BMW 518i 1991 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 518i Year: 1991 Chassis Code: E34 👋 Introduction Market Position Market Segment: Mid-size luxury sedan, competing with Mercedes-Benz E-Class, Audi 100/200, and Lexus LS. Competitive Analysis Strengths Vs Competitors: Known for superior handling dynamics, driver engagement, and build quality. The 518i offered a more accessible entry into BMW's premium sedan segment. Key Features Distinctive Features: Rear-wheel drive platform, sophisticated multi-link rear suspension, comfortable and driver-focused interior, iconic BMW design language. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Clutch, Transmission (Manual & Automatic), Driveshaft, Differential, Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Electrical System (Wiring Diagrams, Lighting, Instrumentation, Accessories), Body & Chassis, Climate Control, Diagnostic Procedures. Page Count Estimated Page Count: Approximately 500-1000 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English (primary, based on product description) Format Format: Likely a digital format (PDF) or a collection of scanned documents, designed for workshop use. 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly and assembly of engine components including cylinder head, pistons, connecting rods, crankshaft, camshafts, timing chain/belt, lubrication system. Fuel System: Bosch Motronic fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel tank and lines. Ignition System: Distributorless ignition system (DIS) components, coil packs, spark plugs, ignition timing adjustments. Cooling System: Radiator, water pump, thermostat, coolant hoses, fan operation, coolant specifications and capacities. Exhaust System: Exhaust manifolds, catalytic converter (if applicable for market), mufflers, pipes, oxygen sensors. Drivetrain Manual Transmission: Manual gearbox overhaul, clutch replacement, gear shift linkage, driveshaft, universal joints, rear axle differential. Drivetrain Automatic Transmission: Automatic transmission service, fluid change, torque converter, shift linkage adjustments (if applicable to the 518i). Suspension Front: MacPherson strut design, control arms, ball joints, sway bar, wheel bearings, alignment specifications. Suspension Rear: Multi-link independent rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications. Steering System: Power steering system, steering rack, tie rods, power steering pump, fluid type and capacity. Brakes Front: Ventilated disc brakes, brake calipers, pads, rotors, brake lines, ABS system (if equipped). Brakes Rear: Solid disc brakes, brake calipers, pads, rotors, parking brake mechanism, brake lines, ABS system (if equipped). Electrical System Overview: Comprehensive wiring diagrams, component identification, electrical troubleshooting techniques. Lighting And Accessories: Headlights, taillights, interior lighting, power windows, central locking, mirrors, wipers, horn. Instrumentation And Gauges: Speedometer, tachometer, fuel gauge, temperature gauge, warning lights, OBC (On-Board Computer) functions. Body And Chassis: Body panel removal and installation, door mechanisms, interior trim, glass replacement, rust prevention and repair guidance. Climate Control: HVAC system, heater core, A/C system components, refrigerant types (R12 for this era), blower motor, controls. Diagnostic Procedures: Troubleshooting charts, symptom-based diagnostics, common fault codes (if applicable for this era's diagnostics). Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change. Engine Overhaul: Complete engine rebuild procedures, cylinder head gasket replacement, piston ring replacement, bearing replacement. Transmission Repair: Manual gearbox component replacement, automatic transmission internal component repair (where feasible). Brake System Repair: Brake pad and rotor replacement, caliper overhaul, brake line replacement, bleeding procedures. Suspension And Steering Repair: Replacement of ball joints, tie rod ends, control arm bushings, shock absorbers, struts, steering rack replacement. Electrical Troubleshooting: Diagnosing and repairing wiring faults, component testing, fuse and relay identification. Bodywork And Trim: Removal and installation of exterior body panels, interior trim pieces, door handles, glass. Climate Control Service: A/C system servicing (likely requires specialized equipment and knowledge for R12 systems), heater core replacement, control module diagnostics. Technical Depth Depth Of Coverage: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications. Diagnostic Information: Detailed troubleshooting charts, electrical schematics, component testing procedures, and likely on-board diagnostics information for the era. Specifications And Tolerances: Includes critical torque specifications, wear tolerances, and measurement guidelines for engine, drivetrain, suspension, and braking components. 📊 Manual Specifications File Format File Format: Likely PDF, often with selectable text for searchability. May also be scanned image-based PDFs. Print Quality Print Quality: High-quality digital reproduction of original workshop manuals, ensuring clarity of text and diagrams. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, naturally aspirated petrol Engine Code Designation: M40B18 Displacement: 1.8 liters (1796 cc) Bore X Stroke: 84.0 mm x 81.0 mm Compression Ratio: 8.8:1 or 9.2:1 (depending on market and specific variant) Performance Horsepower: 113 hp (83 kW) at 5600 rpm Torque: 164 Nm (121 lb-ft) at 4250 rpm Fuel System Fuel Injection System: Bosch Motronic M1.3 or M3.3 (Electronic Fuel Injection and Ignition) Fuel Type: Unleaded gasoline (RON 91-95) Engine Design Valvetrain: Single Overhead Camshaft (SOHC), 8 valves Cooling Method: Water-cooled 🔧...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Chassis Code:

