BMW 3 series E21 1981 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E21 Model Year: 1981 Codes Engine Codes Covered: M10 variants (e.g., M10B18, M10B20), M20 variants (e.g., M20B23) 👋 Introduction Market Position Market Position: Essential reference for BMW E21 owners and independent workshops, providing dealership-level technical information for a classic German sports sedan. Target Audience: BMW E21 owners with basic mechanical skills, DIY enthusiasts, and professional independent auto service technicians. Competitive Analysis Competitive Analysis: Offers specific, manufacturer-provided data for the E21 generation, distinguishing it from generic repair guides. Emphasizes vehicle-specific accuracy for effective maintenance and repair. Key Features Key Features: Step-by-step instructions, detailed diagrams and illustrations, wiring schematics, comprehensive troubleshooting, vehicle-specific specifications, dealer-level accuracy. Illustrations Diagrams: Abundant illustrations and clear diagrams to visually guide the user through complex repair procedures, enhancing understanding and accuracy. 📋 Manual Details Coverage Areas Coverage Areas: All major topics including General Information, Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch, Manual Transaxle, Automatic Transaxle, Driveshaft & Axle, Suspension, Steering, Restraint Systems, Brake System, Body (Interior/Exterior), Body Electrical System, HVAC Page Count Page Count: Not Specified (Implied to be comprehensive) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical (including timing, cylinder head, block, lubrication), Engine electrical (ignition, starting, charging), Emission control systems, Fuel injection and carburetion systems, Clutch operation and repair, Manual and automatic transmission systems, Drivetrain components (driveshaft, differential, axles), Suspension geometry and components, Steering mechanism and linkages, Brake system hydraulics and mechanics, Bodywork (exterior panels, interior trim), Body electrical (lighting, power accessories, instrumentation), HVAC system (heating, ventilation, air conditioning) Restraint System Coverage: Details on seat belt systems, including pre-tensioners (if applicable to specific models/markets) and adjustment mechanisms. Brake System Coverage: Front disc brakes and rear drum brakes (or disc brakes on some higher-performance variants), including brake caliper/wheel cylinder overhaul, pad/shoe replacement, fluid bleeding, and parking brake adjustment. Body Electrical System: Covers headlights, taillights, interior lighting, dashboard instruments, wipers, horn, and accessory electrical circuits. Procedures Included Procedures Included: Step-by-step repair instructions, troubleshooting guides, diagnostic procedures, maintenance schedules, component removal and installation, adjustment procedures, wiring schematic interpretation, torque specifications, fluid capacities and types, electrical system diagnostics Body Repair Procedures: Instructions for body panel alignment, rust repair techniques, interior trim removal and installation, and exterior component replacement. Diagnostic Procedures: Systematic troubleshooting steps for diagnosing mechanical, electrical, and fuel system issues, including symptom-based troubleshooting. Component Rebuild Procedures: Detailed procedures for rebuilding major components like engines, transmissions, brake calipers, and steering racks. Troubleshooting Guides: Structured troubleshooting sections based on symptoms, guiding users to identify and resolve common automotive problems efficiently. Technical Depth Technical Depth: Comprehensive; suitable for basic maintenance to advanced diagnostics and repairs, equivalent to dealer-level technician resources. Wiring Schematic Detail: Includes comprehensive, easily interpretable wiring diagrams for all major electrical systems, aiding in diagnosis and repair of circuits. Torque Specifications: Includes specific torque values for critical engine, chassis, and suspension fasteners, ensuring correct assembly and preventing component damage. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Digital Compatibility: Viewable on PC, Mac, and various devices including phones and e-readers with PDF reader capability. Print Quality Print Quality: Printable pages allowing for high-quality reproduction of diagrams and text. Binding Type Binding Type: Digital (Printable PDF) Paper Type Paper Type: N/A (Digital Format - Printable) ⚙️ Engine Specifications Primary Engine Primary Engine: M10 4-cylinder (various displacements like 1.8L, 2.0L) and M20 6-cylinder (e.g., 2.3L) engines. Performance Performance Data: Covers engine variants producing approximately 90-105 HP for 4-cylinder and 105-140 HP for 6-cylinder models, detailing adjustments for optimal performance. Fuel System Fuel System: Carbureted (e.g., Solex, Zenith) and early Bosch L-Jetronic fuel injection systems, with detailed diagnostic and repair procedures for both. Fuel System Carburetor Details: In-depth information on carburetor models used, including adjustment procedures, idle speed settings, and troubleshooting fuel delivery. Fuel System Injection Details: Troubleshooting and repair for Bosch L-Jetronic fuel injection, including sensor testing, injector diagnostics, and fuel pump checks. Engine Mechanical System Engine Mechanical System: Covers cylinder head, valve train, piston assemblies, crankshaft, connecting rods, lubrication system, cooling system, and timing components. Engine Electrical System Engine Electrical System: Covers ignition system (distributor, coil, spark plugs), starting system (starter motor, solenoid), charging system (alternator, voltage regulator), and engine sensors. Emission Control System Emission Control System: Details on emission control components such as air pumps, EGR valves (if applicable), catalytic converters (later models), and fuel vapor control systems. 🔧 Transmission Standard Standard Transmission: 4-speed and 5-speed manual transmissions (e.g., Getrag 245). Optional Optional Transmission: 3-speed ZF automatic transmission. Features Transmission Features: Details on clutch operation, manual gearbox overhaul, automatic transmission servicing, and driveshaft/axle maintenance. Manual Transaxle System Manual Transaxle System: Detailed overhaul and repair procedures for manual gearboxes, including gear selection mechanisms and bearing replacements. 📐 Dimensions Exterior Exterior...
