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BMW 1989 525i, Service Manual

The BMW 1989 525i Service Manual is a comprehensive guide that allows car owners to easily maintain and repair their vehicle. Available for free download at manualshive.com, this manual provides step-by-step instructions and valuable information to ensure your BMW runs smoothly and efficiently.

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Summary of Contents for 1989 525i

Page 1: ... aO u a SAO 0 989 9 gg4 5 Bentley Publishers ...

Page 2: ...This page intentionally left blank ...

Page 3: ...Brakes General 310 Front Suspension 320 Steering and Wheel Alignment 400 Body General 410 Fenders Engine Hood 510 Exterior Trim Bumpers 512 Door Windows 513 Interior Trim 600 Electrical System General 610 Fuses and Relays 611 Wipers and Washers 612 Switches and Electrical Accessories 720 Seat Belts 721 Airbag System SRS 119 Lubrication System 120 Ignition System DME 121 Battery Starter Alternator ...

Page 4: ...usiast s CompanionHI Im I1 WII I ISBN 0 8376 o2211 3 BMW 6 Series En thusiast s Companion r 1 Im lIIy WII lOII ISBN 0 8376 0 149 5 Unbeatab le BMW Eigh ty Years of Engineering and Motorsport Success It n lIIy WIIII ISBN 0 8376 lJ2lJ6 8 Chevrolet Chevrolet by the Numbers 1955 1959 The Essential Chevrolet Parts Reference Alilll C pill ISBN tl 8376 11875 9 Chevrolet by the Numbers 1960 1964 The Essen...

Page 5: ...echanical skills this manual gives detailed maintenance and repair information In addition the BMW owner who has no intention of working on his or her own car will find that owning and reading this manual will make it possible to be better informed and to discuss repairs more intelligently with a professional technician This manual has been prepared from the repair information that BMW provides to...

Page 6: ...ciding to repair a BMW that may still be covered wholly or in part by any warranties issued by BMW of North America consult your authorized BMW dealer You may find that he can make the repair either free or at minimum cost Regardless of its age and whether or not it is still protected by warranty your BMW is both an easy car to service and an easy car to get serviced So if at any time a repair is ...

Page 7: ... conta in toxic substances many of which are absorbed directly through the skin Read manufacturer s instructions and warnings carefully Use hand and eye protection Avoid direct skin contact Friction materials such as brake or clutch discs rnay contain asbestos fibers Do not create dust by grinding sanding or by cleaning with comp ressed air Avoid breathing asbestos fibers and asbestos dust Breathi...

Page 8: ... the oil Do not pour oil onto the ground down a drain or into a stream pond or lake Consult local ordinances that govem the disposal of wastes On cars equipped with the anti lock brakes ABS the ABS con trol unit cannot withstand temperatures from a paint drying booth or a heat lamp in excess of 203 F 95 C and should not be sub jected to temperatures in excess of 185 F 85 C for more than two hours ...

Page 9: ...ay result TOOLS 010 7 Basic Tool Requirements 010 8 Jack Stands 010 9 Oil Change Equipment 010 10 Torque Wrench 010 10 Feeler Gauges 010 10 Volt Ohm Meter VOM or Multimeter 010 11 BMW Special Tools 010 1 1 EMERGENCIES 010 11 Changing a Tire 010 11 Car Will Not Start 010 12 Jump Starting 010 12 To jump start car 010 12 Overheating 010 13 Low Oil Pressure 010 13 Brake Fluid Level 010 13 Check Engine...

Page 10: ... accident or mechanical failure while driving CAUTfON A caution calls sttention to important precautions to be observed during the repair work that will help prevent accidentally damaging the car or its parts GETTING STARTED NOTE A note contains helpful information tips that will help in doing a better job and compleling it more easily Please read every WARNING CAUTION and NOTE at the front of the...

Page 11: ... to the electrical system The fuel system is designed to retain pressure even when the ignition is off When working with the fuel system loosen the fuel lines slowly to et low the residual pressure to dissipate gradually Take precautions to avoid spraying fuel Lifting the Car For those repairs that require raising the car the proper jack ing points should be used to raise the car safely and avoid ...

Page 12: ...liness Keeping things organized neat and clean is essential to do ing a good job When working under the hood fender covers will protect the finish from scratches and other damage Make sure the car is relatively clean so that dirt under the cover does not scratch the finish Any repair job will be less troublesome if the parts are clean For cleaning old parts many solvents and parts cleaners are ava...

Page 13: ... used as a sub stitute for torques specifically called out in the text throughout this manual NOTE Metric bolt classes or grades are marked on the bolt head The key to seal installation is to get the seal in straight without damaging it Use an object that is the same diameter as the seal housing to gently and evenly drive it into place If a proper size seal driver is not available a socket of the ...

Page 14: ...shrinkable insulating tubing that can be placed onto the wire before connecting slid over the finished joint and shrunk to a tight fit with a heat gun or hair dryer The next best alternative is electrical tape Make sure the wire is clean and free of solder flux or other contamination Wrap the joint tightly to seal out moisture BUYING PARTS Genuine BMW Parts Genuine BMW replacement parts from an au...

Page 15: ...ngine transmission front and rear bumpers front fenders rear quar ter panels hood trunk lid and doors These labels should not be removed as they will tear apart B328 FUN B B328 FUN 8 Fig 6 Labels used to identify parts Ori9 31equipment label will VIN number and roundellogos top ano replacement part la bel with one roundel logo Engine BMWs covered in this manual are powered by vari ous 6 and 8 cyli...

Page 16: ...rx type screwdrivers Wren ches Wrenches come in different styles lor different uses Fig 8 shows several The basic open end wrench is the most widely used but grips on only two sides It can spread apart and slip all more easily The box end wrench has better grip on all six sides of a nut or bolt A 12 point box end can loosen a nut or bolt where there is less room lor movement while a 6 point box en...

Page 17: ...d to remove a nut and bolt Use extra care with adjustable wrenches as they tend to loosen slip and damage fasteners BOOSf NG BOOBFNG Fig 11 Adjustable wrench Compared to a wrench of the correct size an adjustable wrench is always second best They should only be used when the correct size wrench is not available Choose one of average size range about 6 to 8 inches in leng1h Pliers A few of the many...

Page 18: ...h pounds To convert inch pounds to foot pounds divide by 12 Feeler Gauges Feeler gauges are thin metal strips of precise thickness used to measure small clearances They are normally available as a set covering a range of sizes c o 0 V 0 B022FNG B022FNG Fig 13 Oil change equipment Includes drain plug wrench 17mm 8 qt drain pan oil filter wrench and funnel B020FNG Torque Wrench A torque wrench is us...

Page 19: ...the do it yourself owner This manual includes such repairs for the benefit of those with the necessary experience and ac cess to tools For the do it yourselfer the need for special tools is noted in the text and whether or not BMW dealer service is recommended EMERGENCIES Changing a Tire If a tire goes flat while driving pull well off the road Changing a tire on a busy street or highway is very da...

Page 20: ...us gas ses Keep sparks and flames away Do not smoke near betteries Do not jump start the engine it you suspect that the ballery is lrozen Trapped gas may explode Allow the ballery to thaw tirst Do not quick charge the bal ery lor boost stert ing lor longer than one minute and do not ex ceed 15 volts at the ballery with the boosting cables ettecnea Wait at least one minute belore boosting the bal e...

Page 21: ...If there is a slight seepage then it may be possible to drive a short distance adding coolant as needed If either the red engine oil pressure waming light comes on or the check control displays ENGINE OIL PRESS anytime the engine is running immediately stop the car and turn off the en gine Do not run the engine at all and have the car towed the light or graphic display remains on do not run the ca...

Page 22: ... 30 mph 35 km h Be sure the transmission fluid has been topped off before starting the tow Always tow the car with the transmission lever in O N neutral I the tow must exceed 25 miles 40 km add one quart of ATF to the transmission or better yet remove the driveshaft Be sure to drain or pump out the added fluid once the tow has been completed NOTE ATF draining and filling is covered in 240 Automati...

Page 23: ...ure 020 16 Tires rotating 020 16 Wheels aligning 020 16 Brake system inspecting 020 16 Brake hoses and lines inspecting 020 16 Brake pad rotor wear checking 020 16 Brake fluid replacing 020 17 Parking brake checking 020 17 Exhaust system inspecting 020 17 Manual Transmission Service 020 17 Manual transmission oil checking and filling 020 17 Automatic transmission service 020 17 Front suspension an...

Page 24: ...mal use fewer and fewer green LEOs will be illuminated before start up indicating that the next maintenance interval is approaching When the car has accumulated suHicient use to require the next maintenance interval the yellow LEO will come on along with either the OIL SERVICE indicator or the INSPECTION in dicator These LEOs will stay on after the engine is started If maintenance service is delay...

Page 25: ...t tool shown CAUTlON Follow the manufacturer s directions when reset ting the service indicator If the reset procedures are done incorrectly the reset tool or the electron ic service indicator may be damaged Aftermarket reset tools can be purchased from one of the following manufacturers Assenmacher Specialty Tools Boulder CO 80301 303 530 2424 Peake Research Automotive Products Division P O Box 2...

Page 26: ... of washer system Check condition of wiper blades Repair Group 611 Road Test Maintenance item Engine compartment maintenance Change oil and oil filter Check fluid levels coolant steering brake clutch ATF Under car maintenance Check steering box and steering linkages for leaks and excess play Repair Group 320 Inspect brake system Check brake calipers rotors and brake pad thickness Inspect for dam a...

Page 27: ... cable if necessary Repair Group 340 Inspect front and rear suspension including wheel bearings for play Repair Group 320 330 Inspect wheels and tires including spare check tire pressure and condition Check hydraulic fluid level for Level Control System LAD if applicable See Repair Group 330 Body and Interior Maintenance Lubricate door hinges and hood latch hood hinges Check headlight and driving ...

Page 28: ...ter element Check fuel tank fuel lines and all connections for leaks Inspect exhaust system Repair Group 180 I I I Check steering box and steering linkages Check power steering system for leaks Check fluid level Repair Group 320 Inspect brake system for damaged hoses and lines leaks or damage Remove calipers and I check brake pad wear Check brake rotors for scoring damage Repair Group 340 Check pa...

Page 29: ...ion 01 SRS airbag front sensor to body if apoucabte Repair Group 721 Road Test Check braking performance steering HVAC manual or automatic transmission and mirrors Table d Scheduled Maintenance Time Mileage Intervals VI 1 1 VI VI 4l 4l 4l 4l VI VI VI E s c s E E J 0 CT 4l1 l I I I U III 0 0 0 0 0 0 l 1 1 E E E 0 0 C I 0 0 VI 0 t III 4l N Q 0 0 0 VI E N In ID III D E e e e III III 0 4l III III 4l I...

Page 30: ...ain and fill 525i 5351 1 71 1 8 US qt Special oil see 530i 331 Final Drive 540i I 9 I 2 0 US qt Special oil see 331 Final Drive Power steering fluid All models permanently sealed I Dexron If ATF or no drain plug Hydraulic oil CHF 7 1 Reservoir tank I is labeled with oil type 1 Brake flu id All models 1 SAE Oat 4 Engine coolant 525i I M20 engine 10 5 1 11 0 US qt 50 BMW anti M50 engine 10 51 11 0 U...

Page 31: ...ing of clean engine oil Install filter by hand until gas ket contacts mounting flange then turn filter another 2 turn On all engines except M20 engine remove old 0 ring s from cover and from end of bolt as applicable Lubricate and install new O rings in filter cover and on filter bolt M50 M30 engines only Install new filter cartridge and cover See Fig 4 001 1911 Fig 3 Engine all drain plug arrow i...

Page 32: ...e of M50 engine corn panmeru Unchp spring clips arrows 1 0 remove air filter ENGINE COMPARTMENT MAINTENANCE Take note of the installed position of the filter Wipe clean the inside of the air filter housing using a lint free cloth and in stall the new filter Reinstall the upper air filter housing mak ing sure that the two halves are mated correctly Refasten the spring clips and tighten the mounting...

Page 33: ...t Irom March 1993 are equipped witt two fuet filters When replacing the fuel lilter disconnect the battery nega tive cable and clamp the filter inlet and outlet hoses to less en fuel spillage Loosen the clamping bracket and the two hose clamps on either end of the filter Note the arrow or mark ings indicating direction of flow on the new filter Install the fil ter and use new hose clamps 00 9 5 Fi...

Page 34: ...egin by disconnecting the cables Disconnect the negative H cable first Clean the ter minal posts and the cable clamps with a wire brush Clean the main chassis ground terminal next to the battery Corrosion can be washed away with a baking soda and wa ter solution that will neutralize the acid Apply the solution carefully though since it will also neutralize the acid inside the battery Reconnect the...

Page 35: ...the belt or the accessory Ten sion the belt s run the engine for a few minutes at least 1500 rpm then recheck the belt tension Fig 10 Cross section of correct V belt position In pulley Courtesy of Gates Rubber Inc CAUTION 0 0 not over tighten the v betts Overtlghtenmg will cause shaft bearings to fail prematurety Poly ribbed belts checking and replacing M50 and M60 engines The automatic tensioning...

Page 36: ...ef fectiveness replacement of the coolant every 2 3 years is rec ommended As a preventive measure replacement of the cooling system hoses every 4 years is also recommended CAUTION Use only BMW approved long lile anti Ireeze when filling the cooling system Use of snu treeze containing phosphates or a high silicate content is considered to be harmful to the cooling system A translucent expansion tan...

Page 37: ...bricant Specifications NOTE The brake Iuid also serves as the hydraulic Iuid or the clutch on cars with manuat transmission Low lIuid level in the brake Iuid reservoir may be due to leaks in the brake system or in the hydraulic clutch 00 11918 Fig 16 Level indicators on brake flUid reservoir arrows Correct tev et is between MIN ilnd MAX marks Oxygen sensor replacing The oxygen sensor monitors engi...

Page 38: ...s and specifications Brake system inspecting Routine maintenance of the brake system includes main taining an adequate level of brake fluid in the reservoir check ing brake pads for wear checking hand brake function and inspecting the system for fluid leaks or other damage UNDER CAR MAINTENANCE WARNING Friction materials such as brake linings may con tain asbestos fibers Do not create dust by grin...

Page 39: ...ks Check for weakness or perforation due to rust Check to see that all the hangers are in place and properly supporting the system and that the system does not strike the body Alignment of the system and the location of the hangers are described in 180 Exhaust System Manual Transmission Service Manual transmission service consists of inspecting for leaks checking and changing the gear oil checking...

Page 40: ...the type and final drive ratio For example 3 10 means that it is a limited slip differential with a 3 10 final ratio Drive axle boots inspecting The rear drive axle protective boots should be inspected for cracks and any other damage that will allow contaminants to get into the joint If the rubber boots fail the water and dirt that enters the joint will quickly damage it Replacement of the drive a...