👋 Introduction

Market Position

Market Segment:

Mid-size luxury sedan, competing with Mercedes-Benz E-Class, Audi 100/200, and Lexus LS.

Competitive Analysis

Strengths Vs Competitors:

Known for superior handling dynamics, driver engagement, and build quality. The 518i offered a more accessible entry into BMW's premium sedan segment.

Key Features

Distinctive Features:

Rear-wheel drive platform, sophisticated multi-link rear suspension, comfortable and driver-focused interior, iconic BMW design language.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Clutch, Transmission (Manual & Automatic), Driveshaft, Differential, Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Electrical System (Wiring Diagrams, Lighting, Instrumentation, Accessories), Body & Chassis, Climate Control, Diagnostic Procedures.

Page Count

Estimated Page Count:

Approximately 500-1000 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Manual Type:

Service and Repair Workshop Manual

Language

Language:

English (primary, based on product description)

Format

Format:

Likely a digital format (PDF) or a collection of scanned documents, designed for workshop use.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly and assembly of engine components including cylinder head, pistons, connecting rods, crankshaft, camshafts, timing chain/belt, lubrication system.

Fuel System:

Bosch Motronic fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel tank and lines.

Ignition System:

Distributorless ignition system (DIS) components, coil packs, spark plugs, ignition timing adjustments.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan operation, coolant specifications and capacities.

Exhaust System:

Exhaust manifolds, catalytic converter (if applicable for market), mufflers, pipes, oxygen sensors.

Drivetrain Manual Transmission:

Manual gearbox overhaul, clutch replacement, gear shift linkage, driveshaft, universal joints, rear axle differential.

Drivetrain Automatic Transmission:

Automatic transmission service, fluid change, torque converter, shift linkage adjustments (if applicable to the 518i).

Suspension Front:

MacPherson strut design, control arms, ball joints, sway bar, wheel bearings, alignment specifications.

Suspension Rear:

Multi-link independent rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications.

Steering System:

Power steering system, steering rack, tie rods, power steering pump, fluid type and capacity.

Brakes Front:

Ventilated disc brakes, brake calipers, pads, rotors, brake lines, ABS system (if equipped).

Brakes Rear:

Solid disc brakes, brake calipers, pads, rotors, parking brake mechanism, brake lines, ABS system (if equipped).

Electrical System Overview:

Comprehensive wiring diagrams, component identification, electrical troubleshooting techniques.

Lighting And Accessories:

Headlights, taillights, interior lighting, power windows, central locking, mirrors, wipers, horn.

Instrumentation And Gauges:

Speedometer, tachometer, fuel gauge, temperature gauge, warning lights, OBC (On-Board Computer) functions.

