🏷️ Basic Information

Make:

BMW

Model:

520i

Year:

1989

Chassis Code:

E34

👋 Introduction

Market Segment:

Executive Mid-size Sedan

Brand Perception:

Known for luxury, performance, and build quality.

Competitors:

Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, Lexus LS (later in production life)

Styling:

Iconic E34 design by Claus Luthe, known for its aerodynamic efficiency and timeless elegance.

Driving Dynamics:

Renowned for its balanced chassis, rear-wheel drive, and engaging driving experience.

Build Quality:

Exceptional German engineering and construction, contributing to longevity and durability.

📋 Manual Details

Manual Type:

Full Service Repair Manual

Language:

English

Format:

Likely Printed (Digital PDF also common)

Estimated Page Count:

600+

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, rebuild, timing, valve adjustments, cooling system, lubrication system

Engine Fuel System:

Fuel injection system (Bosch Motronic), fuel pump, injectors, pressure regulator, diagnostics

Transmission Manual:

Service, overhaul, clutch replacement, shift linkage, fluid specifications

Transmission Automatic:

Service, diagnostics, fluid changes, common faults (if applicable to 520i E34)

Drivetrain:

Driveshaft, universal joints, differential, axle shafts, wheel bearings

Suspension:

Front and rear suspension components, shock absorbers, struts, control arms, bushings, alignment specifications

Steering:

Power steering system, steering rack, tie rod ends, steering column, diagnosis

Brakes:

Hydraulic system, calipers, pads, rotors, master cylinder, brake lines, ABS system diagnostics and repair

Electrical System:

Wiring diagrams, battery, alternator, starter, lighting, fuses, relays, ignition system

Engine Management:

ECU diagnostics, sensor testing (MAF, O2, coolant temp), ignition timing, idle control

Body And Chassis:

Body panel repair, door mechanisms, windows, locks, sunroof, interior trim

Heating Ventilation Air Conditioning:

HVAC system operation, blower motor, evaporator, condenser, refrigerant charging (R12)

Routine Maintenance:

Oil changes, filter replacements, spark plug changes, belt inspection/replacement, fluid top-offs

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon problems, fault code interpretation

Repair And Rebuild:

Detailed instructions for component removal, installation, and rebuilding (e.g., engine, transmission, suspension)

Diagnostics:

Procedures for checking and diagnosing all major vehicle systems using specialized tools and techniques

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle circuits

Depth:

Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics.

📊 Manual Specifications

File Type:

Likely digital (PDF) for modern sales, or original printed manual.

Searchability:

PDF format typically offers full text search capabilities.

Printability:

Printable pages for workshop use.

Print Quality:

High-resolution scans or original print quality, ensuring clarity of diagrams and text.

Binding Type:

If printed: Likely spiral-bound or comb-bound for lay-flat usability in a workshop.

Paper Type:

If printed: Durable, heavy-weight paper suitable for shop environments.

⚙️ Engine Specifications

Engine Code:

M20B20

Engine Type:

Inline 6-cylinder, SOHC, 12-valve

Displacement:

1990 cc (2.0 Liters)

Horsepower:

129 hp @ 5800 rpm

Torque:

181 Nm (133 lb-ft) @ 4300 rpm

Fuel Delivery:

Bosch Motronic M1.3 fuel injection

Fuel Type:

Unleaded Gasoline (RON 91 or higher recommended)

Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Cooling Type:

Water-cooled

Oil Capacity:

4.5 Liters (with filter)

Recommended Oil Viscosity:

10W-40 or 15W-40 (refer to manual for climate specific recommendations)

Ignition Type:

Electronic ignition with distributor and coil

🔧 Transmission

Transmission Type:

Getrag 260 5-speed Manual Transmission

Transmission Type:

ZF 4HP22 4-speed Automatic Transmission

Clutch Type:

Hydraulically operated single dry plate clutch

Automatic Transmission Features:

Lock-up torque converter, sport mode (depending on specific variant)

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent (e.g., Pentosin).