Page 41: ...inspection information Exterior finish care The longer dirt is left on the paint the greater the risk of damaging the glossy finish either by scratching or by the chemical effect dirt particles may have on the painted surface Washing Do not wash the car in direct sunlight If the engine hood is warm allow it to cool Beads of water not only leave spots when dried rapidly by the sun or heat from the ...

Page 42: ...e the same cleaner applied with a soft cloth or brush on the head liner and side trim panels For cloth covered seat areas use the techniques described previously for cleaning the carpet ing Leather upholstery and trim Leather upholstery and trim should be periodically cleaned using a slightly damp cotton or wool cloth The idea is to get rid of the dirt in the creases and pores that can cause britt...

Page 43: ...ctions 100 13 Ground Connections 100 13 Fuel Supply 100 14 Basic Requirements 100 16 TABLES a Engine Specifications 100 1 b Engine Mechanical Troubleshooting 100 7 c DME Check Engine Light Fault Codes 100 9 d Engine Driveability Troubleshooting 100 15 On a cylinder engines the cylinder block is cast aluminum alloy Instead of steel cylinder liners the cylinders have a Galnikal lining This lining or...

Page 44: ...n words Variable Nockenwellen Steurung The VANOS system electro hydraulically adjusts intake valve timing for enhanced mid range performance The VANOS system is controlled by the DME 3 3 1 Motronic con trol module using engine speed engine load and engine tem perature as the primary inputs At low speeds the intake valves open late to ensure smooth engine operation At mid range speeds the valves op...

Page 45: ...l injectors The ECM electrically controls the opening and closing of the injectors by switching the ground side of each injector circuit The exact amount of fuel injected is determined by the amount of time the injectors are open Four versions of DME systems are used on the cars cov ered by this manual as listed below The differences between the systems are mainly in the electronic circuitry altho...

Page 46: ... lightweight parts such as those in the valvetrain Often a simple valve adjust ment where applicable will cure the problem However val vetrain noise accompanied by blue gray exhaust smoke particularly when the engine is started often indicates worn valve guides Low pitched metallic knocking sounds are usually caused by excessive clearance between heavy components Piston slap caused by too much cle...

Page 47: ...h M20 en gine the timing bell should be replaced al tne specified mileage interval If the timing belt fails in service the valves will contsct the pistons and major engine damage will result See 020 Mainte nance Program for addilional information Compression Test The compression pressures in the individual cylinders can tell a lot about the condition of an engine without the need to take it apart ...

Page 48: ...engines with EML check that the throttle plate opens when the starter is actuated MECHANICAL TROUBLESHOOTING 1l11004 Fig 6 Remove Ignition COils on M50 M60 engines by disconnecting harness connector and removing mounting nuts arrows 9 Release the pressure with the compression gauge valve then remove the gauge from the spark plug hole Repeat the test for each of the other cylinders and com pare the...

Page 49: ... or b Fuel octane level too low Use higher octane fuel detonation c Engine running too hot or overheating Check cooling system Repair Group 170 d Wrong spark plug incorrect heat range Replace spark plugs Repair Group 120 e Air fuel mixture too lean Repair Group 130 f Excessive carbon deposits In combustion chambers Remove cylinder head and decarbonize combustion chamber Repair Group 116 6 Light me...

Page 50: ...roblems Have a fire extinguisher available in case of an emergency DRIVEABILITY TROUBLESHOOTING CAUTION Do not connect any test equipment that delivers a 12 volt power supply to terminal 15 of the ignition coil The current flow may damage tile DME ECM In general connect test equipment only as specified by BMW tnis manual Of tile equipment maker Do not attempt to disable tne ignition system by remo...

Page 51: ...temperature sensor NTC Test coolant temperature sensor Repair Group 130 Code 1224 Air temperature sensor NTC Test intake air temperature sensor Repair Group 130 Code 1225 Knock sensor 1 OME 3 3 3 3 1 only I Check knock sensor and sensor wiring Repair Group 120 Code 1226 Knock sensor 2 OME 3 313 3 1 only Check knock sensor and sensor wiring Repair Group 120 Code 1227 Knock sensor 3 OME 3 3 only Che...

Page 52: ...130 I Code 1261 Fuel pump control Test fuel pump relay and fuel pump circuit Repair group 160 Code 1262 Idle speed control I Test idle air control valve and signal to valve Repair Group 130 Code 1263 Fuel tank evaporative EVAP system Test EVAP purge valve Repair Group 160 Code 1264 Oxygen sensor heater Test oxygen sensor heater and heater relay Repair group 130 Code 1265 Check engine lamp OME 3 3 ...

Page 53: ... engines check that the valves are cor rectly adjusted If the clearances are too small the valves may not close all the way reSUlting in low compression and a loss in power If the clearances are too large the valves may not fully open causing a reduction in engine efficiency Proce dures for checking and adjusting valve clearances are de scribed in 116 Cylinder Head and Valvetrain NOTE M50 and M60 ...

Page 54: ...f the oxy gen sensor see 130 Fuellnjection DME Air Flow Measurement and Vacuum Leaks The primary input used by the fuel injection system to deter mine how much fuel should be delivered is the signal from the air flow meter M20 M30 engines or mass air flow sensor M50 M60 engines in the intake air ductwork DRIVEABIL 7Y TROUBLESHOOTING Fig 8 Oxygen sensor measures oxygen content of exhaust gas as ind...

Page 55: ...nts Often simply disconnecting and recon necting a dirty connector several times will clean the terminals and help to reestablish good electrical contact If a wiring harness connector has no visible faults but is still suspect measure the voltage drop across the connector A large drop indicates excessive resistance meaning the con nector is corroded dirty or damaged Clean or repair the con nector ...

Page 56: ...umble on acceleration An injector that shorts to ground will remain open constantly when the en gine is running creating a rich air fuel mixture that can dilute engine oil foul the spark plugs cause a rough idle and eventu ally destroy the catalytic converter See 130 Fuel Injection DME for fuel injection system troubleshooting and repair The fuel injectors must deliver the fuel in a fine even cone...

Page 57: ...ing necessary Repair Group 130 c d h i Air flow or mass air flow sensor faulty Test air flow or mass air flow sensor Repair I Group 130 a b c d e h Large air intake system leak Check for major intake air leaks downstream of air flow or mass meter a c d e g I h Fuel pressure 100 low Test fuel pressure Repair Group 130 I c f I i Fuel pressure 1 00 high Test fuel pressure Repair Group 130 d e 9 h Fue...

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Page 59: ...nu al Transmission or 240 Automatic Transmission 3 Remove the front exhaust pipes from the exhaust man ifolds See 180 Exhaust System Removing and installing engine M50 engine 110 4 Removing and installing engine M30 engine 110 9 Removing and installing engine M60 engine 110 12 4 Drain the engine coolant from the engine block and from the radiator 170 Radiator and Cooling System NOTE The block drai...

Page 60: ...ove the hose from the side of the air cleaner housing Remove the air cleaner housing from the car See Fig 4 ENGINE REMOVAL AND INSTALLADON Fig 3 Power steering pump f11Ountll1 J nons arrows Fig 4 Air cleaner housing mounting nuts arrows Loosen nuts and lift out nousmq 14 Label and then remove the fuel supply line from the fuel rail and the fuel return line from the pressure regulator See Fig 5 WAR...

Page 61: ...ect and then remove the connector in the middle of the bracket 19 Disconnect the wiring from the starter and the alterna tor Move the wiring out of the way See 121 Battery Starter Alternator 20 Working near the rear of the alternator disconnect the electrical connector for the oil level sensor 21 Working directly below the right engine mount discon nect the electrical connector from the oil pressu...

Page 62: ...lines to radiator use new O rings 20 Nm 1 5 tt lb Coolant drain plug to cylinder block 40 Nm 30 It lb Engine mount to engine bracket or subframe M10 45 Nm 33 It Ib Exhaust pipe to exhaust manifold use new nuts 1st stage 35 Nm 26 ft Ib 2nd stage 55 Nm 41 ft lb Radiator cooling fan to coolant pump 40 Nm 30 tt tb Radiator drain screw to radiator 2 5 Nm 22 in lb Wiring to alternator M8 nut 12 Nm 9 It ...

Page 63: ...y See Fig 11 9 Disconnect the heater hose at the rear bulk head and at the heater valve See Fig 12 10 Disconnect the throttle cable and the cruise control ca ble from the throttle lever Pull the cables from the cable bracket See Fig 13 11 If applicable remove the plastic cover from atop the throttle housing 12 Disconnect the large hose from the brake system vac uum booster Plug the opening in the ...

Page 64: ...connect the ig nition coil harness connectors Working at the fuel in jectors pry open the small wire clips at each injector Remove the two main harness hold down nuts and lift the entire harness away Place the harness out of the way See Fig 15 Fig 15 Remove main harness from top of engine and place at base otwindshield 16 Label and disconnect the coolant hose and throttle switch connector from the...

Page 65: ...ake manifold from the engine by rernov ing the seven mounting nuts from above and the two mounting bracket bolts from below See Fig 19 Fig 18 r uel return line IAI and fuel supply h ne IB Label fuel hnes be tore cl sconnecting them Remove bracket moununq to free lines rarrow Fig 19 Inlake manifold mountinq nuts Also remove wo holts from support brackets arrow s WARNING Fuel may be expelled under p...

Page 66: ... Remove the AlC compressor from its mounting bracket without disconnecting any refrigerant lines See Fig 22 25 Move the AlC compressor out of the way without dis torting or damaging any lines Support the compressor by hanging it from the chassis using stiff wire 26 Remove the power steering pump from its mounting bracket See Fig 23 Use stiff wire to hang the pump from the body 27 Disconnect the wi...

Page 67: ...b Engine mount to engine bracket or subframe M10 45 Nm 33 ft Ib Exhaust pipe to exhaust manifold use new nuts 1st stage 35 Nm 26 ft Ib 2nd stage 55 Nm 41 ft Ib Intake manifold to cylinder head 15 2 Nm 11 1 ft lb Radiator cooling fan to coolant pump 40 Nm 30 ft Ib Radiator drain screw to radiator 2 5 Nm 22 in Ib Wiring to alternator M8 nut 12 Nm 9 ft Ib Wiring to starter M6 nut 5 Nm 44 in Ib M8 nut...

Page 68: ...ter hoses from the heater valve and heater core See Fig 24 10 Remove the V belt from the Ale compressor and re move the compressor from its mounting bracket without disconnecting any refrigerant lines Fig 24 Heater hoses at heater valve tAl and heater core BI 11 Remove the power steering pump V belt and remove the pump from its mounting bracket Leave all hoses connected Use stiff wire to hang the ...

Page 69: ...ottle switch B Coolant temperature sensor C Temperature gauge sender 18 Working beneath the intake manifold disconnect the electrical connectors for the oxygen sensor the oil level sensor and the evaporative purge valve 22 Working under the car remove the nuts and ground strap from the engine mounts 19 Label and then remove the fuel supply line and the fuel return line See Fig 28 23 Install an eng...

Page 70: ...d radiator cooling fan See 170 Ra diator and Cooling System NOTE The radiator cooling fan mounting nut 32 mm wrench has tett beno threads On cars with automatic transmission cap olf the open ATFcooler lines Remove any brackets holding the lines to the engine block ENGINE REMOVAL AND INSTALLATION 6 Remove coolant expansion tank from rear of engine compartment disconnecting hoses and electrical con ...

Page 71: ...wire to hang pump from body See 320 Steering and Wheel Align ment A 00 1533 Fig 32 Ground wire for ignition COils fA and coolant temperature sensors B white connector C black connector 20 Remove NC compressor from its mounting bracket without disconnecting any refrigerant lines Use stiff wire to hang compressor from body CAUTlON The AlC relrigerant lines must not be loosened or disconnected Use ca...

Page 72: ...s and copper paste and new mounting hardware See 180 Exhaust System Be sure harness connectors are correctly installed especially at knock sensors Incorrect installation of connectors at knock sensors may result in serious en gine damage Tightening Torques ATF cooler lines to radiator use new O rings M 18 cap nut 20 Nm 15 ft Ib M 22 cap nut 22 Nm 17 ft Ib Coolant drain plug to cylinder block M14 2...

Page 73: ...ngine 113 17 To remove cylinder head M60 engine left cylinder head 113 19 To install cylinder head M60 engine left cylinder head _ 113 21 To remove cylinder head M60 engine right cylinder head 113 22 To install cylinder head M60 engine right cylinder head 113 2412 NOTE The bloci drain is on the exhaust side of the engine near cylinder no 5 3 Remove all coolant hoses from the thermostat housing Rem...

Page 74: ...arness connector bracket under Intake rn arutotc i12j Also remov oracket rnountmq nuts arrow sl 10 Remove the radiator cooling fan and the radiator fan shroud See 170 Radiator and Cooling System NOTE The radiator cooling Ian nut 32 mm wrench has left hand threads 11 Remove the distributor cap spark plug wires and the distributor rotor as described in 120 Ignition System DME 12 Remove the intake ma...

Page 75: ...linder block for warpage using a straight edge NOTE II the cylinder head has been machined a special 0 3 mmthicker gasket should be installed The thicker gas ket is available from an euttiotized BMW dealer 2 Place a new cylinder head gasket on the surface of the cylinder block The cylinder head gasket will fit correctly in only one orientation Check that the two locating dowels are correctly posit...

Page 76: ...learances as described in 116 Cylinder Head and Valvetraln Install the exhaust front pipe to the ex haust manifold using new nuts Coat the manifold studs with copper paste prior to installing the nuts Refill the cooling system and bleed any trapped air as de scribed in 170 Radiator and Cooling System Change the engine oil and filter as described in 020 Maintenance Pro gram Adjust the accelerator c...

Page 77: ...6 Remove the two small coolant hoses from the side of the air cleaner housing 10 Disconnect the crankcase ventilation hose fitting from the cylinder head cover Remove the wiring cover from the front of the cylinder head and then remove the ground wire s shown in Fig 9 Fig 7 Alternator cooling duel air mass sensor connector intake air duct hose clamp and air cleaner housing mounting nuts arrows 11 ...

Page 78: ...e air temperature sensor See Fig 12 15 Disconnect the vent hose from the evaporate purge valve on the left fender REMOVING AND INSTALLING CrUNDER HEAD Fig 12 Cooiant hose ttuotne switch connector and intake a tern perature sensor connector arrow s to be removed or ens connected 16 Working from the underside of the intake manifold dis connect the large idle air hose from the intake manifold see Fig...

Page 79: ...dentification sensor coolant temperature sensor and the temperature gauge send er connectors shown in Fig 16 Fig 16 Harness connectors 1 0 be cnsconnecteo arrow s 20 Remove the reference speed sensor from the front of the engine and move the sensor and its wiring out of the way See Fig 17 21 Disconnect the heater hose from the rear of the cylinder head 22 Remove the cylinder head cover mounting bo...

