Segment:
Executive Sedan (mid-size)
Era:
Late 1980s to early 1990s
Key Competitors:
Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, Volvo 740/760
Engineering Philosophy:
BMW's 'ultimate driving machine' ethos, focus on driver engagement and build quality
Design Era:
Claus Luthe's design era, introducing the E34's sleeker, more aerodynamic profile compared to its predecessor (E28)
Powertrain:
Engine mechanical, fuel system, cooling system, exhaust system, lubrication system
Drivetrain:
Manual transmission, Automatic transmission (e.g., Getrag 260, ZF 4HP22), Clutch system, Driveshafts, Differentials
Suspension Steering:
Front suspension (MacPherson struts), Rear suspension (Semi-trailing arms), Steering system (rack and pinion), Wheel alignment specifications
Brakes:
Front disc brakes, Rear disc brakes, ABS (Anti-lock Braking System) components and troubleshooting
Electrical Electronics:
Engine control unit (ECU), Ignition system, Lighting system, Instrumentation, Battery and charging system, Fuses and relays, Power windows, Central locking
Body Chassis:
Body panels, Doors, Hood, Trunk, Bumpers, Frame and chassis components, Interior trim
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system operation and repair
Maintenance:
Routine maintenance checks, Oil changes, Filter replacements, Spark plug replacement, Belt adjustments
Troubleshooting:
Diagnostic procedures for common faults, Fault code interpretation (if applicable), Symptom-based troubleshooting guides
Repair:
Component removal and installation, Engine rebuild procedures, Transmission overhaul, Brake caliper replacement, Suspension component renewal
Diagnostics:
Electrical system diagnostics, Fuel injection system testing, Emissions system troubleshooting
Depth:
Comprehensive (from basic maintenance to advanced component overhaul)
Detail Level:
Detailed step-by-step instructions with torque specifications, diagrams, and schematics
Engine Type:
Inline-6 Cylinder (M20B20)
Displacement:
2.0 Liters (1990 cc)
Bore X Stroke:
80.0 mm x 66.0 mm
Horsepower:
129 hp @ 5800 rpm (approximate, depending on market/spec)
Torque:
174 Nm (128 lb-ft) @ 4500 rpm (approximate)
Fuel Delivery:
Bosch Motronic electronic fuel injection (EFI)
Fuel Type:
Unleaded gasoline
ECU System:
Bosch Motronic
Transmission Type Standard:
5-speed Manual Transmission (Getrag 260)
Transmission Type Optional:
4-speed Automatic Transmission (ZF 4HP22)
Clutch Type:
Hydraulically actuated single dry plate clutch
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90 (refer to manual for exact specs)
Automatic Transmission Fluid:
Dexron III (or equivalent, check specific BMW spec)
Crash Test Era:
Pre-modern crash testing standards, focused on occupant protection for the era
ABS:
Optional Anti-lock Braking System (ABS) on later models/trims
Traction Control:
ASC (Automatic Stability Control) was not commonly available on the 520i E34 during this period
Airbags:
Driver's side airbag became standard on later models (check specific production date/market)
Seatbelts:
3-point inertia reel seatbelts front and rear
Body Construction:
Unitized body construction with reinforced safety cage
Radio System:
Factory cassette or radio/cassette combination units from manufacturers like Blaupunkt or Becker.
Speaker System:
Standard 4-6 speaker system, optional premium sound systems.
Cruise Control:
Standard or optional cruise control system.
Auxiliary Inputs:
No factory USB or Bluetooth connectivity; aftermarket solutions are common.
Oil Change Interval:
Typically 7,500-10,000 miles or 12-15,000 km (refer to manual for exact recommendation based on oil type and driving conditions).
Spark Plug Replacement:
Approximately 30,000 miles (48,000 km) for standard plugs, or longer for platinum/iridium (consult manual).
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Engine Oil Type:
API SG/SH, ACEA A2-96. Viscosity: 15W-40, 10W-40, or 5W-30 depending on climate (refer to manual).
Engine Oil Capacity:
Approximately 4.5 Liters (4.8 US Quarts) with filter change.
Coolant Type:
BMW Blue or equivalent Ethylene Glycol based coolant (50/50 mix with distilled water).
Common Electrical Faults:
Wiring harness degradation, headlight module issues, central locking problems, dead pixels in instrument cluster.
Common Engine Issues:
M20 engine can develop oil leaks (valve cover gasket, oil pan gasket), potential head gasket issues if overheated, VANOS not present on this M20 engine.
Common Suspension Issues:
Wear in bushings (control arm, sway bar), shock absorber failure, rear trailing arm bushings.
Common Cooling System Issues:
Plastic coolant expansion tank can become brittle and crack, water pump failure, radiator leaks.
Oil Filter Part Number:
BMW Part Number: 11 42 1 701 001 (Mann-Filter: W930/1, Mahle: OC15)
Air Filter Part Number:
BMW Part Number: 13 72 1 717 937 (Mann-Filter: C2534/1, K&N: 33-2049)
Cabin Filter Part Number:
Not typically fitted to this model year as standard.
Bmw Heritage:
BMW's long-standing reputation for performance, engineering, and luxury sedans dating back to the early 20th century.
E34 Introduction:
The E34 generation succeeded the E28 and was produced from 1987 to 1996. It represented a significant leap in styling, technology, and chassis dynamics for BMW's mid-size executive sedan.
520I Positioning:
The 520i was the entry-level model in many markets, offering a balance of BMW refinement and performance with a more accessible price point than larger-engined variants.
Production Period:
1988-1991 for the 520i variant covered by this manual.
Manufacturing Locations:
Primarily Dingolfing, Germany.
