BMW 520I E34 Service Repair Manual 1988-1991

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🏷️ Basic Information Identification Make: BMW Model: 520i Chassis Code: E34 Model Years Covered: 1988, 1989, 1990, 1991 Codes Engine Code Variant: M20B20 (primary for this range and model) 👋 Introduction Market Position Segment: Executive Sedan (E-segment) Target Audience: Discerning drivers valuing performance, luxury, and engineering quality. Competitive Analysis Key Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ. Key Features Vehicle Design Philosophy: Elegant styling, sophisticated chassis dynamics, driver-focused interior, and robust engineering characteristic of BMW's heritage. Key Features Manual Value Proposition: Empowers owners and independent workshops with the technical knowledge to maintain and repair the E34 520i effectively, reducing reliance on expensive dealerships. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair, maintenance, troubleshooting, and diagnostics for the BMW 520i E34. Specific Systems: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission (Manual & Automatic), Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Climate Control, Interior Components. Page Count Estimated Pages: Hundreds (specific number not provided, but described as 'Hundreds Of Pages') Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures for the M20 inline-six engine, including cylinder head, block, pistons, crankshaft, camshaft, timing belt replacement, valve adjustments. Fuel System: Bosch Motronic fuel injection system diagnostics, fuel pump testing, injector cleaning/replacement, fuel pressure regulation. Ignition System: Ignition coil testing, spark plug specifications, ignition timing procedures, Motronic ignition control module diagnostics. Cooling System: Radiator, water pump, thermostat, coolant hoses, fan clutch, heater core replacement and maintenance procedures. Exhaust System: Catalytic converter replacement, exhaust manifold gasket replacement, muffler and pipe repair. Transmission Manual: Clutch replacement, gearbox overhaul, shift linkage adjustment, transmission fluid specifications and change intervals. Transmission Automatic: Automatic transmission (e.g., ZF 4HP22) service, fluid and filter changes, basic troubleshooting, control module diagnostics. Drivetrain: Driveshaft, universal joints, CV joints, differential (rear axle) service and fluid specifications. Suspension: Front and rear suspension component replacement (struts, shocks, control arms, bushings), wheel alignment specifications. Steering: Power steering system service, steering rack overhaul or replacement, tie rod end replacement, steering fluid specifications. Brakes: Front and rear brake pad and rotor replacement, brake caliper overhaul, bleeding procedures, ABS system troubleshooting, brake fluid type (DOT 4). Electrical System: Complete wiring diagrams, fuse box locations and functions, battery specifications, alternator, starter motor testing and replacement, lighting system repair. Bodywork: Door lock mechanisms, window regulators, sunroof operation, bumper removal/installation, body panel repair basics. Climate Control: HVAC system service, blower motor replacement, heater control valve, A/C system charging and leak detection. Interior Components: Seat removal, dashboard disassembly, instrument cluster repair, glove box, center console access. Procedures Included Routine Maintenance: Oil change, filter replacement (oil, air, fuel), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change. Troubleshooting: Diagnostic flowcharts for common symptoms (e.g., hard starting, poor running, electrical issues), fault code interpretation (if applicable to specific Motronic versions). Repair Overhaul: Step-by-step instructions for major component rebuilds and replacements, including engine, transmission, suspension, and braking systems. Diagnostics: Guidance on using basic diagnostic tools, testing electrical components with multimeters, and identifying mechanical issues through sound and feel. Technical Depth Depth Level: Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds. Diagnostic Focus: Detailed diagnostic procedures for the Motronic engine management system and other key electronic control units. Torque Specifications: Includes critical torque values for engine fasteners, suspension components, and wheel lug nuts. Wiring Diagrams: High-quality, detailed wiring diagrams for all electrical systems, essential for troubleshooting complex issues. 📊 Manual Specifications File Format Format: PDF Searchability: Typically searchable PDF format allowing for quick text-based searches. Printability: Printable pages for easy reference in a workshop environment. Print Quality Image Resolution: High-resolution images and diagrams suitable for clear viewing and printing. Diagram Clarity: Clear, legible technical illustrations and schematics. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: M20B20 Engine Type: Inline-6 Cylinder, SOHC (Single Overhead Camshaft) Displacement: 1990 cc (2.0 Liters) Bore X Stroke: 80.0 mm x 66.0 mm Compression Ratio: 8.8:1 (typical for this engine) Performance Horsepower: 126 hp (93 kW) @ 6000 rpm (approx.) Torque: 174 Nm (128 lb-ft) @ 4300 rpm (approx.) Fuel System Fuel Delivery: Bosch Motronic M1.3 Fuel Injection Fuel Type: Unleaded Gasoline (Octane rating suitable for market, typically 95 RON) Engine Management ECM Type: Motronic M1.3 Emissions Control: Catalytic Converter 🔧 Transmission Standard Type: 5-speed Manual Transmission (e.g., Getrag 260) Optional Type: 4-speed Automatic Transmission (e.g., ZF 4HP22) Features Manual Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance and efficiency understanding. Automatic Control: Electronic control for automatic transmission (if equipped), integrated with engine management. 📐 Dimensions Exterior Length: Approx. 4730 mm (186.2 in) Width: Approx. 1750 mm (68.9 in) Height: Approx. 1410 mm (55.5 in) Wheelbase: Approx. 2795 mm (110.0 in) Weights...

