BMW 8 Series e31 1991 Factory Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: BMW Model: 8 Series Chassis Code: E31 Model Year: 1991 Generation Generation Code: 1st Generation (E31) Codes Engine Codes: M60B30 (3.0L V8), M60B40 (4.0L V8) ๐ Introduction Market Position Market Position: The BMW E31 8 Series was BMW's flagship luxury grand tourer, positioned as a high-performance, technologically advanced, and stylish coupe. It competed with other premium coupes of its era such as the Mercedes-Benz SEC models and the Porsche 928. Competitive Analysis Competitive Analysis: The E31 offered a unique blend of V8 power, sophisticated chassis dynamics, and luxurious appointments. Its design, penned by Klaus Kapitza, was aerodynamic and timeless, setting it apart from more angular competitors. The availability of a V12 engine (though not specified for this 1991 manual) further cemented its elite status. Key Features Key Features: Pop-up headlights, pillarless coupe design, advanced aerodynamics, powerful V8 engines, optional V12 engine, advanced suspension and braking systems for its time, luxurious interior. ๐ Manual Details Coverage Areas Coverage Areas: Complete maintenance, troubleshooting, diagnostics, and repair procedures for all major vehicle systems. Page Count Page Count: Estimated 1000+ pages (typical for factory service manuals of this era and scope) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF ๐ Manual Coverage Systems Covered Systems Covered: Fundamentals, Lubrication and Maintenance, Engine Management/Driveability, Engine Mechanical, Ignition System, Fuel System, Cooling System, Exhaust System and Emission Controls, Manual Transmission and Clutch, Automatic Transmission and Clutch, Driveshaft and Final Drive, Brakes, Suspension and Steering, Body and Interior, Electrical System, Index. Procedures Included Procedures Included: Routine maintenance, scheduled maintenance, component removal and installation, diagnostic procedures, troubleshooting charts, wiring diagrams, torque specifications, special tool requirements, overhaul procedures. Technical Depth Technical Depth: Comprehensive, covering everything from basic fluid checks and filter changes to in-depth engine and transmission overhauls, complex electrical system diagnostics, and body panel repair. ๐ Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for clear digital viewing and printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) โ๏ธ Engine Specifications Primary Engine Primary Engine: M60B40 4.0-liter V8 engine. Performance Engine Power Output M60B40: Approximately 282 hp (210 kW) at 5800 rpm. Engine Torque M60B40: Approximately 295 lb-ft (400 Nm) at 4500 rpm. Engine Power Output M60B30: Approximately 215 hp (158 kW) at 5800 rpm. Engine Torque M60B30: Approximately 290 lb-ft (390 Nm) at 4500 rpm. Fuel System Fuel System: Electronic Fuel Injection (EFI) with Bosch Motronic engine management. Engine Layout Engine Layout: V8 Engine Displacement Engine Displacement: 3.0L (M60B30) and 4.0L (M60B40) Engine Block Material Engine Block Material: Aluminum Engine Head Material Engine Head Material: Aluminum Valve Train Valve Train: DOHC, 4 valves per cylinder (32 valves total) ๐ง Transmission Standard Standard Transmission: 5-speed manual transmission (Getrag 420G for V8 models) Optional Optional Transmission: 4-speed automatic transmission (ZF 4HP24 for V8 models) Features Transmission Features: Self-adjusting clutch, electronic transmission control for automatic (if equipped), hydraulic clutch actuation. ๐ Dimensions Exterior Wheelbase: 111.4 inches (2830 mm) Length: 191.7 inches (4870 mm) Width: 71.7 inches (1820 mm) Height: 51.9 inches (1318 mm) Weights Curb Weight Approx V8: 3,900 - 4,100 lbs (1770 - 1860 kg) Gross Vehicle Weight Rating Approx V8: 4,900 - 5,100 lbs (2220 - 2310 kg) ๐ก๏ธ Safety Features Ratings Safety Ratings: Specific crash test ratings from 1991 are not readily available in modern formats, but BMW vehicles of this era were known for robust construction. Active