M62 (3.5L-4.4L V8), S38 (3.6L-3.8L I6 M-Power).

Performance Examples

Horsepower Range:

Approximately 129 hp (520i M20) to 340 hp (M50 M5 3.8L).

Torque Range:

Approximately 174 Nm (520i M20) to 400 Nm (M50 M5 3.8L).

Fuel System

Injection Type:

Bosch Motronic electronic fuel injection (EFI) across most variants. Early models may feature K-Jetronic (E34 520i M20).

Engine Management

Ignition Type:

Electronic ignition systems, often integrated with Motronic ECU.

Timing System

Valve Timing:

Belt drive for M20/M30, Chain drive for M50/M52/M60/M62/S38. VANOS (Variable Valve Timing) introduced on M50/M52 engines.

🔧 Transmission

Standard Transmission

Manual Gearboxes:

Getrag 260 (5-speed) commonly found on inline-six engines. Other Getrag and ZF units may be present.

Optional Transmission

Automatic Gearboxes:

ZF 4HP22 (4-speed) common on most models, ZF 4HP24 on higher-performance variants. Later models may feature ZF 5HP (5-speed) automatic transmissions.

Features

Clutch Type:

Hydraulically actuated single-plate dry clutch for manual transmissions.

📐 Dimensions

Exterior Sedan

Length Sedan:

Approx. 4710-4780 mm (185.4-188.6 in), varies by model/year.

Exterior Touring

Length Touring:

Approx. 4755-4820 mm (187.2-189.8 in), varies by model/year.

Exterior

Wheelbase:

Approx. 2760 mm (108.7 in)

Weights

Curb Weight:

Approximately 1450-1750 kg (3197-3858 lbs), depending on engine and equipment.

🛡️ Safety Features

Ratings

Crash Test History:

While specific official ratings for the entire E34 production run from modern bodies are limited, the E34 was designed with advanced safety features for its era and generally performed well in contemporary tests. It benefited from a strong safety cage and crumple zones.

Active Features

Standard on most models from mid-production onwards. Optional on earlier models. Advanced ABS system for the time.

Asc Asc T:

Available on some models (Automatic Stability Control / Automatic Stability Control and Traction) for enhanced grip.

Passive Features

Airbags:

Driver's airbag became standard during the E34's lifecycle. Passenger airbag optional on some later models.

Seatbelts:

Pre-tensioned front seat belts with three-point inertia reel belts for all occupants.

💡 Technology Features

Infotainment

Audio System:

BMW Bavaria C Business/Professional radio/cassette players, optional CD changers, premium sound systems (e.g., HiFi). Later models had more advanced head units.

On-Board Computer with functions like fuel consumption, range estimation, outside temperature, and system checks. Often suffers from dead pixels on the LCD display.

Driver Assistance

Cruise Control:

Standard on many models, providing comfortable highway driving.

Connectivity

Telephone:

Optional factory or dealer-installed car phone systems were available on some higher-trim models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 km (6,000-10,000 miles) or 12-24 months, depending on driving conditions and oil type. Check Condition Based Service (CBS) system if equipped.

Spark Plug Replacement:

Varies by plug type; typically 40,000-100,000 km (25,000-60,000 miles). Refer to specific engine variant and plug manufacturer recommendations.

Timing Belt Replacement:

Not applicable for chain-driven engines (M50 onwards). M20/M30 engines use timing belts with recommended replacement intervals typically around 80,000-100,000 km (50,000-60,000 miles).

Fluid Specifications

Engine Oil:

SAE 5W-30, 5W-40, or 10W-40 synthetic/semi-synthetic oil, API SG or higher. BMW Longlife-98 (LL-98) or similar approvals recommended. Check specific engine manual for precise viscosity and API service rating.

Coolant:

BMW Antifreeze/Coolant (G48 or equivalent blue/purple ethylene glycol-based) mixed 50/50 with distilled water. Do not use HOAT or OAT coolants.

Brake Fluid:

DOT 4 low-viscosity (LV) or DOT 4 Plus brake fluid.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, viscosity varies by specific gearbox (e.g., 75W-90, 80W-90). Refer to manual for exact specification.

Transmission Fluid Automatic:

Dexron III / Mercon ATF fluid or BMW LT-3 (for some later models). Essential to use correct fluid for ZF transmissions.

Power Steering Fluid:

BMW Power Steering Fluid (CHF 11S or equivalent green Pentosin) for some models, check manual for correct type.

Known Issues

Common E34 Problems:

Cooling system failures (water pump, thermostat, hoses), head gasket issues on some high-mileage engines, VANOS solenoid/actuator failure (M50/M52), differential mounts, subframe bushings, OBC (On-Board Computer) pixel degradation, ABS sensor failures, fuel pump failure, vacuum leaks.

Preventative Maintenance

Critical Checks:

Regularly inspect cooling system, drive belts, all fluid levels, suspension bushings, and exhaust system for wear or leaks.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's commitment to 'The Ultimate Driving Machine' is reflected in the E34's handling, engine performance, and build quality, continuing the legacy of the E28 predecessor.

Model Evolution

E34 Introduction:

Launched in 1988 (as a 1989 model year in many markets) to replace the E28 generation. Featured a more aerodynamic design and updated technology.

E34 Facelift:

Received a significant facelift (LCI - Life Cycle Impulse) in 1994, introducing updated M50/M52 engines with VANOS, revised exterior styling (kidney grille, headlights, bumpers), and interior refinements.

Production

Production Period:

1988-1996

Manufacturing Locations:

Primarily Dingolfing, Germany. Some assembly may have occurred in other BMW facilities globally.

Notable Variants:

M5 (E34) - high-performance variant with S38 engine; Alpina B10 variants.

🏆 Awards & Recognition

Recognitions

Automotive Journalism Acclaim:

Consistently praised by automotive press for its driving dynamics, build quality, and refinement. Named to Car and Driver's Ten Best list multiple times during its production run.

Ratings

Reliability Perception:

Generally considered a reliable and durable vehicle, though maintenance is key. Specific engine variants (e.g., M50/M52) are known for their longevity when properly cared for.