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BMW 5-Series (E34) BMW 520i 1988-1991 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5-Series Chassis Code: E34 Specific Model Variant: 520i Production Years Covered: 1988-1991 Codes Engine Code Common E34 520I: M20B20 👋 Introduction Market Position...
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BMW 5-Series (E34) BMW 520i 1988-1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5-Series
Chassis Code:
E34
Specific Model Variant:
520i
Production Years Covered:
1988-1991
Codes
Engine Code Common E34 520I:
M20B20
👋 Introduction
Market Position
Segment:
Executive Sedan
Brand Perception:
BMW's reputation for 'The Ultimate Driving Machine' and engineering excellence.
Competitive Analysis
Key Competitors Era:
Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, Lexus LS400 (later in the E34's life)
Key Features
Design Philosophy:
Sophisticated styling, driver-focused cockpit, balanced handling, and robust engineering.
E34 Distinction:
Marks the transition to more aerodynamic designs and increased electronic integration compared to its E28 predecessor.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Target Audience:
Professional Technicians and Enthusiast DIYers
Page Count
Estimated Page Count:
Comprehensive (Typically 500-1000+ pages for full workshop manuals, specific page count not provided in product info)
Manual Type
Type:
Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (Likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete Engine Overhaul, Tuning, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System
Transmission:
Manual and Automatic Transmission Repair, Clutch, Driveshafts, Differential
Chassis And Suspension:
Front and Rear Suspension, Steering System, Wheel Alignment, Shock Absorbers, Springs
Brakes:
Hydraulic System, ABS (if equipped), Brake Pads, Rotors, Calipers, Lines
Electrical System:
Wiring Diagrams, Battery, Alternator, Starter, Lighting, Fuses, Relays, ECU Diagnostics, Sensors
Bodywork And Interior:
Body Panel Repair, Doors, Windows, Seats, Trim, HVAC System (Heating, Ventilation, Air Conditioning)
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Inspection and Replacement, Fluid Checks and Top-offs
Troubleshooting:
Diagnostic Flowcharts, Symptom-based Troubleshooting Guides, Common Fault Identification
Repair And Rebuild:
Detailed Disassembly and Reassembly Instructions for Major Components (Engine, Transmission, Suspension)
Diagnostics:
OBD-I (On-Board Diagnostics) Code Interpretation, Sensor Testing, Component Testing
Technical Depth
Depth:
Comprehensive: Covers routine maintenance to major component overhauls and diagnostic procedures.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - commonly searched, printable, and viewable on various devices.
Print Quality
Quality:
High-resolution scans ensuring clarity of diagrams, text, and images.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Model:
M20B20
Engine Type:
Inline 6-Cylinder, SOHC (Single Overhead Camshaft), 12 Valves
Displacement:
1990 cc (2.0 Liters)
Performance
Horsepower Approx:
129 hp @ 5800 rpm
Torque Approx:
180 Nm (133 lb-ft) @ 4700 rpm
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Management
Ignition System:
Distributorless Ignition System (DIS) or Distributor-based depending on exact build date/market within range
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual
Optional
Optional Transmission:
4-Speed Automatic (e.g., ZF 4HP22)
Features
Clutch Type:
Hydraulically Operated Single Dry Plate Clutch
Driveshaft:
Rear Wheel Drive (RWD) with single-piece driveshaft and universal joints.
📐 Dimensions
Exterior
Body Styles Available:
4-door Sedan (Saloon), 5-door Touring (Estate/Wagon)
Wheelbase Approx Sedan:
2760 mm (108.7 in)
Length Approx Sedan:
4730 mm (186.2 in)
Width Approx:
1750 mm (68.9 in)
Height Approx:
1410 mm (55.5 in)
Weights
Curb Weight Approx 520I Sedan:
1450 - 1550 kg (3197 - 3417 lbs) depending on transmission and options
Gross Vehicle Weight Rating Gvw Approx:
1900 - 2000 kg (4189 - 4409 lbs)
🛡️ Safety Features
Ratings
Crash Test Data Era:
Limited official crash test data readily available for this specific period compared to modern standards, but BMWs of this era were known for robust safety cages and crumple zones.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option on some models.
