🏷️ Basic Information

Make:

BMW

Model:

3 Series Touring

Chassis Code:

E91

Model Years Covered:

2006-2010

Generation Name:

Fifth Generation 3 Series (E90/E91/E92/E93)

Generation Start Year:

2005

Generation End Year:

2013

👋 Introduction

Market Position:

The BMW E91 3 Series Touring represented BMW's premium compact executive estate offering, known for its sporty driving dynamics, sophisticated interior, and practical cargo space, competing with vehicles like the Audi A4 Avant and Mercedes-Benz C-Class Estate.

Competitive Analysis:

Positioned as a more driver-focused alternative to its German rivals, the E91 excelled in chassis tuning and engine responsiveness, offering a blend of performance and everyday usability.

Key Features:

Rear-wheel drive bias (xDrive AWD available), inline-four and inline-six engine options, premium interior materials, advanced chassis dynamics, practical wagon body style.

Manual Value Proposition:

This factory service manual is an indispensable tool for owners and technicians seeking to maintain, diagnose, and repair the BMW E91 3 Series Touring. It provides official procedures, specifications, and diagnostic information crucial for proper servicing.

📋 Manual Details

Engine Coverage:

N43B20, N46B20, N52B25, N52B30, M54B22, M54B25, M54B30, M57D25, M57D30, N57D30

Transmission Coverage:

6-speed manual (GS6-37BZ, GS6-17BG), 6-speed automatic (GA6HP19Z, GA6L45R)

Chassis Coverage:

Suspension, Steering, Brakes, Body Structure, Chassis Electrical

Electrical Coverage:

Engine Management, Body Control Modules (BCM), Comfort Systems, Infotainment, Lighting, Diagnostics

Body Coverage:

Exterior Body Panels, Interior Trim, Glass, Doors, Tailgate, Roof

Estimated Page Count:

1500+

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Systems:

Engine Mechanical, Fuel Delivery, Ignition System, Cooling System, Lubrication System, Emission Control, Engine Management (DME)

Drivetrain Systems:

Clutch, Transmission (Manual/Automatic), Drive Shafts, Differentials, Axles

Suspension Steering:

Front/Rear Suspension Components, Shock Absorbers, Springs, Control Arms, Bushings, Power Steering System

Braking Systems:

Brake System Components (ABS, DSC), Brake Discs, Pads, Lines, Calipers, Parking Brake

Electrical Systems:

Battery, Charging System, Starter Motor, Lighting (Interior/Exterior), Wipers, Horn, Fuses, Relays, Body Electronics

Comfort Systems:

Climate Control (HVAC), Power Seats, Power Windows, Sunroof, Central Locking, Remote Keyless Entry

Infotainment Navigation:

Radio, CD Player, Navigation System, Bluetooth, Speaker System

Safety Systems:

Airbag System, Seatbelt Pretensioners, Parking Sensors

Maintenance Procedures:

Oil Changes, Filter Replacements, Spark Plug Service, Fluid Checks and Replacements, Belt Inspection/Replacement

Diagnostic Procedures:

Troubleshooting Guides, Fault Code Interpretation (DTC), Diagnostic Tool Usage (ISTA/D)

Repair Procedures:

Engine Component Overhaul, Transmission Rebuilds, Suspension Component Replacement, Brake System Service, Electrical Component Repair

Adjustment Procedures:

Wheel Alignment, Headlight Aiming, Door/Tailgate Alignment

Installation Replacement:

Component Removal and Installation (e.g., Alternator, Starter, Water Pump, Control Arms)

Specification Tables:

Torque Specifications, Tolerances, Electrical Schematics

Technical Depth:

Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Searchability:

Full text searchable

Print Quality:

High resolution, suitable for printing

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Variants:

Common variants include the 2.0L N43B20 (petrol), 2.5L N52B25 (petrol), 3.0L N52B30 (petrol), 2.0L M47D20 (diesel - earlier E91s, but N47 took over), 2.0L N47D20 (diesel), and 3.0L M57D30 (diesel), 3.0L N57D30 (diesel).

320I N43B20:

150 PS (110 kW; 148 bhp) @ 6400 rpm, 200 Nm (148 lb-ft) @ 3600 rpm

325I N52B25:

218 PS (160 kW; 215 bhp) @ 6500 rpm, 250 Nm (184 lb-ft) @ 2750 rpm

330I N52B30:

258 PS (190 kW; 255 bhp) @ 6600 rpm, 300 Nm (221 lb-ft) @ 2500 rpm

320D N47D20:

177 PS (130 kW; 175 bhp) @ 4000 rpm, 350 Nm (258 lb-ft) @ 1750 rpm

Fuel System Petrol:

Direct Injection (N43) or Multi-Point Fuel Injection (N52, M54), Electronic Throttle Control (ETC)

Fuel System Diesel:

Common Rail Direct Injection (CRDI)

Engine Management System:

Digital Engine Electronics (DME) - e.g., MSV70, MSV80 for petrol; DDE (Digital Diesel Electronics) for diesel.

Cooling System Type:

Water-cooled, Thermostatically Controlled, Electric Fan (on most models).

Lubrication System Type:

Forced lubrication via oil pump, oil filter, oil cooler (on some variants).

🔧 Transmission

Standard Transmission:

6-speed Manual (e.g., GS6-37BZ for RWD, GS6-17BG for xDrive)

Optional Transmission:

6-speed Steptronic Automatic (e.g., GA6HP19Z, GA6L45R)

Automatic Transmission Features:

Adaptive shift programs, manual mode (Steptronic), sport mode.

