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BMW 520i 1988 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 520i Year: 1988 Codes Chassis Code: E34 Engine Code: M20B20 👋 Introduction Market Position Segment: Executive Sedan Competitors: Mercedes-Benz W124 E-Class, Audi V8,...
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BMW 520i 1988 Service Repair Workshop ManualBMW 520i 1988 Service Repair Workshop ManualBMW 520i 1988 Service Repair Workshop ManualBMW 520i 1988 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
520i
Year:
1988
Codes
Chassis Code:
E34
Engine Code:
M20B20
👋 Introduction
Market Position
Segment:
Executive Sedan
Competitors:
Mercedes-Benz W124 E-Class, Audi V8, Jaguar XJ6, Volvo 740/760
Key Features
Design:
Iconic E34 design characterized by clean lines, aerodynamic efficiency, and premium build quality.
Engineering:
BMW's renowned driving dynamics, balanced chassis, and sophisticated engineering.
📋 Manual Details
Coverage Areas
Scope:
Comprehensive service, repair, and diagnostic information for the 1988 BMW 520i (E34).
Page Count
Estimated Pages:
800+
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
2.0L M20B20 inline-six cylinder, including timing, valve adjustments, lubrication, cooling, fuel injection (Bosch Motronic), ignition, and exhaust systems.
Transmission:
4-speed automatic (4HP22) and 5-speed manual transmissions, including clutch, gearbox, differential, driveshafts, and shift mechanisms.
Chassis:
Suspension (front strut, rear multi-link), steering (power assisted rack and pinion), brakes (front ventilated discs, rear discs, ABS), wheels, and tires.
Electrical:
Complete electrical system, including battery, charging system, starter, lighting, dashboard instruments, ignition switch, wiring diagrams, fuses, relays, power windows, central locking, and HVAC controls.
Bodywork:
Exterior body panels, doors, hood, trunk, bumpers, glass, seals, and interior trim components.
Procedures Included
Maintenance:
Routine maintenance procedures, oil changes, filter replacements, spark plug replacement, brake pad service, fluid checks and replacements.
Repair:
Detailed repair instructions for all major mechanical and electrical components, including engine overhauls, transmission rebuilds, brake caliper service, and suspension component replacement.
Troubleshooting:
Diagnostic charts and troubleshooting guides for common issues related to engine performance, electrical faults, and drivability problems.
Diagnostics:
Step-by-step diagnostic procedures, including use of BMW specialized tools (e.g., diagnostic readout boxes, multimeters) and interpreting fault codes.
Technical Depth
Depth:
Expert-level detail suitable for professional mechanics, including torque specifications, diagnostic trouble codes (DTCs), and specialized tool requirements.
Engine Rebuild:
Detailed procedures for engine disassembly, inspection, component measurement (e.g., cylinder bore, piston ring gap, bearing clearances), and reassembly with specifications.
Electrical Diagrams:
Comprehensive wiring diagrams for all vehicle systems, color-coded and clearly labeled for ease of use.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution scans with searchable text for efficient navigation.
Print Quality
Printable:
Printable pages for workshop use.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Displacement:
2.0 Liters (1990 cc)
Configuration:
Inline-6 Cylinder
Valvetrain:
SOHC (Single Overhead Camshaft), 12 valves
Performance
Horsepower:
129 hp @ 5800 rpm
Torque:
174 Nm (128 lb-ft) @ 4500 rpm
Fuel System
Injection Type:
Bosch Motronic (Electronic Fuel Injection)
Fuel Type:
Unleaded Gasoline (Octane Rating 91+)
Engine Management
ECU:
Bosch Motronic M1.3
🔧 Transmission
Standard
Type:
5-speed Manual
Optional
Type:
4-speed Automatic (4HP22)
Features
Manual Clutch:
Hydraulically actuated single dry plate clutch.
Automatic Modes:
Standard and Sport modes (depending on specific variant/market).
📐 Dimensions
Exterior
Length:
4735 mm (186.4 in)
Width:
1751 mm (68.9 in)
Height:
1412 mm (55.6 in)
Wheelbase:
2799 mm (110.2 in)
Weights
Curb Weight Manual:
1430 kg (3153 lbs)
Curb Weight Automatic:
1470 kg (3241 lbs)
Gross Vehicle Weight:
Approx. 1970 kg (4343 lbs)
🛡️ Safety Features
Ratings
ABS:
Standard (Anti-lock Braking System) on most models/markets.
Active Features
Braking:
Front ventilated discs, rear solid discs with ABS.
Steering:
Power-assisted recirculating ball steering (later E34 models used rack and pinion, but 1988 520i typically had recirculating ball).
Passive Features
Airbags:
Driver's airbag was optional on early E34 models, but became more common later in production.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners for front occupants.
Body Structure:
Reinforced safety cage, crumple zones, and impact-absorbing pillars.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player, often with premium sound options like HiFi system. Speaker quality can vary.
Driver Assistance
ABS:
Standard ABS system for enhanced braking control.
Connectivity
Gsm:
N/A (Pre-dates widespread mobile integration)
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000-15,000 km (6,000-9,000 miles) or annually, depending on driving conditions and oil type used.
Air Filter:
Inspect every 20,000 km (12,000 miles), replace as needed or every 40,000 km (24,000 miles).
Spark Plugs:
Replace every 30,000-50,000 km (18,000-30,000 miles) depending on type (e.g., copper vs. platinum).
Coolant Flush:
Every 2-3 years or 40,000-60,000 km (24,000-37,000 miles).
Fluid Specifications
Engine Oil:
API SG or higher, viscosity 10W-40 or 5W-30 (consult manual for exact BMW specification).
Coolant:
BMW Blue or Green antifreeze mixed 50/50 with distilled water (ethylene glycol based).
Brake Fluid:
DOT 3 or DOT 4.
Transmission Fluid Manual:
GL-4 gear oil (e.g., SAE 75W-90).
Transmission Fluid Automatic:
ATF Dexron II or III (consult specific BMW fluid spec).
Known Issues
Engine M20:
Common issues include head gasket leaks, oil pan gasket leaks, and cracked valve covers due to age and heat cycles. Thermostat housing leaks.
Electrical:
Corrosion in connectors, failure of fuse box terminals, aging wiring harness insulation, and faulty SRS modules (if equipped).
Suspension:
Wear in control arm bushings, ball joints, and shock absorbers leading to noise and handling degradation.
Cooling System:
Plastic coolant expansion tank can become brittle and crack. Water pump failures are also common.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's commitment to 'The Ultimate Driving Machine' ethos, emphasizing performance, luxury, and engineering.
Model Evolution
E34 Introduction:
The E34 generation succeeded the E28 and introduced a more modern, aerodynamic design and improved chassis dynamics.
E34 Production Years:
1987-1996
Production
Manufacturing Locations:
Primary manufacturing in Dingolfing, Germany.
🏆 Awards & Recognition
Recognitions
E34 Reputation:
The E34 generation is widely regarded as one of the best engineered sedans of its era, praised for its build quality and driving dynamics.
Ratings
Carmagazine Rating:
Frequently cited in 'best of' lists for affordable modern classics.
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