Traction Control:
ASC (Automatic Stability Control) or ASC+T (with Traction Control) became available on later E34 models, but less common on early 520i.
Passive Features
Airbags:
Driver's airbag standard on later models within this range, passenger airbag became an option.
Seatbelts:
Three-point inertia-reel seatbelts for all occupants.
Structural Safety:
Reinforced safety cage, impact-absorbing bumpers, and strategically placed crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory fitted BMW Professional radio/cassette systems, often with optional CD changer integration.
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control) with advanced features for its time.
Driver Assistance
Cruise Control:
Standard or optional on most models, contributing to comfortable highway cruising.
Connectivity
Early Integration:
Limited to basic phone integration (if optioned with car phone) and advanced diagnostics via OBD-I.
🔧 Maintenance
Service Intervals
Oil Change Interval Recommendation:
Typically 10,000-15,000 km (6,000-9,000 miles) or annually, depending on driving conditions and oil used.
Spark Plug Replacement Interval:
Every 40,000 - 60,000 km (25,000 - 37,000 miles), depending on spark plug type (e.g., standard copper vs. platinum).
Coolant Flush Interval:
Every 2-3 years or as recommended by coolant type.
Timing Belt Or Chain:
The M20 engine uses a timing belt. Replacement typically recommended every 80,000 - 100,000 km (50,000 - 60,000 miles) or 5-7 years due to risk of catastrophic failure if it breaks.
Fluid Specifications
Engine Oil Type:
API SG/SH or ACEA A2-96, SAE 5W-30, 5W-40, 10W-40, or 10W-50 depending on climate. Check manual for specific recommendations.
Engine Oil Capacity:
Approx. 4.25 liters (4.5 US quarts) with filter change.
Coolant Type:
Ethylene glycol based coolant, typically BMW's original blue coolant or equivalent. Mix 50/50 with distilled water.
Automatic Transmission Fluid Type:
Dexron II or equivalent (check specific ZF transmission requirements).
Brake Fluid Type:
DOT 3 or DOT 4 (check specific recommendations for ABS if equipped).
Known Issues
Cooling System:
Water pump failure, radiator leaks, thermostat housing leaks, and degraded hoses are common due to age.
Fuel System:
Fuel pump wear, clogged injectors, and failing fuel pressure regulators can occur.
Electrical:
Corrosion in wiring connectors (especially ground points), failing alternator, and ECU issues can develop over time.
Suspension And Bushings:
Worn control arm bushings, tie rod ends, and shock absorbers lead to degraded handling and ride comfort.
Engine Management M20:
Idle control valve issues, MAF sensor (Air Flow Meter) problems, and vacuum leaks can cause rough idling or poor performance.
📚 Vehicle History
Brand Heritage
Bmw Legacy:
Building on decades of automotive engineering and motorsport success, BMW solidified its reputation for performance and luxury.
Model Evolution
E34 Introduction:
Launched in 1987 (for the 1988 model year), the E34 replaced the E28 generation and represented a significant step forward in design, technology, and refinement.
E34 Lifespan:
Produced from 1987 to 1996 (with the Touring body style introduced in 1991).
Production
Manufacturing Locations:
Primarily Dingolfing, Germany, with potential assembly in other BMW plants globally.
E34 Sales Volume:
Over 1.3 million E34 sedans and Tourings were produced worldwide.
🏆 Awards & Recognition
Recognitions
Automotive Journalism Acclaim:
The E34 5-Series consistently received praise from automotive journalists for its driving dynamics, build quality, and sophisticated design, earning it a strong reputation as a benchmark in its class.
Ratings
Reliability Perception:
Generally considered a reliable vehicle when properly maintained, though age-related component wear is a factor.
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