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BMW 320i 1989 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 320i Year: 1989 Codes Chassis Code: E30 👋 Introduction Market Position Positioning: The BMW 320i (E30) was positioned as a compact executive sports sedan, known for its engaging driving dynamics, premium build quality, and sporty yet refined image. Competitive Analysis Competitors: Competed with vehicles like the Mercedes-Benz 190E, Audi 80/90, and Alfa Romeo 75. Key Features Driving Dynamics: Renowned for its balanced chassis, rear-wheel-drive layout, and responsive handling, making it a favorite among driving enthusiasts. Design: Iconic 'E30' design characterized by clean lines, a driver-focused cockpit, and a robust, well-built interior. 📋 Manual Details Coverage Areas Covered Models: All 1989 BMW 320i models (all engine, transmission, and trim variants) Page Count Estimated Page Count: Approximately 1500-2000+ pages (typical for comprehensive workshop manuals of this era, though exact count varies by specific edition/compiler) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: M20B20 (2.0L inline-6), engine mechanicals, lubrication, cooling, fuel, ignition, exhaust, engine management (DME) Transmission: Getrag 260 5-speed manual transmission; ZF 4HP22 4-speed automatic transmission, clutch, driveline, driveshaft, differential Brakes: Front vented discs, rear discs (or drums depending on specific market/build), ABS (if equipped), brake system hydraulics, parking brake Suspension: Front MacPherson struts, rear semi-trailing arms, springs, dampers, bushings, steering system (rack and pinion), wheel alignment Electrical: Battery, charging system (alternator), starting system, lighting, instrumentation, dashboard, wiring diagrams, fuse box, relays, ECU Bodywork: Chassis structure, body panels, doors, windows, convertible top (if applicable), interior trim, bumpers, seals HVAC: Heating, ventilation, air conditioning (if equipped), blower motor, controls, refrigerant system Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors (Bosch L-Jetronic or similar), fuel pressure regulator Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, belt inspections/replacements, general tune-ups Troubleshooting: Diagnostic procedures for engine, transmission, electrical, and other systems, fault code interpretation (if applicable) Repair: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair Installation: Component replacement and installation (e.g., alternators, starters, radiators, exhaust systems) Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission overhauls, detailed diagnostic procedures, and electrical system troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (OCR processed if scanned), allowing for quick keyword lookups. Print Quality Print Readability: High-resolution scans ensuring clear text and diagrams for printing. Binding Type Binding For Physical Copy: N/A (Digital PDF) Paper Type Paper Type For Physical Copy: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: M20B20 Engine Type: Inline 6-cylinder, SOHC Displacement: 1990 cc (2.0 Liters) Performance Horsepower: Approx. 125-129 hp (93-96 kW) at 6000 rpm (market dependent) Torque: Approx. 165-170 Nm (122-125 lb-ft) at 4300 rpm (market dependent) Fuel System Injection System: Bosch L-Jetronic or Motronic (likely L-Jetronic for early models, Motronic for later '89 variants) fuel injection Fuel Type: Unleaded Gasoline (RON 91 or higher recommended) Cooling System Coolant Type: Ethylene glycol-based coolant (e.g., BMW P/N 82 14 1 467 704 or equivalent blue coolant) Lubrication Oil Capacity: Approx. 4.25 liters (4.5 US quarts) with filter change Recommended Oil Viscosity: SAE 20W-50 or 15W-40 depending on climate (refer to manual for specific recommendations) 🔧 Transmission Standard Manual Transmission: Getrag 260, 5-speed manual Optional Automatic Transmission: ZF 4HP22, 4-speed automatic Features Clutch Type: Hydraulically operated single dry plate clutch Manual Transmission Fluid: GL-4 gear oil (e.g., Pentosin MTF.2 or equivalent) Automatic Transmission Fluid: Dexron-III/Mercon compatible ATF (e.g., Pentosin ATF 1 or equivalent) 📐 Dimensions Exterior Length: Approx. 4340 mm (170.9 in) Width: Approx. 1675 mm (65.9 in) Height: Approx. 1380 mm (54.3 in) Weights Curb Weight: Approx. 1200-1300 kg (2646-2866 lbs), depending on options and body style Wheelbase: Approx. 2570 mm (101.2 in) Wheels Tires Standard Wheel Size: 14 or 15 inch alloy wheels Standard Tire Size: 195/65HR14 or 195/60HR15 Bolt Pattern: 5x120 🛡️ Safety Features Ratings Crash Test Information: Official crash test ratings from the era are limited and vary by region. However, the E30 chassis was known for its robust safety cage construction and crumple zones. Active Features ABS: Anti-lock Braking System (ABS) was an optional feature on most 320i models of this year. Passive Features Seatbelts: 3-point inertia-reel seat belts for front occupants; lap belts for rear occupants (depending on market). Steering Column: Collapsible steering column for improved impact protection. 💡 Technology Features Infotainment Audio System: Basic analog radio and cassette player, often with optional amplifier and upgraded speaker systems. Driver Assistance Cruise Control: Optional cruise control system available on some models. Traction Control: ASC (Automatic Stability Control) was introduced later in the E30 lifecycle and may be present on some late-model 1989 E30s, though less common on the 320i. Connectivity Connectivity Features: No modern connectivity features like Bluetooth or USB. Communication was through the analog...
