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BMW 3-series (E21) 1978 Service and Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Chassis Code: E21 Model Year: 1978 Generation Generation Code: E21 Production Start Year: 1975 Production End Year: 1983 Codes Engine Codes Covered: M10 (4-cylinder), M20 (6-cylinder) 👋 Introduction Market Position Positioning: High-quality, vehicle-specific factory repair manual for enthusiasts and professionals maintaining the iconic BMW E21 3 Series. Competitive Analysis Advantage: Direct access to dealer-level information, crucial for accurate diagnosis and repair of this classic German sports sedan. Key Features Feature 1: Vehicle-specific, factory-issued content. Feature 2: Complete A-Z repair coverage. Feature 3: Includes diagrams, illustrations, and wiring schematics. Feature 4: Digital format offers convenience and portability. Feature 5: Empowers owners to perform their own maintenance and repairs. 📋 Manual Details Coverage Areas Model Variants Covered: All E21 3 Series models (e.g., 316, 318, 320, 320i, 323i) Repair Scope: Comprehensive A-Z repairs Page Count Estimated Page Count: N/A (Digital Format) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Digital Compatibility: Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac 📖 Manual Coverage Systems Covered Engine: Engine overhaul, diagnostics, performance tuning, cooling system, lubrication system, fuel delivery and control, emission control systems, intake and exhaust systems. Drivetrain: Clutch, manual transmission, automatic transmission, transfer case (if applicable), propeller shaft, drive shafts, differential, axle, suspension systems (front and rear), steering system (column, power steering). Brakes: Brake control systems, hydraulic brake systems, parking brake, brake pad/shoe replacement, caliper/wheel cylinder service, brake bleeding procedures, drum and disc brake systems. Electrical: Ignition system, starting system, charging system (alternator/generator, starter motor, battery), lighting systems, instrumentation, meters, audio/visual systems, horn, windshield wipers and washers, door locks, power windows (if equipped), engine immobilizer, cruise control. Body And Interior: Bodywork, exterior trim, interior trim, seats, seat belts, supplemental restraint systems (airbags, if present), windshield, glass, mirrors, instrument panel, engine hood, doors. Climate Control: Air conditioning system service and repair. Wheels And Tires: Tire and wheel specifications, mounting, balancing. Multiplex Communication: CAN communication systems (relevant to the era). Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups, inspections. Diagnostics: Troubleshooting guides, symptom-based diagnostics, common fault identification. Repair: Step-by-step instructions for component removal, overhaul, and installation across all covered systems. Technical Data: Specifications, torque values, clearances, test procedures, wiring schematics. Technical Depth Depth: Factory-level, detailed diagnostic and repair procedures for technicians and advanced DIY enthusiasts. Accuracy: Vehicle-specific, not generic; identical to dealership technician manuals. 📊 Manual Specifications File Format Format Type: PDF Searchability: Implied searchable text within PDF Print Quality Printability: Yes, individual pages or sections can be printed. Image Scalability: Yes, diagrams and illustrations can be enlarged for printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) Requirements Software Requirements: Adobe PDF Reader, Winzip (free) ⚙️ Engine Specifications Primary Engine Engine Family: M10 (4-cylinder) and M20 (6-cylinder) 4 Cylinder Variants: 2.0L (e.g., 318, 320), 1.8L (e.g., 316) 6 Cylinder Variants: 2.3L (e.g., 323i), 2.0L (e.g., 320/6) Performance Typical Hp Range: 75 hp (316) to 143 hp (323i) Typical Torque Range: 120 Nm (316) to 205 Nm (323i) Fuel System Fuel Delivery: Carburetor (e.g., Solex, Zenith) for most models, Bosch K-Jetronic fuel injection for 320i and 323i. Fuel Type: Unleaded Gasoline (premium recommended for higher compression variants) Cooling System Type: Liquid-cooled Lubrication Oil Type Recommendation: API SG or SH, SAE 20W-50 or 10W-40 (refer to manual for precise viscosity based on climate) Ignition System Type: Distributor-based ignition system (e.g., Bosch) 🔧 Transmission Standard Type 4 Cylinder: 4-speed Manual Transmission Type 6 Cylinder: 4-speed or 5-speed Manual Transmission Optional Automatic Transmission: 3-speed Automatic Transmission (e.g., ZF 3HP18, 3HP22) available on most models. Features Clutch Type: Dry single-plate clutch Transmission Fluid Manual: Manual Gearbox Oil (e.g., SAE 75W-90 GL-4) Transmission Fluid Automatic: ATF Dexron II (or equivalent) 📐 Dimensions Exterior Wheelbase: Approx. 2563 mm (100.9 in) Length: Approx. 4360 mm (171.7 in) Width: Approx. 1670 mm (65.7 in) Height: Approx. 1380 mm (54.3 in) Weights Curb Weight Range: Approx. 1150 kg - 1300 kg (2535 lbs - 2866 lbs) depending on engine and equipment. 🛡️ Safety Features Ratings Era Safety Standards: Compliant with 1970s automotive safety standards; lacks modern active safety systems. Focus on passive safety elements. Active Features Active Safety: Four-wheel disc brakes on most higher-performance models (e.g., 323i); disc front/drum rear on others. Generally effective braking for its era. Passive Features Passive Safety: Rigid safety cage, energy-absorbing steering column, padded dashboard, three-point seat belts (standard front, optional rear). Windshield Glass: Laminated safety glass for windshield, toughened glass for side and rear windows. 💡 Technology Features Infotainment Infotainment Systems: Basic analog radio systems, optional cassette players. Limited in-car entertainment features by modern standards. Driver Assistance Driver Assistance Systems: None by modern definition. Focus on driver feedback and control. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 - 10,000 km (3,000 -...