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Typ: Car

Anbieter:

Art.-Nr: 274189

Sammlungen: ALL BMW

Verfügbarkeit: Auf Lager

Stichworte: 1988 1989 1990 1991 520I BMW Car Cars E34 Misc

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

Chassis Code:

Model Years Covered:

1988, 1989, 1990, 1991

Codes

Engine Code Variant:

M20B20 (primary for this range and model)

👋 Introduction

Market Position

Segment:

Executive Sedan (E-segment)

Target Audience:

Discerning drivers valuing performance, luxury, and engineering quality.

Competitive Analysis

Key Competitors:

Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ.

Key Features Vehicle

Design Philosophy:

Elegant styling, sophisticated chassis dynamics, driver-focused interior, and robust engineering characteristic of BMW's heritage.

Key Features Manual

Value Proposition:

Empowers owners and independent workshops with the technical knowledge to maintain and repair the E34 520i effectively, reducing reliance on expensive dealerships.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair, maintenance, troubleshooting, and diagnostics for the BMW 520i E34.

Specific Systems:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission (Manual & Automatic), Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Climate Control, Interior Components.

Page Count

Estimated Pages:

Hundreds (specific number not provided, but described as 'Hundreds Of Pages')

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul procedures for the M20 inline-six engine, including cylinder head, block, pistons, crankshaft, camshaft, timing belt replacement, valve adjustments.

Fuel System:

Bosch Motronic fuel injection system diagnostics, fuel pump testing, injector cleaning/replacement, fuel pressure regulation.

Ignition System:

Ignition coil testing, spark plug specifications, ignition timing procedures, Motronic ignition control module diagnostics.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan clutch, heater core replacement and maintenance procedures.

Exhaust System:

Catalytic converter replacement, exhaust manifold gasket replacement, muffler and pipe repair.

Transmission Manual:

Clutch replacement, gearbox overhaul, shift linkage adjustment, transmission fluid specifications and change intervals.

Transmission Automatic:

Automatic transmission (e.g., ZF 4HP22) service, fluid and filter changes, basic troubleshooting, control module diagnostics.

Drivetrain:

Driveshaft, universal joints, CV joints, differential (rear axle) service and fluid specifications.

Suspension:

Front and rear suspension component replacement (struts, shocks, control arms, bushings), wheel alignment specifications.

Steering:

Power steering system service, steering rack overhaul or replacement, tie rod end replacement, steering fluid specifications.

Brakes:

Front and rear brake pad and rotor replacement, brake caliper overhaul, bleeding procedures, ABS system troubleshooting, brake fluid type (DOT 4).

Electrical System:

Complete wiring diagrams, fuse box locations and functions, battery specifications, alternator, starter motor testing and replacement, lighting system repair.

Bodywork:

Door lock mechanisms, window regulators, sunroof operation, bumper removal/installation, body panel repair basics.

