BMW 3 Series E30 1991 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Code: E30 Model Year: 1991 Chassis Type: Sedan, Coupe, Convertible, Touring (Wagon) 👋 Introduction Market Position Segment: Compact Executive/Sports Sedan...

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Type: Car

Vendor:

Sku: 431846

Tags: 1991 3 Series E30 BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

3 Series

Model Code:

Model Year:

Chassis Type:

Sedan, Coupe, Convertible, Touring (Wagon)

👋 Introduction

Market Position

Segment:

Compact Executive/Sports Sedan

Target Audience:

Enthusiasts, DIY mechanics, professional repair shops specializing in BMW.

Competitive Analysis

Competitors 1991:

Mercedes-Benz 190E, Audi 80/90, Alfa Romeo 75, Saab 900, Acura Integra.

Key Features

Handling:

Renowned for its balanced chassis, rear-wheel drive dynamics, and engaging driving experience.

Build Quality:

Typical BMW build quality, known for durability and driver-focused ergonomics.

Design:

Iconic 'E30' design language, considered a classic automotive styling.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF)

Coverage Scope:

Comprehensive service and repair instructions for mechanics

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, assembly, disassembly, timing, lubrication, cooling, fuel delivery (carburetor and fuel injection), exhaust systems.

Engine Management:

Ignition system, engine control unit (ECU) diagnostics and repair, sensor testing, fuel injection system troubleshooting (Bosch Motronic variants).

Transmission Manual:

Service, repair, and overhaul of 5-speed Getrag and ZF manual gearboxes used in E30 models.

Transmission Automatic:

Service, repair, and overhaul of ZF 4-speed automatic transmissions, including hydraulic control systems and torque converter.

Drivetrain:

Driveshaft, differential, rear axle service and repair, limited-slip differential (LSD) information.

Suspension:

Front and rear suspension systems, including struts, shocks, control arms, bushings, springs, anti-roll bars, and alignment procedures.

Brakes:

Hydraulic brake system, disc and drum brake service, ABS (if equipped) troubleshooting and repair, master cylinder, brake lines, calipers, pads, rotors.

Steering:

Power steering system service, steering rack, tie rods, steering column, and related components.

Electrical System:

Comprehensive wiring diagrams, battery, alternator, starter motor, lighting systems, fuses, relays, diagnostic connectors.

Body And Chassis:

Body panel repair, door mechanisms, interior trim removal, glass replacement, chassis lubrication.

HVAC:

Heating, ventilation, and air conditioning system service and repair, including refrigerant handling and component replacement.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter replacement, and pressure testing.

Procedures Included

Preventative Maintenance:

Regular maintenance tasks such as oil changes, filter replacements, spark plug changes, coolant flushes, and brake fluid flushes.

Troubleshooting:

Diagnostic procedures for common and uncommon problems across all vehicle systems, including symptom-based troubleshooting guides.

Repair And Rebuild:

Detailed step-by-step instructions for the repair and complete overhaul of major vehicle components and systems.

Component Replacement:

Instructions for replacing individual parts and assemblies, such as water pumps, alternators, starter motors, brake calipers, and suspension arms.

Torque Specifications:

Essential torque values for all critical fasteners and bolts throughout the vehicle.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

Technical Depth

Depth Level:

Professional Mechanic Level

Diagnostic Capability:

Advanced diagnostic procedures for engine management, electrical faults, and mechanical issues.

Rebuild Instructions:

Detailed instructions for complete engine, transmission, and differential rebuilds.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Text-searchable for quick access to information.

Printable:

Printable pages for in-garage use.

Image Quality:

High-resolution diagrams, illustrations, and photographs.

Binding Type

Binding Method:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Variants:

M40 (4-cylinder, 1.6L, 1.8L SOHC), M20 (6-cylinder, 2.0L, 2.5L SOHC), M10 (4-cylinder, 1.8L SOHC - early 91 models), S14 (4-cylinder, 2.3L, 2.5L DOHC - M3 variants).

Performance

Typical Hp Range:

90 hp (1.6L) to 170 hp (325i), up to 238 hp (E30 M3 Sport Evolution).

Typical Torque Range:

100 lb-ft to 160 lb-ft.

Fuel System

Injection System:

Bosch L-Jetronic or Motronic fuel injection on most models; Carburetion on some early 316i/318i variants.

Recommended Fuel:

Premium Unleaded (91 octane or higher recommended for most variants).

🔧 Transmission

Standard

Standard Transmission:

4-speed or 5-speed manual (Getrag 260/5 or ZF S5-16 for many models).