Page 80: ...late See Fig 20 REMOVING AND INSTALLING CYLINDER HEAD Fig 19 Crankshaft IS oosrnonect at TDC when notch on front 1111111 1 0 chain cover IS aligned with OiT mark on vibration damper Fig 20 BMW special tool 11 2 300 inserted Ihrough bBlIIlolJsing hole and into lIywl1eei arrow 25 Remove the three cylinder head cover mounting studs from across the rear of the head Lock the camshafts at TOC by mountin...

Page 81: ...mounting bolts using a Torx E10 socket 30 On 1993 and later cars VANOS remove the six VANOS control unit mounting nuts and the bolt Slide the control unit oil the front of the cylinder head Re move the intake camshaft sprocket mounting nuts Fig 22 Secondary timing chain tensioner being locked down Press tensioner clown fully and insert wife ItlrOlJgh holes arrow 31 Remove the secondary sprockets t...

Page 82: ...LINDER HEAD Fig 25 Cyhncle 1 1 eiKj 1 0 lill1 ng chain COV8 lllourot n9 Jolls Iar rOWSI 37 Using BMW special tool no 11 2 250 or an equivalent loosen the cylinder head bolts in several stages in the sequence shown in Fig 26 Discard the head bolts Fig 26 Cvlincler l ea 1 oott loosen ng sequence rCAUTlON Iorx type cylinder head bolts should not be reo used They are stretch type bolts and must al way...

Page 83: ...e camshafts and the crankshaft locked in the TDC position with the BMW special tools as described earlier set the cylinder head in position guiding the pri mary chain through the cylinder head opening 5 Lightly lubricate the new cylinder head bolts Loosely install the bolts and their washers then thread them in until they are finger tight Install the cylinder head to lower timing chain cover bolts...

Page 84: ...rigger plate to the front of the intake camshaft 11 Install as an assembly the secondary chain sprockets and chain so that the arrow s on the sprocket s are pointing up Center the mounting holes in the sprockets to the bolt holes in the camshafts See Fig 30 On 1993 and later cars install thrust washers to the sprockets CAUTlON On 1993 and later cars mount the intake cam shaft sprocket so that the ...

Page 85: ...e in take side first Tightening Torque 1991 and 1992 M50 engine Secondary timing chain sprocket to camshaft Torx bolts stage 1 5 Nm 44 in Ib stage 2 22 Nm 17 tt Ib 19 On 1991 and 1992 cars install the front timing chain cover to the cylinder head using a new gasket Apply a small amount of liquid gasket sealer Three Bond 1209 or equivalent to the cover alignment dowels 20 On 1993 and later cars pre...

Page 86: ...ke manifold to cylinder head 15 2 Nm 11 1ft lb Radiator cooling fan to coolant pump 40 Nm 30 tt lb Radiator drain screw to radiator 2 5 Nm 22 in Ib To remove cylinder head M30 engine 1 Working beneath rear seat cushion disconnect the negative H terminal of the battery REMOVING AND INSTALLING CYLINDER HEAD CAUTION Disconnecting the bettery cables may erase fault codes stored in control unit memory ...

Page 87: ... from the intake manifold and move the cables out of the way See Fig 36 Fig 35 Air flow sensor rnountinq clips arrows 8 Loosen the air cleaner housing mounting nuts Loosen the intake air boot hose clamps Disconnect the intake air hose and lift the air cleaner housing out 01 the car 9 Disconnect any hoses from the intake air boot between the air flow sensor and the intake manifold Remove the idle a...

Page 88: ...over 19 Remove the upper camshaft timing chain cover See Fig 39 20 Using a socket on the vibration damper mounting bolt turn the engine over in direction of normal rotation until the camshaft sprocket mounting bolts are straight up and down and the locating dowel is in the lower left hand corner See Fig 40 A Throttle switch B Coolant temperature sensor C Temperature gauge sender D Crankshalt posit...

Page 89: ...ith a wooden stick To install cylinder head M30 engine Prior to installation clean the cylinder head and the gasket surface of the cylinder block Clean the threads of the head bolts and bolt holes with a thread chaser and remove all for eign matter and any liquid from the bolt holes Avoid letting de bris into the cylinders or oil passages in lhe cylinder block CAUTtON Do not use a metal scraper or...

Page 90: ...age requires using a special tool BMW Tool no 11 2 110 or a suitebte protrectot to tighten the bolls to a specified torque angle The engine must be fully assembled and run for twenty five mInutes before tightening the head bolts to their tinst torque Refill the cooling system and bleed any trapped air as de scribed in 170 Radiator and Cooling System Change the engine oil and filter as described in...

Page 91: ...removed 3 Remove left exhaust manifold See 180 Exhaust Sys tem Discard mounting nuts 4 Remove ignition coils and spark plugs See 120 IgnI tion System DME 5 Remove intake manifold Remove cover from rear of intake manifold See Fig 43 Remove intake manifold nuts from left and right cylin der heads noting arrangement of rubber grommets beneath nuts Lift intake manifold together with throttle housing f...

Page 92: ...maining three bolts of right camshaft sprockets on both cylinder heads 15 While holding camshaft stationary loosen and remove intake camshaft sprocket bolts on left cylinder head Remove sprocket and secure chain with wire 16 Slowly turn engine over away from direction of normal rotation until cylinder no 1 is at 45 before TOC Bl OC See Fig 45 17 Remove bolts from timing chain guide rails and pull ...

Page 93: ...er head gasket into position Make sure dowel sleeves are correctly positioned in block and not damaged 3 With crankshaft at 45 BTDC set cylinder head in po sition NOTE Be sure to lift crankcase ventilation oil separator away from head as the head is lowered into position 4 Lightly lubricate new cylinder head bolts Loosely in stall bolts with washers Thread all bolts in finger tight CAUT ON Torx ty...

Page 94: ...inder head 40 Nm 30 ft lb Camshaft timing chain cover to cylinder head cylinder block 10 Nm 89 in Ib Cylinder head cover to cylinder head timing chain cover M6 10 Nm 89 in Io M7 15 Nm 11 ft Ib Cylinder head to cylinder block stage 1 30 Nm 22 tt lb stage 2 800 stage 3 80 Exhaust manifold to cylinder head 22 Nm 17 ft Ib Intake manifold to cylinder heads 15 Nm 11 ft lb Radiator cooling fan to coolant...

Page 95: ... and remove sender from cover remove timing chain cover mounting bolts qty 9 and carefully separate cover from cylinder head 11 Remove coolant crosspipe accumulator from rear of engine unbolt coolant expansion tank and set aside remove diagnostic connector retaining clip and free connector from bracket separate main harness plug and set wiring harness aside see Fig 50 disconnect and label harness ...

Page 96: ...inder head bolts are recessed into the head be tow the camshaft towers with little working space To install cylinder head M60 engine right cylinder head Prior to installation clean cylinder head and gasket surfac es Remove all foreign matter and liquid from head bolt holes in cylinder block CAUTlON A minimum waiting time must be observed before installing the cylinder head if the camshafts were pr...

Page 97: ...r oil feed between cover and cylinder head Fig 53 Cylinder head bolt lightening sequence MOO engine 10 Remove protective film from gaskets Seal lower cor ners of cover to cylinder head Tighten bolts in two stages tightening cover to cylinder block bolts first WARNING The use of a special tool BMW Tool No 11 2 110 or a suitable protractor is required to tighten head bolts to a specified torque angl...

Page 98: ...g chain cover to cylinder head cylinder block 10 Nm 89 in lb Cylinder head cover to cylinder headltiming chain cover M6 10 Nm 89 in lb M7 15 Nm 11 tt lb Cylinder head to cylinder block stage 1 30 Nm 22 tt lb stage 2 800 stage 3 800 Exhaust manifold to cylinder head 22 Nm 17 tt lb Intake manifold to cylinder head 15 Nm 11 ft lb Radiator cooling fan to coolant pump 40 Nm 30 tt lb Spark plugs to cyli...

Page 99: ...sembly and reconditioning described in this repair group_Be sure to read each procedure thoroughly betore starting a job to determine which tools and equipment will be necessary CYLINDER HEAD AND VALVETRAIN RECONDITIONING 116 15 Cylinder Head 116 15 Camshaft _ 116 16 Hydraulic Cam Followers M50 M60 engines 116 17 To check hydraulic cam followers 116 17 Rocker Arms and Rocker Arm Shafts M20 and M30...

Page 100: ... head cover mounting nuts 10 Nm 89 in lb 2 Disconnect the breather hose from the cover and re move the eight cover mounting nuts See Fig 2 3 Lift off the ignition wire cover and place it out of the way Lift off the cylinder head cover and its gasket 4 Install a new gasket and the cylinder head cover 5 Install the support bracket s 6 Tighten the mounting nuts in the sequence shown in Fig 3 Reconnec...

Page 101: ...ect the ignition wires from the spark plugs Re move the ignition wiring harness mounting nuts and place the harness out of the way 4 Disconnect the breather hose from the cylinder head cover Remove the nuts and bolts shown in Fig 6 Lift off the cylinder head cover and its gasket 3 Remove the top engine covers See Fig 8 4 Disconnect ignition coil harness connectors from the coils Remove the ignitio...

Page 102: ...ead cover Be sure the hall moon shaped parts of the gasket correctly seat into the rear of the cylinder head and the spark plug gaskets are correctly positioned in Ihe cylinder head cover 7 The remainder of installation is the reverse of removal Be sure to reconnect all hoses and ground wires CYLINDER I iE JD COVER GASKETREPLACFflAEt JT Fig 9 Ignition cClIl l elllg removed COil s r8talneu bv two n...

Page 103: ...se clamps for intake air ducts o Disconnect harness connector from mass air flow sen sor o Remove air flow sensor and ducting 4 Disconnect harness connectors from ignition coils Re move ignition coil mounting nuts and pull coils straight up to remove See Fig 12 NOTE Note ground strap at cylinders 3 and 7 See 120 Ig nilion Syslem DME Fig 12 IgnitiOn coil l eing removed 5 Remove harness connector fr...

Page 104: ...NING Be sure harness connectors are correctly installed especially at knock sensors Incorrect installation of connectors at knock sensors may result in serious engine damage Tightening Torque Cylinder head cover to cylinder head and timing chain cover M6 10 Nm 89 in Ib M7 15 Nm 11 ft Ib VALVE ADJUSTMENT M20 and M30 engines Valve adjustment should be done as part of scheduled maintenance For a list...

Page 105: ...ce Adjustment sequence cylinder no _ 1 5 3 6 2 4 Fig 16 Valve clearance being adjusted Stiff wire hook inserted into hole m eccentric 6 Recheck all clearances before installing the cylinder head cover as described above This will require two complete rotations of the crankshaft pulley CYLINDER HEAD DISASSEMBLY AND ASSEMBLY Some of the disassembly procedures recommend the use of BMW special tools M...

Page 106: ... carrier cluring removal a rrow 4 Adjust the valves to maximum clearance by loosening the adjusting eccentric locknut Rotate the eccentric until the adjusting hole is facing inward CYLINDER HEAD DISASSEMBLYAND ASSEMBLY 5 Remove the rocker arm retainers by lifting them straight off Note that the straight leg of the clamp fits into the slot in the rocker arm shaft Lift out the rocker arm shaft guide...

Page 107: ...d Rocker arm assemblies should always be reinstalled in their original locations 12 Remove the intake side rocker arm shaft using the above procedure 13 Carefully rotate the camshaft out of the head Remove the valves using a standard C type valve spring compressor Label each valve assembly as it is removed Re move and discard the valve stem oil seals from the valve guides Reassembly is the reverse...

Page 108: ...as the tool is slowly tightened into place 6 If the special tool is not available rotate the camshaft until the least number of rocker arms are exerting pres sure on the camshaft Relieve the pressure on the re maining rocker arms by levering them down using a helper s and pull the camshaft out of the head WARNING The valves are under considerable pressure rom the valve springs Use extreme care whe...

Page 109: ...oil sprayer bar will cause accelerated camshaft wear Be sure to use a new center bolt and new washers If the old bolt is reinstalled there is danger of it loosening NOTE A new type sprayer bar hollow bolt was introduced by BMW in 1993 The new bolt is pre coated with a locking compound and should not be reused once torqued The new type bolt can be identified by the groove cut into the boft head and...

Page 110: ...n the remaining camshaft 6 Remove the camshaft carriers by pulling them straight up being careful not to let the hydraulic cam followers fall out CAUTION Do not let the hydraulic cam fol owers fall out as Ihe camshaft carrier is removed Special suction cups are available from BMW special 1001no 11 3 250 10 hold the hydraulic cam fol owers in place during carrier removal The cam followers should be...

Page 111: ...to read the procedure through be fore starting a job CAUTION The process of evenly loosening the camshaft bearing cap nuts is NOT an acceptable method of removing the camshafts The special tools should afways be used to remove the camshafts 1 Remove the cylinder head as described in 113 Cylin der Head Removal and Installation 2 With the cylinder head mounted to an appropriate work stand remove the...

Page 112: ...0 or Fig 31 CYLINDER HEAD D SASSEMBLYAND ASSEMBLY Fig 32 Timing chain tensioner O ring arrow CAUTION A minimum waiting time must be observed before installing the cylinder head to the block When the camshaft is removed the hydraulic cam fol owers expand slightly This expansion causes increased valve lift resulting in open vafves Cylinder head installation waiting times after cylinder head reassemb...

Page 113: ...ilable one al ternative is to install a remanufactured cylinder head Reman ufactured cylinder heads are available from an authorized BMW dealer parts department Cylinder Head The disassembled cylinder head should be inspected for warpage and cracks Check the valve guides and valve seats for wear before machining a warped head Always decarbonize and clean the head before inspecting it A high qualit...

Page 114: ...only should be bolted to the cylinder head before machining CYLINDER HEAD AND VALVETRAIN RECONDITIONING Camshaft Camshaft wear is usually caused by insufficient lubrication On M30 engines the installation of the oil sprayer bar is criti cal A clogged sprayer bar or a loose sprayer bar mounting bolt will reduce oil flow to the camshaft Visually inspect the re moved camshaft lobes and journals for w...

Page 115: ...the follower as described under Cylinder Head Disassembly and Assembly 5 Cylinder head assembly is the reverse of disassembly Tightening Torque Cylinder head cover to cylinder head timing chain cover M6 10 Nm 89 in lb M7 15 Nm 11 ft Ib Rocker Arms and Rocker Arm Shafts M20 and M30 engines Rocker arms and rocker arm shafts are components that wear and are usually the cause of valve train noise Alth...

Page 116: ...n Table g Remove carbon deposits from the valves using a wire brush or wire wheel CYLINDER HEADAND VALVETRAIN RECONDITIONING Fig 39 Valve guide wear being checked with dial indicator insert new valve until stem end is flush with end of guide white arrow See Table f for wear limits Testing Valves for Leakage To test the valves for leakage the camshaft and rocker arm assemblies where applicable shou...