Features Active Safety Features: Anti-lock Braking System (ABS), Traction Control System (ASC+T on some later models, but potentially not standard on 1991). Passive Features Passive Safety Features: Reinforced safety cage, front and side impact beams, three-point inertia-reel seatbelts, driver and passenger airbags (optional or standard depending on market/trim). ๐ก Technology Features Infotainment Infotainment Features 1991: Standard features would have included a high-fidelity sound system with cassette player, digital sound processor (DSP) on higher trims, and a basic onboard computer displaying fuel consumption and range. Analog gauges were prominent. Driver Assistance Driver Assistance Features 1991: ABS, potentially optional traction control (ASC+T on later models, but likely not on 1991). Advanced driver assistance systems as known today were not present. Connectivity Connectivity Features 1991: Limited to factory-installed radio and optional car phone systems. No modern Bluetooth or USB connectivity. ๐ง Maintenance Service Intervals Service Intervals: The manual will detail BMW's specific service intervals, typically involving oil changes every 7,500-10,000 miles, coolant flushes at 30,000-50,000 miles, spark plug replacement around 60,000 miles, and brake fluid changes every 2 years. Fluid Specifications Engine Oil Type Approx: BMW Longlife-98 (LL-98) specification synthetic oil, typically SAE 5W-30 or 5W-40. Coolant Type: Ethylene glycol based coolant, typically BMW blue or green. Brake Fluid Type: DOT 4 Transmission Fluid Manual: GL-4 or GL-5 gear oil (specific viscosity to be detailed in manual, e.g., 75W-90). Transmission Fluid...
The BMW E31 8 Series was BMW's flagship luxury grand tourer, positioned as a high-performance, technologically advanced, and stylish coupe. It competed with other premium coupes of its era such as the Mercedes-Benz SEC models and the Porsche 928.
Competitive Analysis
Competitive Analysis:
The E31 offered a unique blend of V8 power, sophisticated chassis dynamics, and luxurious appointments. Its design, penned by Klaus Kapitza, was aerodynamic and timeless, setting it apart from more angular competitors. The availability of a V12 engine (though not specified for this 1991 manual) further cemented its elite status.
Key Features
Key Features:
Pop-up headlights, pillarless coupe design, advanced aerodynamics, powerful V8 engines, optional V12 engine, advanced suspension and braking systems for its time, luxurious interior.
๐ Manual Details
Coverage Areas
Coverage Areas:
Complete maintenance, troubleshooting, diagnostics, and repair procedures for all major vehicle systems.
Page Count
Page Count:
Estimated 1000+ pages (typical for factory service manuals of this era and scope)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
๐ Manual Coverage
Systems Covered
Systems Covered:
Fundamentals, Lubrication and Maintenance, Engine Management/Driveability, Engine Mechanical, Ignition System, Fuel System, Cooling System, Exhaust System and Emission Controls, Manual Transmission and Clutch, Automatic Transmission and Clutch, Driveshaft and Final Drive, Brakes, Suspension and Steering, Body and Interior, Electrical System, Index.
Comprehensive, covering everything from basic fluid checks and filter changes to in-depth engine and transmission overhauls, complex electrical system diagnostics, and body panel repair.
๐ Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for clear digital viewing and printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
โ๏ธ Engine Specifications
Primary Engine
Primary Engine:
M60B40 4.0-liter V8 engine.
Performance
Engine Power Output M60B40:
Approximately 282 hp (210 kW) at 5800 rpm.
Engine Torque M60B40:
Approximately 295 lb-ft (400 Nm) at 4500 rpm.
Engine Power Output M60B30:
Approximately 215 hp (158 kW) at 5800 rpm.
Engine Torque M60B30:
Approximately 290 lb-ft (390 Nm) at 4500 rpm.
Fuel System
Fuel System:
Electronic Fuel Injection (EFI) with Bosch Motronic engine management.