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Stichworte: 1989 320i BMW Car Cars Misc
BMW 320i 1989 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
320i
Year:
1989
Codes
Chassis Code:
E30
👋 Introduction
Market Position
Positioning:
The BMW 320i (E30) was positioned as a compact executive sports sedan, known for its engaging driving dynamics, premium build quality, and sporty yet refined image.
Competitive Analysis
Competitors:
Competed with vehicles like the Mercedes-Benz 190E, Audi 80/90, and Alfa Romeo 75.
Key Features
Driving Dynamics:
Renowned for its balanced chassis, rear-wheel-drive layout, and responsive handling, making it a favorite among driving enthusiasts.
Design:
Iconic 'E30' design characterized by clean lines, a driver-focused cockpit, and a robust, well-built interior.
📋 Manual Details
Coverage Areas
Covered Models:
All 1989 BMW 320i models (all engine, transmission, and trim variants)
Page Count
Estimated Page Count:
Approximately 1500-2000+ pages (typical for comprehensive workshop manuals of this era, though exact count varies by specific edition/compiler)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
M20B20 (2.0L inline-6), engine mechanicals, lubrication, cooling, fuel, ignition, exhaust, engine management (DME)
Transmission:
Getrag 260 5-speed manual transmission; ZF 4HP22 4-speed automatic transmission, clutch, driveline, driveshaft, differential
Brakes:
Front vented discs, rear discs (or drums depending on specific market/build), ABS (if equipped), brake system hydraulics, parking brake
Suspension:
Front MacPherson struts, rear semi-trailing arms, springs, dampers, bushings, steering system (rack and pinion), wheel alignment
Electrical:
Battery, charging system (alternator), starting system, lighting, instrumentation, dashboard, wiring diagrams, fuse box, relays, ECU
Bodywork:
Chassis structure, body panels, doors, windows, convertible top (if applicable), interior trim, bumpers, seals
HVAC:
Heating, ventilation, air conditioning (if equipped), blower motor, controls, refrigerant system
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors (Bosch L-Jetronic or similar), fuel pressure regulator
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, belt inspections/replacements, general tune-ups
Troubleshooting:
Diagnostic procedures for engine, transmission, electrical, and other systems, fault code interpretation (if applicable)
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair
Installation:
Component replacement and installation (e.g., alternators, starters, radiators, exhaust systems)
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls, detailed diagnostic procedures, and electrical system troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (OCR processed if scanned), allowing for quick keyword lookups.
Print Quality
Print Readability:
High-resolution scans ensuring clear text and diagrams for printing.