Page 117: ...5 mm 5 960 0 015 mm 5 960 0 015 mm 0 2346 0 0006 in 0 2346 0 0006 in 0 2346 0 0006 in I Oversize 1 I intake 7 1 mm 0 280 in 8 1 mm 0 3 19 in I 7 1 mm 0 280 in 6 075 0 015 mm 6 075 0 015 mm 6 075 0 015 mm 0 239 0 0006 in 0 239 0 0006 in 0 239 0 0006 in exhaust 7 1 mm 0 280 in 8 1 mm 0 319 in 7 1 mm 0 280 in 6 060 0 015 mm 6 060 0 015 mm 6 060 0 015 mm 0 239 0 0006 in 0 239 0 0006 in 0 239 0 0006 in...

Page 118: ...40 mm Replacing the valve seats requires heating the cylinder head and chilling the valve seats to a specific temperature as listed in Table i When installing new valve seats they should be installed flush to the cylinder head surface NOTE International Organization for Standardization tSO tolerance classes are given in T able i for machine shop reference ISO allowances are based on nominal shaft ...

Page 119: ...m NIA N A NIA 1 376 in I exhaust N A NIA 32 5 mm N A N A NIA I 1 260 in Valve seat width A intake 1 1 65 0 35 mm 1 4 0 4 mm 1 4 1 9 mm 1 65 l 0 25 mm 1 25 l 0 25 mm I 1 25 l 0 25 mm 0 065 0 014 in 0 055 0 016 in 0 055 0 075 in 0 065 l 0 010 in 0 065 l 0 010 in 0 065 l 0 010 in exhaust 1 65 0 35 mm 1 7 0 4 mm 1 4 1 9 mm 1 65 l 0 25 mm 1 65 l 0 25 mm 1 65 l 0 25 mm 0 065 0 014 in 0 067 0 016 in 0 05...

Page 120: ...H7 I intake standard 43 00 mm 48 00mm 34 0mm 34 0 mm 1 6929 in 1 8898 in 1 339 In 1 339 in 0 4 mm 43 40 mm 48 40 mm 34 4 mm 34 4 mm 33 4 mm 36 4 mm 1 7086 in 1 9055 in 1 354 In 1 354 in 1 315 In 1 433 in exhaust standard 37 50 mm 40 00mm 31 5 mm 31 5 mm 1 4764 in 1 5748 in 1 240 in 1 240 in 0 4 mm I 37 90 mm 4O 40mm 31 9 mm 31 9 mm 29 9mm 31 9 mm 1 4921 In 1 5905 in 1 256 in I 1 256 in i 1 177 in ...

Page 121: ... exhaust cam shaft sprockets are driven by a second set of double row chains off the intake camshaft sprockets The chains are ten sioned by three hydraulic chain tensioners one for each chain CAMSHAFT TIMING CHAIN The timing chains are lubricated by engine oil and do not re quire maintenance A worn timing chain and sprockets can lead to noisy operation and erratic valve timing A faulty timing chai...

Page 122: ...et and tnermostat housmq moununq bolts tarrowsj 6 Remove engine drive belts See 020 Maintenance Program 7 Disconnect the crankcase ventilation hose fitting from the cylinder head cover See Fig 3 8 Remove the top plastic engine covers See Fig 4 Dis connect the ignition coil harness connectors from the coils Remove the ignition coils CAMSHAFT TIMING CHAIN R 11117 Fig 3 Crankcase ventilation hose iil...

Page 123: ...wer timing chain cover See Fig 9 16 Remove the vibration damper mounting bolts and reo move the vibration damper and pulley See Fig 10 17 Secure the crankshaft hub to prevent the crankshaft from turning Using a 22 mm socket loosen but do not remove the crankshaft hub boll Fig 6 001 1 nose ill 011i lIer 10USlfUJ rarrow 11 Remove the drive belt tensioner roller upper See Fig 7 Then remove the tensio...

Page 124: ...stalled by trying to rotate the ctenksnett CAMSHAFT TIMING CHAIN Fig 10 V braIIO l damper with drive lell pulley 1 f lng removed NoW huh locating oowel arrow Fig 11 BMW special tool no 11 2 300 istaneo hrougr bellho J SII Y and in 0 I wheel 19 Remove the crankshaft hub bolt and washer and reo move the hub from the crankshaft 20 Remove the three cylinder head cover mounting studs from across the re...

Page 125: ...ming chain cover Remove the cover mounting bolts and carefully lift the cover oft See Fig 13 CAUTtON Use care when removing the cover from the cylin der head gasket If the cover is stuck use a sharp knife to separate it from the head gasket NOTE The timing chain cover can be removed with the cool ant pump installed 24 On 1993 and later cars disconnect the harness con nector from the VANOS solenoid...

Page 126: ...he front of the intake camshaft CAUTION The crankshaft must not be allowed to rotate once the timing cham is removed The pistons can con tact the valves CAMSHAFT TIMING CHAIN Fig 16 Secondary timing chain tensioner being locked lawn Press tensioner down fully and insert locking wife through holes arrow NOTE Do not remove the secondary sprockets Irom the cham unfess these parts are being replaced W...

Page 127: ...e cover mounting bolts alternately and in stages Tightening Torque Front timing cover to cylinder block or cylinder head 10 Nm 89 in Ib 3 Install the oil pan using a new gasket See 119 Lubri cation System 4 Mount the primary timing chain sprocket to the primary chain 50 that the arrow on the sprocket faces up Mount the sprocket to the camshaft such that the tapped holes in the camshaft are on the ...

Page 128: ...cket stud nut to stud M6 10 1 Nm 89 9 in lb CAMSHAFT TIMING CHAIN 10 On 1991 and 1992 cars inslall the primary chain ten sioner so that the cutout in the tensioner piston engag es the chain rail as shown in Fig 21 The chain should be free of slack 61 1137 Fig 21 Primary timing chain tensioner being installed on 1991 ano 992 cars Piston cutout must IJ e In posmon shown to en gage chain rail Tighten...

Page 129: ...g chain tensione r to tensioner sleeve 50 Nm 37 ft Ib Access plugs to VANOS control unit 50 5 Nm 30 3 ft Ib 20 Install the cylinder head cover mounting studs Install the oil baffle cover Install the cylinder head cover Tightening Torque Cylinder head cover to cylinder head 10 Nm 89 in lb 21 Installation of the remaining parts is the reverse of reo moval When installing the thermostat make sure the...

Page 130: ...e of the meter See Fig 23 CAMSHAFT TIMING CHAIN 8 11087 Fig 23 Air n ow sensor mounting clips arrows 6 Remove the cylinder head cover mounting nuts Dis connect the crankcase breather hose and remove the cover 7 Remove the distributor cap and rotor Irom the front of the camshaft Remove the rotor adaptor from the cam shaft 8 Remove the bolts from the upper timing chain cover See Fig 24 Carefully sep...

Page 131: ...lts are found try dlsassemblmg and cleaning the piston If the piston can not be made to operate correctly it should be repfaced Fig 25 OfT lop dead center mark on vibration damper aligned With mark on timing ellaIn cover arrow Noteposition of sprocket locating dowel t 5 Without disturbing the position of the crankshaft re move the hub vibration damper mounting nut and the hub damper assembly from ...

Page 132: ... cover Temporarily in stall the crankshaft woodruff key together with the crankshaft hublvibration damper Check that both the camshaft and the crankshaft are set at Top Dead Cen ter TOC as shown earlier in Fig 25 3 Install the camshaft sprocket with the chain to the cam shaft so that all chain slack is on the tensioner side of the chain Tighten the sprocket mounting bolts NOTE If any of tile sproc...

Page 133: ...asket Apply an extra amount of sealer Three Bond Silicon 1207 or equiva lent to each corner 01 the oil pan cylinder block surface area Fig 29 Lower tnnlng chain cover mounting bolt locations Tightening Torque Camshaft timing chain tensioner to front timing chain cover 40 Nm 30 tt lb 7 Loosely install the power steering pump bracket 8 When all brackets and bolts are installed tighten the front cove...

Page 134: ...d locking compound on the ignition rotor adaptor bolt Tightening Torque Ignition rotor adaptor to camshaft install with thread locking compound 23 1 Nm 17 1 tt lb 20 Reconnect the battery Check all fluid levels To check and adjust camshaft timing M60 engine Special BMW service tools are needed tor this procedure Read the procedure through before beginning the job II the camshafts are not properly ...

Page 135: ...t and righl cylinder heads NOTE Hold the camshaft stationary at hex on camshaft when loosening or tightening the camshaft sprocket mounting bolts 9 Turn engine over one complete revolution Loosen reo maining bolls on camshaft sprockets 10 Turn engine over to TOG again Hold crankshaft and camshafts at TOG position using BMW special tools See Fig 34 Turn camshafts at hex slightly 10 ensure proper fi...

Page 136: ...ft See Fig 35 When the engine is running the piston housing is supplied with pressurized engine oil At idle the solenoid is in the off position de enerqized and valve timing is maintained in the normal position When the solenoid is energized the gear cup piston moves forward to advance the camshaft by 12 5 VANOS VARIABLE VALVE TIMING Fig 35 VANOS control unit with modified intake camshaft WARNING ...

Page 137: ... the VANOS solenoid connector Connect the positive test lead to the positive ter minal of the battery Connect the negative test lead to chassis ground The solenoid should audibly click and the intake camshaft should advance CAUTION Be sure to connect the test harness potarity cor rectly If the polarity is reversed the internal diode in the VANOSsolenoid will be destroyed Although the solenoid will...

Page 138: ...camshaft NOTE Make note of the mounting bolt insulator arrangement during removal of the cylinder head cover 5 Set the engine to TDC by rotating the engine in the nor mal operating direction until the camshaft lobes at cyl inder no 1 are facing each other and the O rr mark OO TDC on the vibration damper lines up with the cast boss on the lower timing chain cover See Fig 38 VANOS VARIABLE VALVE TIM...

Page 139: ...l toots no t 12300 and 1t 3 240 f the camshafts and crank shaft are not positioned exactly at TOG the valves can contact the pistons when the engine is turned over NOTE Be sure that the secondary timing cham tensioner is tocxea down and the exhaust camshaft mounting bolts are loose before proceeding 2 Remove the primary timing chain tensioner from the side of the cylinder head See Fig 40 Install B...

Page 140: ...m 11 in Ib Then tighten the exhaust camshaft sprocket mounting bolts alternately in two stages Tightening Torque 1993 and later M50TU engine Secondary timing chain sprockets to camshafts Torx bolts stage 1 5 Nm 44 in lb stage 2 22 Nm 17 tt lb VANOS VARIABLE VALVE TIMING 12 Remove the flywheel locking tool from the transmission bellhousing Remove the camshaft locking tool from the rear of the cylin...

Page 141: ...ng fan See 170 Radiator and Cooling System WARNtNG AI ow the cooling system to cool before opening or draining the system NOTE The radiator cooling fan nut 32 mm wrencii has left hand threads 2 Remove the metal coolant cross pipe and its hoses from the front of the engine The pipe is held in place with two bolts 3 Remove the distributor cap the ignition rotor and the black protective cover from be...

Page 142: ... 3 11 Using a socket wrench 22 mm on the center crank shaft hub bolt rotate the crankshaft clockwise until the engine is at Top Dead Center TDC or O IT of the NO 1 cylinder See Fig 4 NOTE At TOC the O IT mark on the vibration damper WIll align with the boss on the lower camshaft drive belt covel The mark on the camshaft drive belt sprocket will align with the mark on the cylinder head See Fig 4 12...

Page 143: ...ly engages the hole in the tensioner and the detent in the coolant pump See Fig 6 To install camshaft drive belt M20 engine 1 Check that the crankshaft and camshaft timing marks are correctly aligned See Fig 4 above Also check that the notch on the inner cover aligns with the mark on the sprocket See Fig 7 2 Install the new belt beginning at the crankshaft sprock et working in a counterclockwise d...

Page 144: ...he vibration damper be sure to align the crankshaft hub locating pin to the hole in the vibration damper See Fig 8 Fig 8 Crankshaft hub locating pin arrow Install the engine V belts and adjust belt tension as de scribed in 020 Maintenance Program Place a label in the engine compartment noting camshaft drive belt replacement date and odometer reading Refill the cooling system as de scribed in 170 R...

Page 145: ...d against bursting the filter due to over pressure and an oil pump pressure relief valve to prevent excessive system pressure TROUBLESHOOTING The lubrication warning system consists of an oil pressure switch mounted in the oil circuit an oil level sensor mounted in the oil pan an instrument panel warning light and graphic check control displays The check control display will also warn the driver i...

Page 146: ...h terminal and the warning light See 600 Electrical Sys tem General for electrical wiring troubleshooting in formation TROUBLESHOOTING 2 If the warning light does not light when the ignition is on remove the connector from the oil pressure switch and use a jumper wire to ground the connector terminal to a clean metal surface NOTE If the warning light comes on check the switch as de scribed in the ...

Page 147: ...nt for raising the engine off its mounts To remove and install oil pan M20 engine 1 Drain the engine oil as described in 020 Maintenance Program Oil Level Sensor Continuity Test Test terminals Bluelyellow wire and ground static switch correcl oil level low oil level Bluelwhite wire and ground dynamic switch low oil level Test results 1k 1 ohms switch open 0 0 2 ohm switch closed no continuily swit...

Page 148: ...emove and install oil pan M30 engine 1 Drain the engine oil as described in 020 Maintenance Program 2 Disconnect the oil level sensor harness connector 3 Remove the radiator cooling fan and the fan shroud See 170 Radiator and Cooling System NOTE The radiator cooling fan nut 32 mm wrench has left hand threads 4 Remove the air cleaner housing from the car OIL PAN 12 Using an engine lifting device at...

Page 149: ... and slip belt on pulleys 5 Without disconnecting any fluid lines remove the pow er steering pump and its bracket from the engine block See Fig 6 Support the pump from the body using stiff wire 6 Remove the oil dipstick guide tube mounting bolt and remove the tube See Fig 7 NOTE The guide tube is sealed in the bloc using an D ring Check that the D ring comes out with the tube Use a new D ring when...

Page 150: ... M60 engine 8 Remove the engine drive belt See 020 Maintenance Program 1 Disconnect negative H terminal at battery 2 Loosen oil filter cover at top of oil filter housing Drain engine oil 3 Remove radiator cooling fan and fan shroud See 170 Radiator and Cooling System 9 Without disconnecting any fluid lines remove power steering pump and its bracket from engine block Sup port the pump from the body...

Page 151: ...to mount carrier 47 Nm 35 It lb Oil pan to engine block M6 bolt 10 Nm 89 in Ib Oil pump sprocket to pump shaft 47 Nm 35 ft lb Oil pump to engine block use new nuts 22 Nm 1 7 ft Ib Oil return line to oil pan banjo bolt 30 Nm 22 ft Ib The oil pump is mounted to the bottom of the cylinder block inside the engine oil pan When the engine is running oil is drawn from the oil pan by the oil pump s pickup...

Page 152: ... threaded spacer on pump fully to stop See Fig 12 Install pump and tighten two nuts on left side of pump See Fig 13 Adjust chain slack by turning spacer using hex wrench See Fig 14 Install and tighten final mounting boll Tightening Torques Oil pump to engine block 22 Nm 16 ft Ib Oil pump sprocket to oil pump shaft M30 engine 25 Nm 18 ft Ib M50 engine left hand thread 25 Nm 18 ft Ib M60 engine 47 N...

