BMW 520 520i 1990 Best Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 520i Model Code: E34 Production Year: 1990 Codes Engine Code Primary: M20B20 Chassis Code: E34 👋 Introduction Market Position Segment: Executive Mid-size Sedan Target Audience: Professionals, families seeking luxury, performance, and build quality. Competitive Analysis Key Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6, Lexus LS 400 (late model). Key Features Vehicle Design Philosophy: BMW's hallmark of 'The Ultimate Driving Machine', emphasizing driver engagement, balanced chassis, and refined engineering. Innovation: E34 represented a significant step in BMW's design language, offering improved aerodynamics and a more modern interior compared to its E28 predecessor. Key Features Manual Value Proposition: Provides authorized repair procedures, specifications, and diagnostic information essential for maintaining and repairing the 1990 BMW 520i, ensuring accuracy and efficiency. 📋 Manual Details Coverage Areas Primary Coverage: BMW 520i (E34) 1990 Model Year Engine Coverage: 2.0L Inline-6 Cylinder (M20B20) Transmission Coverage: Manual and Automatic Transmissions Page Count Estimated Pages: Hundreds (as indicated in description) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, cooling system, lubrication system, fuel delivery (including fuel injection), ignition system, exhaust system. Transmission And Drivetrain: Manual gearbox, automatic transmission (ZF 4HP22 or similar), clutch, driveshafts, differential, axle shafts. Chassis And Suspension: Front suspension (MacPherson struts), rear suspension (multi-link semi-trailing arm), steering system, brakes (front discs, rear discs), ABS (if equipped). Electrical System: Wiring diagrams, starter, alternator, battery, lighting, instrument cluster, power windows, central locking, engine control unit (ECU) diagnostics, fuse box. Body And Interior: Body panel removal and installation, door mechanisms, interior trim, seats, climate control system (HVAC), sound insulation. Procedures Included Maintenance: Scheduled maintenance, oil change, filter replacement, spark plug replacement, brake fluid flush, coolant replacement, belt inspection and replacement. Diagnostics And...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Code:

Production Year:

Codes

Engine Code Primary:

M20B20

Chassis Code:

👋 Introduction

Market Position

Segment:

Executive Mid-size Sedan

Target Audience:

Professionals, families seeking luxury, performance, and build quality.

Competitive Analysis

Key Competitors:

Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6, Lexus LS 400 (late model).

Key Features Vehicle

Design Philosophy:

BMW's hallmark of 'The Ultimate Driving Machine', emphasizing driver engagement, balanced chassis, and refined engineering.

Innovation:

E34 represented a significant step in BMW's design language, offering improved aerodynamics and a more modern interior compared to its E28 predecessor.

Key Features Manual

Value Proposition:

Provides authorized repair procedures, specifications, and diagnostic information essential for maintaining and repairing the 1990 BMW 520i, ensuring accuracy and efficiency.

📋 Manual Details

Coverage Areas

Primary Coverage:

BMW 520i (E34) 1990 Model Year

Engine Coverage:

2.0L Inline-6 Cylinder (M20B20)

Transmission Coverage:

Manual and Automatic Transmissions

Page Count

Estimated Pages:

Hundreds (as indicated in description)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, cooling system, lubrication system, fuel delivery (including fuel injection), ignition system, exhaust system.

Transmission And Drivetrain:

Manual gearbox, automatic transmission (ZF 4HP22 or similar), clutch, driveshafts, differential, axle shafts.

Chassis And Suspension:

Front suspension (MacPherson struts), rear suspension (multi-link semi-trailing arm), steering system, brakes (front discs, rear discs), ABS (if equipped).

Electrical System:

Wiring diagrams, starter, alternator, battery, lighting, instrument cluster, power windows, central locking, engine control unit (ECU) diagnostics, fuse box.

Body And Interior:

Body panel removal and installation, door mechanisms, interior trim, seats, climate control system (HVAC), sound insulation.

Procedures Included

Maintenance:

Scheduled maintenance, oil change, filter replacement, spark plug replacement, brake fluid flush, coolant replacement, belt inspection and replacement.

Diagnostics And Troubleshooting:

Systematic troubleshooting guides for common issues, diagnostic trouble codes (DTCs) for engine management, electrical fault finding.

Repair And Rebuild:

Detailed instructions for component disassembly, repair, and reassembly of engine, transmission, suspension, braking, and electrical systems.

Technical Specifications:

Torque specifications for critical fasteners, engine timing procedures, valve clearance adjustments (if applicable to M20), fluid capacities and types.

Technical Depth

Depth:

Comprehensive, covering routine maintenance to full engine and transmission overhauls, including electrical system diagnostics and wiring diagrams.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text-based PDF, allowing for quick information retrieval.

Print Quality

Quality:

Official factory documentation, typically high-resolution scans with clear diagrams and text.

Binding Type

Binding:

N/A (Downloadable PDF)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 6-Cylinder, Naturally Aspirated

Engine Code:

M20B20

Displacement:

1990 cc (2.0 Liters)

Bore X Stroke:

80.0 mm x 66.0 mm

Compression Ratio:

8.8:1 or 9.4:1 (depending on market/variant)

Performance

Horsepower:

129 hp @ 6000 rpm (approx.)

