🏷️ Basic Information Identification Make: BMW Model: 520i Year: 1991 Codes Chassis Code: E34 Engine Code Typical: M20B20 (though M50B20 became available in later 520i E34 models, the '91 often refers to the M20 for this specific variant) 👋 Introduction Market Position Market Position: The BMW 520i (E34) in 1991 represented BMW's mid-size executive sedan offering, known for its blend of comfort, performance, and luxury, competing against rivals like the Mercedes-Benz W124 E-Class and Audi 100. Competitive Analysis Competitive Analysis: The E34 generation was lauded for its sophisticated chassis, rear-wheel-drive dynamics, and build quality, positioning the 520i as a premium, driver-focused option in its segment. Key Features Key Features: Luxurious interior, refined ride quality, capable handling, iconic BMW design language, and the promise of long-term durability. Chassis And Suspension: Advanced multi-link rear suspension and independent front suspension for superior ride and handling characteristics. 📋 Manual Details Coverage Areas Coverage Areas: All Models/Engines/Trim/Transmissions Types for 1991 BMW 520i (E34) Specific Engine Variants: Covers the 2.0L M20B20 engine, and may include diagnostic information relevant to other E34 models if shared systems exist. Page Count Page Count: Estimated 1000+ pages (typical for comprehensive workshop manuals) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical, Engine Fuel & Emissions, Engine Lubrication & Cooling, Engine Electrical, Ignition System, Clutch, Manual Transmission, Automatic Transmission, Driveshaft & Axles, Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Wheels & Tires, Body (Interior & Exterior), Heating & Air Conditioning (HVAC), Electrical System (Wiring Diagrams, Components), Lighting System, Instrumentation & Information System, Body Control Modules, Safety Systems (ABS if equipped), Diagnostic Procedures Body Electrical: Comprehensive wiring diagrams for all circuits, including lighting, power windows, central locking, mirrors, wipers, and instrument cluster. Climate Control: HVAC system operation, refrigerant handling (R12 for this era), blower motor, evaporator, condenser, and heater core service. Procedures Included Procedures Included: Routine Maintenance, Scheduled Service, Troubleshooting Guides, Diagnostic Flowcharts, Step-by-Step Repair Procedures, Overhaul Instructions, Component Removal & Installation, Torque Specifications, Alignment Procedures, Electrical Component Testing, Wiring Harness Repair, Body Panel Repair & Replacement, HVAC System Servicing, Safety System Diagnostics Troubleshooting Diagnostics: Detailed diagnostic flowcharts for common problems, fault code interpretation (OBD-I), and component testing procedures. Wheel Alignment Specs: Provides camber, caster, and toe specifications for both front and rear axles, along with adjustment procedures. Technical Depth Technical Depth: Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork procedures. Engine Rebuild Procedures: Detailed instructions for cylinder head removal/installation, piston and connecting rod replacement, crankshaft and bearing services, and complete engine teardown/assembly. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes (typical for high-quality PDF manuals) Print Quality Print Quality: High Resolution (suitable for printing) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Primary Engine: 2.0L Inline-6 (M20B20) Performance Horsepower: Approx. 129 hp @ 5,800 rpm Torque: Approx. 174 Nm (128 lb-ft) @ 4,300 rpm Fuel System Fuel System: Bosch Motronic fuel injection Fuel Pump Type: Electric, in-tank Engine Details Bore X Stroke: 80.0 mm x 66.0 mm Compression Ratio: 8.8:1 Valvetrain: SOHC, 12 Valves Displacement: 1990 cc (2.0 Liters) Cooling System Cooling System: Pressurized, glycol-based coolant system with engine-driven water pump and thermostatically controlled radiator. Ignition System Ignition System: Electronic ignition (Bosch Motronic) with distributor and ignition coil. Engine Code Engine Code: M20B20 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic (e.g., ZF 4HP-22) Features Rear Axle Ratio: Typically around 3.46:1 (varies by transmission and region) Gear Ratios Manual Gear Ratios Manual: 1st: 4.00:1, 2nd: 2.15:1, 3rd: 1.43:1, 4th: 1.00:1, 5th: 0.81:1 (Typical for Getrag 260 gearbox) 📐 Dimensions Exterior Length: Approx. 4,730 mm (186.2 in) Width: Approx. 1,751 mm (68.9 in) Height: Approx. 1,410 mm (55.5 in) Wheelbase: Approx. 2,760 mm (108.7 in) Front Overhang: Approx. 860 mm (33.9 in) Rear Overhang: Approx. 1,110 mm (43.7 in) Weights Curb Weight: Approx. 1,470 kg (3,240 lbs) for manual transmission Gross Vehicle Weight Rating: Approximately 1,950 kg (4,300 lbs) Front Axle Load: Approximately 950 kg (2,094 lbs) Rear Axle Load: Approximately 1,000 kg (2,205 lbs) Interior Seating Capacity: 5 🛡️ Safety Features Ratings Safety Ratings: No standardized crash test ratings equivalent to modern NHTSA/Euro NCAP available for this era, but known for robust construction. Active Features Active Features: Optional Anti-lock Braking System (ABS) Traction Control: Not typically available on the 520i of this year; later models and higher trims featured ASC/ASC+T. Passive Features Passive Features: Reinforced chassis, crumple zones, driver's side airbag (often optional or part of specific packages), seat belts 💡 Technology Features Infotainment Infotainment: Basic AM/FM radio with cassette player, optional CD player, analog climate controls. Driver Assistance Driver Assistance: Optional cruise control, optional ABS. Connectivity Connectivity:...