Page 153: ...ly controlled and not adjustable The DME control module uses engine load engine speed coolant temperature and intake air temperature as the basic in puts for timing control On cars with DME 3 3 and DME 3 3 1 knock detection is also an input to the DME control module Testing crankshaft position rpm sensor 120 5 Ignition Firing Order 120 6 Knock Sensors 120 6 IGNITION SYSTEM CIRCUIT SCHEMATICS 120 7...

Page 154: ...ock or ping I The DME engine management system can be disabled by removing the fuel pump relay and the DME main relay The re lays are located in the E box in the right rear of the engine compartment See Fig 3 Warnings and Cautions The DME system contains sensitive electronic compo nents To protect the system and for general safety the fol lowing warnings and cautions should be observed during igni...

Page 155: ...y removing the ptugs and in specting lor differences between them A non or poor liring plug can either be wet with luel and or black and sooty Note that on late cars the tuet injector will be electrically disabled il a laulty coil is detected 1 Turn the ignition off and remove a connector from one of the spark plugs Connect it to a known good spark plug preferably a new plug WARNING Do not hold th...

Page 156: ...removed as described See 170 Rad ia tor and Cooling System The distributor cap is held in place with three screws See Fig 5 Carefullyremove the plastic shield from thecap andthen loosenthe captive screws Leavethe sparkplugwires in the old cap Mount the new cap and tighten the screws Change over one wire at a time from the old cap to the new one 3 Inspect the coil housing for hairline cracks or lea...

Page 157: ... 7 Ignition coil harness connector terminal identification for M50 and MOO engines CAUTION The wiring to terminal 15 of the coil via the igni tion switch is not fuse protected Use care when testing this circuit 4 Use an ohmmeter to test the coil primary Resistance values are listed inTable b Table b Ignition Coil Resistance M50 M60 engines ITerminals Resistance Coil primary 1 and t5 l 0 4 0 8 n Co...

Page 158: ...cytmder head fGNlTlON SYSTEM SERVICE Ignition coil wire Fig 9 Spark plugs wires correctly Installed in cistnbutor cap M201M30 engines Igniti on Firing Order M20 M30 M50 engines 1 5 3 6 2 4 M60 engines 1 5 4 8 6 3 7 2 Knock Sensors Knock sensors are used on DME 3 3 and later engine man agement systems M50 engines use two knock sensors and the M60 engines use four sensors The knock sensors are bolte...

Page 159: ...16 nlllon 011 1 Dist ributor 1 1 ostic __ 1 _ _ IShield I ector I I nai l I _ I 2 6 3 6 1 V _ Shield to Spark plugs I I I _ _I OME Control Module OME 1 3 f 6GN Battery vollage 10 In run or start Dlagn via ignition switch Conn terminal 15 term I r 27 1 18 Ji I pow _ 0 corn pow n I I No 6 cyln Oef ldenl fcatoon InPUt engine speed posf 1Of sensa Input voundS _ I IOlound A A II lll l etay I1 19 8 1 48...

Page 160: ...age in run or start via ignilion switch terminal 15 r r I 56 25 23 24 50 52 5 54 I 1 power Input Powet tnpU1 I I OME cont rol Module OME 3 1 I I K iI P owttf Main tela1 control I 16 28 61 68 i4 55 6 2 6 2 I 1 _ 3S BK I 35 YE I 35 BK I 35 YE Ground RH raar of engina compartment 5BR to Main relay terminal 85 1 0 RO Banery voltage at all times L Ground RH rear of engine compartment BK I sc N Cranksha...

Page 161: ... i II OGN S GN Warning lethal voltage present Banery voltage in run or start via ignition switch terminal 15 L SBA 10 Main relay terminal B5 l ORD Banery voltage at all times J BK 35 YE 2 I l BK sc N Crankshaltlrpm Position Sensor 35 I 35 BK I Knock Sensor Knock Sensor lcyl 1 3 Icyl 4 6 r I 56 50 5 52 2J 2S 2 54 I power w JUt Power wi OME Control Module OME 3 3 1 1 p onpuI n olafcan I 70 69 11 43 ...

Page 162: ...Uage in run or start via ignition switch terminal 15 5BA to Main retay terminal 85 l ORD Battery voltage at alt times l I 1 r I 56 5 49 so 24 52 23 22 51 I po wrf Input I OME Control Modute OME 3 3 I ll nos I A _ P O A VI 1 n lU1 MilJO r r control I 70 69 71 8 67 t3 16 r3J 55 6 26 27 I 1 0 1 35BK l 35 B f5 BAOAl35 B 35 B 35 e 35VE Ii I J J J IJ L I 1 I_ s CII Crank shalUrpm Knock Sensor Knock Sens...

Page 163: ...e battery are not visible confirm the polarity of the battery using a voltmeter To remove and install alternator 121 4 To remove and install voltage regulator 121 5 To inspect and replace brushes 121 5 STARTER SERVICE 121 6 To remove and install starter M20 M30 M50 engines 121 6 To remove and install starter M60 engine 121 6 To remove and install solenoid switch 121 6 TABLES a Open Circuit Voltage...

Page 164: ...normalrange STARTER TROUBLESHOOTING Table b Battery Load Test Minimum Voltage apply 200 amp load for 15 seconds WARNING Always wear protective goggles and clothing when performing a load test Ambient temperature Voltage 80 F 27 C 9 6 V 60 F 1 6 C 9 5 V 40 F 4 C 9 3 V 20 F rC 8 9 V O aF 18 C 8 5 V 89517 I ID Ol II Battery Battery Open Circuit Voltage Test Before making the test load the battery wit...

Page 165: ...yte is spilled clean the area with a solution of baking soda and water o Atways allow a frozen battery to thaw before at tempting to recharge it o Always disconnect both battery cables during battery charging This will prevent damage to the alternator and any solid state components Do not exceed t6 5 votts at the battery ALTERNATOR SERVICE Before checking the alternator and regulator make sure the...

Page 166: ...0 engines disconnect the alternator ducting and loosen the lower pivot bolt Irom below It will be neces sary to remove the engine splash pan s to access the underside 01 the engine 7 Remove upper adjustment mounting bolt and lower bolt s from alternator Protect front of radiator with heavy cardboard or sheet metal See Fig 4 00 1 52 1 Fig 4 Alternator rnoununq bolts arrows Allema or rom MOO en gine...

Page 167: ...m battery 2 Disconnect the ducting from rear of alternator Remove wiring cover and ducting from rear of alternator 3 To replace brushes carefully and as quickly as possi ble unsolder brush lead from brush holder terminal withdrawing brush from holder at same time 3 Remove voltage regulator mounting screws and reo move regulator from alternator See Fig 6 CAUTlON Regulalor brushes are not available ...

Page 168: ...rking from below remove engine splash pans and heat shields from right side of engine 3 Remove heat shield from front suspension crossmem ber 4 Remove heat shield from rear of starter motor 5 Disconnect wiring from starter Label wiring as neces sary 6 Loosen and remove starter bolts from transmission side 7 Installation is reverse of removal STARTER SERVfCE Tightening Torques Battery positive cabl...

Page 169: ...ent that is capable of quickly pinpointing hard Io find DME fuel injection problems Engine coolant temperature ECT sensor replacing 130 14 Throttle position switch or sensor replacing 130 14 Fuel injectors replacing 130 14 Fuel rail and injectors removing M20 engine 130 14 Fuel rail and injectors removing M30 engine 130 15 Fuel rail and injectors removing M50 engine 130 1 6 Fuel rail and injectors...

Page 170: ... is not covered here due to the special electrical testing equipment required to set vice the system See Electrical Wiring Diagrams for the traction control electrical circuits Fuel Metering The ECM meters fuel by changing the opening time pulse width of the fuel injectors To ensure that injector pulse width is the only factor that determines fuel me tering fuel pressure is maintained by a fuel pr...

Page 171: ...ASC Trac tion Control o Connect and disconnect the DME system wiring and test equipment leads only when the ignition is switched off WARNING o Gasoline is highly ffammable and its vapors are explosive Do not smoke or work on a car near heaters or other fire hazards when diagnosing and repairing fuel system problems Have a fire extinguisher available in case of an emergency o When working on an ope...

Page 172: ...nnected with hose cfamps to prevent it from coming loose under pressure System pressure checking System pressure is the pressure value that is created by the fuel pump and maintained by the pressure regulator See Fig 2 System pressure is not adjustable 1 Relieve fuel pressure and connect a pressure gauge as described earlier FUEL PRESSURE TESTS Fig 2 Fuel pressure regulator Fuel pressure deflects ...

Page 173: ...s not maintain pressure there is a leak in the system Check visually for leaks in fuel lines or at unions Leaks can also be due to a leaking injector or a faulty fuel pump check valve Check the pump check valve by re peating the test but before turning the fuel pump off pinch off the return line at the fuel rail If the pressure is now main tained the fault is most likely the fuel pump check valve ...

Page 174: ...ll function cor rectly If vollage is not present at terminal 86 check for voltage at terminal 85 ELECTRICAL CHECKS AND COMPONENT TESTING 87 851 87 186 30 I 30 85 8687 87 I I I I I IV __ J I J Bi 661 Fig 5 Voltage checks at system relay terminals 30 and 86 3 Reinstall the relay and turn the ignition on Gain access to the underside of the relay socket and check for ground at terminal 31 brown wire I...

Page 175: ...or for fuel injection and ignition timing See Fig 7 Fig 7 Intake a temperature sensor ioca ion on M50 engine arrow NOTE On M20 and M30 engines without traction control the intake air temperature tAT sensor IS integrated into the volume air low sensor On M30 engines with trac tion control a separate intake air temperature sensor is used by the electronic throttfe control system and can be tested as...

Page 176: ... voltage VDC between the center terminal and either of the outer terminals of the harness connector If voltage is not present at either wire check the wiring from the ECM The throttle position sensor is mounted on the side of the throttle housing and is directly connected to the throttle valve shaft The ECM sends a voltage signal to the potentiometer type sensor and monitors the voltage that comes...

Page 177: ... flap throughout its range of travel The resistance should change steadily without interruption 4 Connect an ohmmeter across terminals 1 and 4 to test the intake air temperature sensor in the air flow sensor Compare the resistance value to the values listed inTa ble c given earlier 5 If any faults are found the sensor is faulty and should be replaced Air flow sensor checking M50 engine On cars wit...

Page 178: ...ould be ground at pin 4 There should be positive battery voltage at pin 2 8 With the ignition oil disconnect the harness conner tor from air flow sensor Check the resistance at the lest terminals in the meter ELECTRtCAL CHECKS AND COMPONENT TESTING Fig 12 Mass air now sensor terminal idennncaton on cars with DME 3 1 Connect voltmeter across terminals 1 I l and 4 H to check meter burn off voltage A...

Page 179: ...d in Electrical Wiring Diagrams NOTE If there is positive t battery voltage as described in step 3 but there was no response at voltmeter in step 2 check the wirets from the ECM to the injectors If no wiring faults can be found the pulsed ground signal from the control module may be missing Check the outputs Irom the ECM 5 If power is present as described in the above step un plug the injector con...

Page 180: ...e element is electrically open no continuity replace the sensor NOTE o The oxygen sensor heater relay is mounted in the electronics box E box in the right rear of the engine compartment The heater relay is energized with pos itive battery voheqe Irom the DME main relay and a switched ground from the ECM See Electrical Wir ing Diagrams o On 535i models an oxygen sensor heater relay is not used The ...

Page 181: ...dle speed actuator receives positive t battery voltage from the DME main relay 5 If voltage is present as described above check the wir ing between the ECM and the valve If no wiring faults are found check the ECM signal to the valve NOTE The idle speed control valve signal can be checked using a duty cycle meter or dwell meter Connect the meter to the valve following the manufacturer s in structi...

Page 182: ... Fuel injectors replacing The fuel injectors are removed by first removing the corn plete injectorlfuel rail assembly and then unclipping the injec tors from the fuel rail COMPONENT REPLACEMENT Cleanliness is essential when working with fuel circuit com ponents Thoroughly clean the unions before disconnecting any fuel lines Use clean tools WARHIHG Fuel will be expelled when fuel lines are disconne...

Page 183: ...sor and the throttle housing See Fig 19 3 Remove the screws from the injector wiring duct and re move the duct from above the injectors See Fig 20 4 Remove the fuel rail mounting bolts 3 5 Pry up the fuel rail and remove individual injectors by removing the injector retaining clip and pulling the in jector from the rail WARNING Fuel will be discharged Do not disconnect any wires thai could cause e...

Page 184: ...tallation is the reverse of removal Fit new a rings when installing the injectors For ease of installation lightly lubricate the a rings with SAE90 gear lube Check that the injector electrical connections are correctly fitted and that the injectors are fully seated prior to installing the fuel rail mounting bolts Tightening Torque Fuel rail to cylinder head 10 Nm 89 in lb Fuel rail and injectors r...

Page 185: ...ressure regulator at taches to the fuel rail with two bolts Disconnect the vacuum hose and fuel return hose as shown in Fig 24 Remove the bolts and then wrap a shop rag around the regulator Pull the regulator from the fuel rail Installation is the reverse of remov al Always replace a rings 6103 Fig 24 Fuel pressure regulator arrow on M20 engine M30 engine similar WARNING Fuel will be discharged Do...

Page 186: ...p engine covers by prying out caps and removing nu s A Nole rubber gaskets a cover eclg8 arrows 2 Remove the two hold down nuts from the fuel injector wiring duct Pry back the injector connector retainers and lill off the wiring duct 3 Disconnect the intake air boot from the throttle housing Where applicable disconnect the accelerator cable and cruise control cable from their brackets 4 Unbolt the...

Page 187: ...ion Remove bolt between air flow sensor and air cleaner housing Loosen nut on side of air cleaner housing 3 Working inside the upper housing remove the air flow sensor mounting screws 4 Installation is the reverse of removal No adjustment to the air flow sensor is necessary Air flow sensor replacing M30 engine 1 Disconnect the harness connector and the intake air boots from the air flow sensor 2 W...

Page 188: ...onnector from the engine control module CM If the connec tor is removed before this time residual power in the system relay may damage the ECM Always connect or disconnect the control module connector and meter probes with the ignition off When making checks at the ECM itself a breakout box should be used to allow tests to be made with the connector attached to the ECM This also prevents damage to...

Page 189: ... engine lamp control 16 output IFuel injectors cy 1 3 5 IPulsed ground injection pulse width in ms 17 output IFuel injeC1ors cy 2 4 6 Pulsed ground injection pulse width in ms 18 input IPower supply terminal 30 IBattery voltage B at all times terminal 30 19 ground IShielding ground 1 Ground for ECM and sensor shielding 20 vacant I I 21 vacant I I 22 output Idle speed control Pulsed ground duty cyc...

