Bentley_BMW_5-Series_Service_Manual_Searchable.pdf

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Bentley Publishers
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v
vii
back of book
Maintenance
010
Fundamentals for the Do-it-yourself Owner
020
Maintenance Program
119
Lubrication System
Engine Removal and Installation
120
Ignition System-DME
113
Cylinder Head Removal
and Installation
12 1
Battery, Starter, Alternator
130
Fuellnjection-DME
116
Cylinder Head and Valvetrain
160
Fuel Tank and Fuel Pump
117
Camshaft Timing Chain
170
Radiator and Cooling System
118
Camshaft Timing Belt
180
Exhaust System
200
Transmission-General
240
Automatic Transm ission
210
Clutch
250
Gearshift Linkage
230
Manual Transmission
260
Driveshaft
Suspension,
Brakes
300
Suspension, Steering and
Brakes-General
330
Rear Suspension
331
Final Drive
310
Front Suspension
340
Brakes
320
Steering and Wheel Alignment
400
Body-General
411
Doors
410
Fenders, Engine Hood
412
Trunklid, Tailgate
510
Exterior Trim, Bumpers
515
Central Locking
512
Door Windows
520
Seats
513
Interior Trim
540
Sunroof
600
Electrical System-General
620
Instruments
610
Fuses and Relays
630
Exterior Lighting
611
Wipers and Washers
640
Heating and Air Conditioning
612
Switches and Electrical Accessories
650
Radio
Accessories
720
Seat Belts
721
Airbag System (SRS)
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Selected Books and Electronic Editions From Bentley Publishers
Driving
T h e Unfair Advantage
," lll rk 0",,,,1111,'
ISBN 0-1'G76-0073- 1 (h e): 0-R376-001>9-3(pb)
Driv ing Fo rces: The G ra n d Prix Racing
World Caught in the Maelstrom o f the
Third Reich
I't'I a SIt"l~'II~OIl IS BN 0-8371>-02 I7-3
A Fre n ch Ki ss With Death: S te ve
McQueen and the Making of Ll' M IIIIS
Miclllld K,'y s,'I' ISBN 0-8376-0234-3
The Speed Merchants: A Journey Through
the World of Motor Racing 1969-1972
,\-lie/llld K,' I/S<,/ ISBN 0-8376-0232-7
Going Fas te r! Mastering the Art of Race
Driving
Til" Ski!, Bllrba 1{1ll"illg Schoo!
IS BN 0-8376-0227-0
T h e Racing Driver
n ,"I ;S ll'llki ll SOIl ISBN 0-8376-0201-7
S p o rts Ca r and Competition Driving
1'1l1I1 Frere ioitt: j im'w ol'd 1>" I'lI il l lili
ISB
Jeep
jeep Owner's Bible' ~I
M"s.'s Lurid ISBN 0-R376-01:;.t· I
BMW 3 Series (E46) S erv ice Manual:
1999-2001, 323i/Ci , 325i1Ci/,i, 328i1Ci,
330i/Ci/ xi Sedan, Coupe, Convertible and
S p o rt Wagon
[Jmllt'y PIIII/i~/Il'1'S ISBN O-R376-0320-X
BMW 5-Series (E28) Service Manual:
1982-1988 528e, 533i, 535i, 535i s
Belltl"y l'lIl'lisller~ ISBN 0-8376-03 1H-H
BMW 5-Serie s (E34) Service Manual:
1989-1995 525i, 530i, 535i, 540i , in cl u d in g
Touring
B" 1111"y 1'1I1,Ii~hl'l'.< ISHN 0-8376-0319-6
BMW 7 Series (E32) Service Manual:
1988-1994, 735i, 735il., 740i, 740il., 750il.