Body And Chassis:

Body panel removal and installation, door mechanisms, interior trim, glass replacement, rust prevention and repair guidance.

Climate Control:

HVAC system, heater core, A/C system components, refrigerant types (R12 for this era), blower motor, controls.

Diagnostic Procedures:

Troubleshooting charts, symptom-based diagnostics, common fault codes (if applicable for this era's diagnostics).

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change.

Engine Overhaul:

Complete engine rebuild procedures, cylinder head gasket replacement, piston ring replacement, bearing replacement.

Transmission Repair:

Manual gearbox component replacement, automatic transmission internal component repair (where feasible).

Brake System Repair:

Brake pad and rotor replacement, caliper overhaul, brake line replacement, bleeding procedures.

Suspension And Steering Repair:

Replacement of ball joints, tie rod ends, control arm bushings, shock absorbers, struts, steering rack replacement.

Electrical Troubleshooting:

Diagnosing and repairing wiring faults, component testing, fuse and relay identification.

Bodywork And Trim:

Removal and installation of exterior body panels, interior trim pieces, door handles, glass.

Climate Control Service:

A/C system servicing (likely requires specialized equipment and knowledge for R12 systems), heater core replacement, control module diagnostics.

Technical Depth

Depth Of Coverage:

Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.

Diagnostic Information:

Detailed troubleshooting charts, electrical schematics, component testing procedures, and likely on-board diagnostics information for the era.

Specifications And Tolerances:

Includes critical torque specifications, wear tolerances, and measurement guidelines for engine, drivetrain, suspension, and braking components.

📊 Manual Specifications

File Format

File Format:

Likely PDF, often with selectable text for searchability. May also be scanned image-based PDFs.

Print Quality

Print Quality:

High-quality digital reproduction of original workshop manuals, ensuring clarity of text and diagrams.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, naturally aspirated petrol

Engine Code Designation:

M40B18

Displacement:

1.8 liters (1796 cc)

Bore X Stroke:

84.0 mm x 81.0 mm

Compression Ratio:

8.8:1 or 9.2:1 (depending on market and specific variant)

Performance

Horsepower:

113 hp (83 kW) at 5600 rpm

Torque:

164 Nm (121 lb-ft) at 4250 rpm

Fuel System

Fuel Injection System:

Bosch Motronic M1.3 or M3.3 (Electronic Fuel Injection and Ignition)

Fuel Type:

Unleaded gasoline (RON 91-95)

Engine Design

Valvetrain:

Single Overhead Camshaft (SOHC), 8 valves

Cooling Method:

Water-cooled

🔧 Transmission

Standard

Transmission Type Standard:

Getrag 260 5-speed manual transmission

Optional

Transmission Type Optional:

ZF 4HP22 4-speed automatic transmission

Features

Clutch Type:

Single dry plate, hydraulically operated (manual)

Drivetrain:

Rear-wheel drive

Gear Ratios Manual:

Typical ratios: 1st: 4.01, 2nd: 2.04, 3rd: 1.32, 4th: 1.00, 5th: 0.81, Reverse: 3.74 (subject to variation)

📐 Dimensions

Exterior

Length:

4730 mm (186.2 in)

Width:

1751 mm (68.9 in)

Height:

1410 mm (55.5 in)

Wheelbase:

2795 mm (110.0 in)

Weights

Curb Weight:

Approx. 1400-1450 kg (3086-3197 lbs)

Gross Vehicle Weight Rating:

Approx. 1850-1900 kg (4079-4189 lbs)

Cargo

Trunk Capacity:

Approx. 450 liters (15.9 cu ft)

🛡️ Safety Features

Ratings

Safety Ratings:

No specific crash test ratings readily available from official bodies like NHTSA or Euro NCAP for this specific model year and variant, as such testing was less standardized and publicly available in 1991.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS) - Optional on some models, but commonly available. Power-assisted brakes.

