BMW5-Series (E34) 518I 1990-1991 Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E34 Variant: 518i Model Years Covered: 1990-1991 Codes Engine Code Common: M40B18 👋 Introduction Market Position Segment: Executive Sedan Target Audience: Automotive enthusiasts, DIY mechanics, and professional workshops servicing BMW E34 models. Competitive Analysis Competitors: Mercedes-Benz W124 E-Class, Audi V8 quattro, Lexus LS 400. Key Features Vehicle Design: Iconic 'E34' design by Claus Luthe, representing BMW's signature blend of sportiness and luxury. Handling: Renowned for its balanced chassis, rear-wheel drive dynamics, and engaging driving experience. Key Features Manual Manual Advantage: Provides authoritative, factory-level information essential for accurate and efficient maintenance and repair. Value Proposition: Empowers owners and technicians to maintain and repair their E34 518i with confidence, reducing reliance on expensive dealership services. 📋 Manual Details Coverage Areas Comprehensive Coverage: Service, Maintenance, and Repair Page Count Estimated Page Count: Approx. 800-1000+ pages (typical for comprehensive manuals of this era) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, overhaul of M40B18 engine, including fuel injection, ignition, cooling, lubrication. Transmission: Manual and Automatic transmission service, repair, fluid specifications, and troubleshooting. Drivetrain: Driveshaft, differential, axles, wheel bearings, and CV joints. Suspension: Front and rear suspension components, steering system, alignment specifications. Brakes: Brake system diagnosis, repair, ABS (if equipped), hydraulic components, pad/rotor replacement. Electrical: Complete wiring diagrams, component testing, fuse box layout, starter, alternator, battery, lighting, and accessory circuits. Bodywork: Body panel repair, interior trim removal/installation, door mechanisms, glass replacement. HVAC: Heating, Ventilation, and Air Conditioning system diagnosis and repair. Fuel System: Fuel pump, injectors, fuel tank, and lines. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and pipework. Procedures Included Maintenance: Routine service checks, fluid changes, filter replacements, tune-ups. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common issues. Repair: Step-by-step instructions for component removal, installation, and adjustment. Rebuild: Detailed procedures for engine and transmission overhaul. Electrical Diagnostics: Testing and repair of electrical components and circuits using wiring diagrams. Special Tools: Identification and usage of required special tools for specific repairs. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed diagnostics. Illustrations: Includes exploded views, diagrams, and photographic illustrations for clarity. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Text-searchable for quick information retrieval. Print Quality Digital Quality: High-resolution for clear viewing of text and diagrams. Binding Type Digital Binding: N/A (Digital File) Paper Type Digital Paper Type: N/A (Digital File) ⚙️ Engine Specifications Primary Engine Engine Family: M40 Engine Code: M40B18 Configuration: Inline 4-cylinder Displacement: 1.8 Liters (1796 cc) Bore X Stroke: 86.0 mm x 76.8 mm Compression Ratio: 8.8:1 Valvetrain: SOHC, 2 valves per cylinder Performance Horsepower: 115 PS (113 hp; 85 kW) at 5600 rpm Torque: 164 Nm (121 lb-ft) at 4250 rpm Fuel System Fuel Delivery: Bosch Motronic Fuel Injection (e.g., Motronic ML 4.1 or ML 3.1) Fuel Type: Unleaded Gasoline (RON 91 or higher) Ignition System: Electronic ignition with distributor Cooling System Coolant Type: BMW approved ethylene glycol based coolant (e.g., G48) Lubrication System Oil Type: SAE 15W-40 or 10W-40 (refer to specific manual for exact BMW approval) 🔧 Transmission Standard Type: Getrag 260 5-speed Manual Transmission Optional Type: ZF 4HP22 4-speed Automatic Transmission Features Manual Ratios: Specific gear ratios available in manual, e.g., 1st: 4.21, 2nd: 2.19, 3rd: 1.40, 4th: 1.00, 5th: 0.81 Automatic Features: Electronically controlled with lock-up torque converter (depending on exact model year/options). Fluid Specifications Manual Fluid: BMW approved manual transmission fluid (MTF), e.g., SAE 75W-90 GL-4 Automatic Fluid: Dexron II or III automatic transmission fluid (ATF) 📐 Dimensions Exterior Length: Approx. 