BMW 3 Series 1991 1992 1993 94-1999 Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Code: E36 Covered Years: 1991-1999 Codes Engine Codes Covered: M40, M42, M43, M50, M52 (4-cylinder and 6-cylinder petrol engines) Chassis Codes Covered: E36 (Sedan, Coupe, Convertible, Touring) 👋 Introduction Market Position Vehicle Segment: Compact Executive / Sport Sedan Target Audience: Enthusiasts, DIY mechanics, professional repair shops. Competitive Analysis Key Competitors: Mercedes-Benz C-Class (W202), Audi 80/A4 (B4/B5), Lexus ES, Volvo 850, Alfa Romeo 155. Key Features Vehicle Driving Dynamics: Renowned for excellent handling, rear-wheel drive bias, and driver-focused cockpit. Build Quality: Exceptional German engineering and robust construction. Engine Offerings: Range of smooth and powerful inline-4 and inline-6 petrol engines. 📋 Manual Details Coverage Areas Manual Type: Workshop Manual / Service Manual Language: English Format: Digital (PDF) or Printed Page Count Estimated Page Count: 1000+ (comprehensive coverage) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, overhaul procedures for all specified engine variants. Engine Management: Ignition system, fuel injection (Bosch Motronic), emission control systems, diagnostic trouble codes (DTCs). Transmission Manual: Removal, installation, disassembly, assembly, clutch operation. Transmission Automatic: Removal, installation, hydraulic systems, electronic control unit (ECU) diagnosis. Drivetrain: Driveshafts, differential, wheel bearings, axle components. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment procedures. Steering: Power steering system, steering rack, steering column, troubleshooting. Brakes: Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System) diagnosis and repair, brake fluid specifications. Electrical System: Wiring diagrams, charging system (alternator, battery), starting system, lighting, accessories, fuses, relays. Climate Control: HVAC system, air conditioning refrigerant types and servicing, heater core, blower motor. Body And Interior: Body panel removal and installation, interior trim, door mechanisms, glass replacement, sealant application. Body Electrical: Power windows, central locking, mirrors, instrument cluster, warning lights. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspection. Troubleshooting Guides: Diagnostic procedures for common malfunctions, symptom-based troubleshooting trees. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper overhauls. Diagnostic Procedures: Using OBD-I tools (where applicable), interpreting sensor data, electrical circuit testing. Adjustment Procedures: Valve clearance adjustment, throttle body synchronization, handbrake adjustment. Specifications And Tolerances: Tightening torques, clearances, fluid capacities, pressure specifications. Technical Depth Depth Of Information: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Diagnostic Complexity: Covers basic checks to in-depth electronic system diagnosis. Rebuild Procedures: Detailed, step-by-step rebuild instructions for major mechanical components. 📊 Manual Specifications File Format Digital Format: Searchable PDF, allowing quick access to specific information. Printability: Printable pages for on-vehicle use. Print Quality Illustrations Quality: High-quality diagrams, schematics, and photographic illustrations. Binding Type Printed Manual Binding: Durable binding (e.g., spiral-bound or perfect-bound) suitable for workshop environments. Paper Type Printed Manual Paper: High-grade, durable paper resistant to grease and moisture. ⚙️ Engine Specifications Primary Engine Engine Variants: 316i, 318i (M40/M43), 318is (M42), 320i (M50/M52), 325i/325is (M50), 328i/328is (M52). Displacement Range: 1.6L to 2.8L Performance Horsepower Range: 100 HP (316i) to 193 HP (328i) Torque Range: 140 Nm (316i) to 280 Nm (328i) Fuel System Injection System: Bosch Motronic Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Petrol) Engine Features Valve Train: DOHC (Double Overhead Camshafts) for most variants Engine Block Material: Aluminum alloy 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission Optional Optional Transmission: 4-speed Automatic Transmission (Steptronic optional on later models) Features Clutch Type: Single dry plate, hydraulically operated Transmission Fluid Spec: Dexron III (Automatic), Pentosin MTF LT-2 (Manual - check specific manual for exact part number) Differential Type: Open differential (Limited Slip Differential - LSD - optional on M3 and sport models) 📐 Dimensions Exterior Sedan Length: Approx. 4,433 mm (174.5 in) Coupe Length: Approx. 4,433 mm (174.5 in) Convertible Length: Approx. 4,450 mm (175.2 in) Touring Length: Approx. 4,456 mm (175.4 in) Wheelbase: Approx. 2,700 mm (106.3 in) Interior Seating Capacity: 5 Cargo Sedan Trunk Volume: Approx. 430 L (15.2 cu ft) Weights Curb Weight Range: Approx. 1,300 kg to 1,500 kg (depending on model and equipment) Wheel Bolt Pattern: 5x120 🛡️ Safety Features Ratings NHTSA Ratings: Not extensively tested by NHTSA in the modern sense for this era; focus on passive safety features. Active Features ABS: Standard on most models from mid-90s onwards, optional earlier. Passive Features Airbags: Driver airbag standard, passenger airbag optional or standard on later models. Seatbelts: Three-point inertia-reel seatbelts front and rear. Chassis Design: Reinforced safety cage, crumple zones. 💡 Technology Features Infotainment Audio System: Factory cassette player with optional CD changer, basic AM/FM radio. Upgrades common. Display: Simple dot-matrix display for radio and OBC information. Driver Assistance Cruise Control: Optional on most models. Traction Control: ASC (Automatic Stability Control) or ASC+T (with Traction Control) optional on some models. Connectivity Obc: On-Board Computer (OBC) providing checks for fluid levels, lights, and trip computer functions. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 to 10,000 miles (12,000-16,000 km) or...