Binding Type
Binding For Physical Copy:
N/A (Digital PDF)
Paper Type
Paper Type For Physical Copy:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M20B20
Engine Type:
Inline 6-cylinder, SOHC
Displacement:
1990 cc (2.0 Liters)
Performance
Horsepower:
Approx. 125-129 hp (93-96 kW) at 6000 rpm (market dependent)
Torque:
Approx. 165-170 Nm (122-125 lb-ft) at 4300 rpm (market dependent)
Fuel System
Injection System:
Bosch L-Jetronic or Motronic (likely L-Jetronic for early models, Motronic for later '89 variants) fuel injection
Fuel Type:
Unleaded Gasoline (RON 91 or higher recommended)
Cooling System
Coolant Type:
Ethylene glycol-based coolant (e.g., BMW P/N 82 14 1 467 704 or equivalent blue coolant)
Lubrication
Oil Capacity:
Approx. 4.25 liters (4.5 US quarts) with filter change
Recommended Oil Viscosity:
SAE 20W-50 or 15W-40 depending on climate (refer to manual for specific recommendations)
🔧 Transmission
Standard
Manual Transmission:
Getrag 260, 5-speed manual
Optional
Automatic Transmission:
ZF 4HP22, 4-speed automatic
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Manual Transmission Fluid:
GL-4 gear oil (e.g., Pentosin MTF.2 or equivalent)
Automatic Transmission Fluid:
Dexron-III/Mercon compatible ATF (e.g., Pentosin ATF 1 or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 4340 mm (170.9 in)
Width:
Approx. 1675 mm (65.9 in)
Height:
Approx. 1380 mm (54.3 in)
Weights
Curb Weight:
Approx. 1200-1300 kg (2646-2866 lbs), depending on options and body style
Wheelbase:
Approx. 2570 mm (101.2 in)
Wheels Tires
Standard Wheel Size:
14 or 15 inch alloy wheels
Standard Tire Size:
195/65HR14 or 195/60HR15
Bolt Pattern:
5x120
🛡️ Safety Features
Ratings
Crash Test Information:
Official crash test ratings from the era are limited and vary by region. However, the E30 chassis was known for its robust safety cage construction and crumple zones.
Active Features
ABS:
Anti-lock Braking System (ABS) was an optional feature on most 320i models of this year.
Passive Features
Seatbelts:
3-point inertia-reel seat belts for front occupants; lap belts for rear occupants (depending on market).
Steering Column:
Collapsible steering column for improved impact protection.
💡 Technology Features
Infotainment
Audio System:
Basic analog radio and cassette player, often with optional amplifier and upgraded speaker systems.
Driver Assistance
Cruise Control:
Optional cruise control system available on some models.
Traction Control:
ASC (Automatic Stability Control) was introduced later in the E30 lifecycle and may be present on some late-model 1989 E30s, though less common on the 320i.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or USB. Communication was through the analog audio system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-15,000 km) or annually, depending on driving conditions and oil used (refer to manual for specific OEM recommendation).
Spark Plug Replacement:
Around 30,000 miles (48,000 km) for standard plugs, or longer for platinum/iridium plugs if fitted (check specific plug type).
Timing Belt Replacement:
The M20 engine uses a timing *belt*. Replacement is typically recommended every 60,000 miles (96,000 km) or 4-5 years. Crucial to prevent catastrophic engine damage.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (e.g., Ate Super Blue/Gold or equivalent)
Coolant Capacity:
Approx. 7.5 liters (7.9 US quarts)
Known Issues
Engine Oil Leaks:
Common leaks from valve cover gasket, oil pan gasket, and front/rear main seals due to age and material degradation.
Cooling System:
Radiator leaks, hose degradation, water pump failure, and thermostat issues are common due to age.
Fuel System:
Clogged fuel injectors, failing fuel pumps, and degraded fuel lines.
Suspension:
Worn control arm bushings, ball joints, tie rod ends, and sagging springs/shock absorbers are typical wear items.
Electrical:
Degraded wiring insulation, faulty grounds, failing relays, and instrument cluster issues (e.g., flickering gauges).
Rust:
E30s are susceptible to rust, particularly in the jacking points, rocker panels, wheel arches, and around the battery tray.
📚 Vehicle History
Brand Heritage
Bmw Heritage:
BMW has a long-standing reputation for building sporty, driver-focused vehicles, particularly with its acclaimed 3 Series lineage.
Model Evolution
E30 Generation:
The E30 generation (1982-1991) succeeded the E21 and introduced significant advancements in engineering, design, and suspension, setting new benchmarks for the compact executive class.
320I Positioning:
The 320i typically served as an entry-level to mid-range model within the E30 lineup, offering a balance of performance and efficiency with the smooth inline-six engine.
Production
Production Years E30:
1982-1991
Manufacturing Locations:
Primarily Germany (Munich), with some production in Austria and South Africa.
🏆 Awards & Recognition
Recognitions
E30 Reputation:
The E30 generation is widely considered a modern classic and is frequently praised by automotive journalists and enthusiasts for its driving purity and timeless design.
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