4710 mm (185.4 in) Width: Approx. 1750 mm (68.9 in) Height: Approx. 1410 mm (55.5 in) Wheelbase: Approx. 2795 mm (110.0 in) Weights Curb Weight: Approx. 1410-1490 kg (3109-3285 lbs), depending on transmission and options. Gross Vehicle Weight Rating: Refer to VIN plate or manual. Wheels Tires Standard Tire Size: 195/65R15 or 205/60R15 Wheel Bolt Pattern: 5x120 mm Wheel Offset: ET 15 to ET 20 (typical) 🛡️ Safety Features Ratings NHTSA Rating: Not comprehensively rated by modern standards, but generally considered robust for its era. Active Features ABS: Anti-lock Braking System (optional on early models, standard on later ones). Passive Features Airbags: Driver airbag (optional, became standard later in the E34 lifecycle). Seatbelts: Pre-tensioned front seatbelts. Chassis Construction: Unitized body construction with front and rear crumple zones. 💡 Technology Features Infotainment Radio: Factory cassette or radio/cassette combination. Options for CD players existed later in the E34 lifecycle. Speakers: Typically 4 to 8 speakers, depending on trim level and options. Driver Assistance Cruise Control: Standard on many models, optional on others. Trip Computer: Available on higher trim levels, providing basic fuel consumption and range data. Connectivity Connectivity Features: Limited by era; primarily focused on internal systems. No external connectivity...
Body panel repair, interior trim removal/installation, door mechanisms, glass replacement.
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair.
Fuel System:
Fuel pump, injectors, fuel tank, and lines.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, and pipework.
Procedures Included
Maintenance:
Routine service checks, fluid changes, filter replacements, tune-ups.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common issues.
Repair:
Step-by-step instructions for component removal, installation, and adjustment.
Rebuild:
Detailed procedures for engine and transmission overhaul.
Electrical Diagnostics:
Testing and repair of electrical components and circuits using wiring diagrams.
Special Tools:
Identification and usage of required special tools for specific repairs.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed diagnostics.
Illustrations:
Includes exploded views, diagrams, and photographic illustrations for clarity.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Text-searchable for quick information retrieval.
Print Quality
Digital Quality:
High-resolution for clear viewing of text and diagrams.
Binding Type
Digital Binding:
N/A (Digital File)
Paper Type
Digital Paper Type:
N/A (Digital File)
⚙️ Engine Specifications
Primary Engine
Engine Family:
M40
Engine Code:
M40B18
Configuration:
Inline 4-cylinder
Displacement:
1.8 Liters (1796 cc)
Bore X Stroke:
86.0 mm x 76.8 mm
Compression Ratio:
8.8:1
Valvetrain:
SOHC, 2 valves per cylinder
Performance
Horsepower:
115 PS (113 hp; 85 kW) at 5600 rpm
Torque:
164 Nm (121 lb-ft) at 4250 rpm
Fuel System
Fuel Delivery:
Bosch Motronic Fuel Injection (e.g., Motronic ML 4.1 or ML 3.1)
Fuel Type:
Unleaded Gasoline (RON 91 or higher)
Ignition System:
Electronic ignition with distributor
Cooling System
Coolant Type:
BMW approved ethylene glycol based coolant (e.g., G48)
Lubrication System
Oil Type:
SAE 15W-40 or 10W-40 (refer to specific manual for exact BMW approval)
🔧 Transmission
Standard
Type:
Getrag 260 5-speed Manual Transmission
Optional
Type:
ZF 4HP22 4-speed Automatic Transmission
Features
Manual Ratios:
Specific gear ratios available in manual, e.g., 1st: 4.21, 2nd: 2.19, 3rd: 1.40, 4th: 1.00, 5th: 0.81
Automatic Features:
Electronically controlled with lock-up torque converter (depending on exact model year/options).
