BMW 318i 1991 Full Service Repair 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/Coupe/Convertible Target Audience: Enthusiasts, DIY mechanics,...

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Type: Car

Vendor:

Sku: 417487

Tags: 1991 318i BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Chassis Code:

Codes

Engine Code:

M40B18

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Coupe/Convertible

Target Audience:

Enthusiasts, DIY mechanics, owners seeking to maintain or restore their E36 318i.

Competitive Analysis

Key Competitors:

Mercedes-Benz 190E, Audi 80/90, Acura Integra, Lexus ES250.

Key Features

Vehicle Strengths:

Sporty handling, build quality, refined powertrain for its class, excellent driver engagement.

Manual Value Proposition:

Empowers owners with the knowledge to perform all necessary maintenance and repairs, saving money and ensuring longevity.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body & Chassis, Troubleshooting, Specifications, Maintenance Schedules, Diagnostics, Wiring Diagrams, Rebuilding Procedures.

Page Count

Page Count:

Estimated 1500+ pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, cylinder head, piston, connecting rod, crankshaft, valve train, lubrication system, cooling system, timing belt/chain, engine mounts, seals, gaskets.

Engine Management:

Fuel injection system (Bosch Motronic 1.3), ignition system, sensors (MAP, TPS, O2, Crankshaft Position), actuators, emission controls, diagnostics and fault codes.

Transmission:

Manual (Getrag 260) and Automatic (ZF 4HP22) transmission overhaul, clutch system, driveshafts, differential, axle shafts, transmission fluid specifications and replacement.

Suspension:

Front suspension (MacPherson strut), rear suspension (trailing arm, semi-trailing arm), shock absorbers, springs, control arms, bushings, alignment specifications.

Steering:

Power steering system, steering rack, steering column, tie rods, steering fluid specifications, alignment.

Brakes:

Front disc brakes, rear drum brakes (on some models), ABS (Anti-lock Braking System) operation and troubleshooting, brake fluid specifications, bleeding procedures, component replacement.

Electrical System:

Battery, alternator, starter motor, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams for all circuits, ignition switch, power windows, central locking.

HVAC System:

Heating, Ventilation, and Air Conditioning (HVAC) system, blower motor, heater core, evaporator, refrigerant charging, troubleshooting.

Body And Chassis:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, rust prevention and repair, jacking points, towing.

Procedures Included

Maintenance:

Routine service (oil changes, filter replacements, spark plug replacement), belt adjustments, fluid level checks and top-offs, brake pad inspection and replacement, tire rotation.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code interpretation.

Repair:

Step-by-step repair instructions for all major components, including engine rebuilds, transmission overhauls, suspension component replacement, electrical system repairs.

Rebuilding:

Detailed procedures for rebuilding major assemblies such as the engine, transmission, and power steering rack.

Diagnostics:

Diagnostic procedures for engine performance, electrical faults, and mechanical issues, including reading and interpreting diagnostic trouble codes (DTCs).

Technical Depth

Depth:

Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed diagnostic strategies and electrical schematics.

📊 Manual Specifications

File Format

File Format:

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Name:

M40B18

Engine Type:

Inline 4-cylinder, SOHC

Displacement:

1.8 Liters (1796 cc)

Bore X Stroke:

84 mm x 81 mm

Compression Ratio:

8.8:1

Performance

Horsepower:

113 hp @ 5500 rpm

Torque:

115 lb-ft @ 4300 rpm

Fuel System

Fuel Delivery:

Bosch Motronic 1.3 Fuel Injection

Fuel Type:

Unleaded Gasoline (91+ Octane Recommended)

🔧 Transmission

Standard

Transmission Type:

Getrag 260 5-Speed Manual

Optional

Transmission Type:

ZF 4HP22 4-Speed Automatic

Features

Clutch Type:

Hydraulic, Dry Single Plate

Manual Transmission Fluid:

BMW MTF LT-2 or equivalent (e.g., Castrol Syntrans B 75W)

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)

Front Track:

1418 mm (55.8 in)

Rear Track:

1447 mm (57.0 in)

Weights

Curb Weight:

Approx. 1350-1450 kg (2976-3197 lbs)

Gross Vehicle Weight Rating:

Approx. 1800 kg (3968 lbs)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star (driver), 4-star (passenger) - Estimated for the era

Active Features

Standard on most models (Bosch 2.3 ABS)

Passive Features

Airbags:

Driver's side airbag standard (introduced during the E36 generation).

Seatbelts:

Three-point inertia-reel seatbelts front and rear.

Body Structure:

Reinforced passenger compartment, crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette player with optional CD changer and premium speaker options.

Instrument Cluster:

Analog gauges for speedometer, tachometer, fuel level, and temperature. Check Control system for monitoring vehicle status.

Driver Assistance

Standard on most models, enhancing braking stability.

Connectivity

Connectivity Features:

Limited by modern standards; primarily focused on basic vehicle functions and audio entertainment.

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 miles (12,000 km) or 12 months, whichever comes first.

Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plugs:

Replace every 30,000 miles (48,000 km) (specific plug type may vary).

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil:

SAE 5W-30 or 10W-40 (API SG or higher), capacity approx. 4.5 liters (4.8 quarts) with filter.

Coolant:

BMW Blue Antifreeze/Coolant (G48 ethylene glycol based) or equivalent, mixed 50/50 with distilled water.

Brake Fluid:

DOT 4

Known Issues

Coolant Leaks:

Cracked plastic coolant expansion tanks, failing water pumps, brittle hoses.

M40 Engine Specific:

Timing chain guides can wear, potential for valve stem seal degradation leading to oil consumption.

Suspension Wear:

Worn control arm bushings, ball joints, and rear trailing arm bushings are common due to age and mileage.

Electrical Issues:

Corroded wiring connectors, failing window regulators, intermittent central locking issues.

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

Sheer Driving Pleasure, focus on performance, engineering, and driver engagement.

Model Evolution

E36 Generation:

Introduced in 1990 (for the 1991 model year), replacing the E30 3 Series. The E36 marked a significant modernization in design, technology, and safety.

318I Positioning:

Entry-level model in the E36 lineup, offering a balance of efficiency and BMW's characteristic driving dynamics.

Production

Production Period:

1991-1998 (for the E36 generation 318i)

Manufacturing Locations:

Germany (Main), South Africa, Thailand, Brazil.

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The E36 generation (including various 318i variants) was a frequent recipient of Car and Driver's '10Best' lists during its production run, cited for its handling and value.

Ratings

General Reputation:

The E36 3 Series is widely regarded as a benchmark for sports sedan dynamics and driver involvement in its era.