BMW 520i 1989 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 520i Year: 1989 Codes Chassis Code: E34 Engine Code Family: M20 👋 Introduction Market Position Segment: Luxury/Executive Sedan Target Audience: Performance-oriented luxury car...

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Type: Car

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Sku: 434485

Tags: 1989 520i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code Family:

👋 Introduction

Market Position

Segment:

Luxury/Executive Sedan

Target Audience:

Performance-oriented luxury car buyers seeking refined driving dynamics and build quality.

Competitive Analysis

Competitors 1989:

Mercedes-Benz W124 E-Class (e.g., E200, E230), Audi V8, Jaguar XJ6.

Key Features

Driving Dynamics:

Renowned for BMW's signature balanced handling, rear-wheel drive bias, and precise steering.

Build Quality:

Exceptional build quality and durability, characteristic of BMW engineering.

Powertrain Refinement:

Smooth and responsive M20 inline-six engine, providing a good balance of performance and efficiency for its class.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models/Engines/Trim/Transmissions Types

Page Count

Estimated Page Count:

Extensive (typically 1000+ pages for a full workshop manual of this era)

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, repair, timing, valve train, cooling system, lubrication system, fuel injection system (Bosch Motronic).

Engine Electrical:

Ignition system, starter system, charging system, ECU (Engine Control Unit) diagnostics, sensor testing, wiring diagrams.

Transmission Manual:

Disassembly, assembly, inspection, repair, clutch system, shift linkage.

Transmission Automatic:

Disassembly, assembly, inspection, repair, hydraulic system, torque converter, shift control.

Drivetrain:

Driveshaft, universal joints, differential, axles, wheel bearings.

Suspension:

Front suspension (MacPherson struts, control arms, sway bar), rear suspension (multi-link, trailing arms, sway bar), shock absorbers, springs, bushings.

Steering:

Power steering system, steering rack, steering column, wheel alignment specifications.

Brakes:

Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System) components, hydraulic lines, master cylinder, brake fluid specifications.

Electrical System:

Complete vehicle wiring diagrams, lighting system, power windows, central locking, instruments and gauges, horn, battery, fuse/relay identification.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant types, troubleshooting.

Bodywork:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim.

Chassis:

Frame inspection, structural components, mounting points.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement, brake pad replacement, tire rotation.

Troubleshooting:

System diagnostics, fault finding procedures, diagnostic trouble codes (if applicable), common problem resolutions.

Repair:

Component-level repair and overhaul for all major vehicle systems.

Adjustment:

Valve lash adjustment, ignition timing adjustments, throttle linkage adjustments, parking brake adjustments.

Diagnostics:

On-board diagnostics (OBD) information for engine management, electrical system diagnostics, and sensor testing.

Technical Depth

Depth:

Comprehensive, covering from basic preventative maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, enabling quick information retrieval.

Print Quality

Quality:

High-resolution scans suitable for printing key sections or the entire manual.

Binding Type

Binding:

Not applicable (PDF Download)

Paper Type

Paper Type:

Not applicable (PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Name:

BMW M20B20

Engine Type:

Inline 6-cylinder, SOHC (Single Overhead Camshaft)

Displacement:

1990 cc (2.0 Liters)

Performance

Bore X Stroke:

80.0 mm x 66.0 mm

Compression Ratio:

8.8:1 (typical)

Horsepower:

129 hp @ 5800 rpm (approx.)

Torque:

180 Nm @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Bosch Motronic Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Petrol (RON 95 recommended)

Engine Management

ECU Type:

Bosch Motronic (e.g., Motronic ML 4.1 or M 1.3 depending on market specifics)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (Getrag 260)

Optional

Type:

4-speed Automatic Transmission (ZF 4HP22)

Features

Manual Gear Ratios:

Refer to manual for specific ratios; typically a 0.81:1 5th gear for highway cruising.

Automatic Features:

Comfort and Sport modes (on some variants).

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (verify with manual; older specs might be SAE 80W/90).

Automatic Transmission Fluid:

ZF TE-ML 04D or Dexron II (verify with manual).