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BMW 3-series (E21) 1978 Service and Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Chassis Code:
E21
Model Year:
1978
Generation
Generation Code:
E21
Production Start Year:
1975
Production End Year:
1983
Codes
Engine Codes Covered:
M10 (4-cylinder), M20 (6-cylinder)
👋 Introduction
Market Position
Positioning:
High-quality, vehicle-specific factory repair manual for enthusiasts and professionals maintaining the iconic BMW E21 3 Series.
Competitive Analysis
Advantage:
Direct access to dealer-level information, crucial for accurate diagnosis and repair of this classic German sports sedan.
Key Features
Feature 1:
Vehicle-specific, factory-issued content.
Feature 2:
Complete A-Z repair coverage.
Feature 3:
Includes diagrams, illustrations, and wiring schematics.
Feature 4:
Digital format offers convenience and portability.
Feature 5:
Empowers owners to perform their own maintenance and repairs.
📋 Manual Details
Coverage Areas
Model Variants Covered:
All E21 3 Series models (e.g., 316, 318, 320, 320i, 323i)
Repair Scope:
Comprehensive A-Z repairs
Page Count
Estimated Page Count:
N/A (Digital Format)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
Digital Compatibility:
Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, diagnostics, performance tuning, cooling system, lubrication system, fuel delivery and control, emission control systems, intake and exhaust systems.
Drivetrain:
Clutch, manual transmission, automatic transmission, transfer case (if applicable), propeller shaft, drive shafts, differential, axle, suspension systems (front and rear), steering system (column, power steering).
Brakes:
Brake control systems, hydraulic brake systems, parking brake, brake pad/shoe replacement, caliper/wheel cylinder service, brake bleeding procedures, drum and disc brake systems.
Electrical:
Ignition system, starting system, charging system (alternator/generator, starter motor, battery), lighting systems, instrumentation, meters, audio/visual systems, horn, windshield wipers and washers, door locks, power windows (if equipped), engine immobilizer, cruise control.
Body And Interior:
Bodywork, exterior trim, interior trim, seats, seat belts, supplemental restraint systems (airbags, if present), windshield, glass, mirrors, instrument panel, engine hood, doors.
Climate Control:
Air conditioning system service and repair.
Wheels And Tires:
Tire and wheel specifications, mounting, balancing.
Multiplex Communication:
CAN communication systems (relevant to the era).
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups, inspections.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, common fault identification.
Repair:
Step-by-step instructions for component removal, overhaul, and installation across all covered systems.
Technical Data:
Specifications, torque values, clearances, test procedures, wiring schematics.
Technical Depth
Depth:
Factory-level, detailed diagnostic and repair procedures for technicians and advanced DIY enthusiasts.
Accuracy:
Vehicle-specific, not generic; identical to dealership technician manuals.
📊 Manual Specifications
File Format
Format Type:
PDF
Searchability:
Implied searchable text within PDF
Print Quality
Printability:
Yes, individual pages or sections can be printed.
Image Scalability:
Yes, diagrams and illustrations can be enlarged for printing.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
Requirements
Software Requirements:
Adobe PDF Reader, Winzip (free)
⚙️ Engine Specifications
Primary Engine
Engine Family:
M10 (4-cylinder) and M20 (6-cylinder)
4 Cylinder Variants:
2.0L (e.g., 318, 320), 1.8L (e.g., 316)
6 Cylinder Variants:
2.3L (e.g., 323i), 2.0L (e.g., 320/6)
Performance
Typical Hp Range:
75 hp (316) to 143 hp (323i)
Typical Torque Range:
120 Nm (316) to 205 Nm (323i)
Fuel System
Fuel Delivery:
Carburetor (e.g., Solex, Zenith) for most models, Bosch K-Jetronic fuel injection for 320i and 323i.
