🏷️ Basic Information

Make:

BMW

Model:

520i

Model Code:

E34

Generation:

E34

Chassis Code:

E34

👋 Introduction

Positioning:

The E34 5 Series was BMW's mid-size luxury sedan, known for its blend of performance, comfort, and advanced engineering for its era. The 520i was typically an entry-level model in many markets.

Competitors:

Competed against vehicles like the Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, and Volvo 240/740.

Design Philosophy:

Continuation of BMW's 'Ultimate Driving Machine' ethos with a focus on refined handling, powerful inline-six engines (though the 520i featured an inline-four in some markets, the description implies the 520i designation which in Europe often referred to the M20B20 inline-six), and sophisticated chassis dynamics.

Structural Innovation:

The E34 introduced significant aerodynamic improvements and chassis stiffness over its E28 predecessor.

📋 Manual Details

Years Covered:

1988, 1989, 1990, 1991

Estimated Pages:

Varies by original manufacturer publication, typically 800-1500 pages for a full workshop manual.

Type:

Workshop Service Manual / Repair Manual

Language:

English (Primary Language of this specific product description, common for global markets)

Format:

PDF Download

📖 Manual Coverage

Engine:

M20B20 engine specifications, troubleshooting, overhaul, fuel injection, ignition system, emissions control.

Transmission:

Manual and Automatic transmission service, repair, fluid specifications, troubleshooting.

Drivetrain:

Rear-wheel drive system, driveshaft, differential, axle repairs.

Suspension:

Front and rear suspension components, geometry, adjustments, replacement procedures, shocks, struts, bushings.

Steering:

Power steering system, steering rack, column, troubleshooting.

Brakes:

Hydraulic brake system, ABS (if equipped), disc and drum brake service, pad/shoe replacement, fluid bleeding, caliper/master cylinder overhaul.

Electrical:

Wiring diagrams, component testing, starter, alternator, battery, fuses, relays, lighting system, ignition system, diagnostic procedures.

Body:

Body panel repair, door mechanisms, glass, trim, bumpers, interior components, corrosion prevention.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system service, refrigerant handling, component repair.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for common issues, electrical diagnostics.

Engine Repair:

Engine removal/installation, cylinder head overhaul, piston ring replacement, crankshaft/connecting rod service, timing chain/belt service.

Transmission Repair:

Clutch replacement, gearbox overhaul, automatic transmission service, torque converter replacement.

Brake Repair:

Brake caliper rebuilding, master cylinder replacement, parking brake adjustment.

Electrical Diagnostics:

Testing of sensors, actuators, ECUs (Engine Control Units), body control modules.

Suspension And Steering Repair:

Ball joint replacement, tie rod end service, power steering pump replacement.

Bodywork And Interior:

Door hinge lubrication, window regulator repair, dashboard removal.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.

📊 Manual Specifications

PDF Quality:

High resolution, searchable text (typically, dependent on source scan quality).

Printability:

Printable pages for workshop use.

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Code:

M20B20

Engine Type:

Inline-6 Cylinder, SOHC

Displacement:

1990 cc (2.0 Liters)

Bore X Stroke:

80.0 mm x 66.0 mm

Horsepower:

129 hp (95 kW) at 5800 rpm (approx. for European spec)

Torque:

174 Nm (128 lb-ft) at 4300 rpm (approx. for European spec)

Fuel Delivery:

Bosch Motronic Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (95 RON recommended)

Ignition System:

Distributorless Ignition System (DIS) or Distributor-based system depending on exact model year and market.

Coolant Capacity:

Approx. 7.0 Liters

Oil Capacity:

Approx. 4.25 Liters with filter change

🔧 Transmission

Transmission Type:

5-speed Manual (Getrag 260/5)

Transmission Type:

4-speed Automatic (ZF 4HP22)

Manual Gear Ratios:

Refer to manual for specific ratios (typically around 3.71:1 first gear, 1.00:1 fifth gear)

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent GL-4 rated gear oil

Automatic Transmission Fluid:

Dexron II or equivalent ATF

📐 Dimensions

Length:

4730 mm (186.2 in)

Width:

1751 mm (68.9 in)

Height:

1410 mm (55.5 in)

Wheelbase:

2760 mm (108.7 in)

Curb Weight:

Approx. 1500 kg (3307 lbs)

Gross Vehicle Weight Rating:

Approx. 1900 kg (4189 lbs)

🛡️ Safety Features

Crash Test Ratings:

Not extensively tested by modern standards. Refer to historical safety publications for specific results. E34 era safety focused on passive restraints.

ABS:

Optional Anti-lock Braking System (ABS)

Traction Control:

Optional ASC (Automatic Stability Control) in later models or certain markets.

Airbags:

Driver's airbag typically standard from mid-production onwards or optional early on. Passenger airbag optional.

Seatbelts:

Three-point inertia-reel seatbelts front and rear.

Chassis Strength:

High-strength steel safety cage construction.

💡 Technology Features

Audio System:

Original BMW Bavaria C business or professional radio/cassette players, optional CD changer in later models.

Display:

Basic OBC (On-Board Computer) for fuel consumption, range, and diagnostics in higher trims. No central infotainment screen.

Cruise Control:

Optional cruise control system.

Parking Assistance:

No factory-fitted parking sensors or cameras.

Phone Integration:

No integrated Bluetooth or smartphone connectivity. Optional early car phone installations.

🔧 Maintenance

Oil Change Interval:

Typically 10,000-15,000 km or 1 year (refer to specific manual for precise interval and oil type).

Air Filter Replacement:

Every 30,000-50,000 km or as needed based on operating conditions.

Spark Plug Replacement:

Every 40,000-60,000 km for standard spark plugs; longer for platinum or iridium plugs if fitted.

Coolant Flush:

Every 2-3 years or 40,000-60,000 km.

Engine Oil Specification:

API SG / ACEA A2 or higher, viscosity 10W-40 or 15W-40 (check manual for climate-specific recommendations, e.g., 5W-30 for cold climates).

Coolant Specification:

BMW Coolant Antifreeze (G48) or equivalent silicate-free long-life coolant, mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 4.

Common Wear Items:

Cooling system components (radiator, hoses, water pump), fuel pump, ignition coil packs (on later M20 variants), front control arm bushings, rear shock mounts, sunroof drains, heater control valves.

Engine Management Issues:

Idle control valve issues, airflow meter problems, fuel injector clogging, vacuum leaks.

Electrical Issues:

Corroded grounds, failing instrument cluster components, burnt wiring at fuse box.

Key Checks:

Regular inspection of all rubber hoses and belts for cracks/wear, checking for coolant leaks, maintaining proper tire pressures.

📚 Vehicle History

Brand Focus:

BMW has a long-standing reputation for producing driver-focused luxury and performance vehicles with advanced engineering.

Predecessor:

BMW E28 5 Series

Successor:

BMW E39 5 Series

Production Period:

1987–1995 (E34 Generation)

Manufacturing Locations:

Germany (Dingolfing Plant)

🏆 Awards & Recognition

Automotive Press:

The E34 generation was generally praised by automotive journalists for its driving dynamics, build quality, and comfortable ride, often outperforming its rivals in head-to-head comparisons.

Reliability Index:

While generally robust, specific reliability depends heavily on maintenance history. Common issues are well-documented and addressed by this manual.