Page 190: ...t 1 47 input Engine speed and crankshaft position Crankshaft position rpm voltage VAC between pins 47 and 48 sensor 48 input Engine speed and crankshaft position ICrankshaft position rpm voltage VAC between pins 47 and 48 sensor 49 vacant input on Engine torque reductionrcutout on 5351 from Slip control module on 535i wiEML 535i w EML wIEML 50 Ivacant 1 51 Iinput Ignition timing intervention Ifrom...

Page 191: ...44 17 output Fuel consumption ti IFuel consumption output KVA signal to instrument cluster 18 vacant I I 19 I cant 20 vacant IPrimary 0 go 0011 cyl 00 2 21 I vacant 22 vacant 23 output Ignition control terminal cyl no 2 24 output Ignition control terminal cyl no 3 Primary signal ignition coil cyl no 3 Ignition control terminal cyl no 1 25 output Primary signal ignition coil cyl no 1 26 input IPowe...

Page 192: ...tomatic transmission AfT range switch iGround when transmission is in park or neutral 66 vacant 67 Input IEngine speed crankshaft position sensor Crankshaft position rpm voltage VAC between pins 67 and 68 68 Input IEngine speed crankshaft position sensor Crankshaft position rpm voltage VAC between pins 67 and 68 69 vacant 1 70 input Oxygen sensor oxygen sensor signal 0 1 VDC fluctuating with engin...

Page 193: ...ut Ignition coil control cyl 7 Primary signal ignition coil 7 23 output Ignition coil control cyl 6 Primary signal ignition coil 6 24 output Ignition coil control cyl 4 Primary signal ignition coil 4 25 output Ignition coil control cyl 1 Primary signal ignition coil 1 26 input Power supply terminal 30 Battery voltage B at all times 27 input Main relay control Main relay activation terminal 85 28 g...

Page 194: ...ed climate control module 65 input IAlC compressor signal Ifrom integrated climate control module via AlC pressure switch 66 Iinput On board computer Drive away protection enable i 67 input Knock sensor 4 Knock sensor 4 signal 68 input Knock sensor 3 Knock sensor 3 signal 69 input Knock sensor 2 Knock sensor 2 signal 70 input Knock sensor 1 Knock sensor 1 signal 71 ground Ground Ground for analog ...

Page 195: ... 19 vacant 1 20 vacant 21 vacant 22 vacant I 23 output I Ignition coil control cyl 4 Primary signal ignition coil 4 24 output Ignition coil control cyl 6 Primary signal ignition coil 6 I 25 output Ignition coil control cyl 5 Primary signal ignition coilS 26 input Power supply terminal 30 Battery voltage B at all times 27 input Main relay control Main relay activation terminal 85 28 Iground Ground ...

Page 196: ...ge via data link connector 61 vacant 1 62 output Throttle position signal I to Slip control module 63 vacant 64 input N C on signal from integrated climate control module 65 I input NC compressor signal from integrated climate control module via N C pressure switch Drive away protection enable 66 Iinput On board computer 67 vacant 1 68 vacant 1 69 Iinput I Knock sensor 2 cyl 4 5 6 Knock sensor 2 s...

Page 197: ...ated Fuel Pump Tests 160 5 Fuel pump electrical circuit checking 160 6 Fuel pump delivery pressure and delivery rate checking 160 6 Fuel pump power consumption checking 160 7 TABLES a Fuel Level Sender Resistances 160 4 b Fuel Pressure Specifications 160 6 c Fuel Pump Current 160 7 CAUTlON Before making any electrical tests with the igni tion turned on disable the ignition system as de scribed in ...

Page 198: ... be pumped out via a hose inserted in the filler neck The tank can also be drained through the drain plug in the bottom of the tank 2 Remove the fuel tank filler cap and empty the fuel tank using an approved evacuation or draining method 3 Working in the luggage compartment remove the floor carpeting Then remove the access cover above the fuel pump fuel level sender WARNING Belore removing the tan...

Page 199: ...he body Replace rub ber parts that are hardened or damaged Tightening Torques Fuel level sender fuel pump to fuel tank M6 nut 10 Nm 89 in lb M8 bolt 23 Nm 17 fHb Fuel tank to body 23 Nm 17 fHb Heat shield to fuel tank bolts 10 Nm 89 in Ib Fuel tank drain plug with new seal ring 25 Nm 18 tt lb Hose clamps 10 mm to 16 mm diameter 2 0 Nm 18 ln lb Fuel level sender and fuel pump removing The fuel leve...

Page 200: ...values for the sender at various float positions FUEL PUMP Fig 5 Fuel pU lllplievel sender tenrunahoentiticatlon Table a Fuel Level Sender Resistances Connector Float position I Test result ohms terminals G and 31 slowly moving from resistance continuously empty to full position changing no breaks Empty 88 7 2 8 ohms I Full I 3 2 0 7 ohms w and 31 j Empty low fuel continuity warning I FUEL PUMP Th...

Page 201: ...87 with a fused jumper wire Fig 7 shows relay terminal desig nations After completing the tests remove the jumper wire CAUTlON Relay locations may vary Use care when identily ing relays and when troubleshooting the electrical system at the fuse relay panel The fuel pump reo lay is a four pin relay and has a t 5 mm red wire at terminal 30 in the relay socket If in doubt con suIt an authorized BMW d...

Page 202: ...system at the tuse retay panel To resolve problems in identity ing a relay see an authorized BMW dealer 1 Working from the luggage compartment remove the floor carpeting Then remove the access cover from above the fuel pump sender assembly 2 Remove the fuel pump relay and operate the fuel pump as described under Operating Fuel Pump for Tests The pump should run Disconnect the jumper wire when fini...

Page 203: ...lfimeter DMM 3 Run the pump as described in Operating Fuel Pump for Tests WARNING Fuel is highly flammable When working around tu et do not disconnect any wires that could cause electrical sparks Do not smoke or work near heat ers or Ofher fire hazards 4 Compare the ammeter reading with the specification listed in Table c NOTE To achieve accurate test results the battery voltage at the connector s...

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Page 205: ...ture the thermostat opens and coolant circulates through the whole system including the radiator Radiator Expansion Tank and Cooling Fans The radiator is a crossflow design A translucent expansion tank provides for coolant expansion at higher temperatures and easy monitoring of the coolant level On cars with automatic transmission ATF is circulated through an additional heat ex changer ATF cooler ...

Page 206: ...ck that the shaft runs smoothly TROUBLESHOOTING NOTE The coolant provides some lubrication for the pump shaft so an occasional drop of coolant leaking from the pump is acceptable If coolant drips steadily from the vent hole Ihe pump should be replaced The cooling system becomes pressurized at normal operat ing temperature which raises the boiling point of the coolant Leaks may prevent the system f...

Page 207: ...60 engine rear of engine in coolant manifold NOTE On MBOengines remove the top engme cover to ac cess the gauge sender in the cootsnt manifold at the rear 01the engine If the gauge needle reads too high when the engine is cold disconnect the connector from the sender Turn the ignition on If the gauge needle position does not change the wiring or the gauge is shorted to ground If the gauge needle d...

Page 208: ...x Fig 4 Auxiliary radiator cooling fan resistor arrow Wires jumpered Test Test results I conditions VioleVgrey and brown Ignition ON Fan runs on low speed Blacl Jgrey yeliow 19SS 1992 Ignition ON Fan runs on or Black grey 1993 and later high speed and brown Table a Auxiliary Fan Temperature Switch Tests Tightening Torque Temperature switch to radiator 8 Nm 71 in lb If the fan does not run when pow...

Page 209: ...e M60 engine M20 engine M50 engine Air may become trapped in the system during filling Trapped air can prevent proper coolant circulation Whenever the coolant is drained and filled the system should be bled of trapped air Fig 5 Radiator drain plug arrow WARN NG Goo ant is poisonous and letha especially to pets G ean up spills immediately and rinse the area with water 2 On models with radiator moun...

Page 210: ...and fan shroud as de scribed below under Cooling Fan Removal and In stallation Fig 6 COOling svs em b1eecJ screw on 5251models rarrow j Also note cold level mark on expanston tank NOTE The radiator cooling fan nut 32 mm wrench has tett hand threads Fig 7 Cooling system bleed screw arrow on 535 mortel CAUTlON Always use genuine BMW coolant or Its equive lent to avoid the totmetion of harmful cloggi...

Page 211: ... bolts The valves can be damaged il the pistons are accidentally moved white belt tension is relieved 11 Installation is reverse of removal Use a new coolant pump gasket and make sure gasket mating surfaces are clean and dry Fill system with coolant and bleed system as described above in Draining and Filling Coolant B11176 Fig 10 When removing coolant pump remove upper bolts first ar rows pivot pu...

Page 212: ...ellers should not be used 1 Disconnect negative H cable from battery COOLANT PUMP REPLACEMENT 2 With engine cold drain cooling system as described earlier WARNING Allow cooling system to cool before opening or draining system 3 Remove fan clutch assembly and fan shroud as de scribed below under Cooling Fan Removal and In stallation NOTE The radiator cooling fan nul 32 mm wrench has tett hand threa...

Page 213: ...ystem to cool before opening or draining cooling system 3 Remove fan clutch assembly and fan shroud as de scribed under Cooling Fan Removal and Installa tion NOTE The radiator cooling fan nut 32 mm wrench has left hand threads 4 Working from below car remove engine splash guard and then remove heat shields from front suspension crossmember 5 Loosen coolant pump pulley mounting bolts 6 Remove engin...

Page 214: ...r complete with air flow sensor 4 Remove thermostat housing On M20 M30 and M50 engines the thermostat is mounted in the thermostat housing on the front of the engine See Fig 16 On M60 engines the thermostat is mounted in the thermostat housing as part of the coolant pump See Fig 17 THERMOSTAT REPLACEMENT NOTE On M50 and M60 engines removal of the cooling fan and fan shroud will provide additional ...

Page 215: ...ctor from auxiliary fan tern perature switch See Fig t8 6 On M20 and M50 engines disconnect coolant level sensor connector from bottom of radiator expansion tank 7 Disconnect automatic transmission fluid ATF cooler lines from radiator where applicable NOTE Plug the tiiscarmectea ATF cooler lines and position them upwards to avoid loss 01 fluid 8 Pry out radiator retaining clips from top of radiato...

Page 216: ...n nul 32 mm wrench has tett hand threads 2 Remove expansion rivets holding shroud to radiator See Fig 21 8 11183 Fig 20 Radiator cooling fan nul arrow 3 Remove fan and shroud together NOTE Store the removed fan ctutch assembly in an upright position to prevent loss ot clutch fluid COOLING FAN REMOVAL AND INSTALLA nON Fig 21 Fan shroud retaining rivet Pryout center pin arrow and remove nvet 4 To re...

Page 217: ... very tox ic Run the engine only in a welt ventilated area ltn mediatety repair any leaks in the exhaust system or structural damage to the car body that might allow exhaust gases to enter the passenger compartment The oxygen sensor monitors the exhaust gas and provides feedback about combustion efficiency to the DME control unit The oxygen sensor shou ld be replaced as a part of routine maintenan...

Page 218: ...g 2 Fig 2 Exploded view of exhaust system on 1991 and later 525i models with M50 engine 1 2 _ 8 11 183 10 5 7 3 M8x55 M8 2 1 Exhaust manifolds 2 Gasket rings 3 Front pipe with catalytic converter 4 Oxygen sensor and shield 5 Bracket manual trans 6 Bracket automatic trans 7 Rear pipe with muHlers 8 Gasket ring 9 Bracket 2 10 Rubber mounting ring 2 11 Bracketlclamp 2 12 Rubber mounting ring 2 Fig 3 ...

Page 219: ...o cool betore servicing Wear pro tective clolhing to prevent burns Do not use lIam mabIe chemicals near a hot catalytic converter Old corroded exhaust system components crum ble easily and olten have exposed sharp edges To avoid injury wear eye protection and heavy gloves when working with ota exhaust parts Exhaust system removing and installing This section covers removing the exhaust system as a...

Page 220: ... new retaining nuts and gaskets when removing and installing the exhaust manifolds EXHAUST SYSTEM REPLACEMENT 1 Working from beneath rear seat disconnect negative battery cable from battery WARNfNG Disconnecting the bat ery cables may erase fault codes stored in control unit memory 2 On cars with battery mounted in engine compartment remove battery from car and remove battery tray 3 With exhaust s...

Page 221: ...re is sufficient clearance at rear bulkhead when raising engine Installation is the reverse of removal Coat the exhaust manifold mounting studs with copper paste before installing the new nuts Install the manifold gaskets with the arched side facing the manifolds Be sure to reinstall all ground straps ear lier removed Exhaust manifolds removing and installing M60 engine right manifolds 1 Working f...

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Page 223: ...MISSION Four different automatic transmissions are used depending on model and model year and or production date All of the au tomatic transmissions are electro hydraulically controlled with either four or five forward speeds Table a lists automatic trans mission application information NOTE Repair information including lubricating fluid specifica tions for the automatic transmission is covered in...

Page 224: ... Typical location of identification code letters on automatic transmission 6263 Fig 2 Typical location of manual transmission identification code let ters Getrag 260 transmission shown Theclutch is hydraulically actuated For more information on theclutch see 210 Clutch LOCATING TRANSMISSION 10 CODES Oncarswith manual transmission thecode letters andtype numbers can typically be found on the top of...

Page 225: ...actuated by master and slave cyl inders Clutch disc wear is automatically taken up by the push rod travel of the slave cylinder making periodic adjustment unnecessary Fig 1 is a schematic of the clutch assembly NOTE See 200 Transmlsslon General for transmission ap plication information NOTE Although seal rebuild kits are available for the master and slave cylinders replacement of leaking master or...

Page 226: ...not siphon brske ffuid with your mouth Wear hand and eye protection 3 Disconnect fluid feeder hose from the master cylinder Be prepared to catch any leaking fluid 4 Working on engine side of bulkhead disconnect fluid line fitting from master cylinder 5 Remove lower left instrument panel trim On cars with SRS airbag remove the lower dashboard panel CLUTCH HYDRAULIC 6 Remove eccentric bolt connectin...

Page 227: ...ylinder is mounted to the left hand driver s side of the transmission 1 Remove brake fluid reservoir cap Using a clean sy ringe remove brake fluid from reservoir WARNING Brake fluid is poisonous Do not siphon brake fluid with your mouth Always dispose of old fluid properly 2 Loosen fluid line filling at slave cylinder Unbolt slave cylinder from transmission and disconnect fluid pipe Catch excess f...

Page 228: ...ar crankshaft oil seal Remove the flywheel to access the rear seal A faulty seal should be replaced NOTE II the flywheel is removed new bolts must be used when remounting the flywheel The old bolts should not be reused Clutch removing 1 Remove transmission from engine See 230 Manual Transmission 2 Lock engine flywheel in position and unbolt pressure plate Loosen bolts in stages until spring pressu...

