Positioning Statement:
The BMW 520i (E34) represented a blend of luxury, performance, and advanced engineering in the mid-size executive sedan market of its time.
Key Competitors:
Mercedes-Benz W124 E-Class, Audi 100/200, Volvo 740/760, Jaguar XJ6
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel drive dynamics, and engaging driving experience.
Build Quality:
Exceptional build quality and durability, a hallmark of BMW vehicles from this era.
Engineering:
Sophisticated engineering with advancements in engine technology, suspension, and electronics.
Major Topics Covered:
Full service and repair instruction
Estimated Page Count:
Likely 500+ pages (typical for comprehensive BMW workshop manuals of this era)
Manual Type:
Service Repair Workshop Manual
Language:
English (presumed based on typical market)
Format:
Digital (PDF) or Printed (as sold)
Engine Mechanical:
Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, lubrication system, cooling system
Engine Management:
Fuel injection system (Bosch Motronic), ignition system, emissions control system, diagnostic procedures
Transmission:
Manual and automatic transmission overhaul, clutch, driveshaft, differential
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment specifications
Brakes:
Brake system components (discs, calipers, pads), hydraulic system, ABS (if equipped), parking brake
Steering:
Power steering system, steering gear, steering column, tie rods
Electrical:
Wiring diagrams, battery, alternator, starter motor, lighting system, instruments, relays, fuses, comfort electronics
Bodywork:
Body panels, doors, windows, bumpers, interior trim, convertible top (if applicable)
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and top-ups, belt inspection and replacement
Troubleshooting:
Diagnostic flowcharts for common drivability and electrical issues
Repair Overhaul:
Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation
Diagnostics:
Procedures for checking ignition timing, fuel pressure, engine compression, and electrical system voltages
Depth Of Coverage:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts, covering everything from basic maintenance to full engine rebuilds and electrical system diagnostics.
File Format Details:
PDF (if digital) with searchable text and high-resolution images/diagrams. Printable pages.
Print Quality Details:
High-quality scans or original print for clarity of text and diagrams. Accurate color reproduction for wiring diagrams.
Binding Type Details:
Perfect binding or spiral binding for printed versions, allowing lay-flat viewing.
Paper Type Details:
Durable, semi-gloss paper suitable for workshop environments for printed versions.
Engine Type:
Inline 6-cylinder, DOHC, 24 valves
Displacement:
1990 cc (2.0 Liters)
Horsepower:
Approx. 150 PS (148 hp) at 5900 rpm (DIN)
Torque:
Approx. 190 Nm (140 lb-ft) at 4200 rpm (DIN)
Fuel Delivery:
Bosch Motronic M3.1 Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (Premium recommended)
Coolant Type:
BMW Premium Coolant or equivalent (typically ethylene glycol-based, blue or green)
Oil Capacity With Filter:
Approx. 5.0 Liters (5.3 US quarts)
Recommended Oil Viscosity:
SAE 5W-30 or 5W-40 (depending on climate, check manual for specific recommendations)
Spark Plug Type:
Bosch F7DC0 or equivalent (e.g., NGK BCP6ES)
Transmission Type Standard:
5-speed Manual Transmission
Transmission Type Optional:
4-speed Automatic Transmission (ZF 4HP22)
Clutch Type:
Hydraulically actuated single dry plate clutch
Manual Transmission Fluid:
BMW Synchromesh Fluid or equivalent GL-4 rated gear oil
Automatic Transmission Fluid:
Dexron III or Mercon compatible ATF
Length:
Approx. 4720 mm (185.8 inches)
Width:
Approx. 1751 mm (68.9 inches)
Height:
Approx. 1410 mm (55.5 inches)
Wheelbase:
Approx. 2761 mm (108.7 inches)
Curb Weight:
Approx. 1450 - 1550 kg (3197 - 3417 lbs), depending on transmission and equipment
Crash Test Data:
While specific NHTSA/Euro NCAP ratings for 1990 models are less standardized than today, the E34 chassis was known for its robust safety cage and crumple zones.
ABS:
Anti-lock Braking System (ABS) available as an option or standard on certain trims.
Airbags:
Driver's airbag optional or standard on later models, passenger airbag not typically available for 1990.
Seatbelts:
Three-point inertia-reel seatbelts with front seatbelt pretensioners.
Body Structure:
Reinforced safety cell with strategically placed crumple zones.
Audio System:
Factory radio/cassette player, often with premium sound system options (e.g., HiFi or Harman Kardon).
Cruise Control:
Electronic cruise control system.
Climate Control:
Manual or automatic climate control systems.
Early Features:
While limited by modern standards, options like integrated telephones were available on some models.
Oil Change Interval:
Every 10,000-15,000 km (6,000-10,000 miles) or annually, whichever comes first (check manual for exact recommendation).
Major Service Interval:
Typically around 50,000-60,000 km (30,000-37,000 miles) for inspection of belts, hoses, brakes, and suspension components.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual)
Power Steering Fluid:
BMW Power Steering Fluid (often a Pentosin CHF 11S or similar hydraulic fluid).
Cooling System Failures:
Plastic coolant expansion tank and hoses can degrade and crack. Water pump seal leaks. Check for leaks regularly.
Vanos System Wear:
While the M50 engine in the 520i (1990) often did NOT have VANOS, later M50 variants did. If equipped, VANOS solenoids and seals can fail, leading to rough idle and power loss.
Oil Leaks:
Valve cover gasket and oil pan gasket are common sources of oil leaks.
E34 Specific Wear:
Subframe bushings, trailing arm bushings, and sway bar links can wear, affecting ride and handling. Headlight leveling system (if equipped) can fail.
Oem Part Numbers:
Manual will contain specific OEM part numbers for most components, facilitating accurate replacement.
Bmw Philosophy:
BMW's long-standing reputation for building the 'Ultimate Driving Machine' with a focus on performance, engineering, and driver involvement.
E34 Introduction:
The E34 generation of the 5 Series was introduced in 1988 (Europe) and 1989 (North America), replacing the E28.
E34 Design:
Designed by Boyke Boyer, the E34 featured a more aerodynamic and contemporary design compared to its predecessor, with signature BMW Hofmeister kink.
Production Period:
1987-1996
Manufacturing Locations:
Primary production in Dingolfing, Germany, with some assembly in other BMW facilities worldwide.