📐 Dimensions

Exterior

Length:

4734 mm (186.4 inches)

Width:

1751 mm (68.9 inches)

Height:

1410 mm (55.5 inches)

Wheelbase:

2799 mm (110.2 inches)

Weights

Curb Weight:

Approx. 1450-1550 kg (depending on transmission and equipment)

Gross Vehicle Weight Rating:

Refer to vehicle placard or manual.

🛡️ Safety Features

Ratings

Crash Test Data:

Era-specific safety standards. Refer to manual for detailed structural integrity information and potential supplementary safety data.

Active Features

Standard on most E34 models, including the 520i. Provides Anti-lock Braking System functionality.

Traction Control:

Optional on some later E34 variants, but less common on the 1989 520i.

Passive Features

Airbags:

Driver airbag was optional and became more common towards the end of the E34's production cycle. Passenger airbag was rare for this year.

Seatbelts:

Three-point inertia-reel seatbelts in front and rear.

💡 Technology Features

Infotainment

Head Unit:

Typically an AM/FM stereo with cassette player, often from Blaupunkt or BMW's own brand. Optional CD player available on higher trims.

Speaker System:

Standard 4-6 speaker system. Hi-Fi upgrade available on some models.

Driver Assistance

On-Board Computer providing basic information like average speed, fuel consumption, and exterior temperature on higher-spec models.

Cruise Control:

Optional electronic cruise control system.

Connectivity

Connectivity Options:

No modern connectivity features (Bluetooth, USB, etc.). Analog systems only.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 - 10,000 miles (12,000 - 16,000 km) or 12 months, whichever comes first. Refer to manual for exact recommendations.

Spark Plug Replacement:

Around 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type (e.g., standard copper vs. platinum).

Timing Belt Replacement:

The M20 engine uses a timing chain, not a belt, requiring less frequent replacement but still periodic inspection for wear.

Fluid Specifications

Engine Oil Type:

API SG/SH, ACEA A2 or A3. Viscosity typically 10W-40 or 15W-40. Check manual for exact specification and SEVERE service recommendations.

Engine Oil Capacity:

Approximately 4.25 Liters (4.5 US Quarts) with oil filter change.

Coolant Type:

BMW Blue Antifreeze/Coolant (Glysantin G48 equivalent) or a high-quality ethylene glycol-based coolant with corrosion inhibitors. 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4

Known Issues

Cooling System:

Plastic coolant expansion tank can become brittle and crack; thermostat housing leaks; water pump leaks.

Electrical:

Corrosion in wiring harness connectors (especially ground points), failing OBC (On-Board Computer) pixels, weak alternator, starter motor failure.

Suspension Bushings:

Wear in control arm bushings, subframe bushings, and shock mounts leading to vague handling and clunking noises.

Fuel System:

Clogged fuel injectors, weak fuel pump, faulty airflow meter (AFM), or idle control valve (ICV) can affect engine running.

Interior Trim:

Sagging headliner, deteriorating door panel cards, and cracking dashboard material due to age and UV exposure.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's long-standing reputation for building sporty, driver-focused luxury sedans with sophisticated engineering.

Model Evolution

E34 Introduction:

The E34 generation of the 5 Series replaced the E28 and was produced from 1988 to 1996. It was a significant step forward in aerodynamics, chassis technology, and interior design.

520I Positioning:

The 520i served as the entry-level model in many markets, offering the core BMW 5 Series experience at a more accessible price point than the larger-engined variants.

Production

Production Period E34:

1988-1996

Manufacturing Locations:

Primary production in Dingolfing, Germany, with some assembly in other BMW facilities worldwide.

🏆 Awards & Recognition

Recognitions

Editorial Reviews E34:

Consistently praised by automotive journalists of the era for its driving dynamics, build quality, and refined interior, often winning comparison tests against its German rivals.

Model Legacy:

The E34 5 Series is considered one of BMW's classic generations, laying the groundwork for the modern 5 Series with its sophisticated chassis and timeless design.