Automatic Transmission Fluid:

Dexron II or III (or BMW approved equivalent)

📐 Dimensions

Length:

4720 mm (185.8 inches)

Width:

1751 mm (68.9 inches)

Height:

1410 mm (55.5 inches)

Wheelbase:

2760 mm (108.7 inches)

Curb Weight:

Approx. 1450 kg (3197 lbs) for manual transmission

Gross Vehicle Weight Rating:

Approx. 1950 kg (4299 lbs)

Trunk Volume:

Approx. 460 liters (16.2 cubic feet)

🛡️ Safety Features

Safety Ratings Era:

Data from this era is not directly comparable to modern NCAP standards. Generally considered safe for its time.

ABS:

Anti-lock Braking System (ABS) available as an option on some models.

Traction Control:

ASC (Automatic Stability Control) became available on later E34 models, potentially on later 1989 builds or as an option.

Airbags:

Driver's side airbag became optional or standard on later E34 models, check specific vehicle.

Seatbelts:

3-point inertia-reel seatbelts front and rear.

Body Structure:

Reinforced passenger safety cell with crumple zones.

💡 Technology Features

Audio System:

Factory BMW radio/cassette player, often with basic EQ and 4-6 speakers. Aftermarket upgrades are common.

Climate Control:

Manual or optional automatic climate control (ECC - Electronic Climate Control).

Cruise Control:

Optional feature on most models.

Connectivity Features:

Limited by era. Typically no integrated Bluetooth or USB ports. Aftermarket solutions are available.

🔧 Maintenance

Oil Change Interval:

Every 10,000-15,000 km (6,000-9,000 miles) or annually, depending on driving conditions. Refer to manual for specific recommendations.

Air Filter Replacement:

Every 30,000-50,000 km (18,000-30,000 miles) or as needed based on inspection.

Spark Plug Replacement:

Every 40,000-60,000 km (24,000-36,000 miles). Use recommended spark plug type.

Coolant Flush:

Every 2-3 years or 40,000-60,000 km (24,000-36,000 miles).

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Coolant:

BMW Blue Antifreeze/Coolant or equivalent (e.g., ethylene glycol-based with corrosion inhibitors).

Power Steering Fluid:

ATF Dexron II or III, or CHF 11S depending on system type. Check manual.

Cooling System:

Plastic coolant expansion tanks can become brittle and crack. Check water pump and thermostat housing for leaks.

Electrical:

Wiring harness degradation over time, especially in engine bay. Check fan clutch, alternator output, and ECU for common faults.

Suspension:

Worn control arm bushings, ball joints, and tie rod ends are common due to age and mileage.

Fuel System:

Potential for fuel pump failure, clogged injectors, or a leaking fuel pressure regulator.

Interior:

Sagging headliner, worn seat bolsters, and malfunctioning electronic accessories (e.g., power windows, central locking).

📚 Vehicle History

Brand History:

BMW (Bayerische Motoren Werke AG) has a long-standing reputation for engineering, performance, and luxury vehicles since its founding in 1916.

E34 Generation:

The E34 generation of the 5 Series was introduced in 1987 (as a 1988 model year in some markets) and replaced the E28. It represented a significant advancement in styling, technology, and chassis dynamics.

E34 Variants:

The E34 range included various engine sizes (4-cylinder, 6-cylinder, V8) and body styles (sedan and touring wagon). The 520i was a popular entry-level model in many markets, particularly Europe.

Production Years:

1987–1996

Manufacturing Locations:

Primarily Dingolfing, Germany, with some assembly in other BMW plants globally.

🏆 Awards & Recognition

Automotive Awards:

The E34 generation was widely acclaimed for its engineering and driving dynamics. While specific awards for the 520i variant might be scarce, the E34 chassis itself garnered significant praise and was a benchmark in its class.