Ek ll /It'y 1'1I1,lisll"r~ ISBN 0-R376-03 21l-:;
BMW Z3 Roadster Serv ice Manual:
1996-1998,4- and 6-cylinder engines
Ilm/It'y I'IIMi~IIC1'~ ISBN 0-8376 -0328 -:;
BMW En t h u sias t's Companion T M
BAH\' Cllr CE ll I< " ,. A inericn
ISBN 1l.8376-032 1. R
BMW 3 Series En th u s ias t's
Companion HI
Im ''' I1/ WII/I,," ISBN 0-8376-o2211-3
BMW 6 Series En th usiast's
Companion r~1
Im 'lIIy WII/lOII ISBN 0-8376 -0 149-5
U n b e a ta b le BMW: Eigh ty Years of
En gin e e ri n g and Motorsport Success
It'n'lIIy WIIII ,'" ISBN 0·8376-lJ 2lJ6 -8
Porsche
Porsche 911 Ca rrera Se rvi ce Manual:
1984-1989, Coupe, Targa and Cabriolet
lk ll tI,'..'! 1'1I/,Ii~/1L'rs ISBN 1l·8376-029 1·2
I'orsche 911 S C S ervice Manual :
1978-1983, Coupe, Ta rg a and Cabriolet
1l" IIt1"y PII1'li~lIas ISBN O-R376-0290-l
Saab
Saab 900 16 Valve Official Se rvice
Manual: 1985-1993
B.."tI"y 1'1I1'/islll'l'~ ISBN 0-8376-03 12-9
S aa b 900 8 Valve Official Service Manual:
1981-1988
llelltl"y 1'111,1 islll'r~ IS BN 11-8376-03 1l1 -2
Toyota
To yota Truck & I.and Cruiser Owner's
Bible T M
MMl'> 1. 11 .11'1 ISBN 0·8376·0159-2
0-8376-0202-5
Engin eering
Maximum Boo st: Designing, Testin g, and
In stalling Turbocharger Systems
Corky 0,,11 ISBN 0-R376-0 160-6
Bosch Fuel Injection and En g in e
Mana gement
Cluirlcs O. l'nJbs/, SA L: ISBN 0-R376-0300-5
Race Car Aerodynamics
Illsl'!'IJ KIlI~ ISBN 0-8376-0142-8
Volkswagen
Battle for the Beetle: The Story of the Battle
for the Giant VW Factory a n d the Ca r that
Became an Icon Around the Globe
Kllrl LIII/1>ig" m ISBN OS376 -0U7 1-5
Volkswagen Sport Tuning for Street and
Competition
Per Sdtl'O.·,ler ISBN 1l·R176-0 161-4
[etta, Golf, G TI S erv ice Manual: 1999-2002
2,01. Gasoline, 1.91. TDI Diesel, 2 .81. VR6,
1.81. Turbo
lk ll /It'.'Il'lIl<lisllL'rs ISBN 0·8 376-0388·9
[etta, Golf, GTl, Cabrio S e rv ice Manual:
1993-1999, including jellallJ and Golf llJ
1lt" lfI,'!/ I'II MisllL'rs ISBN O·8376-03 66·H
Pa s sat Official Factory Repair Manual
1998-2000 Electro n ic Ed it io n
Bcn l lci; PIiMis/lC1'S IS BN 11-8376-0763-9
Ch evrolet
C h e v ro le t by the Numbers 1955-1959 :
The Esse n tia l Chevrolet Parts Reference
Ali lll C" /pi ll ISBN tl-8376 ·11875 -9
Chevrolet b y the Numbers 1960-1964:
T h e Esse n tia l Chevrolet Parts Reference
11/"" C" /lIi ll ISBN 11-8376-11936-1
Corvette 427: Practical Restoration of a
' 67 Roadster
n Oli SIIt'/'JIIIlJ/ ISBN 0-8376-02 1fl - I
Corvette Fuel Injection & Electronic
En g in e Management: 1982-2001
Chllrles 0 . I'IOb~I, SAL: ISBN 0· 8376-086 1·9
Referel1ce
Road & Track Illustrated Automotive
Dictionary
10111I Oillkd ISBN 0-8376-0 143-6
Audi
Audi TT Official Factory Repair Manual
MY 2000 Electr o n ic Edition
Audi of AlII<'I'iCIl ISBN 0-8371>-0758-2
Audi A4fS4 Official Factory Repair Manual
1996-2000 Ele ctron ic Ed ition
Bm tll'lf 1'III>I isll" I'> ISBN O·8376-lJ761·2
Audi 80, 90 Coupe, Quattro Official
Factory Repair Manual: 1988-1992
Ford
Fo rd Fuel Injection and Electronic En gin e
Control: 1988-1993
Charle» O. I'IOb,,', SAL: ISBN 1l·8 376-1l.101 -3
The Official Fo rd Mustang 5,0 Technical
Re ference & Performance Handbook
1979-1993
ti l Kirscl''''' /''lJ/ III ISBN 0·8376 ·021l1·6
Volvo
Volvo 240 S e rv ice Manual: 1983-1993
Bl'lIl lell I'liblislle!'s ISBN O·S:l76·02H5·g
A ll di or Amcrir« ISBN 0-R376-0368-4
BMW
Co m p le te Rounde11969-1998
8 CD-ROM se t: 30 Ye a rs of the Magazine
of the BMW Car Club o f America, Inc.
