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...

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Distributeur:

UGS: 433839

Mots clés: 1991 318i BMW Car Cars Misc

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Chassis Code:

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:

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:

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

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:

Production End Year E36:

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)