Segment:
Executive/Luxury Mid-size Sedan
Key Competitors:
Mercedes-Benz W124 E-Class, Audi V8 Quattro, Volvo 740/760, Jaguar XJ6.
Design Philosophy:
Classic BMW ' Hofmeister kink ' rear window design, balanced chassis, driver-focused interior, and refined engineering.
Target Audience:
Affluent buyers seeking a blend of performance, luxury, and build quality.
Utility:
Essential resource for DIY enthusiasts and professional technicians to maintain and repair the E34 520i efficiently and accurately.
General Coverage:
Comprehensive service and repair for BMW 520i (E34) 1989 model year.
Specific Systems:
Engine, transmission, drivetrain, suspension, steering, brakes, electrical system, fuel system, cooling system, HVAC, bodywork, diagnostics.
Type:
Service Repair Workshop Manual
Format:
Digital (likely PDF)
Engine:
Detailed information on the M20B20 inline-six engine, including component identification, disassembly, assembly, and specifications.
Transmission:
Coverage for both manual (Getrag 260) and automatic (ZF 4HP22) transmissions, including overhaul, adjustments, and fluid specifications.
Electrical System:
Extensive wiring diagrams, component testing procedures, fuse locations, relay functions, and troubleshooting for ECUs, sensors, and actuators.
Brakes:
Detailed procedures for ABS (Anti-lock Braking System) diagnostics, caliper servicing, rotor replacement, brake fluid bleeding, and component testing.
Suspension Steering:
Information on MacPherson strut front suspension, multi-link rear suspension, power steering system maintenance, alignment procedures, and component replacement.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, coolant flushes, belt tensioning, and lubrication points.
Repair Overhaul:
Complete engine rebuild procedures, cylinder head removal and installation, piston and connecting rod service, crankshaft and bearing replacement.
Troubleshooting:
Systematic diagnostic flowcharts and common fault finding procedures for engine performance, starting issues, electrical faults, and cooling system problems.
Special Tools:
Identification and usage of specialized BMW tools required for specific repair and diagnostic tasks.
Depth:
Designed for professional mechanics, covering detailed disassembly, assembly, torque specifications, diagnostic procedures, and component-level repair.
Engine Type:
Inline-6, SOHC
Displacement:
1990 cc (2.0 Liters)
Horsepower:
129 hp @ 5800 rpm (approx.)
Torque:
174 Nm (128 lb-ft) @ 4500 rpm (approx.)
Fuel Delivery:
Bosch Motronic fuel injection (e.g., Motronic 1.3)
Bore X Stroke:
80.0 mm x 66.0 mm
Coolant Type:
BMW Blue Coolant (or equivalent G48 ethylene glycol-based)
Ignition Type:
Electronic ignition with distributor and coil.
Type:
5-speed Manual (Getrag 260/5)
Type:
4-speed Automatic (ZF 4HP22)
Manual Clutch:
Hydraulic clutch actuation.
Modes:
Standard and Economy (Sport/Economy switch may be present).
Manual Transmission Fluid:
GL-4 SAE 75W-90 or SAE 80W-90 gear oil (check manual for exact spec, e.g., BMW ATF Dextron II for older specs, but modern GL-4 is often recommended).
Automatic Transmission Fluid:
Dexron II (or equivalent Dexron III/VI as a modern replacement, consult manual for precise BMW specification).
NHTSA Rating:
Not officially rated by NHTSA as per modern standards. Known for solid construction.
ABS:
Standard Anti-lock Braking System (ABS) on all models.
Traction Control:
Optional ASC (Automatic Stability Control) may have been available on later E34 models, but less common on early 520i.
Airbags:
Driver airbag became standard in later E34 production; early 1989 models may not have it. Passenger airbag was optional.
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners for front occupants. Inertia-reel belts for rear passengers.
Body Structure:
Reinforced safety cage, crumple zones front and rear, side-impact protection beams.
Audio System:
Factory fitted AM/FM stereo cassette player, often with premium sound options (e.g., HiFi system with amplifier and multiple speakers).
Display:
Basic analog gauges for speedometer, tachometer, fuel, and temperature. OBC (On-Board Computer) optional on higher trims, featuring basic diagnostics and trip information.
Cruise Control:
Optional cruise control system, operated via steering wheel or stalk controls.
Climate Control:
Manual or automatic climate control systems available, depending on trim level. HVAC system includes heating, ventilation, and A/C.
Original Connectivity:
Limited by era; basic radio and optional antenna booster. No modern Bluetooth or USB integration from factory.
Oil Change Interval:
Every 10,000-15,000 km (6,000-9,000 miles) or annually, depending on driving conditions. Check manual for specific recommendation based on oil type.
Spark Plug Replacement:
Typically every 30,000-40,000 km (18,000-25,000 miles) for standard ignition. Check manual for specific plug type and interval.
Timing Belt Replacement:
The M20 engine uses a timing belt. Replacement interval is critical, typically every 50,000-80,000 km (30,000-50,000 miles) or 4-5 years. Consult manual for exact specification.
Engine Oil Capacity:
Approx. 4.75 Liters (5.0 US Quarts) with filter change. Oil type: BMW High Performance Synthetic 5W-30 or 5W-40 recommended, or 10W-40 for warmer climates. Consult manual for API/ACEA ratings.
Coolant Capacity:
Approx. 9.0 Liters (9.5 US Quarts). Use BMW Blue Coolant or equivalent.
Common Engine Problems:
Head gasket failures (especially if overheated), oil leaks from valve cover and oil pan, cooling system component wear (radiator, hoses, water pump), starter motor issues, and fuel injector cleaning.
Common Electrical Problems:
Corrosion in fuse box and relay holders, intermittent dashboard lights, dead pixels in instrument cluster, window regulator failures, and ABS sensor issues.
Common Suspension Steering Problems:
Worn control arm bushings, worn ball joints, shock absorber leaks, steering rack leaks, and clunking noises from the front suspension.
Oil Filter Part Number:
Example: Mann-Filter HU 718/1y or Mahle OC 44.
Air Filter Part Number:
Example: Mann-Filter C 24 210 or K&N 33-2072.
Bmw Philosophy:
BMW's long-standing reputation for 'The Ultimate Driving Machine' emphasizing performance, handling, and driver engagement.
E34 Generation:
The E34 generation (1988-1996) was a significant redesign, introducing more aerodynamic styling, advanced suspension, and improved safety features over its E28 predecessor.
Production Years:
E34 series: 1988-1996. 520i specifically from 1988-1992 in most markets for the M20 engine.
Manufacturing Plants:
Primary manufacturing in Dingolfing, Germany, with assembly possible in other BMW facilities globally.
Industry Recognition:
The E34 generation was widely praised for its driving dynamics, build quality, and sophisticated design, contributing to BMW's reputation as a leader in its segment.
Performance Handling:
Consistently received positive reviews from automotive publications for its handling, ride comfort, and powerful inline-six engines.
Quality Standards:
Built to stringent German engineering and manufacturing standards.