Fuel Type:
Unleaded Gasoline (premium recommended for higher compression variants)
Cooling System
Type:
Liquid-cooled
Lubrication
Oil Type Recommendation:
API SG or SH, SAE 20W-50 or 10W-40 (refer to manual for precise viscosity based on climate)
Ignition
System Type:
Distributor-based ignition system (e.g., Bosch)
🔧 Transmission
Standard
Type 4 Cylinder:
4-speed Manual Transmission
Type 6 Cylinder:
4-speed or 5-speed Manual Transmission
Optional
Automatic Transmission:
3-speed Automatic Transmission (e.g., ZF 3HP18, 3HP22) available on most models.
Features
Clutch Type:
Dry single-plate clutch
Transmission Fluid Manual:
Manual Gearbox Oil (e.g., SAE 75W-90 GL-4)
Transmission Fluid Automatic:
ATF Dexron II (or equivalent)
📐 Dimensions
Exterior
Wheelbase:
Approx. 2563 mm (100.9 in)
Length:
Approx. 4360 mm (171.7 in)
Width:
Approx. 1670 mm (65.7 in)
Height:
Approx. 1380 mm (54.3 in)
Weights
Curb Weight Range:
Approx. 1150 kg - 1300 kg (2535 lbs - 2866 lbs) depending on engine and equipment.
🛡️ Safety Features
Ratings
Era Safety Standards:
Compliant with 1970s automotive safety standards; lacks modern active safety systems. Focus on passive safety elements.
Active Features
Active Safety:
Four-wheel disc brakes on most higher-performance models (e.g., 323i); disc front/drum rear on others. Generally effective braking for its era.
Passive Features
Passive Safety:
Rigid safety cage, energy-absorbing steering column, padded dashboard, three-point seat belts (standard front, optional rear).
Windshield Glass:
Laminated safety glass for windshield, toughened glass for side and rear windows.
💡 Technology Features
Infotainment
Infotainment Systems:
Basic analog radio systems, optional cassette players. Limited in-car entertainment features by modern standards.
Driver Assistance
Driver Assistance Systems:
None by modern definition. Focus on driver feedback and control.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 10,000 km (3,000 - 6,000 miles) or annually, depending on driving conditions and oil quality used.
Spark Plug Replacement:
Every 20,000 - 40,000 km (12,000 - 25,000 miles), depending on spark plug type.
Timing Belt Chain Service:
M10 and M20 engines use a timing chain, which requires inspection for wear and tensioner adjustment; no scheduled replacement interval unless symptomatic.
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5 - 5.5 liters (4.7 - 5.8 US quarts), varies by engine.
Coolant Capacity:
Approx. 7.0 - 8.0 liters (7.4 - 8.5 US quarts), varies by engine.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Issue 1:
Rust and corrosion, particularly on wheel arches, sills, and underbody.
Common Issue 2:
Carburetor tuning and fuel system issues (especially with older fuel and ethanol content).
Common Issue 3:
Aging rubber components (bushings, hoses, seals) leading to leaks and poor handling.
Common Issue 4:
Electrical system gremlins (corroded connections, failing relays, faulty grounds).
Common Issue 5:
Cooling system component wear (radiator leaks, fan clutch failure, thermostat issues).
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's reputation for 'The Ultimate Driving Machine' was solidified with the E21, emphasizing sporty handling, performance, and build quality.
Model Evolution
E21 Introduction:
Introduced in 1975 as the successor to the successful 02 Series, the E21 marked BMW's first foray into a modern compact executive sedan with a more integrated design and improved aerodynamics.
E21 Updates:
Facelifted in 1977 with minor styling revisions and engine upgrades; further updates in 1980 included revised engines, improved aerodynamics (e.g., front spoiler), and interior enhancements.
Production
Production Period:
1975-1983
Manufacturing Locations:
Germany (Munich, Dingolfing), South Africa, Belgium, and other assembly plants.
Total Production:
Over 1.3 million units
🏆 Awards & Recognition
Recognitions
Design Awards:
The E21's clean and functional design was well-received and set a benchmark for the compact executive class.
Ratings
Driving Dynamics Rating:
Consistently rated highly for its engaging driving dynamics and handling characteristics.
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