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BMW 520i 1991 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 520i Year: 1991 Generation Chassis Code: E34 Codes Engine Code Common: M50B20 👋 Introduction Market Position Segment: Executive Sedan Target Audience: Enthusiasts, DIY...
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UGS: 421411
Mots clés: 1991 520i BMW Car Cars Misc
BMW 520i 1991 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
520i
Year:
1991
Generation
Chassis Code:
E34
Codes
Engine Code Common:
M50B20
👋 Introduction
Market Position
Segment:
Executive Sedan
Target Audience:
Enthusiasts, DIY mechanics, and professional workshops specializing in BMWs.
Competitive Analysis
Key Competitors Era:
Mercedes-Benz W124 E-Class, Audi V8 Quattro, Lexus LS 400 (later in production).
Key Features
Vehicle Appeal:
Renowned for its balanced chassis, refined engineering, and driver-focused experience.
Manual Value Proposition:
Empowers owners to maintain and repair their classic BMW, preserving its performance and value.
📋 Manual Details
Coverage Areas
Primary Focus:
Full Service and Repair
Secondary Focus:
Maintenance, Rebuilding, Refurbishment, Restoration, Diagnostics
Page Count
Estimated Pages:
Detailed, likely exceeding 500 pages for comprehensive coverage
Manual Type
Type:
Full Service & Repair Manual
Language
Language:
English
Format
Format:
Likely digital (PDF) given typical modern offerings, potentially available in print.
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, internal components, cooling system, lubrication, fuel delivery, ignition, emissions control.
Transmission:
Manual and Automatic transmission service, repair, and overhaul.
Drivetrain:
Driveshafts, differentials, axle components.
Suspension:
Front and rear suspension components, alignment, shock absorbers, springs.
Brakes:
Hydraulic system, disc brake components (front and rear), parking brake, ABS (if equipped).
Steering:
Power steering system, steering column, linkages.
Electrical:
Wiring diagrams, lighting, ignition system, starting and charging, fuse/relay identification, instrument cluster.
Body And Chassis:
Body panel removal/installation, doors, windows, interior trim, chassis components.
Climate Control:
HVAC system service and repair.
Fuel System:
Fuel pump, injectors, fuel lines, evaporative emissions control.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, belt inspections.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues.
Repair And Rebuild:
Step-by-step instructions for component replacement and full rebuilds.
Adjustments:
Valve adjustments, clutch adjustments, idle speed adjustments.
Diagnostics:
Engine performance diagnostics, electrical system diagnostics, ABS diagnostics (if applicable).
Installation And Replacement:
Detailed guides for component installation and replacement.
Technical Depth
Depth Level:
Comprehensive, covering everything from basic checks to complete engine and transmission rebuilds.
Diagrams And Illustrations:
Extensive use of detailed diagrams, exploded views, and schematics.
Torque Specifications:
Precise torque values for all critical fasteners.
Diagnostic Codes:
Information on diagnostic trouble codes (DTCs) and their interpretation, if applicable to E34 generation.
📊 Manual Specifications
File Format
Digital Format Details:
Likely searchable PDF with high-resolution scans of original manual pages.
Print Quality
Print Quality Description:
If printed, expect clear, legible text and high-quality reproductions of diagrams.
Binding Type
Binding Type Description:
If printed, typically coil-bound or perfect-bound for lay-flat use in a workshop.
Paper Type
Paper Type Description:
If printed, often on durable, coated paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, DOHC (Double Overhead Camshaft)
Displacement:
2.0 Liters (1991cc)
Bore X Stroke:
80.0 mm x 72.0 mm (typical for M50B20)
Compression Ratio:
8.8:1 or 9.0:1 (depending on specific variant)
Valvetrain:
4 valves per cylinder, DOHC
Engine Management:
Bosch Motronic (likely Motronic 3.1 or similar)
Performance
Horsepower Peak:
Approx. 150 PS (148 hp; 110 kW) at 6000 rpm
Torque Peak:
Approx. 190 Nm (140 lb-ft) at 4300 rpm
Fuel System
Fuel Delivery:
Bosch LE-Jetronic or Motronic fuel injection
Recommended Fuel:
Unleaded gasoline, Octane rating 91 or higher (RON/MON)
Emissions Control:
Catalytic converter, Lambda sensor (oxygen sensor)
🔧 Transmission
Standard
Type:
Getrag 260 5-speed manual transmission
Optional
Type:
ZF 4HP22 4-speed automatic transmission
Features
Clutch:
Hydraulically actuated single dry plate clutch (manual transmission)
Rear Axle Ratio:
Typically 3.15:1 or similar, depending on transmission and market.
📐 Dimensions
Exterior
Length:
Approx. 4730 mm (186.2 in)
Width:
Approx. 1751 mm (68.9 in)
Height:
Approx. 1412 mm (55.6 in)
Wheelbase:
Approx. 2760 mm (108.7 in)
Weights
Curb Weight:
Approx. 1450-1550 kg (3197-3417 lbs), depending on equipment
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official crash test data from era, but E34 chassis known for robust construction.
Active Features
ABS:
Anti-lock Braking System (standard on most models, check specific VIN)
Traction Control:
ASR (Automatic Stability Control) available as an option on some models.
Passive Features
Airbags:
Driver's side airbag typically standard from this year.
Seatbelts:
3-point inertia-reel seatbelts front and rear.
💡 Technology Features
Infotainment
Audio System:
Original cassette player with AM/FM radio, optional CD changer integration.
Climate Control Type:
Manual or optional automatic climate control (ECC - Electronic Climate Control).
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Early Telematics:
Limited or no integrated smartphone connectivity; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, per manual recommendations.
Spark Plug Replacement:
Around 30,000-60,000 miles (48,000-96,000 km), depending on plug type.
Timing Belt Chain:
The M50B20 engine features a timing chain, which is designed to last the life of the engine and does not require regular replacement like a belt. However, tensioners and guides can wear.
Fluid Specifications
Engine Oil Type:
API SG, ACEA A2 or A3 specification. Viscosity typically 5W-30, 5W-40, or 10W-40 depending on climate and specific engine wear.
Engine Oil Capacity:
Approx. 5.0 Liters (5.3 US quarts) with filter change.
Coolant Type:
BMW Blue Antifreeze (G48) or equivalent ethylene glycol based coolant.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 75W-80 synthetic gear oil.
Transmission Fluid Automatic:
Dexron III (or equivalent) automatic transmission fluid.
Brake Fluid Type:
DOT 4
Known Issues
Cooling System:
Plastic coolant expansion tanks can become brittle and crack. Water pump impellers can degrade.
Engine Management:
Cracked intake manifold boots (M50), failing MAF sensors, vacuum leaks.
Electrical:
Corroded grounds, failing door lock actuators, aging wiring harnesses.
Suspension:
Worn control arm bushings, ball joints, and tie rod ends are common due to age and mileage.
Exhaust:
Rusted exhaust systems, particularly the rear muffler and catalytic converter heat shields.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
BMW's reputation for engineering excellence, performance, and luxury.
Model Evolution
E34 Generation:
Introduced in 1987 as the successor to the E28 5 Series. The 1991 model year falls within the early to mid-production phase of the E34 generation.
Production
Manufacturing Locations:
Primarily Dingolfing, Germany.
Production Years For E34:
1987-1996
🏆 Awards & Recognition
Recognitions
E34 Reputation:
The E34 generation generally received praise for its driving dynamics, build quality, and comfort, often cited as a benchmark in its class during its production run.
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