Positioning:
The BMW 520i (E34) represented BMW's mid-size luxury executive sedan, competing with rivals like the Mercedes-Benz E-Class and Audi 100/200. It offered a blend of sporting prowess, luxury, and advanced engineering for its era.
Competitors:
Mercedes-Benz W124 E-Class, Audi 100/200 (C3/C4), Volvo 740/760.
Design:
Iconic E34 styling by Claus Luthe, characterized by clean lines, Hofmeister kink, and a driver-focused interior.
Engineering:
Rear-wheel drive platform, sophisticated independent suspension, emphasis on driving dynamics and build quality.
Value Proposition:
This manual is essential for owners and independent mechanics seeking to maintain, repair, or restore their 1988-1991 BMW 520i (E34). It provides the authoritative technical information required for accurate diagnostics and effective repairs, saving time and money on dealership visits.
Engine:
Engine mechanical, cooling system, lubrication system, fuel system, ignition system, emissions control, engine management (ECU).
Transmission:
Manual transmission (Getrag 260), automatic transmission (ZF 4HP22), clutch, driveshaft, differential.
Chassis And Body:
Suspension (front and rear), steering system, braking system (front discs, rear discs), wheels and tires, body panels, doors, windows, sunroof, interior trim.
Electrical:
Battery, charging system, starting system, lighting system, instrument cluster, wipers and washers, horn, power accessories (windows, mirrors, seats, locks), climate control system, audio system, diagnostic connectors.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt replacement.
Repair And Rebuild:
Complete engine overhaul, transmission rebuild, brake system repairs, suspension component replacement, electrical system troubleshooting and repair, bodywork repair.
Troubleshooting:
Diagnostic procedures, common fault diagnosis, wiring diagrams, symptom-based troubleshooting guides.
Depth:
Comprehensive; covers basic maintenance to complete vehicle rebuilds and advanced diagnostics.
Detail Level:
Detailed step-by-step instructions, torque specifications, special tool requirements, wiring diagrams, exploded views.
File Format Quality:
High-resolution, searchable text, printable pages.
Print Quality Description:
Clear diagrams, legible text, accurate schematics.
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Engine Type:
Inline 6-cylinder, naturally aspirated, SOHC
Displacement:
1990 cc (2.0 Liters)
Bore X Stroke:
80.0 mm x 66.0 mm
Valve Train:
SOHC, 2 valves per cylinder
Horsepower:
129 hp (96 kW) @ 5800 rpm
Torque:
174 Nm (128 lb-ft) @ 4500 rpm
Fuel Delivery:
Bosch L-Jetronic Fuel Injection (often referred to as LE2-Jetronic or Motronic depending on exact year/market)
Fuel Type:
Unleaded gasoline, premium octane recommended
Fuel Tank Capacity:
70 liters (18.5 US gallons)
Standard Transmission:
Getrag 260 5-speed manual transmission
Optional Transmission:
ZF 4HP22 4-speed automatic transmission
Clutch Type:
Hydraulically operated single dry plate clutch
Rear Axle Ratio:
Typically 3.46:1 (for manual), 3.23:1 or 3.46:1 (for automatic) depending on market and options.
Crash Test Results:
Specific ratings from official bodies like NHTSA or Euro NCAP for this era are difficult to find for individual models, but the E34 chassis was known for its robust safety cage construction.
ABS:
Anti-lock Braking System (ABS) was available as an option or standard on later models within this range.
Airbags:
Driver's side airbag became available as an option during this model run, and was standard on some later E34s.
Seatbelts:
Three-point inertia-reel seat belts for all occupants, pre-tensioners for front seat belts often optional or standard on higher trims.
Chassis Design:
Reinforced safety cell, crumple zones front and rear.
Audio System:
BMW Bavaria C Business or C Professional cassette radio systems, optional CD changer.
Climate Control:
Manual or optional automatic climate control (IHKA - Integrated Automatic Heating and Air Conditioning).
Cruise Control:
Available as an option.
Onboard Computer:
Optional OBC (Onboard Computer) providing basic trip data.
OBD Port:
BMW's proprietary diagnostic connector (often under the hood or dash), requiring specific diagnostic tools for comprehensive fault code reading.
Oil Change Interval:
Typically every 10,000-15,000 km (6,000-10,000 miles) or annually, depending on driving conditions and oil quality. Refer to specific market recommendations.
Spark Plug Replacement:
Approx. 40,000-60,000 km (25,000-37,000 miles) for standard ignition plugs, longer for platinum/iridium.
Coolant Flush:
Every 2-3 years or 40,000-60,000 km (25,000-37,000 miles).
Transmission Fluid Service:
Manual: typically clutch fluid every 2 years. Automatic: fluid and filter change recommended around 80,000-100,000 km (50,000-60,000 miles), though often considered 'lifetime' by manufacturers historically.
Engine Oil Type:
API SG or higher. Viscosity typically 10W-40 or 5W-30 depending on climate. Refer to manual for precise BMW specifications (e.g., BMW High Performance or Longlife-98 recommendations).
Engine Oil Capacity:
Approx. 4.5 liters (4.8 US quarts) with filter change.
Coolant Type:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. BMW specified BMW Antifreeze/Coolant (G48 is a common modern equivalent for older BMWs).
Brake Fluid:
DOT 4 (low viscosity, high temperature).
Power Steering Fluid:
ATF Dexron II or equivalent.
Manual Transmission Fluid:
BMW recommends specific gear oil grades (e.g., SAE 75W-90 or 75W-80 GL-4 or GL-5, depending on specific transmission).
Automatic Transmission Fluid:
ZF TE-ML 04D, TE-ML 14A, or Dexron II/III equivalents.
Common Problems:
Cooling system leaks (radiator, hoses, water pump), fuel pump failures, vacuum leaks leading to rough idle, wiring harness degradation (especially underhood), rear subframe mount issues, heater control valve leaks, driver's seat module failures (if equipped), door seal degradation.
M20 Engine Quirks:
Known for reliable operation, but susceptible to timing belt wear (critical replacement interval), valve cover gasket leaks, and potentially worn valve stem seals in higher mileage examples.
Bmw Legacy:
BMW has a long-standing reputation for building driver-oriented, sporty luxury sedans with a focus on engineering excellence and performance.
E34 Introduction:
The E34 generation of the 5 Series was introduced in 1987 as a successor to the E28. It represented a significant leap forward in design, technology, and chassis dynamics.
E34 520I Positioning:
The 520i was the entry-level model in many markets for the E34 generation, offering BMW's characteristic build quality and driving experience at a more accessible price point.
Production Years:
E34 generation produced from 1987 to 1996. This manual specifically covers 1988-1991 models.
Manufacturing Location:
Primarily Dingolfing, Germany.
