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BMW 520 520i 1988-1991 Workshop Service Repair Manual

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$16.99
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Model Variant: 520i Generation Generation Code: E34 Codes Chassis Code: E34 Engine Codes: M20B20 👋 Introduction Market Position Vehicle Class: Executive...
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BMW 520 520i 1988-1991 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
5 Series
Model Variant:
520i
Generation
Generation Code:
E34
Codes
Chassis Code:
E34
Engine Codes:
M20B20
👋 Introduction
Market Position
Vehicle Class:
Executive Sedan
Segment:
Mid-size Luxury Sedan
Competitive Analysis
Key Competitors:
Mercedes-Benz W124 E-Class, Audi V8 Quattro, Jaguar XJ, Lexus LS 400 (later in generation)
Key Features
Design Philosophy:
Balanced performance, luxury, and engineering prowess, characteristic of BMW's 'ultimate driving machine' ethos.
Chassis Innovation:
Introduction of MacPherson strut front suspension and semi-trailing arm rear suspension for improved handling.
Aerodynamics:
Designed with a focus on improved aerodynamics over its predecessor, the E28.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Complete Workshop Service Repair
Page Count
Estimated Page Count:
500+
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System
Drivetrain:
Transmission (Manual & Automatic), Clutch, Driveshafts, Differential, Axles
Chassis:
Suspension (Front & Rear), Steering System, Braking System (ABS equipped variations covered)
Electrical:
Starter, Alternator, Battery, Lighting System, Instrumentation, Wiring Diagrams, ECU (Engine Control Unit)
Body And Interior:
Body Panels, Doors, Bumpers, Seats, Interior Trim, Climate Control System, Sunroof (if equipped)
Procedures Included
Maintenance Procedures:
Oil Changes, Filter Replacements, Spark Plug Service, Coolant Flush, Belt Inspection/Replacement, Brake Pad Replacement, Tire Rotation
Diagnostic Procedures:
Troubleshooting Faults, Reading Diagnostic Codes (OBD I), Component Testing
Repair Procedures:
Engine Rebuilds, Transmission Overhaul, Suspension Component Replacement, Brake System Repairs, Electrical Component Replacement, Body Panel Repair
Adjustment Procedures:
Valve Adjustment, Idle Speed Adjustment, Clutch Adjustment, Headlight Aiming
Installation Procedures:
Component Installation, Accessory Installation (factory specified)
Technical Depth
Diagnostic Depth:
Advanced, including electrical schematics and component testing procedures
Repair Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhaul
Specifications Detail:
Detailed torque specifications, clearances, fluid capacities, and electrical resistance values
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Searchable text for quick information retrieval
Print Quality
Printable:
Yes, fully printable
Resolution:
High resolution for clear diagrams and text
Binding Type
Binding Type For Printed:
N/A (Digital Download)
Paper Type
Paper Type For Printed:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, DOHC (Double Overhead Camshaft)
Engine Code:
M20B20
Displacement:
1990 cc (2.0 Liters)
Bore X Stroke:
80.0 mm x 66.0 mm
Performance
Horsepower:
129 hp @ 5800 rpm (approx.)
Torque:
174 Nm (128 lb-ft) @ 4300 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Features
Valvetrain:
SOHC (Single Overhead Camshaft) with 2 valves per cylinder
Compression Ratio:
8.5:1 (typical)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic (ZF 4HP22)
Features
Drive Type:
Rear-Wheel Drive (RWD)
Clutch Type:
Hydraulic Actuated Single Dry Plate
📐 Dimensions
Exterior
Length:
4719 mm (185.8 in)
Width:
1751 mm (68.9 in)
Height:
1412 mm (55.6 in)
Wheelbase:
2799 mm (110.2 in)
Weights
Curb Weight:
1430 kg (3153 lbs) (approx. manual transmission)
Gross Vehicle Weight:
1950 kg (4299 lbs) (approx.)
Cargo
Trunk Volume:
460 liters (16.2 cu ft)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited specific published ratings for this model year and variant; rely on general E34 platform safety characteristics.
Active Features
Braking System:
Hydraulically operated, power-assisted disc brakes (front), drum or disc (rear). ABS optional on some models.
Traction Control:
ASC (Automatic Stability Control) available on some later E34 models, but less common on 520i.
Passive Features
Airbags:
Driver airbag became standard later in the E34 lifecycle; early models may not have one.
Seatbelts:
Three-point inertia-reel seatbelts with front-seat belt pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory BMW Bavaria C or similar radio/cassette systems, with optional CD changer.
Onboard Computer:
Optional On-Board Computer (OBC) displaying fuel consumption, average speed, and fault codes.
Driver Assistance
Cruise Control:
Standard or optional cruise control system.
Park Distance Control:
Not typically available on this model.
Connectivity
Connectivity Features:
Limited to basic radio and optional external phone integration for its era.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, whichever comes first (BMW Condition Based Service recommended).
Spark Plug Replacement:
Approximately every 30,000 miles (48,000 km) for standard plugs, longer for platinum/iridium.
Coolant Flush Interval:
Every 2-3 years or 30,000 miles (48,000 km).
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 10W-50 synthetic or semi-synthetic oil meeting BMW Longlife-98 specifications (check manual for exact spec).
Coolant Type:
Ethylene Glycol based coolant (BMW blue or green coolant) mixed with distilled water at a 50/50 ratio.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (check manual for specific viscosity and API rating, often 75W-90 or 80W-90).
Transmission Fluid Automatic:
Dexron II or Dexron III ATF (Automatic Transmission Fluid).
Known Issues
Common Wear Items:
Vibration damper pulley (harmonic balancer), fuel pump, window regulators, coolant expansion tank, front suspension bushings.
Engine M20 Specific:
Head gasket leaks, timing belt tensioner wear, idle control valve issues, intake manifold vacuum leaks.
Electrical Gremlins:
Corroded connectors, failing OBC (On-Board Computer) pixels, intermittent electrical faults common in older vehicles.
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW, founded in 1916, has a long history of producing performance-oriented luxury vehicles known for driving dynamics and engineering excellence.
Model Evolution
E34 Introduction:
The E34 generation of the BMW 5 Series replaced the E28 and was introduced in 1987. It marked a significant step forward in design, technology, and chassis dynamics.
E34 Lifecycle:
The E34 was produced from 1987 to 1996, with the 520i being a key entry-level model in many markets, especially Europe.
Production
Production Location:
Mainly produced in Dingolfing, Germany.
🏆 Awards & Recognition
Recognitions
Automotive Journalism Awards:
The E34 generation was well-regarded by automotive publications for its driving dynamics, build quality, and refined interior, though specific awards for the 520i variant may be less documented than higher-performance models.
Ratings
Consumer Reports Ratings:
While direct ratings for this exact variant from contemporary consumer reports may be scarce, the E34 platform generally received praise for its performance and handling, with typical concerns around the reliability of older electronics and suspension components.
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