Fluid Specifications
Manual Fluid:
BMW approved manual transmission fluid (MTF), e.g., SAE 75W-90 GL-4
Automatic Fluid:
Dexron II or III automatic transmission fluid (ATF)
📐 Dimensions
Exterior
Length:
Approx. 4710 mm (185.4 in)
Width:
Approx. 1750 mm (68.9 in)
Height:
Approx. 1410 mm (55.5 in)
Wheelbase:
Approx. 2795 mm (110.0 in)
Weights
Curb Weight:
Approx. 1410-1490 kg (3109-3285 lbs), depending on transmission and options.
Gross Vehicle Weight Rating:
Refer to VIN plate or manual.
Wheels Tires
Standard Tire Size:
195/65R15 or 205/60R15
Wheel Bolt Pattern:
5x120 mm
Wheel Offset:
ET 15 to ET 20 (typical)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not comprehensively rated by modern standards, but generally considered robust for its era.
Active Features
ABS:
Anti-lock Braking System (optional on early models, standard on later ones).
Passive Features
Airbags:
Driver airbag (optional, became standard later in the E34 lifecycle).
Seatbelts:
Pre-tensioned front seatbelts.
Chassis Construction:
Unitized body construction with front and rear crumple zones.
💡 Technology Features
Infotainment
Radio:
Factory cassette or radio/cassette combination. Options for CD players existed later in the E34 lifecycle.
Speakers:
Typically 4 to 8 speakers, depending on trim level and options.
Driver Assistance
Cruise Control:
Standard on many models, optional on others.
Trip Computer:
Available on higher trim levels, providing basic fuel consumption and range data.
Connectivity
Connectivity Features:
Limited by era; primarily focused on internal systems. No external connectivity like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 - 15,000 km (6,000 - 9,000 miles) or 12 months, whichever comes first (refer to manual for specific interval).
Spark Plug Replacement:
Every 30,000 - 40,000 km (18,000 - 25,000 miles) for standard spark plugs, or as per manual for longer-life options.
Coolant Flush:
Every 2-3 years or 50,000 km (30,000 miles).
Transmission Fluid Change:
Manual: Every 50,000 - 80,000 km (30,000 - 50,000 miles). Automatic: Every 40,000 - 60,000 km (25,000 - 37,000 miles).
Fluid Specifications
Engine Oil Capacity:
Approx. 4.25 Liters (4.5 US Quarts) with filter change.
Coolant Capacity:
Approx. 7.5 Liters (7.9 US Quarts).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine M40:
Timing chain stretch, valve guide wear, oil leaks from valve cover gasket and oil pan gasket, idle control issues.
Cooling System:
Plastic expansion tank can become brittle and crack, radiator leaks, water pump failure.
Electrical:
Wiring harness degradation (especially in engine bay), failing door lock actuators, instrument cluster issues, rear window defroster grid failure.
Suspension:
Worn control arm bushings, worn tie rod ends, strut mounts failing.
Fuel System:
Fuel pump failure, clogged fuel injectors.
Preventative Maintenance
Emphasis:
Regular inspection and replacement of rubber components, preventative replacement of known failure points (e.g., plastic coolant parts).
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's commitment to 'The Ultimate Driving Machine' ethos, evident in engineering and driving dynamics.
Model Evolution
E34 Introduction:
Introduced in 1987 (1988 model year in North America) as a successor to the E28 5 Series. The E34 represented a significant leap in aerodynamics, technology, and refinement.
E34 Lifespan:
Produced from 1987 to 1996 (sedan) and 1990 to 1996 (touring).
518I Positioning:
The 518i was the entry-level model in many markets, offering a more accessible entry into the 5 Series range.
Production
Manufacturing Location:
Dingolfing, Germany
Production Volume:
The E34 overall sold over 1.3 million units. Specific figures for the 518i are not as commonly segmented.
🏆 Awards & Recognition
Recognitions
Automotive Press:
The E34 generation was widely praised for its driving dynamics and build quality by automotive journalists of its time.
Car And Driver:
Car and Driver's '10Best' list multiple times during its production run, highlighting its class-leading attributes.
Ratings
Reliability Perception:
Generally good reliability, but requires consistent and proper maintenance due to its complex German engineering.
Certifications
Manual Standard:
Aligns with industry standards for technical repair documentation, providing factory-level detail.