Essential reference for BMW E21 owners and independent workshops, providing dealership-level technical information for a classic German sports sedan.
Target Audience:
BMW E21 owners with basic mechanical skills, DIY enthusiasts, and professional independent auto service technicians.
Competitive Analysis
Competitive Analysis:
Offers specific, manufacturer-provided data for the E21 generation, distinguishing it from generic repair guides. Emphasizes vehicle-specific accuracy for effective maintenance and repair.
Abundant illustrations and clear diagrams to visually guide the user through complex repair procedures, enhancing understanding and accuracy.
📋 Manual Details
Coverage Areas
Coverage Areas:
All major topics including General Information, Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch, Manual Transaxle, Automatic Transaxle, Driveshaft & Axle, Suspension, Steering, Restraint Systems, Brake System, Body (Interior/Exterior), Body Electrical System, HVAC
Page Count
Page Count:
Not Specified (Implied to be comprehensive)
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical (including timing, cylinder head, block, lubrication), Engine electrical (ignition, starting, charging), Emission control systems, Fuel injection and carburetion systems, Clutch operation and repair, Manual and automatic transmission systems, Drivetrain components (driveshaft, differential, axles), Suspension geometry and components, Steering mechanism and linkages, Brake system hydraulics and mechanics, Bodywork (exterior panels, interior trim), Body electrical (lighting, power accessories, instrumentation), HVAC system (heating, ventilation, air conditioning)
Restraint System Coverage:
Details on seat belt systems, including pre-tensioners (if applicable to specific models/markets) and adjustment mechanisms.
Brake System Coverage:
Front disc brakes and rear drum brakes (or disc brakes on some higher-performance variants), including brake caliper/wheel cylinder overhaul, pad/shoe replacement, fluid bleeding, and parking brake adjustment.
Step-by-step repair instructions, troubleshooting guides, diagnostic procedures, maintenance schedules, component removal and installation, adjustment procedures, wiring schematic interpretation, torque specifications, fluid capacities and types, electrical system diagnostics
Body Repair Procedures:
Instructions for body panel alignment, rust repair techniques, interior trim removal and installation, and exterior component replacement.
Diagnostic Procedures:
Systematic troubleshooting steps for diagnosing mechanical, electrical, and fuel system issues, including symptom-based troubleshooting.
Component Rebuild Procedures:
Detailed procedures for rebuilding major components like engines, transmissions, brake calipers, and steering racks.
Troubleshooting Guides:
Structured troubleshooting sections based on symptoms, guiding users to identify and resolve common automotive problems efficiently.
Technical Depth
Technical Depth:
Comprehensive; suitable for basic maintenance to advanced diagnostics and repairs, equivalent to dealer-level technician resources.
Wiring Schematic Detail:
Includes comprehensive, easily interpretable wiring diagrams for all major electrical systems, aiding in diagnosis and repair of circuits.
Torque Specifications:
Includes specific torque values for critical engine, chassis, and suspension fasteners, ensuring correct assembly and preventing component damage.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Digital Compatibility:
Viewable on PC, Mac, and various devices including phones and e-readers with PDF reader capability.
