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BMW 520i Complete Workshop Service Repair Manual 1988 1989 1990 1991

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🏷️ Basic Information Identification Make: BMW Model: 520i Model Code: E34 Product Name: BMW 520i Complete Workshop Service Repair Manual 1988 1989 1990 1991 Codes Engine Code Identifier: M20B20 (early...
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BMW 520i Complete Workshop Service Repair Manual 1988 1989 1990 1991
🏷️ Basic Information
Identification
Make:
BMW
Model:
520i
Model Code:
E34
Product Name:
BMW 520i Complete Workshop Service Repair Manual 1988 1989 1990 1991
Codes
Engine Code Identifier:
M20B20 (early models) / M50B20 (later models)
👋 Introduction
Market Position
Market Position:
Mid-size luxury sedan, known for its blend of performance, comfort, and build quality in its era.
Competitive Analysis
Key Competitors:
Mercedes-Benz E-Class (W124), Audi 100 (C3/C4), Lexus ES250/ES300
Key Features
Design Philosophy:
Classic BMW design cues, driver-oriented cockpit, focus on handling dynamics.
Target Audience:
Discerning drivers seeking a sophisticated, reliable, and engaging driving experience.
📋 Manual Details
Coverage Areas
Coverage Years:
1988, 1989, 1990, 1991
Covered Models:
BMW 520i (E34 chassis)
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection (Bosch Motronic), ignition system, cooling system, exhaust system, engine management diagnostics
Transmission Systems:
Manual transmission (Getrag 260), Automatic transmission (ZF 4HP22), clutch system, driveline
Chassis Systems:
Suspension (front strut, rear multi-link), steering system (power steering), braking system (ABS equipped models), wheels and tires
Electrical Systems:
Wiring diagrams, lighting system, charging system (alternator, battery), starter motor, instrument cluster, ECUs, comfort electronics
Body And Interior:
Body panels, doors, windows, seats, trim, HVAC system (climate control), sunroof
Procedures Included
Routine Maintenance:
Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid replacement, belt inspection/replacement
Repair And Overhaul:
Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, steering rack repair
Diagnostics And Troubleshooting:
Fault code retrieval (OBD I for M20, OBD II readiness for early M50), symptom-based troubleshooting guides, wiring diagram analysis
Installation And Replacement:
Component replacement procedures for major systems, torque specifications for critical fasteners
Technical Depth
Depth Of Coverage:
Comprehensive, from basic fluid checks to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text content
Print Quality
Print Quality:
High-resolution scans, suitable for printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, DOHC
Displacement:
2.0 Liters (1990cc)
Bore X Stroke:
80.0 mm x 66.0 mm
Compression Ratio:
8.8:1 (M20) / 8.8:1 or 10.0:1 (M50)
Performance
Horsepower M20:
129 hp @ 5800 rpm
Torque M20:
174 Nm (129 lb-ft) @ 4300 rpm
Horsepower M50:
150 hp @ 5600 rpm (early M50B20)
Torque M50:
190 Nm (140 lb-ft) @ 4300 rpm (early M50B20)
Fuel System
Fuel Delivery:
Bosch Motronic fuel injection
Fuel Type:
Unleaded gasoline (95 RON recommended)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual (Getrag 260)
Optional
Optional Transmission:
4-speed automatic (ZF 4HP22)
Features
Transmission Fluid Type Manual:
BMW MTF LT-2 or equivalent (e.g., Pentosin MTF 2)
Transmission Fluid Type Auto:
Dexron III or Dexron VI (check specific vehicle)
📐 Dimensions
Exterior
Length:
4711 mm (185.5 in)
Width:
1751 mm (68.9 in)
Height:
1410 mm (55.5 in)
Wheelbase:
2795 mm (110.0 in)
Weights
Curb Weight:
Approx. 1500-1580 kg (3307-3483 lbs)
Gross Vehicle Weight Rating:
Approx. 2000 kg (4409 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
No standardized ratings like NHTSA/Euro NCAP for this era, but generally considered safe for its time.
Active Features
ABS:
Available on most models, especially later production.
Traction Control:
Optional on some models (ASC/ASC+T)
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional or introduced later in the run.
Seatbelts:
Three-point inertia-reel seatbelts
💡 Technology Features
Infotainment
Infotainment System:
Basic analog radio/cassette system. Optional CD player or upgraded sound systems available.
Driver Assistance
Driver Assistance Features:
Primarily focused on driving dynamics. Features like ABS and optional traction control are the main electronic aids.
Connectivity
Connectivity Options:
No integrated Bluetooth or modern connectivity. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 - 10,000 miles (12,000 - 15,000 km) or annually. Check oil level frequently.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on conditions.
Spark Plug Replacement M20:
Approx. 30,000 miles (48,000 km)
Spark Plug Replacement M50:
Approx. 60,000 miles (96,000 km) for twin-electrode plugs
Fluid Specifications
Engine Oil Type:
Synthetic 5W-30, 5W-40, or 10W-40 depending on climate and manufacturer recommendation (e.g., BMW High Performance SAE 5W-40)
Engine Oil Capacity:
Approx. 4.25 - 4.5 Liters (with filter)
Coolant Type:
BMW Blue Antifreeze/Coolant or equivalent G48 ethylene glycol based coolant
Brake Fluid Type:
DOT 4
Known Issues
Common Issues:
Head gasket leaks (M20), cooling system leaks (hoses, water pump), VANOS issues (M50 - though less common on the 2.0L), idle control valve problems, door seal degradation, window regulator failures, seized sunroof motors.
Maintenance Considerations:
Regular inspection of rubber hoses and seals is crucial due to age. Timing belt replacement (if applicable to specific variant/engine) is critical. ABS sensor cleaning and checking can resolve common ABS light issues.
📚 Vehicle History
Brand Heritage
Brand Heritage:
BMW, a German manufacturer with a long history of producing high-performance and luxury vehicles, known for its 'Ultimate Driving Machine' slogan.
Model Evolution
E34 Generation:
The E34 generation of the 5 Series was produced from 1987 to 1996, replacing the E28 and preceding the E39.
520I Positioning E34:
The entry-level 5 Series model in many markets, offering a balance of BMW engineering and efficiency.
Production
Production Years E34:
1987-1996
Production Locations:
Germany, South Africa
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
The E34 generation generally received positive reviews from automotive publications for its handling, comfort, and build quality.
Ratings
Reliability Perception:
Generally considered reliable with proper maintenance, but age-related component failures are common.
Certifications
Manual Certification:
N/A (Represents manufacturer's technical documentation)
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