🏷️ Basic Information

Make:

BMW

Model:

5-Series

Chassis Code:

E34

Engine Variant:

520i

Model Years:

1988-1991

👋 Introduction

Segment:

Executive Sedan / Mid-size Luxury Car

Era:

Late 1980s to early 1990s premium automotive segment.

Key Competitors:

Mercedes-Benz W124 E-Class, Audi V8 Quattro, Jaguar XJ, Lexus LS 400 (later in the generation).

Bmw Philosophy:

Emphasis on driving dynamics, engineering precision, and build quality characteristic of BMW's 'Ultimate Driving Machine' ethos.

Design Language:

Conservative yet elegant styling by BMW designer Claus Luthe, featuring clean lines and the signature kidney grille.

Customer Profile:

Discerning buyers seeking a blend of performance, luxury, comfort, and advanced engineering.

📋 Manual Details

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Printable (digital copy)

Completeness:

Complete Official Full Factory Documentation

📖 Manual Coverage

Engine Service:

Detailed overhaul, tuning, diagnostics, and repair procedures for the M20B20 engine.

Fuel System:

Bosch Motronic fuel injection system diagnosis, repair, and component replacement (injectors, fuel pump, pressure regulator).

Ignition System:

Ignition timing, coil replacement, spark plug specifications, and ECU diagnosis.

Transmission Service:

Repair and maintenance for both manual (Getrag 260) and automatic (ZF 4HP22) transmissions.

Drivetrain:

Rear axle differential, driveshaft, and CV joint service procedures.

Suspension System:

Front and rear suspension component replacement (struts, control arms, bushings), alignment procedures.

Steering System:

Power steering system diagnosis, fluid replacement, pump and rack repair.

Brake System:

Disc brake overhaul, ABS system troubleshooting, brake fluid specifications, and rotor/pad replacement.

Electrical System:

Wiring diagrams, fuse box layouts, component testing, starter, alternator, and battery service.

Climate Control:

HVAC system diagnosis, refrigerant charging (R12), blower motor, and evaporator service.

Body And Trim:

Door panel removal, exterior trim replacement, headlight adjustment, and body panel repair guidance.

Interior Systems:

Seat adjustment mechanisms, dashboard component removal, and instrument cluster diagnostics.

Routine Maintenance:

Oil change, filter replacement, spark plug replacement, coolant flush, and belt inspection/replacement.

Troubleshooting:

Systematic diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems.

Component Replacement:

Detailed step-by-step instructions for replacing major and minor components across all systems.

Engine Overhaul:

Full engine rebuild procedures including disassembly, cleaning, inspection, and reassembly with torque specifications.

Transmission Rebuild:

Guidance on clutch replacement (manual), valve body service (automatic), and general transmission overhaul.

Electrical Diagnostics:

Testing procedures for sensors, actuators, control modules, and wiring harnesses using multimeters and oscilloscopes.

Alignment Procedures:

Front and rear wheel alignment specifications and adjustment methods.

Body Repairs:

Panel alignment, door and hood adjustment, and basic collision repair guidance.

Diagnostic Capabilities:

Advanced diagnostic procedures including sensor data interpretation and fault code identification (where applicable to the era).

Repair Complexity:

Covers everything from basic fluid changes to complete engine and transmission rebuilds.

Wiring Diagrams:

Comprehensive and detailed electrical schematics for all vehicle systems.

Torque Specifications:

Extensive list of torque values for all critical fasteners.

Special Tools:

Identification of specific BMW special tools required for certain procedures.

📊 Manual Specifications

Digital Format:

Likely PDF, optimized for printing and digital use.

Page Count Estimated:

Several hundred pages (exact count not specified, but described as 'hundreds').

Resolution:

High-resolution scans or original factory documents ensuring clarity of diagrams and text.

Searchability:

Typically searchable text if provided as a properly created PDF.

For Printed Version:

Professional binding (likely comb or spiral bound for ease of use in a workshop).

For Printed Version:

Durable paper stock suitable for workshop environments.

