Vehicle Segment:
Executive/Luxury Mid-size Sedan.
Bmw Philosophy:
Represents BMW's commitment to driving dynamics, build quality, and refined engineering during the late 1980s.
Key Rivals:
Mercedes-Benz W124 E-Class, Audi 100/200, Volvo 240/740, Jaguar XJ6.
Driver Focus:
Known for its driver-oriented cockpit, balanced chassis, and responsive handling.
Quality And Longevity:
E34 chassis is recognized for its robust construction and potential for long-term durability with proper maintenance.
Primary Coverage:
Complete service and repair procedures for the BMW 520i (E34) 1988-1991 model years.
Specific Systems:
Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Exhaust System, Body and Chassis, Climate Control, Interior Components.
Estimated Page Count:
Approximately 1000-1500 pages (typical for comprehensive workshop manuals of this era).
Type:
Workshop Service Repair Manual
Engine Management:
Detailed diagnostics, repair, and specifications for the M20B20 engine, including fuel injection (Bosch Motronic), ignition system, emission control systems.
Drivetrain:
Repair and maintenance of manual and automatic transmissions, clutch operation, driveshafts, differentials, and axle components.
Suspension Steering:
Front and rear suspension geometry, component replacement (struts, control arms, bushings), steering system diagnostics and repair (rack and pinion).
Braking System:
Service procedures for hydraulic systems (master cylinder, lines, calipers), brake pad and rotor replacement, ABS system (if equipped), parking brake.
Electrical System:
Comprehensive wiring diagrams, fuse box locations, component testing, starter, alternator, lighting systems, instrument cluster, power windows, central locking.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug service, coolant flushes, brake fluid replacement, belt tensioning.
Troubleshooting:
Systematic diagnostic procedures for common drivability issues, electrical faults, starting problems, and performance degradation.
Major Repairs:
Engine overhauls, transmission rebuilds, suspension component overhauls, brake system overhauls, fuel system component replacement.
Bodywork:
Minor body panel adjustments, door and lock mechanisms, trim component replacement, glass replacement procedures.
Diagnostic Capability:
Advanced diagnostic information, including specifications for checking sensor readings, actuator operation, and ECU fault codes (where applicable for the era).
Rebuild Instructions:
Detailed step-by-step instructions and torque specifications for complete engine, transmission, and differential rebuilds.
Special Tools:
Identification and usage of specialized BMW tools required for specific repair procedures.
Engine Type:
Inline 6-Cylinder, SOHC
Displacement:
1990 cc (2.0 Liters)
Bore X Stroke:
80.0 mm x 66.0 mm
Compression Ratio:
8.8:1 (typical for M20B20)
Horsepower:
129 hp @ 5800 rpm (approximate for European spec)
Torque:
180 Nm (133 lb-ft) @ 4500 rpm (approximate for European spec)
Induction:
Electronic Fuel Injection (EFI) - Bosch Motronic system.
Fuel Type:
Unleaded Gasoline (Premium Octane recommended)
System:
Distributorless Ignition System (DIS) or Distributor with Electronic Control Unit.
Type:
5-speed Manual Transmission
Type:
4-speed Automatic Transmission (ZF)
Clutch:
Hydraulically actuated single dry plate clutch (manual transmission).
Manual Transmission Fluid:
BMW MTF LT-2 or equivalent (e.g., Castrol TAF-X 75W-90)
Automatic Transmission Fluid:
Dexron III or Mercon compatible ATF
Crash Test Era:
Era-specific safety standards; modern ratings not directly applicable.
ABS:
Anti-lock Braking System (ABS) available as an option on later models.
Airbags:
Driver-side airbag optional on some late models, passenger airbag not standard.
Seatbelts:
3-point inertia-reel seatbelts with front-seat belt pretensioners.
Chassis Structure:
Reinforced safety cage, crumple zones, and side-impact protection beams.
Audio System:
Factory-installed AM/FM stereo cassette player with premium sound options available.
Climate Control:
Manual or optional automatic climate control (ECC - Electronic Climate Control).
Cruise Control:
Standard or optional cruise control system.
Era Connectivity:
Limited by modern standards; primarily focused on car-to-driver communication via instrument cluster warnings.
Oil Change:
Every 7,500 - 10,000 miles (12,000 - 15,000 km) or annually, whichever comes first. Consult manual for specific conditions.
Coolant Flush:
Every 2-3 years or as recommended in the manual.
Spark Plugs:
Typically every 30,000 - 50,000 miles, depending on plug type (e.g., standard vs. platinum).
Engine Oil:
API SG or higher, SAE 10W-40 or 15W-40 (refer to manual for specific viscosity based on temperature).
Coolant:
BMW Coolant/Antifreeze or equivalent ethylene glycol-based mixture (50/50 with distilled water).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Cooling System:
Plastic coolant expansion tank can become brittle and crack; water pump impeller can degrade.
Engine Management:
Idle Control Valve (ICV) can become dirty and cause rough idling; MAF sensor issues are possible.
Electrical:
Corrosion in fuse box connectors; aging wiring harnesses can lead to intermittent faults.
Suspension:
Worn control arm bushings, ball joints, and tie rod ends are common wear items.
Oil Filter:
Mann-Filter W 101 or equivalent (e.g., Mahle OC 26).
Air Filter:
Mann-Filter C 3426 or equivalent (e.g., Mahle LX 45).
Bmw Legacy:
BMW has a long-standing reputation for producing driver-focused, high-performance vehicles.
E34 Introduction:
The E34 generation replaced the E28 5 Series and was produced from 1987 to 1996, with the 520i being a key entry-level model in many markets.
520I Positioning:
The 520i offered a more accessible entry point into the E34 range, prioritizing refinement and handling over raw power.
Manufacturing Location:
Germany (Dingolfing Plant primarily)
