BMW5-Series (E34) 518I 1990-1991 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 5 Series Chassis Code: E34 Variant: 518i Model Years Covered: 1990-1991 Codes Engine Code Common: M40B18 👋 Introduction Market Position Segment: Executive Sedan...

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Tags: 1990 1991 5-Series (E34) 518I BMW Car Cars Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

5 Series

Chassis Code:

Variant:

Model Years Covered:

1990-1991

Codes

Engine Code Common:

M40B18

👋 Introduction

Market Position

Segment:

Executive Sedan

Target Audience:

Automotive enthusiasts, DIY mechanics, and professional workshops servicing BMW E34 models.

Competitive Analysis

Competitors:

Mercedes-Benz W124 E-Class, Audi V8 quattro, Lexus LS 400.

Key Features Vehicle

Design:

Iconic 'E34' design by Claus Luthe, representing BMW's signature blend of sportiness and luxury.

Handling:

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

Key Features Manual

Manual Advantage:

Provides authoritative, factory-level information essential for accurate and efficient maintenance and repair.

Value Proposition:

Empowers owners and technicians to maintain and repair their E34 518i with confidence, reducing reliance on expensive dealership services.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Service, Maintenance, and Repair

Page Count

Estimated Page Count:

Approx. 800-1000+ pages (typical for comprehensive manuals of this era)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnosis, repair, overhaul of M40B18 engine, including fuel injection, ignition, cooling, lubrication.

Transmission:

Manual and Automatic transmission service, repair, fluid specifications, and troubleshooting.

Drivetrain:

Driveshaft, differential, axles, wheel bearings, and CV joints.

Suspension:

Front and rear suspension components, steering system, alignment specifications.

Brakes:

Brake system diagnosis, repair, ABS (if equipped), hydraulic components, pad/rotor replacement.

Electrical:

Complete wiring diagrams, component testing, fuse box layout, starter, alternator, battery, lighting, and accessory circuits.

Bodywork:

Body panel repair, interior trim removal/installation, door mechanisms, glass replacement.

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis and repair.

Fuel System:

Fuel pump, injectors, fuel tank, and lines.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, and pipework.

Procedures Included

Maintenance:

Routine service checks, fluid changes, filter replacements, tune-ups.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues.

Repair:

Step-by-step instructions for component removal, installation, and adjustment.

Rebuild:

Detailed procedures for engine and transmission overhaul.

Electrical Diagnostics:

Testing and repair of electrical components and circuits using wiring diagrams.

Special Tools:

Identification and usage of required special tools for specific repairs.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed diagnostics.

Illustrations:

Includes exploded views, diagrams, and photographic illustrations for clarity.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Text-searchable for quick information retrieval.

Print Quality

Digital Quality:

High-resolution for clear viewing of text and diagrams.

Binding Type

Digital Binding:

N/A (Digital File)

Paper Type

Digital Paper Type:

N/A (Digital File)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Engine Code:

M40B18

Configuration:

Inline 4-cylinder

Displacement:

1.8 Liters (1796 cc)

Bore X Stroke:

86.0 mm x 76.8 mm

Compression Ratio:

8.8:1

Valvetrain:

SOHC, 2 valves per cylinder

Performance

Horsepower:

115 PS (113 hp; 85 kW) at 5600 rpm

Torque:

164 Nm (121 lb-ft) at 4250 rpm

Fuel System

Fuel Delivery:

Bosch Motronic Fuel Injection (e.g., Motronic ML 4.1 or ML 3.1)

Fuel Type:

Unleaded Gasoline (RON 91 or higher)

Ignition System:

Electronic ignition with distributor

Cooling System

Coolant Type:

BMW approved ethylene glycol based coolant (e.g., G48)

Lubrication System

Oil Type:

SAE 15W-40 or 10W-40 (refer to specific manual for exact BMW approval)

🔧 Transmission

Standard

Type:

Getrag 260 5-speed Manual Transmission

Optional

Type:

ZF 4HP22 4-speed Automatic Transmission

Features

Manual Ratios:

Specific gear ratios available in manual, e.g., 1st: 4.21, 2nd: 2.19, 3rd: 1.40, 4th: 1.00, 5th: 0.81

Automatic Features:

Electronically controlled with lock-up torque converter (depending on exact model year/options).