Clutch Type:

Dry single-plate clutch (manual transmission)

Transfer Case AWD:

xDrive all-wheel drive system (electronically controlled multi-plate clutch).

📐 Dimensions

Length:

4527 mm (178.2 in)

Width:

1781 mm (70.1 in)

Height:

1418 mm (55.8 in)

Wheelbase:

2760 mm (108.7 in)

Passenger Volume:

Approx. 2.6 m³ (92 cu ft)

Cargo Volume Seats Up:

460 liters (16.2 cu ft)

Cargo Volume Seats Down:

1385 liters (48.9 cu ft)

Curb Weight Approx:

1500-1650 kg (3307-3638 lbs), depending on engine and drivetrain

Gross Vehicle Weight Rating Approx:

2000-2150 kg (4409-4740 lbs)

Towing Capacity Braked Approx:

1500-1800 kg (3307-3968 lbs)

🛡️ Safety Features

NHTSA Front Crash Test:

5-Star (for E90 Sedan, applicable to similar structural integrity in E91)

IIHS Front Offset Crash Test:

Good (for E90 Sedan)

Active Safety Features:

Anti-lock Braking System (ABS), Dynamic Stability Control (DSC), Dynamic Traction Control (DTC), Cornering Brake Control (CBC), Run-flat tires (optional).

Passive Safety Features:

Front airbags, Side airbags (integrated into seats), Head protection system (Air curtains), Seatbelt pretensioners, Active head restraints (front), Reinforced chassis.

Child Safety Anchors:

ISOFIX (child seat mounting points)

💡 Technology Features

Infotainment System:

iDrive system (various iterations), Professional Radio, Business CD, optional Navigation systems (CCC, CIC).

Connectivity Options:

Bluetooth hands-free interface, USB audio interface (optional), Aux input.

Driver Assistance Features:

Parking Distance Control (PDC) - front and rear, Cruise control, Rain-sensing wipers, Automatic headlights.

Comfort Features:

Dual-zone automatic climate control, Heated seats, Power-adjustable front seats with memory, Electric sunroof.

Lighting Technology:

Halogen headlights, optional Bi-Xenon headlights with Adaptive Headlights, LED taillights (on facelift models).

🔧 Maintenance

Oil Service Interval:

Condition Based Service (CBS): Typically 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil quality. Check CBS display for exact interval.

Spark Plug Replacement:

Petrol engines: Approx. 60,000 miles (check specific engine variant and documentation).

Brake Fluid Change:

Every 2 years (regardless of mileage).

Air Filter Replacement:

Approx. 30,000-40,000 miles or as per CBS.

Cabin Filter Replacement:

Annual replacement recommended, or as per CBS.

Engine Oil Specification:

BMW Longlife-01 (LL-01) or Longlife-04 (LL-04) for diesel engines. Viscosity grades typically 5W-30 or 0W-30. Always verify specific engine requirement.

Coolant Specification:

BMW Blue (G48) or BMW Pentosin XLC / G48. Mix with distilled water at 50/50 ratio.

Brake Fluid Specification:

DOT 4 High Performance.

Automatic Transmission Fluid:

ATF Dexron VI or equivalent. BMW recommends specific fluid (e.g., 83220039738 or 83222344016). Check manual for correct type per transmission code.

Manual Transmission Fluid:

BMW MTF LT-2 or MTF LT-3. Check manual for correct type per transmission code.

Known Issues:

Water pump failure (especially electric ones on later N52/N54), VANOS solenoid issues, Oil leaks (valve cover gasket, oil pan gasket), Injector issues (particularly on early N43 petrol engines), Glow plug issues (diesel), Thermostat failure, PCV valve issues (crankcase ventilation).

Oil Filter Example:

Mann-Filter HU816Z, Mahle OX353D, Hengst E1050LI

Air Filter Example:

Mann-Filter C35174, Mahle LX1815

Cabin Filter Example:

Mann-Filter CU25001 (Activated Carbon)

📚 Vehicle History

Brand Heritage:

BMW, Bayerische Motoren Werke AG, is a German luxury vehicle and motorcycle manufacturer renowned for its performance-oriented vehicles, premium quality, and innovative engineering since its founding in 1916.

E91 Model Evolution:

The E91 is the Touring (wagon) variant of the fifth-generation BMW 3 Series (E90 platform), which debuted in 2005. It replaced the E46 Touring and offered a significant advancement in technology, safety, and chassis dynamics. It was produced alongside the E90 sedan, E92 coupe, and E93 convertible.

Production Years E91:

2005-2012

Production Locations:

Mainly BMW's Munich plant, Germany, and Rosslyn, South Africa. Some assembly may have occurred in other BMW facilities or through contract manufacturing depending on market.

Facelift Year:

2008 (LCI - Life Cycle Impulse), which included updated exterior styling (headlights, taillights, bumpers), interior refinements, and new engine options.

🏆 Awards & Recognition

Award Examples:

While the E91 itself might not have individual awards, the 3 Series platform consistently received accolades for its driving dynamics, design, and safety from publications like Car and Driver, MotorTrend, and What Car?.

Consumer Ratings:

Generally high consumer satisfaction for build quality, driving experience, and engine performance, with typical criticisms focused on specific reliability concerns mentioned in maintenance.

Emissions Certifications:

Complies with Euro 4 (pre-facelift) and Euro 5 (post-facelift) emissions standards in Europe.