🏷️ Basic Information Identification Make: BMW Model: 520i Model Code: E34 Product Name: BMW 520i Complete Workshop Service Repair Manual 1988 1989 1990 1991 Codes Engine Code Identifier: M20B20 (early models) / M50B20 (later models) 👋 Introduction Market Position Market Position: Mid-size luxury sedan, known for its blend of performance, comfort, and build quality in its era. Competitive Analysis Key Competitors: Mercedes-Benz E-Class (W124), Audi 100 (C3/C4), Lexus ES250/ES300 Key Features Design Philosophy: Classic BMW design cues, driver-oriented cockpit, focus on handling dynamics. Target Audience: Discerning drivers seeking a sophisticated, reliable, and engaging driving experience. 📋 Manual Details Coverage Areas Coverage Years: 1988, 1989, 1990, 1991 Covered Models: BMW 520i (E34 chassis) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection (Bosch Motronic), ignition system, cooling system, exhaust system, engine management diagnostics Transmission Systems: Manual transmission (Getrag 260), Automatic transmission (ZF 4HP22), clutch system, driveline Chassis Systems: Suspension (front strut, rear multi-link), steering system (power steering), braking system (ABS equipped models), wheels and tires Electrical Systems: Wiring diagrams, lighting system, charging system (alternator, battery), starter motor, instrument cluster, ECUs, comfort electronics Body And Interior: Body panels, doors, windows, seats, trim, HVAC system (climate control), sunroof Procedures Included Routine Maintenance: Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid replacement, belt inspection/replacement Repair And Overhaul: Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, steering rack repair Diagnostics And Troubleshooting: Fault code retrieval (OBD I for M20, OBD II readiness for early M50), symptom-based troubleshooting guides, wiring diagram analysis Installation And Replacement: Component replacement procedures for major systems, torque specifications for critical fasteners Technical Depth Depth Of Coverage: Comprehensive, from basic fluid checks to complete engine and transmission rebuilds 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text content Print Quality Print Quality: High-resolution scans, suitable for printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, DOHC Displacement: 2.0 Liters (1990cc) Bore X Stroke: 80.0 mm x 66.0 mm Compression Ratio: 8.8:1 (M20) / 8.8:1 or 10.0:1 (M50) Performance Horsepower M20: 129 hp @ 5800 rpm Torque M20: 174 Nm (129 lb-ft) @ 4300 rpm Horsepower M50: 150 hp @ 5600 rpm (early M50B20) Torque M50: 190 Nm (140 lb-ft) @ 4300 rpm (early M50B20) Fuel System Fuel Delivery: Bosch Motronic fuel injection Fuel Type: Unleaded gasoline (95 RON recommended) 🔧 Transmission Standard Standard Transmission: 5-speed manual (Getrag 260) Optional Optional Transmission: 4-speed automatic (ZF 4HP22) Features Transmission Fluid Type Manual: BMW MTF LT-2 or equivalent (e.g., Pentosin MTF 2) Transmission Fluid Type Auto: Dexron III or Dexron VI (check specific vehicle) 📐 Dimensions Exterior Length: 4711 mm (185.5 in) Width: 1751 mm (68.9 in) Height: 1410 mm (55.5 in) Wheelbase: 2795 mm (110.0 in) Weights Curb Weight: Approx. 1500-1580 kg (3307-3483 lbs) Gross Vehicle Weight Rating: Approx. 2000 kg (4409 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: No standardized ratings like NHTSA/Euro NCAP for this era, but generally considered safe for its time. Active Features ABS: Available on most models, especially later production. Traction Control: Optional on some models (ASC/ASC+T) Passive Features Airbags: Driver airbag standard, passenger airbag optional or introduced later in the run. Seatbelts: Three-point inertia-reel seatbelts 💡 Technology Features Infotainment Infotainment System: Basic analog radio/cassette system. Optional CD player or upgraded sound systems available. Driver Assistance Driver Assistance Features: Primarily focused on driving dynamics. Features like ABS and optional traction control are the main electronic aids. Connectivity Connectivity Options: No integrated Bluetooth or modern connectivity. Aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500 - 10,000 miles (12,000 - 15,000 km) or annually. Check oil level frequently. Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on conditions. Spark Plug Replacement M20: Approx. 30,000 miles (48,000 km) Spark Plug Replacement M50: Approx. 60,000 miles (96,000 km) for twin-electrode plugs Fluid Specifications Engine Oil Type: Synthetic 5W-30, 5W-40, or 10W-40 depending on climate and manufacturer recommendation (e.g., BMW High Performance SAE 5W-40) Engine Oil Capacity: Approx. 4.25 - 4.5 Liters (with filter) Coolant Type: BMW Blue Antifreeze/Coolant or equivalent G48 ethylene glycol based coolant Brake Fluid Type: DOT 4 Known Issues Common Issues: Head gasket leaks (M20), cooling system leaks (hoses, water pump), VANOS issues (M50 - though less common on the 2.0L), idle control valve problems, door seal degradation, window regulator failures, seized sunroof motors. Maintenance Considerations: Regular inspection of rubber hoses and seals is crucial due to age. Timing belt replacement (if applicable to specific variant/engine) is critical. ABS sensor cleaning and checking can resolve common ABS light issues. 📚 Vehicle...