BMW 3 Series 318i 1983-1991 Workshop Service Repair Manual

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Basic Information Identification Make: BMW Model: 3 Series Model Variant: 318i Codes Chassis Code: E30 Engine Code: M10 (various sub-variants) Introduction Market Position Segment: Compact Executive Sedan/Coupe/Convertible Reputation: Renowned for...

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Description

Basic Information
Identification
Make:	BMW
Model:	3 Series
Model Variant:	318i
Codes
Chassis Code:	E30
Engine Code:	M10 (various sub-variants)

Introduction
Market Position
Segment:	Compact Executive Sedan/Coupe/Convertible
Reputation:	Renowned for sporty handling, build quality, and driver engagement. A benchmark in its class during its production run.
Competitive Analysis
Key Competitors:	Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Ford Sierra, Opel Vectra.
Key Features
Driving Dynamics:	Excellent chassis balance, responsive steering, and independent rear suspension contribute to superior handling characteristics.
Design:	Iconic E30 design, characterized by clean lines, a driver-oriented interior, and the distinctive BMW 'kidney' grille.
Powertrain Reliability:	The M10 engine, while not the most powerful, is known for its robust construction and longevity with proper maintenance.

Manual Details
Coverage Areas
Applicable Years:	1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Page Count
Total Pages:	225
Manual Type
Type:	Workshop Service Repair Manual
Language
Language:	English
Format
Format:	PDF (Digital Download)

Manual Coverage
Systems Covered
Engine Mechanical:	Detailed disassembly, inspection, and reassembly of the M10 engine, including cylinder head, block, pistons, connecting rods, crankshaft, camshaft, valves, and timing components.
Engine Fuel System:	Bosch LE-Jetronic fuel injection system diagnosis and repair, fuel pump, injectors, fuel pressure regulator, throttle body, air flow meter, and associated sensors.
Engine Ignition System:	Ignition coil, distributor, spark plugs, ignition control module, timing adjustments, and troubleshooting ignition system faults.
Engine Cooling System:	Radiator, fan, water pump, thermostat, coolant hoses, and troubleshooting overheating issues.
Engine Exhaust System:	Exhaust manifold, catalytic converter (if applicable for later models), muffler, pipes, and oxygen sensor diagnosis.
Transmission Manual:	Getrag 240 5-speed manual transmission disassembly, repair, clutch replacement, and gearbox fluid specifications.
Transmission Automatic:	ZF 4HP22 4-speed automatic transmission (if optioned on 318i) diagnosis, repair, fluid, and filter service.
Drivetrain:	Driveshaft, universal joints, CV joints (if applicable), differential, axle shafts, and wheel bearings.
Suspension:	Front MacPherson struts, rear semi-trailing arms, control arms, ball joints, tie rods, bushings, shock absorbers, and springs. Alignment specifications.
Brakes:	Front ventilated discs, rear drums (or discs on later/performance models), brake calipers, master cylinder, brake booster, ABS system (if equipped), fluid specifications, and bleeding procedures.
Steering:	Steering rack, tie rods, power steering pump, steering fluid specifications, and troubleshooting steering system issues.
Electrical System:	Battery, alternator, starter motor, fuse box, wiring diagrams, lighting systems, horn, and accessory circuits.
Body And Interior:	Door mechanisms, window regulators, seat adjustments, dashboard removal, interior trim, and body panel repair.
Heating Ventilation Air Conditioning:	HVAC system operation, blower motor, heater core, A/C compressor, refrigerant, and climate control diagnosis.
Procedures Included
Routine Maintenance:	Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid replacement, and routine inspections.
Troubleshooting:	Systematic diagnostic procedures for common drivability issues, electrical faults, and mechanical problems.
Repair Procedures:	Step-by-step guides for component replacement and repair for all major vehicle systems.
Component Rebuild:	Detailed instructions for rebuilding engine, transmission, and other key components.
Technical Specifications:	Torque values, clearances, fluid capacities, electrical data, and critical dimensions.
Wiring Diagrams:	Comprehensive electrical schematics for various vehicle systems.
Technical Depth
Depth:	Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Suitable for both DIY enthusiasts and professional mechanics.

Manual Specifications
File Format
File Type:	PDF
Searchability:	Searchable text content for quick information retrieval.
Print Quality
Image Resolution:	High-resolution scans ensuring clarity of diagrams and text.
Printable:	Printable pages for on-demand hard copy access.
Binding Type
Binding:	N/A (Digital PDF)
Paper Type
Paper:	N/A (Digital PDF)

Engine Specifications
Primary Engine
Engine Code:	M10 (Specific variants like M10B18)
Engine Type:	Inline-4 Cylinder, SOHC (Single Overhead Camshaft)
Displacement:	1.8 Liters (1766 cc)
Performance
Horsepower:	Approximately 98-105 hp (depending on market and exact model year)
Torque:	Approximately 100-105 lb-ft (depending on market and exact model year)
Fuel System
Fuel Delivery:	Bosch LE-Jetronic Electronic Fuel Injection (EFI)
Fuel Type:	Unleaded Gasoline (Octane rating varies by market, typically 91 RON or higher recommended)
Engine Management
ECU Type:	Motronic (specific generation for the LE-Jetronic system)