Print Quality
Print Quality:
Printable pages allowing for high-quality reproduction of diagrams and text.
Binding Type
Binding Type:
Digital (Printable PDF)
Paper Type
Paper Type:
N/A (Digital Format - Printable)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
M10 4-cylinder (various displacements like 1.8L, 2.0L) and M20 6-cylinder (e.g., 2.3L) engines.
Performance
Performance Data:
Covers engine variants producing approximately 90-105 HP for 4-cylinder and 105-140 HP for 6-cylinder models, detailing adjustments for optimal performance.
Fuel System
Fuel System:
Carbureted (e.g., Solex, Zenith) and early Bosch L-Jetronic fuel injection systems, with detailed diagnostic and repair procedures for both.
Fuel System Carburetor Details:
In-depth information on carburetor models used, including adjustment procedures, idle speed settings, and troubleshooting fuel delivery.
Fuel System Injection Details:
Troubleshooting and repair for Bosch L-Jetronic fuel injection, including sensor testing, injector diagnostics, and fuel pump checks.
Covers ignition system (distributor, coil, spark plugs), starting system (starter motor, solenoid), charging system (alternator, voltage regulator), and engine sensors.
Emission Control System
Emission Control System:
Details on emission control components such as air pumps, EGR valves (if applicable), catalytic converters (later models), and fuel vapor control systems.
🔧 Transmission
Standard
Standard Transmission:
4-speed and 5-speed manual transmissions (e.g., Getrag 245).
Optional
Optional Transmission:
3-speed ZF automatic transmission.
Features
Transmission Features:
Details on clutch operation, manual gearbox overhaul, automatic transmission servicing, and driveshaft/axle maintenance.
Manual Transaxle System
Manual Transaxle System:
Detailed overhaul and repair procedures for manual gearboxes, including gear selection mechanisms and bearing replacements.
📐 Dimensions
Exterior
Exterior Dimensions:
Detailed dimensions for sedan body style, wheelbases, and track widths specific to the E21 chassis.
Weights
Curb Weight:
Approximate curb weights ranging from 1100-1300 kg depending on engine and options.
Suspension System
Suspension System:
Covers front and rear suspension components, including struts, control arms, bushings, shock absorbers, and wheel bearings, along with alignment specifications.
Steering System
Steering System:
Details on the steering gearbox, tie rods, steering column, and power steering assist system (if equipped).
🛡️ Safety Features
Ratings
Safety Ratings:
Covers passive safety features and structural integrity relevant to 1980s vehicle safety standards. No modern crash test data available.
Basic radio systems with analog tuning, speaker configurations typical for the era.
Driver Assistance
Driver Assistance Features:
Limited to basic driver aids like power steering (where equipped) and standard braking systems; no electronic driver assistance features found in modern vehicles.
Connectivity
Connectivity Features:
No electronic connectivity features as understood in modern vehicles. Manual covers basic vehicle electrical systems.
🔧 Maintenance
Service Intervals
Service Intervals:
Details common service intervals for oil changes (e.g., 5,000-7,500 miles), filter replacements, spark plug changes, and brake inspections.
Spark Plug Replacement Interval:
Typically every 15,000-20,000 miles, depending on spark plug type and engine condition.
Air Filter Replacement Interval:
Every 15,000-30,000 miles or as needed based on driving conditions.
BMW recommended coolant mixture (e.g., ethylene glycol based antifreeze with distilled water).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (specific viscosity varies by temperature, e.g., 75W-90).
Transmission Fluid Automatic:
Dexron-III or equivalent ATF fluid.
Differential Fluid:
GL-5 gear oil (e.g., 75W-90).
Known Issues
Known Issues:
Common E21 issues covered may include fuel delivery problems, ignition system faults, rust susceptibility (especially in wheel wells and sills), cooling system leaks, and suspension wear.
📚 Vehicle History
Brand Heritage
Brand Heritage:
BMW's reputation for sporty sedans and driver-focused engineering, building on the success of the 02 Series.
Model Evolution
Model Evolution:
The first generation of the 3 Series, introduced in 1975 as a successor to the 02 Series, evolving into the iconic E21.
E21 Key Innovations:
Introduction of the McPherson strut front suspension, rack-and-pinion steering, and a more integrated chassis design compared to its predecessor.
Production
Production Years:
1975-1982 (model year 1981 falls within this range).