🏷️ Basic Information Identification Make: BMW Model: 5-Series Chassis Code: E34 Engine Variant: 520i Model Years Covered: 1990, 1991 Codes Engine Code Typical: M50B20 👋 Introduction Market Position Era: Late 1980s / Early 1990s executive sedan Segment: Mid-size Luxury Sedan Competitive Analysis Competitors: Mercedes-Benz W124 E-Class, Audi V8 Quattro, Jaguar XJ. Key Features Design Philosophy: Focus on driver engagement, build quality, and refined performance. Powertrain Development: Introduction of BMW's M50 engine series, known for its smoothness and power delivery. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Scope: Complete Official Factory Service Manual Page Count Estimated Pages: Over 1000 (typical for factory manuals of this era) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, disassembly, assembly, lubrication, cooling, fuel delivery, exhaust. Engine Management: Engine Control Unit (ECU) diagnosis, sensor testing, ignition system, emissions control. Transmission: Manual and Automatic transmission diagnosis, repair, overhaul, fluid changes. Drivetrain: Driveshafts, differential, clutch (manual), axles, wheel bearings. Brakes: Hydraulic system, ABS (if equipped), calipers, rotors, lines, bleeding procedures. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment. Steering: Power steering system, steering rack, pump, linkages, alignment. Electrical System: Battery, charging system, starter, lighting, wiring diagrams, fuses, relays, control modules. Body And Chassis: Body panels, doors, hinges, locks, glass, interior trim, structural components. Heating And Air Conditioning: HVAC system operation, components, refrigerant handling, diagnosis. Wheels And Tires: Specifications, installation, balancing. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plugs, fluid checks, belt inspections. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for all major systems. Repair Procedures: Step-by-step instructions for component replacement and repair across all systems. Disassembly And Assembly: Detailed procedures for major component removal and reinstallation. Electrical Diagnostics: Wiring diagrams, pinouts, component testing, voltage checks. Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds. Diagnostics: Includes diagnostic trouble codes (DTCs) and procedures for the era's ECUs. Special Tools: Lists and describes necessary special tools for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if properly OCR'd Print Quality Quality: High resolution, clear diagrams and text Binding Type Binding: N/A (Digital format) Paper Type Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, DOHC, 24 valves Displacement: 1990 cc (2.0 Liters) Bore X Stroke: 80.0 mm x 66.0 mm Performance Horsepower: Approx. 150 PS (148 bhp) @ 5,600 rpm Torque: Approx. 190 Nm (140 lb-ft) @ 4,700 rpm Fuel System Fuel Injection: Bosch Motronic electronic fuel injection Fuel Type: Unleaded gasoline Engine Management Engine Control: Motronic M3.1 or similar 🔧 Transmission Standard Type: 5-speed Manual Optional Type: 4-speed Automatic (ZF 4HP22 or similar) Features Clutch: Hydraulically actuated single dry plate Fluid Specifications Manual Gearbox Oil: GL-4 or GL-5, SAE 75W-90 (check specific manual) Automatic Transmission Fluid: Dexron III (or equivalent) 📐 Dimensions Exterior Length: Approx. 4720 mm (185.8 inches) Width: Approx. 1751 mm (68.9 inches) Height: Approx. 1410 mm (55.5 inches) Wheelbase: Approx. 2760 mm (108.7 inches) Weights Curb Weight: Approx. 1450-1550 kg (3197-3417 lbs) depending on transmission and options 🛡️ Safety Features Ratings Crash Testing Era: Tested under European standards of the time (e.g., Euro NCAP precursors, ADAC) Active Features ABS: Anti-lock Braking System (optional or standard depending on market/build date) Traction Control: ASR (Automatic Stability Control) was available on later models but less common on early E34 520i. Passive Features Airbags: Driver's side airbag became standard in the E34 series, passenger airbag often optional. Seatbelts: Three-point inertia-reel seatbelts, pre-tensioners available on some models. 💡 Technology Features Infotainment Head Unit: Factory AM/FM cassette radio, optional CD player. Speakers: Various configurations, often with door-mounted speakers and rear parcel shelf speakers. Driver Assistance Cruise Control: Standard or optional electronic cruise control. Parking Sensors: Not available on this generation. Connectivity Phone Integration: No native smartphone integration; Bluetooth was not a factory option. Climate Control System: Manual or optional automatic climate control (ECC - Electronic Climate Control). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000-15,000 km or 6-12 months (dependent on driving conditions and oil type used). Spark Plug Replacement: Every 20,000-30,000 km (for platinum tipped plugs, older recommendations may vary). Coolant Flush: Every 2-3 years or 40,000-60,000 km. Fluid Specifications Engine Oil Type: API SJ/SL or higher, SAE 5W-30 or 5W-40 recommended (refer to manual for precise grade). Engine Oil Capacity: Approx. 5.5 Liters (5.8 US Quarts) with filter change. Coolant Type: BMW Blue or G48 ethylene glycol coolant concentrate mixed with distilled water (50/50 ratio). Brake Fluid Type: DOT 4 Known Issues Cooling System: Plastic coolant expansion tanks and pipes are prone to cracking with age; water pump failures. Engine M50: VANOS (Variable Valve Timing) unit can develop issues leading to rough idle or loss of power; valve cover gasket...