Bmw 520i 525i 535i 1988 1989 1990 1991 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E34 Generation Generation Designation: Second Generation (E34) Codes Specific Models Covered: 520i, 525i, 535i Model Years Covered: 1988, 1989, 1990, 1991 👋 Introduction Market Position Market Segment: Executive/Luxury Sedan Era: Late 1980s / Early 1990s Premium European Sedan Competitive Analysis Key Competitors: Mercedes-Benz W124 E-Class, Audi V8 Quattro, Lexus LS 400 (late in the generation's life) Key Features Driving Dynamics: Renowned for its balanced handling, rear-wheel drive bias, and driver-focused cockpit Build Quality: Exceptional build quality and longevity, characteristic of BMW's engineering prowess Design Philosophy: Understated elegance, aerodynamic efficiency, and functional interior design 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service and Repair Page Count Estimated Pages: Approximately 1500-2000 (typical for a complete E34 service manual set) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF/eBook) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, timing, valve adjustments, piston/ring replacement, crankshaft/bearing service, cylinder head reconditioning Engine Management: Bosch Motronic (M1.3/M2.1/M2.5/M2.7) fuel injection and ignition systems, sensor diagnostics, ECU troubleshooting, idle control, emissions control Transmission Manual: S3.10/S3.26/S3.71/S3.90 gearboxes: clutch, gearbox overhaul, gear shift mechanisms, differential service Transmission Automatic: ZF 4HP22/4HP24 automatic transmissions: fluid changes, valve body diagnosis, torque converter, gearbox rebuild procedures Suspension: Front strut assemblies, rear multi-link suspension, springs, shock absorbers, control arms, sway bars, power steering system Brakes: Front vented discs, rear solid discs (or vented on some 535i), ABS (Anti-lock Braking System) diagnosis and repair, brake fluid flushing, caliper and master cylinder service Electrical System: Complete wiring diagrams, fuse box layout, relay functions, battery and charging system, starter, alternator, lighting systems, horn, wipers, power windows/locks/seats Body And Chassis: Body panel repair, door mechanisms, hood/trunk operation, interior trim, underbody protection, rust prevention HVAC: Climate control system, A/C compressor, refrigerant system,...

Tipo: Car

Proveedor:

SKU: 586281

Colecciones: ALL BMW

Etiquetas: BMW Misc

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Generation

Generation Designation:

Second Generation (E34)

Codes

Specific Models Covered:

520i, 525i, 535i

Model Years Covered:

1988, 1989, 1990, 1991

👋 Introduction

Market Position

Market Segment:

Executive/Luxury Sedan

Late 1980s / Early 1990s Premium European Sedan

Competitive Analysis

Key Competitors:

Mercedes-Benz W124 E-Class, Audi V8 Quattro, Lexus LS 400 (late in the generation's life)

Key Features

Driving Dynamics:

Renowned for its balanced handling, rear-wheel drive bias, and driver-focused cockpit

Build Quality:

Exceptional build quality and longevity, characteristic of BMW's engineering prowess

Design Philosophy:

Understated elegance, aerodynamic efficiency, and functional interior design

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive Service and Repair

Page Count

Estimated Pages:

Approximately 1500-2000 (typical for a complete E34 service manual set)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF/eBook)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, timing, valve adjustments, piston/ring replacement, crankshaft/bearing service, cylinder head reconditioning

Engine Management:

Bosch Motronic (M1.3/M2.1/M2.5/M2.7) fuel injection and ignition systems, sensor diagnostics, ECU troubleshooting, idle control, emissions control

Transmission Manual:

S3.10/S3.26/S3.71/S3.90 gearboxes: clutch, gearbox overhaul, gear shift mechanisms, differential service

Transmission Automatic:

ZF 4HP22/4HP24 automatic transmissions: fluid changes, valve body diagnosis, torque converter, gearbox rebuild procedures

Suspension:

Front strut assemblies, rear multi-link suspension, springs, shock absorbers, control arms, sway bars, power steering system

Brakes:

Front vented discs, rear solid discs (or vented on some 535i), ABS (Anti-lock Braking System) diagnosis and repair, brake fluid flushing, caliper and master cylinder service

Electrical System:

Complete wiring diagrams, fuse box layout, relay functions, battery and charging system, starter, alternator, lighting systems, horn, wipers, power windows/locks/seats

Body And Chassis:

Body panel repair, door mechanisms, hood/trunk operation, interior trim, underbody protection, rust prevention

HVAC:

Climate control system, A/C compressor, refrigerant system, heater core, blower motor, control panels

Fuel System:

Fuel pump, fuel filter, fuel injectors, fuel tank, fuel pressure regulator, EVAP system

Exhaust System:

Catalytic converter, muffler, exhaust pipes, oxygen sensors

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, coolant flushes, brake fluid service, spark plug replacement, belt inspection/replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, fault code interpretation (where applicable)

Repair Procedures:

Step-by-step repair instructions for all major components and systems

Diagnostic Procedures:

Engine timing checks, compression tests, fuel pressure testing, electrical system diagnostics

Alignment And Balancing:

Wheel alignment specifications and procedures, wheel balancing

Component Replacement:

Detailed instructions for replacing common wear items and major assemblies

Technical Depth

Depth:

Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts

Diagnostic Capabilities:

Extensive, including electrical schematics and diagnostic trees

Rebuild Specifications:

Includes critical torque specifications, clearances, and tolerances for engine and transmission rebuilds

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Searchability:

Full text search functionality for quick information retrieval

Print Quality

Readability:

High-resolution scans ensuring clear text and diagrams

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

520I Engine:

M50B20 (2.0L Inline-6)

525I Engine:

M50B25 (2.5L Inline-6)

535I Engine:

M30B35 (3.5L Inline-6)

Performance

520I Horsepower:

150 PS (148 hp; 110 kW) @ 6000 rpm (M50)

525I Horsepower:

192 PS (189 hp; 141 kW) @ 5800 rpm (M50)

535I Horsepower:

208 PS (205 hp; 153 kW) @ 5700 rpm (M30)

520I Torque:

190 Nm (140 lb-ft) @ 4300 rpm (M50)

525I Torque:

245 Nm (181 lb-ft) @ 4200 rpm (M50)

535I Torque:

305 Nm (225 lb-ft) @ 4000 rpm (M30)

Fuel System

Fuel Injection System:

Bosch Motronic Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (RON 95 / 98 recommended)

Engine Design

Configuration:

Inline 6-cylinder, DOHC (M50) or SOHC (M30)

Bore X Stroke 520I:

80.0 mm x 66.0 mm (M50B20)

Bore X Stroke 525I:

84.0 mm x 75.0 mm (M50B25)

Bore X Stroke 535I:

92.0 mm x 86.0 mm (M30B35)

Compression Ratio 520I:

8.8:1 (M50B20)

Compression Ratio 525I:

10.0:1 (M50B25)

Compression Ratio 535I:

8.0:1 (M30B35)

🔧 Transmission

Standard

520I Transmission:

5-speed Manual (Getrag 260/5, later possibly Getrag 260/6 on some markets)

525I Transmission:

5-speed Manual (Getrag 260/5 or Getrag 260/6)

Optional

Optional Transmission:

4-speed Automatic (ZF 4HP22 or ZF 4HP24)

Features

Manual Gear Ratios 525I Example:

1st: 4.215, 2nd: 2.195, 3rd: 1.421, 4th: 1.000, 5th: 0.812 (approximate, varies by specific gearbox)

Automatic Features:

Electronic control (later models), sport mode (selector lever).

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-2 (or equivalent API GL-4 75W-90 gear oil)

Automatic Transmission Fluid:

BMW ATF LT 71141 (or equivalent Dexron III/Mercon equivalent)

📐 Dimensions

Exterior

Length:

Approx. 4710-4720 mm (185.4-185.8 in)

Width:

Approx. 1750 mm (68.9 in)

Height:

Approx. 1410-1420 mm (55.5-55.9 in)

Wheelbase:

Approx. 2790-2830 mm (109.8-111.4 in)

Weights

Curb Weight 520I:

Approx. 1400-1500 kg (3086-3307 lbs)

Curb Weight 525I:

Approx. 1450-1550 kg (3197-3417 lbs)

Curb Weight 535I:

Approx. 1550-1650 kg (3417-3638 lbs)

Cargo

Trunk Volume:

Approx. 460-500 liters (16.2-17.7 cu ft)

🛡️ Safety Features

Ratings

Era Specific Ratings:

Modern crash test data is limited for this era; relied on passive safety features of the time.