Climate Control:

HVAC system service, blower motor replacement, heater control valve, A/C system charging and leak detection.

Interior Components:

Seat removal, dashboard disassembly, instrument cluster repair, glove box, center console access.

Procedures Included

Routine Maintenance:

Oil change, filter replacement (oil, air, fuel), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change.

Troubleshooting:

Diagnostic flowcharts for common symptoms (e.g., hard starting, poor running, electrical issues), fault code interpretation (if applicable to specific Motronic versions).

Repair Overhaul:

Step-by-step instructions for major component rebuilds and replacements, including engine, transmission, suspension, and braking systems.

Diagnostics:

Guidance on using basic diagnostic tools, testing electrical components with multimeters, and identifying mechanical issues through sound and feel.

Technical Depth

Depth Level:

Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds.

Diagnostic Focus:

Detailed diagnostic procedures for the Motronic engine management system and other key electronic control units.

Torque Specifications:

Includes critical torque values for engine fasteners, suspension components, and wheel lug nuts.

Wiring Diagrams:

High-quality, detailed wiring diagrams for all electrical systems, essential for troubleshooting complex issues.

📊 Manual Specifications

File Format

Format:

Searchability:

Typically searchable PDF format allowing for quick text-based searches.

Printability:

Printable pages for easy reference in a workshop environment.

Print Quality

Image Resolution:

High-resolution images and diagrams suitable for clear viewing and printing.

Diagram Clarity:

Clear, legible technical illustrations and schematics.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M20B20

Engine Type:

Inline-6 Cylinder, SOHC (Single Overhead Camshaft)

Displacement:

1990 cc (2.0 Liters)

Bore X Stroke:

80.0 mm x 66.0 mm

Compression Ratio:

8.8:1 (typical for this engine)

Performance

Horsepower:

126 hp (93 kW) @ 6000 rpm (approx.)

Torque:

174 Nm (128 lb-ft) @ 4300 rpm (approx.)

Fuel System

Fuel Delivery:

Bosch Motronic M1.3 Fuel Injection

Fuel Type:

Unleaded Gasoline (Octane rating suitable for market, typically 95 RON)

Engine Management

ECM Type:

Motronic M1.3

Emissions Control:

Catalytic Converter

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (e.g., Getrag 260)

Optional

Type:

4-speed Automatic Transmission (e.g., ZF 4HP22)

Features

Manual Gear Ratios:

Specific gear ratios are detailed within the manual, crucial for performance and efficiency understanding.

Automatic Control:

Electronic control for automatic transmission (if equipped), integrated with engine management.

📐 Dimensions

Exterior

Length:

Approx. 4730 mm (186.2 in)

Width:

Approx. 1750 mm (68.9 in)

Height:

Approx. 1410 mm (55.5 in)

Wheelbase:

Approx. 2795 mm (110.0 in)

Weights

Curb Weight:

Approx. 1450-1550 kg (3200-3420 lbs), varies by equipment and transmission.

Gross Vehicle Weight:

Typically around 1950-2050 kg.

Cargo

Trunk Volume:

Approx. 500-550 Liters (17.7-19.4 cu ft), depending on exact configuration.

Wheels Tires

Standard Wheel Size:

15-inch alloy wheels (e.g., 7J x 15 ET 20)

Standard Tire Size:

205/65 R15

Wheel Bolt Pattern:

5x120 mm

Center Bore:

74.0 mm

🛡️ Safety Features

Ratings

Crash Test Data:

While specific official ratings for this era are limited by modern standards, the E34 chassis was known for its robust construction and safety features.

Active Features

Anti-lock Braking System (ABS) was available, often standard on higher trims or later production models.

Traction Control:

ASR (Automatic Stability Control) was optional on some models, but less common on the 520i E34 compared to higher engine variants.

Passive Features

Airbags:

Driver's airbag was optional and became more common during the E34's production life. Passenger airbag was less common in early models.

Seatbelts:

Three-point inertia-reel seatbelts for all occupants, pre-tensioners for front seats typically standard.