Page 229: ...ooved input shaft ball bearing in crankshaft center Replace bearing if it does not rotate smoothly 8 Assemble clutch disc and pressure plate assembly to flywheel Thread new pressure plates bolts in hand tight NOTE Make sure the pressure plate is aligned on the fly wheel guide pins Be sure the clutch disc is installed correctly The new disc should be marked with engine side and trans mission side 9...

Page 230: ...to be greased arrows NOTE To help align the input shaft in the clutch disc rotate the transmission output shaft stowty as the transmission is seated CLUTCH MECHANICAL Fig 8 Clutch release beanng correctly installed Bearing tabs A align with contact points 1 8 on release lever ...

Page 231: ...e normal ly filled with automatic transmission fluid ATF although al ternative lubricants may be used depending on transmission type gear noise levels and shifting eHort in cold climates NOTE Manual transmissions Iil ed With ATF use t 7mm ex ternal hex drain and fil plugs In addition a red fluid specification label W ith the markmgs ATF OIU is et tached to the right hand side of the bel housing So...

Page 232: ... can also be due to a leaking rear crankshaft seal NOTE Before assuming faulty transmission seals check the vent on the top of the case A ctogged or damaged vent can cause excess Internal pressure and oil loss Output shaft oil seal replacing transmission installed 1 Remove complete exhaust system See 180 Exhaust System 2 Disconnect driveshaft from transmission See 260 Driveshaft TRANSMISSION SERVI...

Page 233: ...Shde locking sleeve B and push pin A through to remove coupling WARNING Do nol mar the housing when removing oit seal NOTE To improve access to the selector shah suppon the transmission from below and remove Ihe bolts from the Iransmission crossmember Then tower the transmis sion for better access the selector shafl 4 Pry out seal using pick or small screwdriver See Fig 4 Seal 65 l2 MAO 5 44 Fig 4...

Page 234: ...the transmission disconnect harness connector from switch and unscrew switch from transmission 7 Thoroughly clean guide sleeve mounting bolts sealing surfaces and threads in case Apply sealer t octite 243 or equivalent to guide sleeve sealing surface and bolts Reinstall guide sleeve and spacer s Tightening Torques Guide sleeve to transmission M8x22 18 Nm 13 ft Ib M8x30 25 Nm 18 ft Ib M6x10 10 Nm 8...

Page 235: ...nsole from top of transmission See 250 Gearshift Linkage 7 Unbolt clutch slave cylinder from side of transmission Do not disconnect fluid hose Suspend slave cylinder from body using stiff wire CAUTfON Do not operate clutch with slave cylinder removed from transmission 8 Support transmission from below with jack Unbolt transmission cross support and bracket Lower trans mission engine assembly until...

Page 236: ...ill make them difficult to loosen Tightening Torques Transmission to engine Torx head M8 23 Nm 17 ft Ib M10 43 Nm 32 ft lb M1 2 72 Nm 53 ft Ib Rear transmission support to body bolt 23 Nm 17 ft lb Rubber mount to transmission or bracket nut 43 Nm 32 ft Ib Transmission drain plug fill plug 50 Nm 37 tt lb install the driveshaft and preload the center bearing bracket as described in 250 Drlveshaft Re...

Page 237: ...st behind the manual valve lever ATF service A4S 31OR 240 14 ATF service A5S 31OZ 240 15 ATF service A5S 560Z 240 1 6 Automatic Transmission Seal Replacement 240 17 Torque Converter Seal 240 17 Output Shaft Seal 240 1 7 Manual Valve Seal 240 18 TABLES a Automatic Transmission Applications 240 1 b Automatic Transmission Troubleshooting 240 3 C AIT Stall Speed Specifications 240 4 d AIT Main Pressur...

Page 238: ... dipsticks Checking the ATF level on these transmissions must be done while mono itoring the ATF temperature with the engine idling The BMW dealer is equipped with the special equipment to make this check If in doubt about the fluid level one option is 10 completely drain the old fluid and add Ihe specified amount of new fluid See ATF Service TROUBLESHOOTING Inspect the transmission for external d...

Page 239: ...n DME moving selector b ATF level low b Check and correct ATF level See ATF service lever from N c Faulty transmissi on range switch c Replace transmission range switch See 250 Gearshift Linkage to 0 or R d Internal transmission fault d Overhaul or replace Iransmission a Hard jolt on upshift a Faulty ctutchtes a Overhaul or replace transmission or downshift b Valve body faulty b Replace valve body...

Page 240: ...he car when the engine is running and tests are being made NOTE It is normal for the stall speed to be 125 rpm lower than specified for each 1 000 meters 3 200 It above sea levef High ambient air temperature can also cause a drop in stall speed DIAGNOSTIC TESTING Table c Aff Stall Speed Specifications Transmission Stall speed rpm 4 HP 221EH 525i 2300 2500 535i 2100 2300 A4S 310R 2200 2400 A5S 31 0...

Page 241: ...ace by removing ATF sump and filter screen Low pressure may also indicate a worn ATF pump or inter nal ATF pump leak past seals gaskets or metal mating sur faces These repairs require that the transmission be removed and disassembled Transm ission Test pressure engine rpm 4HP 221EH o drive 5 5 7 7 bar 80 111 psi at idle 9 0 11 0 bar 130 160 psi at kickdown R rev 11 14 bar 160 189 psi at idle 17 0 ...

Page 242: ...n lines and holes to prevent con tamination 6044 Fig 5 Bellnousmq reinforcement plate mounting bolls arrows 8 Disconnect electrical harness connector s from trans mission 9 On 525i models unbolt transmission bellhousing rein forcement plate See Fig 5 10 Remove torque converter mounting bolts 3 from the perimeter of driveplate Turn driveplate to access bolts NOTE On 535i models it is necessary to f...

Page 243: ...ve plate check that the tabs on the torque converter align with the indentations on the driveplate Use alignment dowel BMW tool no 24 2 300 if necessary Check the torque converter installation once the trans mission is installed When correctly installed the mounting surface of torque converter should be slightly below the edge of the transmission case CAUTION Betote installing a new or rebuilt tra...

Page 244: ... transmission Turn bayonet lock counterclockwise to disconnect Dis connect speed sensor plug at transmission 11 Remove access plug to reach torque converter mount ing bolts 7 Disconnect driveshaft from transmission flange unbolt flex disc from transmission flange NOTE The access plug for the torque converter bolts is tocat ed in one of two tocations either in the side cover be low the exhaust mani...

Page 245: ...pe to prevent the engine from lowering Installation is reverse of removal To avoid damage when installing the transmission rotate the torque converter back and forth to check that it has engaged its splines and be sure to correctly align the torque converter to the drive plate Use a new gasket on the ATF sump drain plug and new a rings on the ATF filler tube and cooler lines Adjust the transmissio...

Page 246: ...t 1 frcm selector cable and slide cable out of bracket 2 NOTE Counterhold selector cable clamping sleeve when loosening clamping nut This will prevent bending or distorting cable TRANSMISSIONSERVICE 6 Disconnect main harness connector at transmission Turn connector counter clockwise and pull straight off Unclip harness See Fig 14 1 0011589 Fig 14 Disconnect harness connector 1 1 and remove harness...

Page 247: ...ess bolts 14 Remove the bolts from transmission bellhousing See Fig 18 0011593 Fig 18 Transmission to engine mounting bolts arrows Bolts at top are no size All others are T1 2 size Note that bolts at starter are fitted with nuts at front 15 Using a lever to make sure that the torque converter stays firmly mounted to the transmission pull the trans mission off of the engine and lower out of car CAU...

Page 248: ...engine check that the tabs on the torque converter align with the in dentations on the driveplate Use alignment dowel BMW tool no 24 2 300 if necessary CAUTlON When installing a new or rebuilt transmission the ATF cooler and lines must be blown clean with compressed air and then thoroughly flushed twice with clean ATF This will clean any dirt or Iriction lining particles that could clog the pes sa...

Page 249: ... s Clean the sump and the sump magnets using a lint free cloth When mounting the sump mount the curved sump clamping brackets at the front and rear corners of the sump Mount the straight clamping brackets at the sump sides The short legs on the clamps should contact the oil sump Fill the transmission with the specified amount of fluid NOTE Check the ATF level with the car on level surface en gine ...

Page 250: ...ch bolls not metric bolls 4 Remove strainer mounting screws and remove strainer together with gasket See Fig 25 TRANSMISSION SERVICE 0 0011596 Fig 25 ATF fluid strainer mounting bolts arrow s on A4S 31OR Installation is the reverse of removal Always replace the drain plug seal and all gasket s Clean the sump and the sump magnet using a lint free cloth Use new bolts at the sump and tighten the bolt...

Page 251: ...67 F 24 mm 0 94 in 36 mm 1 42 in 80 C 176 F 26 mm 1 02 in 38 mm 1 50 in 85 C 185 F 29 mm 1 14 in 41 mm 1 61 in 90 C 194 F 31 mm 1 22 in 43 mm 1 69 in ATF service ASS 310Z The A5S 3102 transmission is not fitted with an ATF level dipstick Therefore it is recommended that ATF level check ing be left to authorized BMW dealer with the appropriate tern perature measuring equipment The most accurate che...

Page 252: ...e sump magnets using a lint free cloth To remove the expansion tank lift it straight off the sump The fluid level is correct when it begins to spillirom the fill hole when the ATF temperature is between 30 50 C 86 122 F ATF Specification Oil change volume Dexron II 3 0 L 3 2 qt ATF service ASS S60Z NOTE For the most accura te check of the ATF level the car must be on level surface and unloaded pre...

Page 253: ...ion of the collar nut requires a new lockplate and application of a sealant to prevent transmission fluid leakage BMW specifies Curil K2 or l octite 572 which shou ld be available from your BMW dealer Torque Converter Seal ATF leaking from the torque converter seal will usually be seen at the bottom of the bellhousing To replace the output shaft seal bend back the locking tab on the lockplate show...

Page 254: ...of the ATF sump To replace the manual valve seal remove the manual valve lever from the transmission shown in Fig 33 Pry out the old seal using a small screwdriver or hooked tool Lubricate the new seal with ATF and drive it into place When installing the manual lever torque the nut Tightening Torque Manual lever to selector 8 to 10 Nm 71 to 89 in Ib If the linkage was not disconnected from the man...

Page 255: ...ssembly An exploded view of the gearshift mechanism is shown in Fig 1 3 A 1 5 7 I 12 11 1 Shift knob lever Pull straight up to remove will require about 90 lbs of force to remove 2 Shift boot cover 3 Shift lever 4 Dust boot 5 Shift lever retaining ring 6 Nut 7 Bearing bracket Lubricate bearing surface Attach bracket to retainer lugs when installing 8 Shift console 9 Washer 10 Shift rod 11 Washer 1...

Page 256: ... Fig 4 6 Working from inside passenger compartment dlsen gage retaining ring and lift shift lever out from above Installation is the reverse of removal Check the condition of all rubber and plastic bushings and washers Replace circlips and any worn parts Remove old grease from shift lever bear ing and lubricate with molybdenum disulfide grease Align the tabs on the plastic retaining ring with the ...

Page 257: ...problems and erratic trsnsmis sion operation 1 Pry out transmission program switch from center con sole cover and disconnect electrical connection 2 Remove hex head screw 3 mm from shift lever handle and remove handle 3 Remove cover from shift lever console See Fig 7 4 Disconnect harness connector from gear position neu tral safety switch and remove mounting screws See Fig 8 5 Remove gear position...

Page 258: ... Align drive gate on switcn 1 0 pill on le w l 00 116 17 Fig 7 Console cover showo removect Pry cover UP tram rront and men I tl off eftf retalfllllQ chps Fig 8 Disconnect harness connector by pressing connector reo lalnmg clips together arrows Switch mountmg screws shown at 1 Fig 11 Engage release butron pin 1 0 hole m pull rod SELECTOR LEVER SERVICE ...

Page 259: ...7 Screw tighten to 4 5 Nm 40 in Ib 8 Console 9 Nut 10 Gasket 11 Cotter pin 12 Selector lever shaft 13 Screw tighten to 7 Nm 62 in Ib 14 Cable 15 Screw 16 Bracket 17 Nut 18 Manual valve lever 19_Clamping sleeve 20 Clamping bolt 21 Nut tighten to 10 Nm 89 ln lb 6530 Fig 12 Exploded view of shift mechanism on cars with automatic transmission SELECTOR LEVER SERVICE ...

Page 260: ...for wiring faults to or from the transmission control module TCM NOTE The solenoid is controlled via the TeM using brake pedal position engine speed and road speed inputs SELECTOR LEVER SERVICE Shift interlock checking function 1993 and latercarsare equipped with shift interlock The shift interlock usesa bowden type cable between the ignition switch andtheshiftlever Thecablemechanically locks thes...

Page 261: ... replacing 260 7 Front centering guide replacing 260 8 Driveshaft constant velocity CV joint replacing 260 9 TABLES a Driveshaft Troubleshooting 260 3 The rear of the driveshaft is connected to the final drive through a constant velocity joint The driveshaft is supported in the center by a center bearing The bearing is rubber mounted to isolate vibration NOTE For information the rear axle final dr...

Page 262: ... a problem Further inspection requires removal of the driveshaft Check the front centering guide for correct installation as de scribed in Drlveshaft centering guide replacing Also check runout at the transmission output flange and output shaft and at the final drive input flange Check the bolt hole bores in the flange for wear TROUBLESHOOTING Driveshaft flange runout max allowable Transmission ou...

Page 263: ...ling seized e Remove driveshaft and check movement of sliding coupling Clean coupling splines and replace parts as necessary I Driveshaft misaligned f Check driveshatt alignment 3 VIbration audible a Front centering guide worn or a Check front centering guide and replace if necessary Check rumble over 35 driveshafl mounting flanges out of runout of drlveshatt mounting flanges mph 60 km h round or ...

Page 264: ...en the transmission or engine mounts to repo sition them then retighten the mounts The driveshaft is cen tered when it is positioned as shown See Fig 2 The second important driveshaft alignment check is more complicated It checks the amount the driveshaft is angled vertically at the joints This angle is known as driveshaft de flection In general there should be little deflection in the driveshaft ...

Page 265: ... bolts 5267 Fig 4 Front drivesnalt to transrrnssion mounting oou being removed Note open end wrench used to counterhold bolt WARNtNG Do not let the rear section rest on the luettank con nection line 7 Remove driveshaft Bend driveshalt down at center bearing and then pull it oHat front If necessary slide driveshalt together at splined coupling NOTE Do not pUll driveshalt sections apart On models wi...

Page 266: ... turn one section 180 and reassemble Installation is the reverse of removal Lightly lubricate the centering guide in the flex disc with molybdenum disulfide grease Molykote Longterm 2 Y or equivalent Fig 6 To remove vibration damper turn damper about 60 and pull off flange Reinstall the driveshaft by first positioning it against the final drive flange and then sliding it onto the transmission flan...

