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BMW 318i 1991 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 318i Year: 1991 Chassis Code: E36 Codes Engine Code: M40B18 👋 Introduction Market Position Segment: Compact Executive Sedan Reputation: Known for its sporty handling, build quality, and driver-focused experience. Competitive Analysis Competitors: Mercedes-Benz 190E, Audi 80, Alfa Romeo 155, Volvo 240/740. Key Features Handling Dynamics: Renowned for its rear-wheel-drive dynamics and balanced chassis. Build Quality: Typical BMW build quality with a focus on durable materials. Driver Experience: Offers a connected and engaging driving experience. 📋 Manual Details Coverage Areas All Models Trims Engines Transmissions: True Page Count Estimated Page Count: Approximately 1000+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed engine overhaul, including cylinder head, block, pistons, rings, crankshaft, camshaft, timing systems, lubrication, and cooling. Engine Management: Bosch Motronic 1.3 fuel injection and ignition system diagnostics, component testing, and troubleshooting. Fuel System: Fuel pump, injectors, fuel pressure regulator, fuel filter replacement, and tank servicing. Cooling System: Radiator, water pump, thermostat, hoses, fan, and coolant specifications. Exhaust System: Catalytic converter, muffler, exhaust manifold, and gasket replacement. Transmission Manual: GmbH Getrag 5-speed manual transmission overhaul, clutch replacement, gear linkage adjustment, and fluid specifications. Transmission Automatic: ZF 4HP22 4-speed automatic transmission overhaul, torque converter, shift control, and fluid specifications. Drivetrain Rear Axle: Differential, driveshaft, CV joints, rear axle bearings, and seals. Suspension Front: MacPherson strut assembly, control arms, ball joints, sway bar, and wheel bearings. Suspension Rear: Multi-link independent rear suspension, trailing arms, shock absorbers, springs, and subframe. Steering System: Power steering pump, steering rack, tie rods, and alignment specifications. Brakes Front: Ventilated disc brakes, calipers, pads, rotors, and brake lines. Brakes Rear: Solid disc brakes, calipers, pads, rotors, and parking brake mechanism. Electrical System Charging: Alternator, voltage regulator, battery, and wiring diagrams. Electrical System Ignition: Ignition coil, spark plugs, distributor (if applicable), and ignition timing. Lighting System: Headlights, taillights, interior lights, and fuse box diagrams. Body Interior: Door panels, seats, dashboard, climate control vents, and trim removal. Body Exterior: Bumpers, fenders, hood, trunk lid, doors, mirrors, and glass replacement. Climate Control: HVAC system, blower motor, evaporator, condenser, heater core, and refrigerant charging. Safety Systems: Seat belts, airbag systems (if equipped), and ABS diagnostics (if applicable). Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks, belt inspections, and spark plug replacement. Troubleshooting Diagnostics: Step-by-step diagnostic procedures for common and complex issues, including symptom-based fault finding. Component Replacement: Detailed instructions for replacing all major and minor components of the vehicle. Engine Rebuild: Complete engine disassembly, inspection, measurement, and reassembly procedures. Transmission Repair: Detailed overhaul procedures for both manual and automatic transmissions. Brake System Service: Pad and rotor replacement, caliper service, brake fluid flush and bleed. Electrical Diagnostics: Wiring diagrams, component testing, and troubleshooting of electrical circuits. Suspension And Steering Alignment: Front and rear suspension component replacement, steering system repair, and wheel alignment specifications. Bodywork And Trim: Removal and installation of interior and exterior body panels and trim pieces. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Diagnostics Level: Advanced diagnostic procedures, including interpretation of fault codes and sensor data. Repair Scope: Covers routine maintenance to major component overhauls and rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for easy navigation and information retrieval. Print Quality: High-resolution, clear diagrams and text suitable for printing. Binding Type Binding: Not applicable (Digital PDF) Paper Type Paper: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, naturally aspirated Displacement: 1.8 liters (1796 cc) Bore X Stroke: 84.0 mm x 81.0 mm Compression Ratio: 8.8:1 Performance Horsepower Net: 113 hp (83 kW) @ 5500 rpm Torque Net: 119 lb-ft (162 Nm) @ 4250 rpm Fuel System Fuel Delivery: Bosch Motronic 1.3 Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (91 octane recommended) Fuel Tank Capacity: 55 liters (14.5 US gallons) Lubrication Oil Type: SAE 5W-30 or 5W-40 (API SG or higher) Oil Capacity W Filter: 4.25 liters (4.5 US quarts) 🔧 Transmission Standard Transmission Type: Getrag 260 5-speed manual transmission Optional Transmission Type: ZF 4HP22 4-speed automatic transmission Features Clutch Type: Single dry plate, hydraulic actuation (Manual) Automatic Control: Electronic control with Sport/Economy modes (Automatic) Fluid Specifications Manual Fluid: BMW Synchromesh Fluid (e.g., Pentosin MTF.00) Automatic Fluid: Dexron III/Mercon Automatic Transmission Fluid (ATF) 📐 Dimensions Exterior Length: 4430 mm (174.4 in) Width: 1711 mm (67.4 in) Height: 1393 mm (54.8 in) Wheelbase: 2700 mm (106.3 in) Front Track: 1418 mm (55.8 in) Rear Track: 1430 mm (56.3 in) Weights Curb Weight Manual: 1320 kg (2910 lbs) Curb Weight Automatic: 1345 kg (2965 lbs) Gross Vehicle Weight Rating Gvwr: 1800 kg (3968 lbs) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Not Rated (Vehicle predates extensive NHTSA testing protocols) IIHS Side Impact: Not Rated Active Features...