Engine Layout
Engine Layout:
V8
Engine Displacement
Engine Displacement:
3.0L (M60B30) and 4.0L (M60B40)
Engine Block Material
Engine Block Material:
Aluminum
Engine Head Material
Engine Head Material:
Aluminum
Valve Train
Valve Train:
DOHC, 4 valves per cylinder (32 valves total)
๐ง Transmission
Standard
Standard Transmission:
5-speed manual transmission (Getrag 420G for V8 models)
Optional
Optional Transmission:
4-speed automatic transmission (ZF 4HP24 for V8 models)
Features
Transmission Features:
Self-adjusting clutch, electronic transmission control for automatic (if equipped), hydraulic clutch actuation.
๐ Dimensions
Exterior
Wheelbase:
111.4 inches (2830 mm)
Length:
191.7 inches (4870 mm)
Width:
71.7 inches (1820 mm)
Height:
51.9 inches (1318 mm)
Weights
Curb Weight Approx V8:
3,900 - 4,100 lbs (1770 - 1860 kg)
Gross Vehicle Weight Rating Approx V8:
4,900 - 5,100 lbs (2220 - 2310 kg)
๐ก๏ธ Safety Features
Ratings
Safety Ratings:
Specific crash test ratings from 1991 are not readily available in modern formats, but BMW vehicles of this era were known for robust construction.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Traction Control System (ASC+T on some later models, but potentially not standard on 1991).
Passive Features
Passive Safety Features:
Reinforced safety cage, front and side impact beams, three-point inertia-reel seatbelts, driver and passenger airbags (optional or standard depending on market/trim).
๐ก Technology Features
Infotainment
Infotainment Features 1991:
Standard features would have included a high-fidelity sound system with cassette player, digital sound processor (DSP) on higher trims, and a basic onboard computer displaying fuel consumption and range. Analog gauges were prominent.
Driver Assistance
Driver Assistance Features 1991:
ABS, potentially optional traction control (ASC+T on later models, but likely not on 1991). Advanced driver assistance systems as known today were not present.
Connectivity
Connectivity Features 1991:
Limited to factory-installed radio and optional car phone systems. No modern Bluetooth or USB connectivity.
๐ง Maintenance
Service Intervals
Service Intervals:
The manual will detail BMW's specific service intervals, typically involving oil changes every 7,500-10,000 miles, coolant flushes at 30,000-50,000 miles, spark plug replacement around 60,000 miles, and brake fluid changes every 2 years.
Fluid Specifications
Engine Oil Type Approx:
BMW Longlife-98 (LL-98) specification synthetic oil, typically SAE 5W-30 or 5W-40.
Coolant Type:
Ethylene glycol based coolant, typically BMW blue or green.
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (specific viscosity to be detailed in manual, e.g., 75W-90).
Transmission Fluid Automatic:
ZF Lifeguardfluid5 (or equivalent specification as per manual).
Known Issues
Known Issues:
While the manual focuses on repair, common E31 issues often include VANOS system (if applicable to later M60 engines, though early M60 had simpler systems), cooling system components (radiator, hoses, water pump), ABS/ASC system electronics, window regulators, and potential wiring harness degradation due to age.
๐ Vehicle History
Brand Heritage
Brand Heritage:
BMW, Bayerische Motoren Werke AG, has a long-standing reputation for building performance-oriented luxury vehicles, often referred to as the ultimate driving machine. Their history includes aviation engines, motorcycles, and a vast array of iconic automobiles.
Model Evolution
Model Evolution:
The E31 8 Series was introduced in 1989 as a replacement for the BMW E24 6 Series coupes. It was designed to be a more technologically advanced and luxurious grand tourer. The V8 engines were introduced in 1990, followed by the V12 (850i) in 1990 as well.
Production
Production Years E31:
1989-1999
Production Locations
Production Locations:
Dingolfing, Germany
๐ Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 1991 model year are not prominently listed, the E31's design was highly acclaimed, and it was recognized as a benchmark for automotive engineering and luxury GT cars of its era. It was featured in numerous automotive publications and often lauded for its blend of performance and comfort.