DOHC (Double Overhead Camshafts) for most variants
Engine Block Material:
Aluminum alloy
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed Automatic Transmission (Steptronic optional on later models)
Features
Clutch Type:
Single dry plate, hydraulically operated
Transmission Fluid Spec:
Dexron III (Automatic), Pentosin MTF LT-2 (Manual - check specific manual for exact part number)
Differential Type:
Open differential (Limited Slip Differential - LSD - optional on M3 and sport models)
📐 Dimensions
Exterior
Sedan Length:
Approx. 4,433 mm (174.5 in)
Coupe Length:
Approx. 4,433 mm (174.5 in)
Convertible Length:
Approx. 4,450 mm (175.2 in)
Touring Length:
Approx. 4,456 mm (175.4 in)
Wheelbase:
Approx. 2,700 mm (106.3 in)
Interior
Seating Capacity:
5
Cargo
Sedan Trunk Volume:
Approx. 430 L (15.2 cu ft)
Weights
Curb Weight Range:
Approx. 1,300 kg to 1,500 kg (depending on model and equipment)
Wheel Bolt Pattern:
5x120
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not extensively tested by NHTSA in the modern sense for this era; focus on passive safety features.
Active Features
ABS:
Standard on most models from mid-90s onwards, optional earlier.
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional or standard on later models.
Seatbelts:
Three-point inertia-reel seatbelts front and rear.
Chassis Design:
Reinforced safety cage, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory cassette player with optional CD changer, basic AM/FM radio. Upgrades common.
Display:
Simple dot-matrix display for radio and OBC information.
Driver Assistance
Cruise Control:
Optional on most models.
Traction Control:
ASC (Automatic Stability Control) or ASC+T (with Traction Control) optional on some models.
Connectivity
Obc:
On-Board Computer (OBC) providing checks for fluid levels, lights, and trip computer functions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles (12,000-16,000 km) or annually, depending on driving conditions and oil used. Check OBC (On-Board Computer) if equipped.
Coolant Flush Interval:
Every 2-4 years or 30,000-60,000 miles. Use BMW-approved coolant.
Transmission Fluid Change:
Manual: Lifetime fill, but recommended change around 60,000-100,000 miles. Automatic: 50,000-75,000 miles (check specific interval).
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 or 5W-40, API SJ/SL or ACEA A3/B3, often BMW LL-98 or LL-01 certified (check manual for exact spec based on engine).
Coolant Specification:
BMW Blue Coolant or equivalent ethylene glycol-based antifreeze (50/50 mix with distilled water).
Brake Fluid Specification:
DOT 4
Known Issues
Cooling System:
Plastic expansion tank can crack, water pump impeller failure (especially plastic ones), thermostat housing leaks.
Oil Leaks:
Valve cover gasket, oil pan gasket, front and rear main seals are common leak points.
Suspension:
Front control arm bushings (vibrations/clunking), rear trailing arm bushings, shock absorber wear.
Electrical:
Fan clutch failure, ABS sensor issues, central locking pump failure, window regulator problems.
BMW, Bayerische Motoren Werke AG, is a German luxury vehicle and motorcycle manufacturer founded in 1916, known for its 'Ultimate Driving Machine' slogan and focus on performance and engineering.
Model Evolution
E36 Introduction:
The E36 succeeded the E30 3 Series in 1990 (as a 1991 model year in North America) and represented a significant modernization with improved aerodynamics, ride comfort, and technology.
Body Styles:
Introduced as a sedan, followed by coupe, convertible, hatchback (3 Series Compact - E36/5), and touring (wagon) variants.
M3 Variant:
The performance-oriented M3 variant (E36 M3) was a highly acclaimed model, featuring more powerful engines and chassis upgrades.
Production
Production Years:
1990-2000 (global), 1991-1999 (North America)
Manufacturing Locations:
Germany (Munich, Dingolfing, Regensburg), South Africa, Mexico, Thailand.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
3 Series models (including E36) frequently appeared on Car and Driver's '10Best' lists during its production run.
Motor Trend Car Of The Year:
While not 'Car of the Year' for this specific generation, the 3 Series has won numerous accolades throughout its history.
Ratings
Consumer Reports:
Generally rated well for performance and handling, with noted concerns in specific areas like cooling system reliability in some reports.
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