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Labels: 1991 318i BMW Car Cars Misc
BMW 318i 1991 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
318i
Year:
1991
Chassis Code:
E36
Codes
Engine Code:
M40B18
👋 Introduction
Market Position
Segment:
Compact Executive Sedan
Reputation:
Known for its sporty handling, build quality, and driver-focused experience.
Competitive Analysis
Competitors:
Mercedes-Benz 190E, Audi 80, Alfa Romeo 155, Volvo 240/740.
Key Features
Handling Dynamics:
Renowned for its rear-wheel-drive dynamics and balanced chassis.
Build Quality:
Typical BMW build quality with a focus on durable materials.
Driver Experience:
Offers a connected and engaging driving experience.
📋 Manual Details
Coverage Areas
All Models Trims Engines Transmissions:
True
Page Count
Estimated Page Count:
Approximately 1000+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed engine overhaul, including cylinder head, block, pistons, rings, crankshaft, camshaft, timing systems, lubrication, and cooling.
Engine Management:
Bosch Motronic 1.3 fuel injection and ignition system diagnostics, component testing, and troubleshooting.
Fuel System:
Fuel pump, injectors, fuel pressure regulator, fuel filter replacement, and tank servicing.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, and coolant specifications.
Exhaust System:
Catalytic converter, muffler, exhaust manifold, and gasket replacement.
Transmission Manual:
GmbH Getrag 5-speed manual transmission overhaul, clutch replacement, gear linkage adjustment, and fluid specifications.
Transmission Automatic:
ZF 4HP22 4-speed automatic transmission overhaul, torque converter, shift control, and fluid specifications.
Drivetrain Rear Axle:
Differential, driveshaft, CV joints, rear axle bearings, and seals.
Suspension Front:
MacPherson strut assembly, control arms, ball joints, sway bar, and wheel bearings.
Suspension Rear:
Multi-link independent rear suspension, trailing arms, shock absorbers, springs, and subframe.
Steering System:
Power steering pump, steering rack, tie rods, and alignment specifications.
Brakes Front:
Ventilated disc brakes, calipers, pads, rotors, and brake lines.
Brakes Rear:
Solid disc brakes, calipers, pads, rotors, and parking brake mechanism.
Electrical System Charging:
Alternator, voltage regulator, battery, and wiring diagrams.
Electrical System Ignition:
Ignition coil, spark plugs, distributor (if applicable), and ignition timing.
Lighting System:
Headlights, taillights, interior lights, and fuse box diagrams.
Body Interior:
Door panels, seats, dashboard, climate control vents, and trim removal.
Body Exterior:
Bumpers, fenders, hood, trunk lid, doors, mirrors, and glass replacement.
Climate Control:
HVAC system, blower motor, evaporator, condenser, heater core, and refrigerant charging.
Safety Systems:
Seat belts, airbag systems (if equipped), and ABS diagnostics (if applicable).
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, fluid checks, belt inspections, and spark plug replacement.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and complex issues, including symptom-based fault finding.
Component Replacement:
Detailed instructions for replacing all major and minor components of the vehicle.
Engine Rebuild:
Complete engine disassembly, inspection, measurement, and reassembly procedures.
Transmission Repair:
Detailed overhaul procedures for both manual and automatic transmissions.
Brake System Service:
Pad and rotor replacement, caliper service, brake fluid flush and bleed.
Electrical Diagnostics:
Wiring diagrams, component testing, and troubleshooting of electrical circuits.
Suspension And Steering Alignment:
Front and rear suspension component replacement, steering system repair, and wheel alignment specifications.
Bodywork And Trim:
Removal and installation of interior and exterior body panels and trim pieces.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics.
Diagnostics Level:
Advanced diagnostic procedures, including interpretation of fault codes and sensor data.
Repair Scope:
Covers routine maintenance to major component overhauls and rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for easy navigation and information retrieval.
Print Quality:
High-resolution, clear diagrams and text suitable for printing.
