BMW 320i 1991 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: 320i Year: 1991 Codes Chassis Code: E36 Engine Code Prefix: M40 👋 Introduction Market Position Positioning: The BMW 320i E36 represented BMW's entry-level luxury compact sedan, renowned for its sporty handling and premium feel, competing with vehicles like the Mercedes-Benz 190E and Audi 80. Competitive Analysis Competitors: Mercedes-Benz W201 (190E), Audi 80/90, Alfa Romeo 75, Saab 900 Key Features Handling: Renowned for its excellent chassis dynamics, rack-and-pinion steering, and balanced weight distribution, characteristic of BMW's 'Ultimate Driving Machine' ethos. Build Quality: High level of interior and exterior build quality, typical of German luxury vehicles of the era. 📋 Manual Details Coverage Areas Market Coverage: All Models/Engines/Trim/Transmission Types Page Count Estimated Pages: 500+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, tuning, fuel injection, ignition system, cooling system, exhaust system Transmission: Manual and Automatic transmission service, overhaul, diagnostics, fluid specifications Brakes: Disc and drum brake systems, ABS diagnostics and repair, hydraulic systems Electrical: Wiring diagrams, component testing, diagnostic procedures, ECU troubleshooting, lighting, power windows, central locking Suspension Steering: Front and rear suspension components, steering rack, power steering system, wheel alignment Bodywork: Panel removal and installation, door mechanisms, glass replacement, trim, interior components HVAC: Heating, ventilation, and air conditioning system service and repair Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and changes Troubleshooting: Diagnostic flowcharts, common fault finding, symptom-based troubleshooting Repair: Component replacement, engine rebuild procedures, transmission rebuild, brake caliper overhaul, suspension arm replacement Diagnostics: Engine management system diagnostics, sensor testing, actuator testing, ABS code reading Technical Depth Depth: Comprehensive, from basic fluid changes to complete engine and transmission overhauls, including electrical system diagnostics 📊 Manual Specifications File Format File Type: PDF Searchable: Yes Printable:...

Type: Car

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Sku: 433993

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Engine Code Prefix:

👋 Introduction

Market Position

Positioning:

The BMW 320i E36 represented BMW's entry-level luxury compact sedan, renowned for its sporty handling and premium feel, competing with vehicles like the Mercedes-Benz 190E and Audi 80.

Competitive Analysis

Competitors:

Mercedes-Benz W201 (190E), Audi 80/90, Alfa Romeo 75, Saab 900

Key Features

Handling:

Renowned for its excellent chassis dynamics, rack-and-pinion steering, and balanced weight distribution, characteristic of BMW's 'Ultimate Driving Machine' ethos.

Build Quality:

High level of interior and exterior build quality, typical of German luxury vehicles of the era.

📋 Manual Details

Coverage Areas

Market Coverage:

All Models/Engines/Trim/Transmission Types

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, tuning, fuel injection, ignition system, cooling system, exhaust system

Transmission:

Manual and Automatic transmission service, overhaul, diagnostics, fluid specifications

Brakes:

Disc and drum brake systems, ABS diagnostics and repair, hydraulic systems

Electrical:

Wiring diagrams, component testing, diagnostic procedures, ECU troubleshooting, lighting, power windows, central locking

Suspension Steering:

Front and rear suspension components, steering rack, power steering system, wheel alignment

Bodywork:

Panel removal and installation, door mechanisms, glass replacement, trim, interior components

HVAC:

Heating, ventilation, and air conditioning system service and repair

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks and changes

Troubleshooting:

Diagnostic flowcharts, common fault finding, symptom-based troubleshooting

Repair:

Component replacement, engine rebuild procedures, transmission rebuild, brake caliper overhaul, suspension arm replacement

Diagnostics:

Engine management system diagnostics, sensor testing, actuator testing, ABS code reading

Technical Depth

Depth:

Comprehensive, from basic fluid changes to complete engine and transmission overhauls, including electrical system diagnostics

📊 Manual Specifications

File Format

File Type:

Searchable:

Printable:

Print Quality

Image Resolution:

High-resolution for clear diagrams and text

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, naturally aspirated

Engine Code:

M40B20

Displacement:

1991 cc (2.0 L)

Bore X Stroke:

84.0 mm x 89.6 mm

Compression Ratio:

8.8:1

Performance

Horsepower:

129 PS (127 hp; 95 kW) @ 5500 rpm

Torque:

180 Nm (133 lb-ft) @ 4250 rpm

Fuel System

Fuel Delivery:

Bosch Motronic fuel injection (e.g., Motronic M1.3)

Fuel Type:

Unleaded gasoline (Octane rating typically 91 RON or higher)

Engine Features

Valve Train:

SOHC (Single Overhead Camshaft), 8 valves

Timing Drive:

Timing belt

🔧 Transmission

Standard

Type:

Getrag 260 5-speed manual transmission

Optional

Type:

ZF 4HP22 4-speed automatic transmission

Features

Clutch:

Hydraulically actuated single dry plate clutch

Fluid Specifications

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent (e.g., ATF Dexron II/III for some early models, check specific variant)

Automatic Transmission Fluid:

Dexron III or equivalent

📐 Dimensions

Exterior

Length:

4433 mm (174.5 in)

Width:

1711 mm (67.4 in)

Height:

1393 mm (54.8 in)

Wheelbase:

2700 mm (106.3 in)

Weights

Curb Weight:

Approx. 1300-1350 kg (2866-2976 lbs)

Gross Vehicle Weight:

Approx. 1800 kg (3968 lbs)

Wheels Tires

Standard Tire Size:

195/65 R15

Wheel Bolt Pattern:

5x120 mm

Wheel Offset:

🛡️ Safety Features

Ratings

Crash Test Era:

Early 90s safety standards (less stringent than modern standards). Euro NCAP not established for this model year.

Active Features

Available as an option on some models

Passive Features

Airbags:

Driver's side airbag standard or optional depending on market/trim.

Seatbelts:

Front seatbelt pre-tensioners

Chassis Design:

Reinforced passenger cell, crumple zones

💡 Technology Features

Infotainment

Audio System:

Standard cassette player and radio. Optional CD changer available. Early E36 models might have analog climate controls.

Driver Assistance

Cruise Control:

Available as an option.

Connectivity

Connectivity Features:

Limited by era; primarily focused on car systems, not external device connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000-15,000 km (6,000-10,000 miles) or annually, depending on driving conditions. Consult manual for specific recommendations.

Timing Belt Replacement:

Crucial! Recommended every 60,000-100,000 km (37,000-60,000 miles) or 4-5 years due to interference engine design. A snapped belt will cause severe engine damage.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 or 5W-40, API SJ/SL or ACEA A3/B3. Check manual for exact BMW approval (e.g., BMW Longlife-01 or LL-98).

Coolant Type:

BMW Blue Antifreeze/Coolant or equivalent (ethylene glycol based, phosphate-free).

Brake Fluid Type:

DOT 4

Known Issues

Cooling System:

Plastic coolant expansion tanks are prone to cracking. Water pump failure is also common.

Engine Management:

Mass Air Flow (MAF) sensor issues, Idle Control Valve (ICV) problems, VANOS (if applicable to later E36 models with M50/M52, but M40 does not have VANOS) issues on other E36 variants.

Suspension:

Worn control arm bushings, rear trailing arm bushings (RTABs), and shock absorber mounts are common, affecting handling and ride comfort.

Electrical:

Corroded battery terminals, faulty window regulators, heater blower motor resistor failure.

Fuel System:

Fuel pump failures can occur over time.

📚 Vehicle History

Brand Heritage

Brand Focus:

BMW, Bayerische Motoren Werke AG, is renowned for its performance-oriented luxury vehicles, sporty driving dynamics, and innovative engineering since its inception in 1916.

Model Evolution

E36 Introduction:

The E36 3 Series was introduced in 1990 as a successor to the highly successful E30. The 320i was a core model within this generation.

E36 Significance:

The E36 platform marked a significant technological leap for the 3 Series, introducing a more sophisticated multi-link rear suspension, improved aerodynamics, and advanced electronics.

Production

Production Years:

E36 3 Series production: 1990-2000. 1991 model year is an early production year for the E36.

Manufacturing Locations:

Primarily Germany (Munich, Dingolfing), but also plants in the USA, South Africa, and Mexico.

🏆 Awards & Recognition

Recognitions

Critical Acclaim:

The E36 generation was generally well-received for its driving dynamics and improved refinement over the E30, although some critics noted a slight loss of the raw feel of its predecessor.

Ratings

Car And Driver 10Best:

While the 320i itself might not have been explicitly on the 10Best list, the E36 generation as a whole was a frequent recipient of this award in various engine configurations (e.g., 325i, M3).