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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...
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Mots clés: 1991 320i BMW Car Cars Misc
BMW 320i 1991 Workshop Repair Service ManualBMW 320i 1991 Workshop Repair Service ManualBMW 320i 1991 Workshop Repair Service ManualBMW 320i 1991 Workshop Repair Service Manual
🏷️ 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:
Yes
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:
ET47
🛡️ 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
ABS:
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).
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