Optional

Optional Transmission:

ZF 4HP22 4-speed automatic transmission.

Features

Clutch Type:

Single dry plate, hydraulically actuated.

Differential:

Open differential standard, optional limited-slip differential (LSD) available on many models, particularly sport variants.

📐 Dimensions

Exterior

Wheelbase:

Approx. 101.2 inches (2570 mm).

Length:

Approx. 170.5 inches (4330 mm) for sedan/coupe.

Width:

Approx. 65.4 inches (1660 mm).

Height:

Approx. 55.4 inches (1407 mm) for sedan/coupe.

Weights

Curb Weight Range:

Approx. 2600 - 3000 lbs (1180 - 1360 kg) depending on body style and engine.

Gross Vehicle Weight Rating:

Varies by model, typically around 3800-4000 lbs.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not rated by NHTSA under modern standards. Early E30s predated many rigorous testing protocols.

Active Features

Optional on many models, standard on some higher-performance variants.

Traction Control:

Rarely available, typically only on very late or specialized models.

Passive Features

Airbags:

Driver airbag became optional/standard in later years of the E30 generation, particularly on 1990-1991 models. Passenger airbags were not common.

Seatbelts:

3-point inertia-reel seatbelts front and rear.

Crumple Zones:

Designed with front and rear crumple zones for energy absorption.

💡 Technology Features

Infotainment

Radio:

Factory AM/FM radio with cassette player, often with optional premium sound systems. Aftermarket head unit upgrades are common.

Speakers:

Typically 4-6 speakers, with some models featuring upgraded 'HiFi' systems.

Driver Assistance

Cruise Control:

Optional on many models.

Connectivity

Auxiliary Input:

Not standard. Aftermarket solutions required for audio connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or annually, depending on driving conditions and oil type used. Check manual for specific recommendations.

Spark Plug Replacement:

Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (copper, platinum, iridium). Consult manual for specific engine.

Timing Belt Replacement:

For M40 and M44 engines, typically every 40,000-60,000 miles (64,000-96,000 km). SOHC M20 and M10 engines use chains. Crucial to replace proactively to avoid catastrophic engine damage.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 5W-30, 5W-40, 10W-40, or 15W-50 depending on climate and engine. Consult manual for specific viscosity and capacity (typically 4.5-6.5 liters).

Coolant Type:

BMW Blue Antifreeze/Coolant, or equivalent ethylene glycol-based coolant with corrosion inhibitors. Mix 50/50 with distilled water. Capacity ~8-10 liters.

Brake Fluid Type:

DOT 3 or DOT 4. Should be flushed and replaced every 2 years.

Transmission Fluid Manual:

BMW MTF LT-2 or equivalent manual transmission fluid. Capacity ~1.2-1.5 liters.

Transmission Fluid Automatic:

Dexron III (or equivalent ATF fluid). Capacity ~1.5-2.0 liters for torque converter refill, higher for full system flush.

Known Issues

Common Problems Engine:

Head gasket leaks (especially M20), oil leaks from valve cover and oil pan gaskets, cooling system leaks (water pump, hoses, radiator), starter motor issues, idle control valve problems.

Common Problems Suspension:

Worn control arm bushings (eccentric bushings), trailing arm bushings, shock absorber failure, ball joint wear.

Common Problems Electrical:

Corroded grounds, failing instrument clusters, intermittent power to accessories, fuel pump relay failure, starter solenoid issues.

Common Problems Body:

Rust (especially wheel wells, rocker panels, strut towers), door seal deterioration, sunroof leaks.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW's reputation for producing driver-focused, well-engineered vehicles, building on success of models like the 2002.

Model Evolution

E30 Introduction:

Introduced in 1982 as the successor to the E21 3 Series, the E30 defined the modern compact executive car segment.

E30 Facelift:

Significant facelift in 1987 introduced revised bumpers, updated interior, and new engine options. The 1991 model year represents the final iteration of the E30 generation.

E30 M3:

The iconic E30 M3, launched in 1986, utilized a unique chassis and the high-revving S14 engine, becoming a homologation special and a legendary performance car.

Production

Production Years:

1982-1991 (global production).

Manufacturing Locations:

Germany (Dingolfing, Munich), South Africa, Thailand, Mexico, USA (Spartanburg - limited M3 production).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E30 3 Series (specifically the 325is/e models) was a frequent entrant on Car and Driver's '10Best' list in the late 1980s, lauded for its driving dynamics.

Automotive Journalism Acclaim:

Widely praised by automotive press for its handling, build quality, and balance of sport and luxury.

Certifications

Certification Standard:

N/A (Manual is a technical document, not a certified product itself).