Torque:

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

Fuel System

Induction:

Bosch Motronic electronic fuel injection

Fuel Type:

Unleaded Gasoline (RON 91 or higher recommended)

Fuel Pump Pressure:

3.0 - 3.5 bar (specified in manual)

Cooling System

Coolant Type:

BMW Antifreeze/Coolant (e.g., G48 ethylene glycol based) or equivalent, 50/50 mix with distilled water.

Coolant Capacity:

Approx. 10.0 liters

Ignition System

Spark Plugs:

NGK BPR6ES or equivalent (specified in manual)

Ignition Timing:

Base timing typically 2° BTDC at idle (ECU controlled, adjust via diagnostic tool or specific procedure if applicable).

🔧 Transmission

Standard

Type Standard:

5-speed Manual Transmission

Optional

Type Optional:

4-speed Automatic Transmission (ZF 4HP22 or similar)

Features

Clutch Type:

Hydraulically actuated single-plate dry clutch

Manual Fluid Type:

BMW MTF LT-2 or Dexron III equivalent (check manual for exact specification).

Automatic Fluid Type:

Dexron III ATF (Automatic Transmission Fluid) or BMW approved equivalent.

Automatic Fluid Capacity:

Approx. 1.5 liters (drain and fill), higher for full overhaul.

Differential Fluid Type:

API GL-5, SAE 75W-90 or 80W-90 hypoid gear oil.

📐 Dimensions

Exterior

Length:

4730 mm (186.2 in)

Width:

1751 mm (68.9 in)

Height:

1410 mm (55.5 in)

Wheelbase:

2799 mm (110.2 in)

Weights

Curb Weight:

Approx. 1450-1550 kg (depending on equipment)

Gross Vehicle Weight Rating:

Approx. 2000 kg (specified in manual)

Wheels Tires

Wheel Bolt Pattern:

5x120 mm

Standard Tire Size:

205/65 VR 15 or 225/55 VR 15 (depending on market/options)

🛡️ Safety Features

Ratings

Crash Test Data:

While specific NHTSA/Euro NCAP ratings for this exact 1990 model may be limited, the E34 platform was known for its robust safety cage construction and engineered crumple zones.

Active Features

Anti-lock Braking System (optional or standard depending on market).

Traction Control:

ASC (Automatic Stability Control) or ASC+T (Traction Control) available on some models, though less common on the 520i base engine.

Passive Features

Airbags:

Driver airbag typically optional for 1990; passenger airbag became available later in the E34 lifecycle.

Seatbelts:

Three-point inertia-reel seatbelts for all occupants; front seatbelt pretensioners may be present.

Chassis Design:

Reinforced passenger cell, energy-absorbing steering column, door impact beams.

💡 Technology Features

Infotainment

Audio System:

Factory cassette player with AM/FM radio, often with amplifier and equalizer options. CD changers were optional.

On Board Computer:

Optional On-Board Computer (OBC) displaying fuel economy, range, exterior temperature, and basic diagnostics.

Driver Assistance

Cruise Control:

Standard or optional cruise control system.

Connectivity

No Modern Connectivity:

No integrated Bluetooth, USB, or Wi-Fi connectivity typical of modern vehicles. External aux input adapters or aftermarket head units are common upgrades.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 - 15,000 km or 12 months, whichever comes first (refer to manual for precise BMW recommendation for this year).

Coolant Flush Interval:

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

Brake Fluid Flush Interval:

Every 2 years, regardless of mileage.

Spark Plug Replacement:

Every 30,000 - 50,000 km for standard plugs (check manual for exact spec).

Fluid Specifications

Engine Oil Type Viscosity:

BMW High Performance Synthetic SAE 5W-30 or 5W-40 (e.g., Castrol GTX or BMW branded oil). Manual will specify approved oils.

Engine Oil Capacity:

Approx. 4.25 liters (without filter), 4.5 liters (with filter).

Known Issues

Cooling System Weaknesses:

Plastic coolant expansion tanks can become brittle and crack; water pump impellers can degrade.

Fuel System Issues:

Failing fuel pump, clogged fuel injectors, or deteriorating fuel lines can occur with age.

Electrical System Issues:

Wire harness degradation (especially around the engine bay), corroded grounds, failure of OBC (On-Board Computer) or instrument cluster components.

Suspension Wear:

Worn control arm bushings, ball joints, and rear trailing arm bushings are common due to age and mileage.

Interior Wear:

Seat bolster wear, sagging headliner, and aging interior plastics are common signs of age.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW, Bayerische Motoren Werke AG, has a long history of producing performance-oriented luxury vehicles, renowned for engineering prowess and driving dynamics.

Model Evolution

E34 Introduction:

The E34 generation of the 5 Series debuted in 1987 (for the 1988 model year) and succeeded the E28. It was a significant evolution in design, technology, and performance.

E34 Lifecyle:

The E34 was produced from 1987 to 1996 (sedan) and 1991 to 1996 (touring), with a facelift in 1994. The 1990 model falls within the early production phase.

Production

Manufacturing Locations:

Primarily Dingolfing, Germany, with potential assembly in other locations like South Africa and Mexico.

🏆 Awards & Recognition

Recognitions

General Recognition:

The E34 generation was widely praised by automotive journalists for its driving dynamics, build quality, and comfort, solidifying BMW's reputation in the executive sedan segment.

Ratings

Performance Ratings:

Consistently ranked among the best-handling sedans of its era.

Certifications

Quality Certification:

Represents BMW's commitment to German engineering and manufacturing standards.