🏷️ Basic Information

Make:

BMW

Model:

520i

Generation:

E34

Model Code:

E34

👋 Introduction

Positioning:

The BMW 520i E34 was positioned as a premium mid-size luxury sedan, offering a blend of performance, comfort, and sophisticated engineering. It competed against rivals like the Mercedes-Benz E-Class, Audi 100, and Lexus ES.

Competitors:

Mercedes-Benz W124 E-Class, Audi C3/C4, Lexus ES 250/300, Volvo 740/940.

Design:

Elegant and aerodynamic design penned by Ercole Spada, featuring BMW's signature kidney grille and Hofmeister kink.

Engineering:

Renowned BMW driving dynamics, balanced chassis, rear-wheel drive, and advanced (for its time) suspension systems.

Interior:

Driver-focused cockpit, high-quality materials, comfortable seating, and a focus on ergonomics.

📋 Manual Details

Covered Years:

1988, 1989, 1990, 1991

Covered Models:

All 520i models and trims for the specified years

Engine Coverage:

All applicable engines for the 520i during these years

Estimated Page Count:

Likely 1500-2500+ pages (typical for comprehensive BMW workshop manuals of this era)

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Engine mechanicals (M20B20 for early models, M50B20 for later), cooling system, lubrication system, fuel system, ignition system, emissions control.

Transmission:

Manual and automatic transmission overhaul, diagnostics, fluid specifications, and shift mechanism.

Drivetrain:

Clutch, driveshaft, differential, axles, and wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.

Brakes:

Brake system diagnostics, repair procedures, ABS (Anti-lock Braking System) if equipped, hydraulic components, pad and rotor replacement, fluid specifications.

Steering:

Power steering system, steering rack, tie rods, steering column, and alignment.

Electrical:

Complete electrical system schematics, battery, charging system (alternator), starting system, lighting, instrumentation, power windows, central locking, body control modules.

HVAC:

Heating, ventilation, and air conditioning system operation, diagnosis, refrigerant handling, component replacement.

Bodywork:

Body panel removal/installation, door mechanisms, glass, bumpers, trim, corrosion prevention.

Diagnostic Troubleshooting:

General diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation (if applicable for the era).

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug changes, coolant flushes, brake fluid changes, belt inspections and replacements.

Repair:

Detailed step-by-step repair instructions for all major and minor components, including engine rebuilds, transmission overhauls, suspension and brake work, electrical component replacement.

Troubleshooting:

Comprehensive troubleshooting trees and guides for diagnosing common and uncommon problems across all vehicle systems.

Diagnostics:

Methods for diagnosing issues using onboard diagnostics (OBD I for this era) and specialized tools, electrical system testing.

Specifications:

Torque specifications, clearance measurements, fluid capacities, alignment angles, electrical component resistance values.

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Type:

PDF

Searchable:

Likely searchable text (depending on the quality of the scan/digitization)

Printability:

Designed for printing, allowing users to print specific sections or the entire manual.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code Early:

M20B20 (2.0L Inline-6 SOHC)

Engine Code Later:

M50B20 (2.0L Inline-6 DOHC VANOS)

Displacement M20:

1990 cc

Horsepower M20:

129 hp @ 5800 rpm

Torque M20:

174 Nm (128 lb-ft) @ 4500 rpm

Displacement M50:

1991 cc

Horsepower M50:

150 hp @ 6000 rpm

Torque M50:

190 Nm (140 lb-ft) @ 4300 rpm

Fuel Delivery:

Bosch Motronic fuel injection (various versions depending on year and engine)

Fuel Type:

Unleaded Gasoline

Ignition System:

Distributorless ignition system (DIS) for M50 engines, traditional distributor for M20 engines.

🔧 Transmission

Standard Transmission:

Getrag 260 5-speed manual transmission

Optional Transmission:

ZF 4HP22 4-speed automatic transmission

Transmission Features:

Rear-wheel drive, limited-slip differential often optional.

