BMW 520 520i 1988-1991 Best Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 520 / 520i Codes Chassis Code: E34 Engine Code 520I: M20B20 👋 Introduction Market Position Segment: Executive/Luxury Mid-size Sedan Competitive Analysis Key Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, Lexus LS (later in production). Key Features Vehicle Philosophy: Known for its driver-focused dynamics, build quality, and refined engineering. Manual Advantage: Essential for owners and independent mechanics to maintain the complex systems of these advanced vehicles. 📋 Manual Details Coverage Areas Countries Covered: Global (with focus on European markets where E34 was prevalent) Page Count Estimated Pages: 500-800 (typical for comprehensive BMW service manuals of this era) Manual Type Type: Full Service Repair Manual / Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, valve timing, cooling system, lubrication system Fuel System: Fuel injection (Bosch Motronic), fuel pump, injectors, fuel pressure regulation, emissions control Ignition System: Ignition timing, coil, distributor (if applicable), spark plugs, ECU control Transmission Manual: Clutch operation, gearbox overhaul, shift linkage, driveshafts Transmission Automatic: Automatic gearbox (e.g., ZF 4HP22), hydraulic control, torque converter, electronic control unit (if applicable) Suspension: Front and rear suspension components, struts, shock absorbers, control arms, bushings, alignment procedures Steering: Power steering system, steering rack, steering column, tie rods Brakes: Brake system components (discs, pads, calipers), hydraulic system, ABS (if equipped), bleeding procedures Electrical System: Battery, charging system (alternator), starter motor, lighting, horn, wipers, power windows, central locking Electronics Control: ECU functions, sensor diagnostics (e.g., MAF, O2, crank/cam sensors), EWS (if applicable) Body Exterior: Body panel removal/installation, doors, hood, trunk, bumpers, glass replacement Body Interior: Dashboard, seats, trim panels, carpeting, headliner HVAC: Heating, ventilation, and air conditioning system components, refrigerant, diagnostics Procedures Included Maintenance: Oil changes, filter replacements, tune-ups, belt replacement, fluid checks and changes Diagnostics:...

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Tags: 1988 1989 1990 1991 520 520i BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

520 / 520i

Codes

Chassis Code:

Engine Code 520I:

M20B20

👋 Introduction

Market Position

Segment:

Executive/Luxury Mid-size Sedan

Competitive Analysis

Key Competitors:

Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ, Lexus LS (later in production).

Key Features

Vehicle Philosophy:

Known for its driver-focused dynamics, build quality, and refined engineering.

Manual Advantage:

Essential for owners and independent mechanics to maintain the complex systems of these advanced vehicles.

📋 Manual Details

Coverage Areas

Countries Covered:

Global (with focus on European markets where E34 was prevalent)

Page Count

Estimated Pages:

500-800 (typical for comprehensive BMW service manuals of this era)

Manual Type

Type:

Full Service Repair Manual / Workshop Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, valve timing, cooling system, lubrication system

Fuel System:

Fuel injection (Bosch Motronic), fuel pump, injectors, fuel pressure regulation, emissions control

Ignition System:

Ignition timing, coil, distributor (if applicable), spark plugs, ECU control

Transmission Manual:

Clutch operation, gearbox overhaul, shift linkage, driveshafts

Transmission Automatic:

Automatic gearbox (e.g., ZF 4HP22), hydraulic control, torque converter, electronic control unit (if applicable)

Suspension:

Front and rear suspension components, struts, shock absorbers, control arms, bushings, alignment procedures

Steering:

Power steering system, steering rack, steering column, tie rods

Brakes:

Brake system components (discs, pads, calipers), hydraulic system, ABS (if equipped), bleeding procedures

Electrical System:

Battery, charging system (alternator), starter motor, lighting, horn, wipers, power windows, central locking

Electronics Control:

ECU functions, sensor diagnostics (e.g., MAF, O2, crank/cam sensors), EWS (if applicable)

Body Exterior:

Body panel removal/installation, doors, hood, trunk, bumpers, glass replacement

Body Interior:

Dashboard, seats, trim panels, carpeting, headliner

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant, diagnostics

Procedures Included

Maintenance:

Oil changes, filter replacements, tune-ups, belt replacement, fluid checks and changes

Diagnostics:

Troubleshooting guides, common fault codes, symptom-based diagnostics

Repair:

Step-by-step repair procedures for all major systems

Overhaul:

Complete engine and transmission rebuild instructions

Torque Specifications:

Detailed torque values for critical fasteners

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Special Tools:

Identification and usage of BMW-specific tools required for repairs

Technical Depth

Depth:

Comprehensive: Covers routine maintenance, in-depth diagnostics, component replacement, and complete overhaul procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable, allowing for quick location of specific information.

Print Quality

Printability:

Designed for printing, allowing users to print specific sections or the entire manual.

Binding Type

Binding Options:

Not applicable for digital download, but user can print and bind themselves.

Paper Type

Paper Recommendation:

Standard printer paper; heavier stock recommended for frequently accessed pages.