Passive Features

Passive Safety Features:

Reinforced passenger safety cell, energy-absorbing steering column, three-point seat belts (front and rear), driver and front passenger airbags (optional on early E34 models, but often present on later 1991 cars).

💡 Technology Features

Infotainment

Infotainment System:

Basic AM/FM radio with cassette player. Optional CD changer available. Emphasis on sound quality for its era.

Driver Assistance

Driver Assistance Features:

ABS (Anti-lock Braking System) was a key feature, optional on lower trims. Traction control (ASC) was available on higher-spec E34 models, less common on the 518i.

Connectivity

Connectivity Features:

Limited connectivity by modern standards. Features included power windows, power mirrors, central locking, and optional features like cruise control and power seats.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 to 10,000 miles (12,000 to 16,000 km) or annually, whichever comes first. Specific interval depends on driving conditions and oil used.

Air Filter Replacement:

Every 15,000 to 30,000 miles (24,000 to 48,000 km) or annually, or as needed based on inspection.

Spark Plug Replacement:

Every 30,000 to 40,000 miles (48,000 to 64,000 km) for standard plugs, or longer for platinum/iridium (though less common in this era). Refer to manual for exact type.

Fluid Specifications

Engine Oil Type:

API SG/SH, ACEA A2 or A3. Viscosity typically 5W-30, 5W-40, 10W-40, or 10W-50 depending on ambient temperature. Consult manual for precise recommendations.

Engine Oil Capacity:

Approximately 4.5 liters (4.8 US quarts) with filter change.

Coolant Type:

Ethylene glycol based antifreeze. BMW recommends their own coolant or equivalent that meets BMW specifications. Typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 or DOT 3 (check specific vehicle application, DOT 4 preferred for systems with ABS).

Power Steering Fluid Type:

BMW specified hydraulic fluid, often Dexron II or III ATF for this era, or a specific CHF 11S for some hydraulic systems. Manual consultation is vital.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil. Viscosity typically 75W-90 or 80W-90.

Transmission Fluid Automatic:

Dexron II or Dexron III Automatic Transmission Fluid (ATF). BMW may have had specific formulations.

Known Issues

Common Problems M40 Engine:

Head gasket failure (due to design with coolant passages near combustion chambers), timing chain tensioner wear and failure (can lead to valve damage), oil leaks from valve cover gasket and oil pan. The M40 engine used a duplex timing chain in some later variants, but earlier ones had issues.

Common Problems E34 Chassis:

Coolant leaks from plastic coolant pipes and reservoir, failing blower motor resistors (leading to non-functional HVAC fan speeds), sagging headliner, worn suspension bushings (especially rear trailing arm bushings), ABS sensor failures, rust in common areas (wheel wells, rocker panels, around windows).

Common Problems Electrical:

Corroded wiring harness connectors, failing OBC display pixels, intermittent power to accessories, door lock actuator failure.

📚 Vehicle History

Brand Heritage

Bmw Philosophy At The Time:

BMW's reputation for 'The Ultimate Driving Machine' was firmly established, emphasizing performance, engineering, and driver involvement.

Model Evolution

E34 Generation Introduction:

The E34 generation of the 5 Series was introduced in 1987 (as a 1988 model year) and represented a significant evolution in BMW's mid-size executive sedan offerings, replacing the E28.

518I Positioning:

The 518i was typically the entry-level model in the E34 lineup, offering a more fuel-efficient and affordable option while still providing the core BMW driving experience.

Production

Manufacturing Location:

Primarily manufactured in Dingolfing, Germany, with potential assembly in other international locations.

Production Years E34:

1987-1996 (sedan), 1990-1996 (touring)

🏆 Awards & Recognition

Recognitions

Automotive Journalism Recognition:

The E34 generation as a whole received widespread critical acclaim for its driving dynamics, build quality, and refined engineering from automotive publications like Car and Driver, MotorTrend, and Road & Track upon its release.