📐 Dimensions

Length:

Approx. 4711 mm (185.5 in)

Width:

Approx. 1751 mm (68.9 in)

Height:

Approx. 1410 mm (55.5 in)

Wheelbase:

Approx. 2761 mm (108.7 in)

Curb Weight:

Approx. 1450-1550 kg (3197-3417 lbs) depending on configuration

Gross Vehicle Weight Rating:

Varies by model, typically around 2000-2100 kg

🛡️ Safety Features

Safety Ratings Era:

While formal crash test ratings (like NCAP) were less standardized, BMWs of this era were known for robust build quality and safety features for their time.

ABS:

Anti-lock Braking System (ABS) often standard or optional depending on market and trim.

Airbags:

Driver airbag typically optional or standard on later models. Passenger airbag became available in later E34 production.

Seatbelts:

Three-point inertia-reel seatbelts with pretensioners for front occupants, rear seatbelts.

Chassis Design:

Reinforced safety cell, crumple zones, energy-absorbing steering column.

💡 Technology Features

Radio Cassette:

Premium BMW sound systems with cassette players and multi-speaker configurations available. Optional CD players in later models.

Onboard Computer:

Optional On-Board Computer (OBC) providing functions like fuel consumption, average speed, and distance to empty. Often prone to display segment failure.

Cruise Control:

Electronic cruise control standard or optional on most models.

Early Cellular:

Some very late models or optional equipment might have featured early, integrated cellular phone systems, though rare.

🔧 Maintenance

Oil Change Interval:

Every 10,000-15,000 km (6,000-9,000 miles) or annually, whichever comes first (BMW's 'Condition Based Service' or similar early interval systems).

Air Filter Replacement:

Every 30,000-50,000 km (18,000-30,000 miles) or as needed based on conditions.

Spark Plug Replacement:

Every 50,000-100,000 km (30,000-60,000 miles) depending on plug type (e.g., copper vs. platinum).

Coolant Flush:

Every 2-3 years or 40,000-60,000 km (24,000-36,000 miles).

Engine Oil Type:

API SG or higher, viscosity typically 5W-30, 5W-40, 10W-40, or 10W-30 depending on climate and specific BMW recommendations. Synthetic oils are highly recommended.

Coolant Type:

BMW Blue Coolant or compatible ethylene glycol-based antifreeze with corrosion inhibitors. Mixture typically 50/50 with distilled water.

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil. Check specific manual for exact specification (e.g., BMW Gear Oil SAF-XJ for some LSDs).

Transmission Fluid Automatic:

Dexron II or equivalent (e.g., ZF Lifeguardfluid5 for later ZF transmissions, but Dexron II is common for this era). Refer to specific manual for exact type and capacity.

Brake Fluid Type:

DOT 4

Power Steering Fluid:

ATF Dexron II or equivalent (BMW PSF-V).

Common Problems M20:

Head gasket failures, oil leaks from valve cover and oil pan, coolant leaks from hoses and water pump, timing belt tensioner failure (critical), fuel pump issues.

Common Problems M50:

VANOS solenoid failures, oil leaks (valve cover, oil filter housing), water pump failures, crankcase ventilation system issues.

Electrical Issues:

Corrosion in wiring harnesses and connectors, failing OBC (On-Board Computer), intermittent electrical gremlins, window regulator failures.

Suspension Wear:

Worn control arm bushings, ball joints, and tie rod ends leading to vague steering and poor alignment. Sagging springs.

Cooling System Aging:

Plastic coolant expansion tanks can become brittle and crack, radiator leaks, perished hoses.

📚 Vehicle History

Bmw Heritage:

BMW (Bayerische Motoren Werke AG) has a long-standing reputation for building high-performance, driver-focused vehicles with exceptional engineering and quality.

E34 Introduction:

The E34 generation of the 5 Series succeeded the E28 and was produced from 1987 to 1996. The 520i was a key model in its lineup, particularly in European markets.

E34 Design Philosophy:

The E34 was designed to be a more aerodynamic and technologically advanced successor to the E28, with a focus on improved handling, comfort, and build quality.

Production Period:

1988-1991 for the 520i E34 model in this manual's scope.

Manufacturing Locations:

Primarily Dingolfing, Germany. Also assembled in other BMW facilities worldwide.

🏆 Awards & Recognition

Awards E34 Era:

The E34 generation was widely praised by automotive journalists for its driving dynamics, build quality, and sophisticated design, earning it numerous accolades as a benchmark in the luxury sedan segment during its production run.