⚙️ Engine Specifications

Primary Engine

Engine Type 520I:

Inline 6-cylinder, DOHC

Engine Code 520I:

M20B20

Displacement 520I:

1990 cc (2.0 Liters)

Bore X Stroke 520I:

80.0 mm x 66.0 mm

Performance

Horsepower 520I Eu:

129 hp @ 5800 rpm (approx.)

Torque 520I Eu:

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

Fuel System

Fuel Injection Type:

Bosch Motronic (e.g., Motronic 1.3)

Fuel Type:

Unleaded gasoline (Premium recommended)

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual

Optional

Transmission Type Optional:

4-speed Automatic (ZF 4HP22)

Features

Clutch Type:

Hydraulically operated single dry plate clutch

📐 Dimensions

Exterior

Length Mm:

4710 mm (approx.)

Width Mm:

1751 mm (approx.)

Height Mm:

1410 mm (approx.)

Weights

Curb Weight Kg Manual:

1420 kg (approx.)

Curb Weight Kg Auto:

1450 kg (approx.)

Gross Vehicle Weight Kg:

1950 kg (approx.)

Wheelbase Mm:

2760 mm (approx.)

Track Front Mm:

1470 mm (approx.)

Track Rear Mm:

1478 mm (approx.)

🛡️ Safety Features

Ratings

E নির্ভরযোগ্য:

Not officially rated by modern standards like NHTSA/Euro NCAP during its production era, but BMWs of this period were known for robust construction.

Active Features

Anti-lock Braking System (ABS) available as an option or standard on some models.

Traction Control:

ASC+T (Automatic Stability Control and Traction) became available later in the E34 generation, may not be present on all 1988-1991 models.

Passive Features

Airbags:

Driver-side airbag was optional and became more common towards the end of this range.

Seatbelts:

Three-point seatbelts with pre-tensioners (standard).

Body Structure:

Reinforced safety cage, crumple zones.

💡 Technology Features

Infotainment

Radio Options:

Factory fitted BMW radios (e.g., Bavaria C, RDS variants) with cassette player. Aftermarket upgrades common.

Driver Assistance

Availability of Anti-lock Braking System (ABS).

Connectivity

Oem Diagnostics:

On-board diagnostics (OBD) system, though pre-OBD-II standards (e.g., BMW proprietary system). This manual will cover these diagnostic procedures.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000-15,000 km or 12 months, depending on driving conditions and oil quality. Check manual for exact BMW recommendations.

Spark Plug Replacement:

Refer to manual; typically around 30,000-50,000 km for conventional plugs, longer for platinum/iridium.

Coolant Flush:

Every 2-3 years or specified mileage.

Transmission Fluid Change:

Manual: Check for life; often considered 'sealed for life' but fluid change is recommended. Automatic: Typically 80,000-100,000 km, check fluid condition.

Fluid Specifications

Engine Oil Type:

API SG/SH or higher, viscosity typically 5W-30, 5W-40, or 10W-40 depending on climate. Consult manual for specific BMW approval.

Coolant Type:

BMW Blue or compatible ethylene glycol-based antifreeze.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid:

BMW approved hydraulic fluid or Pentosin CHF 11S (verify specific requirement for E34).

Known Issues

M20 Engine Common Problems:

Head gasket leaks, valve stem seals, oil pan gasket leaks, idle control valve issues, timing belt tensioner wear.

E34 Body Common Problems:

Rust in common areas (wheel arches, rocker panels, under battery tray), headliner sagging, door seal degradation, sunroof drain blockage.

Electrical Common Problems:

Fuse box corrosion, wiring harness issues (especially around engine bay), instrument cluster failures, power window regulator failure.

Part Numbers Example

Oil Filter Part Number:

Mann-Filter W915/2 or equivalent (verify with specific VIN)

Air Filter Part Number:

Mann-Filter C35170 or equivalent (verify with specific VIN)

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Bayerische Motoren Werke AG, renowned for producing performance-oriented luxury vehicles with a focus on driving dynamics and engineering excellence.

Model Evolution

E34 Introduction:

The E34 generation of the 5 Series replaced the E28 and was produced from 1988 to 1996. The 520 and 520i were key entry-level models in this lineup.

520I Engine Transition:

The M20B20 engine, a reliable but somewhat less powerful unit for the E34 chassis, was used in the early models of the 520i. Later E34 generations saw an upgrade to the M50 engine for the 520i.

Production

Production Years Covered:

1988, 1989, 1990, 1991

Manufacturing Locations:

Primary production in Germany (Dingolfing), with assembly potentially in other BMW facilities globally.

🏆 Awards & Recognition

Recognitions

General E34 Reputation:

The E34 generation is highly regarded by automotive enthusiasts for its build quality, driving dynamics, and classic BMW styling. It often featured in 'best cars' lists of its era.

Manual Utility:

This manual is essential for preserving and maintaining the classic status and performance of the E34 5 Series.