Binding Type
Binding:
Not applicable (Digital PDF)
Paper Type
Paper:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, naturally aspirated
Displacement:
1.8 liters (1796 cc)
Bore X Stroke:
84.0 mm x 81.0 mm
Compression Ratio:
8.8:1
Performance
Horsepower Net:
113 hp (83 kW) @ 5500 rpm
Torque Net:
119 lb-ft (162 Nm) @ 4250 rpm
Fuel System
Fuel Delivery:
Bosch Motronic 1.3 Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (91 octane recommended)
Fuel Tank Capacity:
55 liters (14.5 US gallons)
Lubrication
Oil Type:
SAE 5W-30 or 5W-40 (API SG or higher)
Oil Capacity W Filter:
4.25 liters (4.5 US quarts)
🔧 Transmission
Standard
Transmission Type:
Getrag 260 5-speed manual transmission
Optional
Transmission Type:
ZF 4HP22 4-speed automatic transmission
Features
Clutch Type:
Single dry plate, hydraulic actuation (Manual)
Automatic Control:
Electronic control with Sport/Economy modes (Automatic)
Fluid Specifications
Manual Fluid:
BMW Synchromesh Fluid (e.g., Pentosin MTF.00)
Automatic Fluid:
Dexron III/Mercon Automatic Transmission Fluid (ATF)
📐 Dimensions
Exterior
Length:
4430 mm (174.4 in)
Width:
1711 mm (67.4 in)
Height:
1393 mm (54.8 in)
Wheelbase:
2700 mm (106.3 in)
Front Track:
1418 mm (55.8 in)
Rear Track:
1430 mm (56.3 in)
Weights
Curb Weight Manual:
1320 kg (2910 lbs)
Curb Weight Automatic:
1345 kg (2965 lbs)
Gross Vehicle Weight Rating Gvwr:
1800 kg (3968 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Not Rated (Vehicle predates extensive NHTSA testing protocols)
IIHS Side Impact:
Not Rated
Active Features
ABS:
Anti-lock Braking System (ABS) available on some models
Traction Control:
Traction Control System (ASC) available on some later E36 models, less common on early '91 318i
Passive Features
Airbags:
Driver's side airbag standard, passenger airbag optional.
Seatbelts:
3-point inertia-reel seat belts with pretensioners for front occupants.
Body Structure:
Reinforced safety cage, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory BMW Business Cassette or CD player with optional amplifier.
Speakers:
Typically 4-6 speakers depending on options.
Driver Assistance
Cruise Control:
Optional electronic cruise control.
Onboard Computer:
Optional OBC (On-Board Computer) offering basic diagnostics and trip functions.
Connectivity
Bluetooth Integration:
Not factory equipped.
Usb Ports:
Not factory equipped.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, whichever comes first. Consult manual for specific conditions.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) with appropriate plugs (e.g., Bosch W8DC or equivalent).
Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Coolant:
BMW Blue Coolant or equivalent (50/50 mix with distilled water)
Power Steering Fluid:
Pentosin CHF 11S or equivalent Dexron III ATF (check manual for specific variant).
Brake Fluid:
DOT 4
Known Issues
Cooling System Leaks:
Plastic coolant expansion tanks and thermostat housings are prone to cracking.
Vanos System:
Not applicable to M40 engine, but later M50/M52 engines had VANOS issues.
Fuel Pump Reliability:
Fuel pumps can become weak over time, leading to hesitation or hard starting.
Window Regulators:
Plastic components in window regulators can break.
Idle Control Valve:
Can become dirty or fail, causing rough idle or stalling.
Driveshaft Center Bearing:
Can wear out, causing vibration at speed.
Heater Control Valve:
Common failure point, leading to no heat or insufficient heat.
📚 Vehicle History
Brand Heritage
Brand Legacy:
BMW's long-standing reputation for engineering excellence, performance, and luxury.
Model Evolution
E36 Introduction:
The E36 generation debuted in 1990, replacing the E30 3 Series. The 318i was a key entry-level model.
318I Positioning:
Positioned as the most accessible model in the E36 range, offering BMW characteristics at a lower price point.
Production
Production Start Year E36:
1990
Production End Year E36:
2000
Manufacturing Locations:
Germany (primarily Munich, Dingolfing, Regensburg), also South Africa, and parts assembly/final assembly in USA.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The E36 generation (including variants like the 325i) was frequently recognized by Car and Driver as one of its 10Best lists.
Ratings
Car Magazine Reviews:
Generally received excellent reviews for its handling, build quality, and value proposition as a premium sports sedan.
Certifications
Epa Fuel Economy City:
Approx. 19-21 MPG (Manual), 18-20 MPG (Automatic)
Epa Fuel Economy Highway:
Approx. 27-29 MPG (Manual), 25-27 MPG (Automatic)
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