⚙️ Engine Specifications

Engine Code:

M20B20

Configuration:

Inline 6-cylinder, 24-valve (common for later M20s, check specific E34 M20B20)

Displacement:

1991 cc (2.0 Liters)

Bore X Stroke:

80.0 mm x 66.0 mm

Compression Ratio:

8.8:1

Horsepower:

129 hp @ 5800 rpm (approximate, depending on market specification)

Torque:

180 Nm (133 lb-ft) @ 4500 rpm (approximate)

Injection Type:

Bosch Motronic M1.3 Electronic Fuel Injection

Fuel Type:

Unleaded Gasoline (RON 91 or higher recommended)

Coolant Type:

BMW Blue Antifreeze/Coolant (Glysantin G48 equivalent recommended)

Capacity:

Approx. 9.5 Liters (including heater core)

🔧 Transmission

Type:

5-speed Manual Transmission (Getrag 260/5)

Type:

4-speed Automatic Transmission (ZF 4HP22)

Manual Fluid Spec:

BMW MTF LT-2 (or equivalent GL-4, SAE 75W-90)

Automatic Fluid Spec:

Dexron III (or equivalent)

📐 Dimensions

Length:

4734 mm (186.4 in)

Width:

1751 mm (68.9 in)

Height:

1380 mm (54.3 in)

Wheelbase:

2793 mm (110.0 in)

Curb Weight Approx:

1450 kg (3197 lbs) - Manual Transmission

Gross Weight Rating Approx:

1950 kg (4300 lbs)

🛡️ Safety Features

Historical Context:

Safety standards of the late 80s/early 90s, focused on passive restraint systems. Official crash ratings (like NHTSA/Euro NCAP) were less standardized than today.

ABS:

Anti-lock Braking System (ABS) was available as an option or standard depending on market.

Airbags:

Driver's side airbag was optional and became more common later in the E34's lifecycle. Passenger airbags were rare for this period.

Seatbelts:

3-point seatbelts with pretensioners for front occupants.

Body Structure:

Reinforced safety cage and crumple zones designed to absorb impact energy.

💡 Technology Features

Audio System:

Factory fitted radio cassette player, often with optional CD changer. Speaker quality varied by trim and options.

Climate Control Type:

Manual HVAC controls, with optional automatic climate control (ACC) on higher trims or as an option.

Cruise Control:

Standard or optional on most models, providing highway cruising comfort.

Early Features:

Basic connectivity through radio and telephone preparation (rare for this period).

🔧 Maintenance

Oil Change:

Every 10,000 - 15,000 km (6,000 - 9,000 miles) or annually, whichever comes first (check manual for precise BMW recommendation).

Air Filter Replacement:

Every 30,000 - 40,000 km (18,000 - 25,000 miles).

Spark Plug Replacement:

Every 40,000 - 60,000 km (25,000 - 37,000 miles) depending on plug type (e.g., standard vs. platinum).

Coolant Flush:

Every 2-3 years or 50,000 km (30,000 miles).

Engine Oil:

SAE 15W-40 or 10W-40 (API SG or higher specification recommended). Check manual for specific BMW approvals.

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

CHF 11S or Pentosin equivalent.

Cooling System:

Plastic coolant expansion tanks are prone to cracking, leading to leaks. Water pump failure can also occur.

Head Gasket:

While less common on the M20 compared to some other engines, head gasket leaks can occur, especially with overheating.

Fuel Leaks:

Aging fuel lines and O-rings can develop leaks. Inspect regularly.

Window Regulators:

Manual and electric window regulators can fail, causing windows to drop.

ABS Module:

ABS control modules are known to fail, leading to ABS warning lights and loss of ABS function.

Idle Control Valve:

The idle control valve can become clogged or fail, leading to rough idling or stalling.

📚 Vehicle History

Bmw Legacy:

BMW's reputation for engineering excellence, sporty driving characteristics, and luxury motoring built over decades.

E34 Introduction:

Launched in 1987 as the successor to the E28 5-Series, it represented a significant step forward in styling, technology, and chassis design.

E34 Generation Progression:

The 520i was an entry-level model for the E34, offering a more accessible entry into BMW ownership while retaining core brand values.

Production Period:

1987-1996 (E34 generation)

Manufacturing Location:

Mainly Dingolfing, Germany.

🏆 Awards & Recognition

Editorial Acclaim:

The E34 generation was widely praised by automotive journalists for its excellent driving dynamics, build quality, and comfortable ride, earning it a strong reputation in the luxury sedan market.

Industry Standing:

Consistently ranked among the best sedans of its time for blending sportiness and luxury.