Chassis Strength:

High-strength steel safety cage, crumple zones front and rear.

💡 Technology Features

Infotainment

Audio System:

Factory BMW cassette radio with potential for CD changer integration (optional). Speaker systems varied by trim.

Climate Control Tech:

Manual HVAC controls with optional automatic climate control (e.g., IHKA) on higher-spec models, offering more precise temperature management.

Driver Assistance

Cruise Control:

Standard or optional feature, providing convenient highway driving.

Parking Sensors:

Not typically available on the 1988-1991 models.

Connectivity

Phone Integration:

No native smartphone integration. Early cellular phone options might have been available, but are obsolete.

Lighting

Headlights:

Halogen headlights, often with integrated fog lamps in the bumper assembly. Projector-style headlights available on some models.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, depending on driving conditions and oil used. Check manual for specific recommendations.

Air Filter:

Replace every 30,000-60,000 km (18,000-36,000 miles) or as needed based on inspection.

Fuel Filter:

Replace every 40,000-60,000 km (24,000-36,000 miles).

Spark Plugs:

Replace every 60,000-100,000 km (36,000-60,000 miles) depending on plug type (standard vs. long-life).

Coolant Flush:

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

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil:

API SG or higher, viscosity typically 10W-40 or 5W-40 (synthetic recommended). Check manual for exact BMW specifications (e.g., BMW Longlife-98 compatibility if applicable to specific batches).

Coolant:

BMW Blue coolant (Glysantin G48 or equivalent) or a mixture of antifreeze and distilled water (50/50).

Brake Fluid:

DOT 4 (low viscosity, dry boiling point >230°C, wet boiling point >140°C).

Power Steering Fluid:

BMW Power Steering Fluid (or Dexron II/III ATF in some cases – consult manual for definitive type).

Transmission Fluid Manual:

GL-4 Gear Oil, SAE 75W-90 or 80W-90.

Transmission Fluid Automatic:

Dexron II or Dexron III ATF. Capacity typically 1.5-2.0 liters for a drain and fill.

Differential Fluid:

API GL-5, SAE 75W-90 or 80W-90 Hypoid Gear Oil. Capacity approx. 1.0-1.5 liters.

Known Issues

Engine Oil Leaks:

Common leak points include valve cover gasket, oil pan gasket, and front crankshaft seal due to age and material degradation.

Cooling System:

Plastic coolant expansion tanks can become brittle and crack. Water pump and thermostat failures are also not uncommon with age.

Electrical Gremlins:

Corrosion in wiring harnesses, faulty door modules (EWS if applicable early), and instrument cluster issues can arise.

Suspension Wear:

Worn control arm bushings, tie rod ends, and shock absorbers are typical wear items that affect handling and ride comfort.

Fuel Pump:

In-tank fuel pumps can become weak or fail entirely, leading to starting issues or power loss.

Heater Control Valve:

Common failure point in the HVAC system, leading to no heat or inconsistent temperature control.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's reputation for 'The Ultimate Driving Machine' is deeply ingrained in the E34's design, focusing on driver engagement, handling, and performance.

Model Evolution

E34 Generation:

The E34 generation (1987-1996) replaced the E28 and was known for its significant advancements in aerodynamics, technology, and refinement. The 520i represented the entry-level six-cylinder offering in many markets.

Design Influence:

Designed by Joji Nagashima, the E34 featured a cleaner, more aerodynamic profile than its predecessor, incorporating BMW's signature Hofmeister kink and kidney grille.

Production

Production Period:

1987-1996 (E34 generation). This manual specifically covers the 1988-1991 model years.

Manufacturing Locations:

Primarily manufactured in Germany (Dingolfing).

🏆 Awards & Recognition

Recognitions

Automotive Press Awards:

The E34 generation consistently received positive reviews from automotive journalists for its driving dynamics, build quality, and refinement, often cited as a benchmark in its class.

Industry Rankings:

Frequently appeared on 'best of' lists for executive sedans of its era.

Certifications

Safety Standard Compliance:

Designed and manufactured to meet all applicable safety and emissions standards for its respective markets during the production period.