Fluid Specifications

Manual Fluid:

BMW approved manual transmission fluid (MTF), e.g., SAE 75W-90 GL-4

Automatic Fluid:

Dexron II or III automatic transmission fluid (ATF)

📐 Dimensions

Exterior

Length:

Approx. 4710 mm (185.4 in)

Width:

Approx. 1750 mm (68.9 in)

Height:

Approx. 1410 mm (55.5 in)

Wheelbase:

Approx. 2795 mm (110.0 in)

Weights

Curb Weight:

Approx. 1410-1490 kg (3109-3285 lbs), depending on transmission and options.

Gross Vehicle Weight Rating:

Refer to VIN plate or manual.

Wheels Tires

Standard Tire Size:

195/65R15 or 205/60R15

Wheel Bolt Pattern:

5x120 mm

Wheel Offset:

ET 15 to ET 20 (typical)

🛡️ Safety Features

Ratings

NHTSA Rating:

Not comprehensively rated by modern standards, but generally considered robust for its era.

Active Features

Anti-lock Braking System (optional on early models, standard on later ones).

Passive Features

Airbags:

Driver airbag (optional, became standard later in the E34 lifecycle).

Seatbelts:

Pre-tensioned front seatbelts.

Chassis Construction:

Unitized body construction with front and rear crumple zones.

💡 Technology Features

Infotainment

Radio:

Factory cassette or radio/cassette combination. Options for CD players existed later in the E34 lifecycle.

Speakers:

Typically 4 to 8 speakers, depending on trim level and options.

Driver Assistance

Cruise Control:

Standard on many models, optional on others.

Trip Computer:

Available on higher trim levels, providing basic fuel consumption and range data.

Connectivity

Connectivity Features:

Limited by era; primarily focused on internal systems. No external connectivity like Bluetooth or USB.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 - 15,000 km (6,000 - 9,000 miles) or 12 months, whichever comes first (refer to manual for specific interval).

Spark Plug Replacement:

Every 30,000 - 40,000 km (18,000 - 25,000 miles) for standard spark plugs, or as per manual for longer-life options.

Coolant Flush:

Every 2-3 years or 50,000 km (30,000 miles).

Transmission Fluid Change:

Manual: Every 50,000 - 80,000 km (30,000 - 50,000 miles). Automatic: Every 40,000 - 60,000 km (25,000 - 37,000 miles).

Fluid Specifications

Engine Oil Capacity:

Approx. 4.25 Liters (4.5 US Quarts) with filter change.

Coolant Capacity:

Approx. 7.5 Liters (7.9 US Quarts).

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Engine M40:

Timing chain stretch, valve guide wear, oil leaks from valve cover gasket and oil pan gasket, idle control issues.

Cooling System:

Plastic expansion tank can become brittle and crack, radiator leaks, water pump failure.

Electrical:

Wiring harness degradation (especially in engine bay), failing door lock actuators, instrument cluster issues, rear window defroster grid failure.

Suspension:

Worn control arm bushings, worn tie rod ends, strut mounts failing.

Fuel System:

Fuel pump failure, clogged fuel injectors.

Preventative Maintenance

Emphasis:

Regular inspection and replacement of rubber components, preventative replacement of known failure points (e.g., plastic coolant parts).

📚 Vehicle History

Brand Heritage

Bmw Philosophy:

BMW's commitment to 'The Ultimate Driving Machine' ethos, evident in engineering and driving dynamics.

Model Evolution

E34 Introduction:

Introduced in 1987 (1988 model year in North America) as a successor to the E28 5 Series. The E34 represented a significant leap in aerodynamics, technology, and refinement.

E34 Lifespan:

Produced from 1987 to 1996 (sedan) and 1990 to 1996 (touring).

518I Positioning:

The 518i was the entry-level model in many markets, offering a more accessible entry into the 5 Series range.

Production

Manufacturing Location:

Dingolfing, Germany

Production Volume:

The E34 overall sold over 1.3 million units. Specific figures for the 518i are not as commonly segmented.

🏆 Awards & Recognition

Recognitions

Automotive Press:

The E34 generation was widely praised for its driving dynamics and build quality by automotive journalists of its time.

Car And Driver:

Car and Driver's '10Best' list multiple times during its production run, highlighting its class-leading attributes.

Ratings

Reliability Perception:

Generally good reliability, but requires consistent and proper maintenance due to its complex German engineering.

Certifications

Manual Standard:

Aligns with industry standards for technical repair documentation, providing factory-level detail.