Transmission
Standard
Type:	Getrag 240 5-speed Manual Transmission
Optional
Type:	ZF 4HP22 4-speed Automatic Transmission (less common on 318i compared to other E30 models)
Features
Clutch Type:	Hydraulic Actuation
Manual Fluid Spec:	BMW ATF Dextron II or equivalent (check specific manual for precise fill)
Automatic Fluid Spec:	ZF TE-ML 04D or equivalent (check specific manual for precise fill)

Dimensions
Exterior
Body Styles:	2-door Sedan (Saloon), 4-door Sedan (Saloon), Convertible, Touring (Wagon - less common for 318i), Sport Utility Coupe (E30 M3 basis, not typically 318i)
Length:	Approx. 168.4 inches (4277 mm) for sedan models
Width:	Approx. 66.1 inches (1679 mm)
Height:	Approx. 54.7 inches (1390 mm) for sedan models
Weights
Curb Weight:	Approx. 2500-2700 lbs (1134-1225 kg)

Safety Features
Ratings
Federal Safety Standards:	Designed to meet FMVSS standards prevalent during its production years.
Active Features
Braking:	Front ventilated disc brakes, rear drum brakes (or optional rear discs on later models). ABS available on some later models.
Passive Features
Seatbelts:	Three-point inertia-reel seatbelts for front occupants, lap belts for rear (later models often featured three-point rear belts).
Body Construction:	Reinforced safety cell, crumple zones front and rear.

Technology Features
Infotainment
Audio System:	Factory fitted radios were typically cassette players with AM/FM. Speaker quality varied by trim level. Modern head unit upgrades are common.
Driver Assistance
ABS:	Anti-lock Braking System (ABS) was optional on some models, particularly later production years and higher trim levels.
Connectivity
Connectivity Features:	Basic by modern standards. No integrated Bluetooth, USB, or navigation from the factory. Antennas were typically manual or electric for radio reception.

Maintenance
Service Intervals
Oil Change:	Every 5,000-7,500 miles or annually, whichever comes first. Refer to manual for specific oil type and capacity.
Spark Plugs:	Approximately 30,000 miles, depending on plug type (e.g., copper vs. platinum). Consult manual for correct part numbers and gap.
Coolant Flush:	Every 2 years or 30,000 miles.
Brake Fluid Change:	Every 2 years, regardless of mileage, to prevent moisture absorption.
Fluid Specifications
Engine Oil:	API SG/SH or ACEA A2/A3 rated, viscosity typically 10W-40 or 15W-40 depending on climate. Consult manual for exact BMW LL-01 or equivalent recommendation for the era.
Coolant:	Ethylene glycol based antifreeze (typically a 50/50 mix with distilled water). BMW recommends their own G48 coolant or equivalent. Check manual for correct color/type.
Brake Fluid:	DOT 3 or DOT 4. Always use fresh, sealed fluid.
Known Issues
Cooling System:	Plastic coolant expansion tanks can become brittle and crack; water pump failure is also common with age.
Fuel System:	Fuel pump relays can fail, leading to no-start conditions. Injector seals can degrade.
Suspension:	Worn control arm bushings, rear trailing arm bushings ('RTABs'), and shock absorbers are common wear items leading to degraded handling.
Electrical:	Corroded wiring connections, especially in engine bay and grounds. Instrument cluster problems (like 'check panel' lights).
Rust:	Common on E30s, particularly around wheel arches, rocker panels, and strut towers. Early inspection and rust prevention is crucial.

Vehicle History
Brand Heritage
Brand Identity:	BMW (Bayerische Motoren Werke AG) has a long-standing heritage of producing driver-focused, performance-oriented vehicles with a reputation for engineering excellence and luxury.
Model Evolution
Generation Code:	E30 (First generation 3 Series)
Introduction Year:	1982 (globally, E30 introduced), 318i variant phased in from 1983/1984.
Facelift:	Mid-cycle facelift occurred around 1987-1988, introducing revised bumpers (larger plastic 'diving boards'), updated interior trim, and some mechanical tweaks.
Production
Production Period:	1982-1994 (E30 platform as a whole), 318i specifically for the 1983-1991 range covered by this manual.
Manufacturing Locations:	Primary production in Germany, with some assembly in other BMW facilities globally.

Awards & Recognition
Recognitions
Automotive Press Accolades:	The E30 generation as a whole received numerous accolades for its driving dynamics and engineering, often praised by automotive journalists worldwide.
Classic Car Status:	The E30 3 Series, including the 318i, is widely regarded as a modern classic and is highly sought after by enthusiasts for its purity of driving experience.