This manual covers the 5 Series 525i, specifically the E34 chassis code, produced between 1989 and 1995. The 525i is celebrated for its refined M50 inline-six engine, delivering a balance of performance and smooth power delivery, and its reputation for exceptional driving dynamics and build quality. As an executive mid-size sedan, it was engineered to offer superior handling, comfort, and a driver-focused experience, making it a benchmark in its class against competitors such as the Mercedes-Benz W124 E-Class and Audi V8 Quattro. Its robust construction and engineering prowess have cemented its status as a desirable vehicle for automotive enthusiasts and those who appreciate a well-built luxury sedan. This comprehensive workshop service manual provides detailed technical information essential for the maintenance, repair, and diagnostics of the 5 Series 525i (E34). It covers a wide range of systems, including the M50 engine, manual and automatic transmissions, suspension, brakes, ABS, and the complete electrical system with detailed wiring diagrams. The manual includes step-by-step procedures for routine maintenance, complex overhauls, and troubleshooting common issues, making it an indispensable resource for owners, DIY mechanics, and professional technicians alike. Its thoroughness ensures that users can effectively maintain the vehicle's integrity and performance throughout its service life. 🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 525i Codes Chassis Code Series: E34 Engine Code Series: M50 👋 Introduction Market Position Segment: Executive mid-size sedan. Target Audience: Automotive enthusiasts, DIY mechanics, professional repair shops, and owners seeking to maintain their E34 525i. Competitive Analysis Key Competitors: Mercedes-Benz W124 E-Class, Audi V8 Quattro, Lexus LS 400, Jaguar XJ6. Key Features Driver Focus: Renowned for its superior driving dynamics, balanced chassis, and refined inline-six engines. Build Quality: Exceptional build quality and longevity, characteristic of BMW's engineering prowess during this era. Manual Utility: Provides essential, detailed technical information crucial for maintaining the integrity and performance of the E34 525i. 📋 Manual Details Coverage Areas Manual Title: BMW 5 Series 525i 1989-1995 Workshop Service Manual Applicable Years: 1989, 1990, 1991, 1992, 1993, 1994, 1995 Covered Models: 525i Page Count Total Pages: 450 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Full coverage of M50B25 inline-six engine, including diagnostics, repair, and overhaul. Fuel System: Detailed information on fuel injection system (DME, injectors, fuel pump, regulator) and fuel tank. Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications, and fan clutch. Ignition System: Ignition coils, spark plugs, DME control, and diagnostic procedures. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, and oxygen sensors. Transmission Manual: Complete repair and overhaul procedures for Getrag 260 5-speed manual gearbox. Transmission Automatic: Repair and diagnostic procedures for ZF 4HP22/4HP24 automatic transmissions. Drivetrain: Driveshaft, universal joints, differential, axles, and wheel bearings. Suspension Front: MacPherson struts, control arms, sway bar, bushings, and alignment specifications. Suspension Rear: Multi-link independent rear suspension, shock absorbers, springs, bushings, and alignment. Steering: Power steering system (pump, rack, hoses), steering column, and alignment. Brakes Front: Ventilated disc brakes, calipers, pads, rotors, and fluid specifications. Brakes Rear: Solid disc brakes, calipers, pads, rotors, and parking brake. ABS: Antilock Braking System (ABS) components, diagnostics, and bleeding procedures. Electrical System Overview: Comprehensive wiring diagrams, fuse box locations, relay assignments, and electrical component testing. Battery Charging: Alternator, voltage regulator, battery specifications, and testing. Lighting Exterior: Headlights, taillights, turn signals, fog lights, bulb types, and wiring. Lighting Interior: Dome lights, instrument cluster illumination, and courtesy lights. Instrument Cluster: Speedometer, tachometer, fuel gauge, temperature gauge, warning lights, and diagnostics. Climate Control: HVAC system operation, blower motor, heater core, evaporator, A/C compressor, refrigerant, and diagnostics. Body Exterior: Body panel repair, door mechanisms, hood, trunk, bumpers, and glass replacement. Body Interior: Seat removal, dashboard disassembly, headliner, door panels, and trim components. Chassis Frame: Underbody structural components and corrosion protection. Safety Restraints: Seat belt operation and inspection (pre-tensioners not typically present on this model). Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection. Engine Overhaul: Detailed steps for engine disassembly, component inspection, reassembly, and break-in procedures. Transmission Repair: Complete procedures for clutch replacement, gearbox rebuild, and automatic transmission servicing. Brake System Service: Pad and rotor replacement, caliper service, brake fluid flush, and ABS bleeding. Suspension Components: Replacement of struts, shocks, control arms, bushings, ball joints, and tie rod ends. Steering System Repair: Power steering pump replacement, rack and pinion service, and alignment adjustments. Electrical Troubleshooting: Systematic diagnostic trees, fault code retrieval (where applicable), and component testing. Diagnostics: Fault finding for engine, transmission, ABS, and other key systems. Wiring Diagrams: Detailed, high-quality wiring schematics for all vehicle systems. Body And Trim: Removal and installation of interior and exterior body panels, trim pieces, and accessories. Heating And Air Conditioning: Service and repair of the climate control system, including leak detection and refrigerant handling. Technical...