Active Features

Standard on most models, optional on early E34s

Traction Control:

Optional (ASC/ASC+T on later models)

Passive Features

Airbags:

Driver's airbag standard from 1990 onwards, passenger airbag optional.

Seatbelts:

Front and rear seat belts with pretensioners for front occupants

Body Structure:

Reinforced safety cage, crumple zones, side impact protection beams

💡 Technology Features

Infotainment

Audio System:

Original BMW cassette player (e.g., Bavaria C Business/Professional) with optional CD changer; speaker systems varied by trim.

Climate Control:

Manual climate control or optional automatic climate control (ECC - Electronic Climate Control) with cabin air filter.

Driver Assistance

Cruise Control:

Optional cruise control system.

Park Assist:

Rear park distance control (PDC) introduced later in the E34's lifecycle, but not common in early models.

Connectivity

Phone Integration:

Optional integrated car phone systems were available on some higher-spec models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 - 10,000 miles (12,000 - 15,000 km) or annually, whichever comes first (depending on driving conditions and oil used).

Spark Plug Replacement:

Approx. 30,000 miles (48,000 km) for standard spark plugs; longer for platinum/iridium plugs (if applicable in later production).

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km).

Brake Fluid Flush:

Every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil Capacity 520I 525I:

Approx. 5.7 - 6.0 liters (6.0 - 6.3 US qt) with filter (M50 engine)

Engine Oil Capacity 535I:

Approx. 6.5 liters (6.9 US qt) with filter (M30 engine)

Engine Oil Viscosity Recommendation:

SAE 15W-40 or 10W-40 (depending on climate); 5W-30/5W-40 for colder regions.

Coolant:

BMW Blue Antifreeze (G48 ethylene glycol based) or equivalent, mixed 50/50 with distilled water.

Known Issues

Cooling System Weaknesses:

Plastic coolant expansion tanks can become brittle and crack; water pump impeller can degrade (especially earlier M30 engines).

Vanos Issues M50:

Variable valve timing (VANOS) system can develop issues with solenoids or seals leading to rough idle or loss of power (on later M50 engines).

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and front/rear main seals are common sources of leaks due to age and material degradation.

Suspension Wear:

Control arm bushings, ball joints, and tie rod ends are common wear items that can lead to alignment issues and poor handling.

Electrical Gremlins:

aging wiring harness, faulty relays, and corroded connectors can lead to intermittent electrical issues.

📚 Vehicle History

Brand Heritage

Bmw Heritage:

BMW's long-standing reputation for building driver-oriented, high-quality automobiles with a focus on performance and engineering.

Model Evolution

E34 Introduction:

Introduced in 1987 (as a 1988 model year in North America), the E34 was the successor to the E28 5 Series.

E34 Design Highlights:

Designed by Ercole Spada, it featured a more aerodynamic and refined design compared to its predecessor, with a smoother silhouette and integrated bumpers.

E34 Engine Lineup Evolution:

Initial models used the M20 and M30 engines, with the introduction of the advanced M50 DOHC inline-six engine for the 520i and 525i in 1990.

Production

Production Years:

1987-1996 (globally)

Production Facelift:

Minor facelift in 1993 (e.g., new kidney grille, updated bumpers, side skirts).

🏆 Awards & Recognition

Recognitions

Car And Driver 5Best Tvs:

The E34 5 Series was a frequent recipient of Car and Driver's 10Best awards during its production run for its excellent driving dynamics and overall competence.

Ratings

Automotive Journalism Reviews:

Consistently praised by automotive journalists for its sophisticated chassis, powerful engines, and luxurious interior.