BAli V CIlI' ClIIII of .-\ 1II" l'i(l1 ISBN 1l·IU76-0322-6
BMW 3-Series (DOl Se rv ice Manual:
1984-1990 318i, 325, 325e(es), 325i(is).
a n d 325i Co n ve rt i b le
Bmtll'll I'lIlI/isl,<'I's ISBN 0-8376 ·0325·0
BM W 3 S e ries lE36) Se rv ic e Manual:
1992-1998, 318i/is/iC, 323i s/i C, 325i/i s/iC,
328i/i s/i C, M3
llell l k " I'liblisll"l's ISBN 0·8376-0.126-9
~B1 B~WntleyPublishers
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Harley-Davidson
Harley-Davidson Evolution V-Twin
Owner's Bible H 1
A·rose,; LIJl /d ISBN 1l·8.176-0 146-0
AUTOMOTIVE BOOKS AND MANUALS
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Honda
Ci v ic Duty: T he Ultimate Guide to the
World's Most Popular Sport Co m p acl
Car, the Honda Civic
AIIIII Paradisr ISBN 1l·8376-02 15-7
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Foreword
This BMW 5-Series Service Manua l covers the 1989 through 1995 525i mode ls, the 1989
through 1993 535i models, and the 1994 and 1995 530i and 540i models, and is specifically de-
signed to cove r only those models built for sale in the United States.
BMW and most accessories and parts selle rs spec ializing in BMWs refer to the 5-Se ries covered
by this manual as the E34 model. The code "E34" is BMW's internal code for the basic platform
shared by all of the ca rs covered by this manual. Except for the engine and a few other components,
the mode ls cove red by this man ual share many of same components such as suspension pa rts,
body panels, and the interior pieces . When ordering parts, espe cially body parts, knowing the E34
code may be helpful.
BMW also uses an internal code for the various engines used in the E34 models. The engines
used in the 525i models are either M20 , M50, or M50TU . The engine used in the 535i is known as
the M30 . The engine used in the 530i and 540i is known as the M60. This information is primarily
used intemally by BMW , but may be helpful if you have access to BMW technical information.
For the BMW owner with basic mechanical skills, this man ual gives detailed maintenance and
repair information. In addit ion, the BMW owner who has no intention of working on his or her own
car will find that owning and reading this manual will make it possible to be bette r informed and to
discuss repairs more intelligently with a professional technician. This manual has been prepared
from the repair information that BMW provides to its factory-trained techn icians and has been de-
veloped primarily with the do-it-yourself BMW owner in mind. The aim throughout has been clarity
and understanding with practical funct ional descriptions , step-by-step procedures, and accurate
specifications.
The BMW owner intending to do maintenance and repair should have a set of tools including a set
of metric wrenches and sockets, screwdrivers. a torque wrench , and feeler gauges, since these ba-
sic tools will be used to do the majority of Ihe maintenance and repair procedures described in this
manua l. This man ual includes detailed information on these basic tools and othe r tips for the begin-
ner in the first section of the manual , entitled Fundamentals for the Do-It-Yourself Owner. For some
of the repairs described in this manual, BMW technicians use special tools. The text will note whe n
a repair requires these special tools and . where possible, will recommend practical alternatives.
v
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