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BMW 316i 1991 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 316i Year: 1991 Generation Chassis Code: E36 Codes Engine Code Family: M40 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Target Audience: Enthusiast...
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BMW 316i 1991 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
316i
Year:
1991
Generation
Chassis Code:
E36
Codes
Engine Code Family:
M40
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Target Audience:
Enthusiast owners, DIY mechanics, professional workshops
Competitive Analysis
Key Competitors:
Mercedes-Benz 190E, Audi 80, Alfa Romeo 155, Volvo 240/740
Key Features
Driving Dynamics:
Renowned BMW handling, balanced chassis, rear-wheel drive platform
Build Quality:
Reputation for solid build and durable engineering
📋 Manual Details
Coverage Areas
Primary Market:
Global (with region-specific variations)
Region Focus:
Primarily European market specification
Page Count
Estimated Pages:
500-800 (typical for a comprehensive service manual)
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, engine management (DME), cooling system
Transmission:
Manual transmission (Getrag 260/5), clutch system, automatic transmission (optional, e.g., ZF 4HP22/24 - though less common for 316i)
Chassis:
Suspension (front MacPherson struts, rear multi-link), steering system (power assisted), braking system (front vented discs, rear discs), wheels and tires
Electrical:
12V electrical system, battery, alternator, starter motor, lighting system, instrumentation, basic body electronics, fuse box locations and functions
Body:
Body shell construction, exterior trim, interior trim, doors, windows, seats, HVAC system (heating, ventilation, air conditioning - if equipped)
Procedures Included
Maintenance:
Routine maintenance (oil changes, filter replacements, spark plugs, coolant checks), brake pad/rotor replacement, fluid flushes
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems; diagnostic trouble codes (DTCs) where applicable to the era
Repair:
Detailed step-by-step repair instructions for major components: engine rebuild (pistons, rings, bearings), cylinder head, transmission overhaul, brake caliper rebuilding, suspension component replacement
Refurbishment:
Guidance on restoring worn or damaged components, bodywork repair, interior refurbishment
Technical Depth
Diagnostic Level:
Advanced diagnostics including interpretation of sensor data (where possible with era-appropriate tools), circuit testing, and mechanical fault finding.
Rebuild Scope:
Complete engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences.
Electrical Schematics:
Inclusion of detailed wiring diagrams for major systems.
📊 Manual Specifications
File Format
Searchability:
Searchable text for quick access to information.
Resolution:
High resolution for clear visibility of diagrams and text.
Print Quality
Printability:
Designed for easy printing of specific sections or the entire manual.
Binding Type
Binding:
Not applicable (Digital PDF format)
Paper Type
Paper Type:
Not applicable (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, DOHC, 16-valve (M40B18 engine variant for 316i)
Displacement:
1796 cc (1.8 Liters)
Bore X Stroke:
84 mm x 81 mm
Compression Ratio:
8.8:1
Power Output Hp:
100 hp (74 kW) @ 5000 rpm
Power Output Ps:
102 PS @ 5000 rpm
Torque Output Nm:
150 Nm (111 lb-ft) @ 3250 rpm
Performance
0 To 60 Mph:
11.4 seconds (approx.)
Top Speed:
192 km/h (119 mph)
Fuel System
Fuel Delivery:
Bosch Motronic M1.3 Fuel Injection
Fuel Type:
Unleaded gasoline (RON 91 minimum)
Fuel Tank Capacity:
55 Liters (14.5 US gallons)
🔧 Transmission
Standard
Type:
5-speed Manual (Getrag 260/5)
Optional
Type:
4-speed Automatic (ZF 4HP22/24 - less common for 316i, more for larger engines)
Features
Clutch:
Hydraulically actuated single dry plate clutch
📐 Dimensions
Exterior
Length:
4433 mm (174.5 inches)
Width:
1711 mm (67.4 inches)
Height:
1370 mm (53.9 inches)
Wheelbase:
2700 mm (106.3 inches)
Weights
Curb Weight Kg:
1320 kg (approx.)
Gross Vehicle Weight Rating Kg:
1800 kg (approx.)
Cargo
Trunk Volume Liters:
430 Liters (approx.)
🛡️ Safety Features
Ratings
Crash Test Era:
Tests from the era, often focusing on frontal impact. Later E36 models saw improvements.
Active Features
ABS:
Anti-lock Braking System (ABS) - standard on most European models
Passive Features
Airbags:
Driver's airbag - optional on early E36 models, standard on later ones
Seatbelts:
Three-point inertia-reel seatbelts front and rear
Chassis Design:
Reinforced safety cell, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory BMW AM/FM cassette player, optional CD player integration
Display:
Basic LCD display for radio and clock
Driver Assistance
Cruise Control:
Optional
Connectivity
Connectivity Features:
Limited; analog systems. Optional remote central locking available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000-15,000 km (6,000-10,000 miles) or annually
Spark Plug Replacement:
Every 40,000-60,000 km (25,000-37,000 miles)
Coolant Flush:
Every 2-3 years or 40,000-60,000 km
Transmission Fluid Change:
Manual: Inspect, typically no fixed interval; Automatic: Every 60,000-100,000 km
Fluid Specifications
Engine Oil Type:
BMW Longlife-98 (LL-98) or equivalent SAE 5W-30, 5W-40, or 10W-40 (check owner's manual for precise viscosity based on climate)
Engine Oil Capacity:
4.5 Liters (4.8 US Quarts) with filter change
Coolant Type:
BMW Blue Antifreeze/Coolant (ethylene glycol based) mixed 50/50 with distilled water
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Pentosin CHF 11S or Dexron III (check specific vehicle requirement)
Known Issues
Head Gasket:
M40 engine can be prone to head gasket issues if overheated.
Cooling System:
Plastic coolant expansion tank can become brittle and crack.
Suspension Bushings:
Worn control arm bushings and trailing arm bushings can lead to vague handling.
Electrical Connectors:
Corrosion on electrical connectors, particularly in older vehicles.
Window Regulators:
Plastic components in window regulators can degrade.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
Sheer Driving Pleasure, focus on performance and driver engagement
Model Evolution
E30 Successor:
The E36 generation replaced the highly successful E30 3 Series.
E36 Design:
Marked a significant departure in styling and technology, featuring more aerodynamic lines and a modernized interior.
Production
Production Period:
1990-2000 (E36 generation)
Manufacturing Locations:
Germany (Dingolfing, Munich), Austria, South Africa, Mexico, Thailand, and more.
🏆 Awards & Recognition
Recognitions
E36 Generation Reputation:
The E36 generation was generally well-received for its driving dynamics and modern design, though the 316i was positioned as the entry-level model.
Benchmark Status:
Set a benchmark in its class for handling and chassis tuning.
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