Page 267: ...n or if the flex disc came supplied with one The bolt grade is marked on the bolt head When re placing bolts only use bolts of the same strenglh and hardness as the originals inslalled 4 Reinstall the driveshaft NOTE Removal and installation 01the bolts may be made eas ier by placing a large hose clamp around the flex disc and tightening the clamp slightly to compress the cou pling 3 Install new f...

Page 268: ... bearing circlip and dust guard if appli cable See Fig 12 Remove bearing Irom driveshalt us ing puller 5334 Fig 12 Center bearing circlip arrow to be removed Driveshaf1 shown installed DRIVESHAFr SERVICE Tightening Torque Clamping sleeve 10 Nm 7 5 tt lb Front centering guide replacing The Iront centering guide centers the driveshaft in relation to the transmission The guide is press lit into a cav...

Page 269: ...items on hand before starting the job 1 Remove driveshaft See Driveshaft removing and installing 2 Remove boot clamp at back of CV joint 3 At front of joint remove circlip securing joint to shaft Pull joint of driveshaft using a suitable puller Remove bolts from joint NOTE The CV joint is cemented Loctite to driveshaft and will require a puller to break free The CVjoint mounting bolt shoulders are...

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Page 271: ...ing 300 6 GENERAL 3 Suspension Steering and Brakes covers repairs to the front and rear suspension the braking system and the steer ing system including wheel alignment Front Suspension Fig 1 shows the double pivot independentfront suspension Two main structural members serve as rigid mounting points for the suspension components The control and thrust arms control front to beckand side to side mo...

Page 272: ...n noise and vibration Steering The variable assist power steering system consists of an engine driven hydraulic pump a ball and nut type steering gearbox with integral hydraulic control valve and connecting linkage to the road wheels At low speeds maximum power assist is provided to ease parking and city driving At high speeds assist is reduced to ensure stability The standard power steering syste...

Page 273: ...s automatically adjust for brake pad and rotor wear Brake pads in the left front and right rear brakes contain wear sensors When the pads need replacement the sensors illu minate a light on the dashboard BMW E34 cars include several advanced systems that inte grate with other systems to enhance driveability safety and performance ABS is standard on all E34 cars Other integrat ed systems include tr...

Page 274: ...control In addition to the normal ASS function the traction control system also controls engine throttle and engine timing to reduce engine torque so that maximum vehicle stability is maintained Fig 5 Schematic representation of ASS Each of the traction control systems are designed to be maintenance free There are no adjustments that can be made Repair and troubleshooting of the ASC and ASC T syst...

Page 275: ... displayed The camber warning switch is mounted on the rear axle subframe For additional in formation on LAD see 330 Rear Suspension SUSPENSION AND STEERING TROUBLESHOOTING Stable handling and ride comfort both depend on the integ rity of the suspension and steering components Any symp tom of instability or imprecise road feel may be caused by worn or damaged suspension components In addition to i...

Page 276: ... a Replace strut cartridges bouncing after bumps suspension bottoms out easily 5 Suspension noise a Worn front upper strut bearings s a Replace upper strut bearings especially over bumps b Loose front strut cartridge b Check tighten strut cartridge collar nut c Worn suspension bushings control arm thrust c Replace worn bushings arm trailing arm crossmember d Worn stabilizer bar rubber mounts d Rep...

Page 277: ...ts see 300 Suspension Steering and Brakes General STABILIZER BAR 310 8 To remove and install stabilizer bar 310 8 THRUST ARMS 310 9 To remove and install thrust arm 310 9 To replace thrust arm bushings 310 10 SUBFRAME CROSSMEMBER 310 11 To remove subframe crossmember 310 11 To install subframe crossmember 310 12 TABLE a Front Ride Height Specifications 310 5 Special service tools are required for ...

Page 278: ...aise the car and remove the front wheel WARNING Make sure that the car is firmly supported on jack stands designed for the purpose Place the jack stands beneath a structural chassis point Do not place jack stands under suspension parts 00 11191 2 Unbolt the brake caliper assembly keeping the brake hose connected Secure the brake caliper with wire and do not let it hang from the brake hose See 340 ...

Page 279: ...0 10 Nm 74 7 ft lb Stabilizer link to strut housing 59 Nm 43 ft tb To disassemble and assemble strut Replacing the upper strut mount spring and strut cartridge requires that the strut first be disassembled This procedure requires a spring compressor specifically designed for the purpose Springs and strut cartridges should always be replaced in pairs WARNING Do not attempt to disassemble the struts...

Page 280: ...venly allowing the spring to slowly expand 6 Remove the rubber stop and protective tube from the strut cartridge shaft 7 Loosen the strut cartridge retaining collar and remove the cartridge from the housing B If there is oil in the housing pour it out Clean out the housing NOTE Hydrautic type strut cartridges are installed in the strut housing with a small amount of oil for cooling Gas pressure st...

Page 281: ...at 68 kg 150 Ib Center of rear seat 68 kg 150 Ib Trunk 21 kg 46 Ib Fuel tank full Table a Front Ride Height Specifications Wheel rim installed I Ride Height 15 in standard suspension 588 mm 23 8 in Sport suspension 568 mm 22 3 8 in M Technic suspension 563 mm 22 8 in TRX 390 standard suspension 592 mm 23 4 in Sport suspension 572 mm 22 12 in M Technic suspension 568 mm 22 3 8 in TRX 415 standard s...

Page 282: ...rut making sure the mating notch is aligned See Fig 4 given earlier Use locking compound Loctite 270 R or equivalent on the bolts and tighten CONTROL ARMS Fig 9 Conuol ann mrouqn ooit arrow Tightening Torques Strut housing to steering arm use Loctite 270 or equivalent 110 Nm 81 tt lb 10 Install the wheel and lower the car Load the car to the normal loaded position as described earlier under Ride H...

Page 283: ...ck stands designed for the purpose Place the jack stands beneath a structurat chassis point Do not place jack stands under suspension parts 2 Pry oH the grease cap from the center of the wheel hub 3 Bend back the staked part of the wheel hub collar nut See Fig 10 Fig 10 Staked part of collar nut bent back arrow 4 Remount the wheel and lug nuts Lower the car to the ground to gain leverage in loosen...

Page 284: ...nd remove the wheel 17 Install the brake caliper as described in 340 Brakes STABILIZER BAR Tightening Torque Brake caliper to strut housing 110 Nm 81 ft Ib 18 Install a new grease cap using Loctite 638 sealant or equivalent 19 Install the wheel and lower the car Tightening Torque Road wheel to hub 100 10 Nm 74 7 ft Ib STABILIZER BAR To remove and install stabilizer bar 1 Raise the car and remove b...

Page 285: ...very early 1988 cars may be equipped with the old style rubber bushings These rubber bushings should have been removed and replaced with the newer hydraulic bushings during the new car pre de livery inspection or during the first service visit The hydraulic bushings can be identified by plastic clips on either side of the bushing If the old style rubber bush ings are still installed they should be...

Page 286: ...e jack stands under suspension parts 00 1 1 3 Fig 14 Thrust ann ball jOint being removed from steenng arm 2 Remove the thrust arm from the car as described ear lier 4 Clean the bushing bore and press in the new bushing while aligning the arrow on the bushinq with the mark on the thrust arm See Fig 16 Press the bushing in so it protrudes equally from both sides of the thrust arm CAUTfON To avoid da...

Page 287: ... 200 and 11 0 020 slightly raise the engine just until the weight of the engine is supported See 110 Engine Re moval and Installation 2 Working in the engine compartment remove the top nut from the right engine mount 3 Raise the car and remove the front wheels WARNING Make sure thar the car and the engine are firmly supported on jack stands designed lor the purpose Place the jack stands beneath a ...

Page 288: ...Idler arm to subframe crossmember self locking nut M10 bolt 42 Nm 32 ft Ib M12 bolt 85 Nm 63 ft Ib Steering gear box to subframe crossmember self locking nuts M10 10 9 bolts 42 Nm 31 ft Ib M12 bolts 80 Nm 59 ft Ib 4 Install the control arms to the crossmember Do not tighten the control arm through bolts and new self lock ing nuts to their final torque at this time 5 Lower the engine onto the engin...

Page 289: ...coated wilh unaer coating wax as correct tightening torque cannot be assured Always clean the threads with sol vent before inslallation or install new parts Do not ettemp to weld or straighten any steering components Always replace damaged parts To remove and install outer lie rods 320 7 To replace tie rod ends 320 7 To replace center tie rod 320 8 WHEEL ALIGNMENT 320 8 Camber 320 8 Caster 320 8 F...

Page 290: ...locking nul on steering wheel The nut is designed to be used only once STEERING WHEEL Tightening Torques Steering wheel to steering column spindle sell locking nut 80 Nm 59 fHb bolt 63 Nm 46 ft Ib 7 Install the airbag unit See 721 Alrbag System SRS WARNlNG Once the airbag unit is installed and all other set vice procedures have been completed start the en gine and cheel that the SRS warning light ...

Page 291: ... Working beneath the car insert a piece of wood at the idler arm to block the steering from reaching full lock about 1 2 turn before full lock 0006587 7 Repeat procedures 5 and 6 above for the left side 6 Start the car and have a helper turn the steering wheel to the right until the idler arm contacts the block Hold the wheel against the stop for about 5 seconds Record the pressure At each wheel l...

Page 292: ...Ib Tighten pump mounting bolts 9 On engines with a single poly V ben install the belt to the pulleys and release the tensioner Tightening Torque Power steering pump bracket to engine block or oil pan self locking nuts 22 Nm 16 It lb 10 Install the power steering fluid hoses to the pump Make sure the hoses have adequate clearance from the chassis Do not overtorque the banjo bolts Use new sealing wa...

Page 293: ... sure the car is firmly supported on jack stands designed for the purpose Place the jack stands be neath a structural chassis point Do not place jack stands under suspension parts 4 Remove the center tie rod self locking nut at the pitman arm See Fig 4 Then using a press BMW special tool no 32 2 040 or equivalent remove the tie rod from the pitman arm 5 Remove the lower steering column universal j...

Page 294: ...r M10 bolt class 10 9 bolt only 42 Nm 32 ft Ib M12 bolt 85 Nm 63 ft Ib 10 Install the steering column universal joint to the steer ing gearbox shaft Center the steering column to the gearbox by aligning the universal joint split with the mark on the steering gearbox See Fig 5 given earlier Use a new self locking nut on the clamping bolt NOTE Make sure the clamping bolt fils into the machined groov...

Page 295: ...ack stands designed for the purpose Place the jack stands be neath a structural chassis point Do not place jack stands under suspension parts 2 If replacing the tie rod or tie rod ends measure the overall length of the complete installed tie rod assem bly Record the measurement NOTE Accurate measuring 01 the tie rod assembly will help to approximate wheel alignment when new parts are in stalled 3 ...

Page 296: ...klnq nuts Check the tie rod end ball joints and idler arm bushing for wear Have the car professionally aligned WHEEL ALIGNMENT Tightening Torques Center tie rod to outer tie rod ends 37 Nm 28 tt lb Center tie rod to pitman arm 59 Nm 44 tt lb Center tie rod to idler arm 37 Nm 28 fl Ib WHEEL ALIGNMENT Proper handling stability and driving ease depend upon the correct alignment of all four wheels The...

Page 297: ...orrection is made by removing the trailing arm and re placing the outer trailing arm pivot bushing with an eccentric version The eccentric bushing repositions the trailing arm slightly resulting in a toe in change The eccentric bushings are marked indicating increments of change and can be installed in any pos ition to produce a specific amount of toe correction NOTE Traifing arm bushing replaceme...

Page 298: ...n O IB 5 1 SO 30 13 30 7 S3 30 BOB t30 30 12 4 30 12 4 30 OtIS 41 32 11 m 35 7 ft Sport suspension O lB 5 I 2 4 30 30 30 BOB 30 B 26 30 30 12 3T 30 12 38 30 O IS 41 32 I 11 m 35 7 ft M Technlc suspension O lB 5 _2 10 30 2B 30 BO13 30 BO2B t30 30 12 41 t30 12 4L30 OtIS 43 33 11 m 35 7 ft Table b Rear Wheel Alignment Specifications base suspension Sport suspension touring I M Technlc suspension I To...

Page 299: ... new self locking nuts TRAILING ARMS 330 8 To remove and install trailing arm 330 8 To replace trailing arm bushings 330 10 SELF LEVELLING SUSPENSION LAD 330 10 To pressure test LAD system 330 11 To adjust ride height cars with LAD 330 11 To fill and bleed LAD system 330 12 To replace LAD regulator valve 330 13 To replace LAD fluid accumulator 330 13 TABLES Table a Rear Ride Height Specifications ...

Page 300: ...Normal loaded position Each front seat 68 kg 150 Ib Center of rear seat 68 kg 150 Ib Trunk 21 kg 46 Ib Fuel tank full Table a Rear Ride Height Specifications Wheel Installed sedan touring 15 in rims standard 522 mm 20 2 in 522 mm 20 1 2 in Sport 513 mm 20 4 in 507 mm 20 in M Technic 512 mm 20 4 in NA TRX 390 rims standard 526 mm 20 314 in 526 mm 20 3 4 in Sport 51 7 mm 20 3 8 in 511 mm 20 8 in M T...

Page 301: ... pan beneath the pressure regulating valve on the driver s side of the axle subframe Loosen the valve s bleeder screw and allow the hydraulic pressure to discharge See Fig 3 NOTE Store the removed strut assembly upright Do not allow it to lie horizontally or upside down lor any length 01 time If incorrect storage has occurred place the strut assembly upright with the rod lully extended lor at leas...

Page 302: ...ig 5 shows the rear strut assembly WARNING Do not attempt to disassemble the struts without a spring compressor designed specifically for this job 1 Remove the strut assembly from the car as described above Protective _ tube I _J Washer 0011240 2 Using a spring compressor compress the spring until the spring force on the upper mount is relieved WARNING Make sure the spring compressor grabs the spr...

Page 303: ...pose Place the jack stands beneath a structural chassis point Do not place jack stands under suspension parts 2 Remove the drive axle outer CV joint from the wheel drive flange as described below under Drive Axles Support the drive axle from the chassis with wire 3 Pry the lockplate off the drive flangecollar nul See Fig 7 00 11 242 Fig 7 Drive flange collar nut and lockplate arrowi 4 Lower the ca...

Page 304: ...k onto the stub axle until it is flush with the end 01 the axle Using a sott laced hammer tap the stub axle out 01 the bearing 11 II necessary use a puller to remove the bearing inner race Irom the stub axle REAR WHEEL BEARINGS NOTE BMW specifies special toots 10 pulf Ihe sust axle through Ihe wheel bearing into posilion If using etter native tools 10 install the axle be sure to support the bearin...

Page 305: ...nd remove the drive ax le from the car See Fig 10 00 12 5 Fig 10 Drive axle outer CV J Oint boll being removed 3 Installation is the reverse of removal Make sure all thread bores bolts and mating surfaces are clean Make sure the lockplates are reinstalled Tightening Torque Drive axle to differential and drive flange standard Ml0 bolt 83 Nm 61 ft Ib lock tooth Ml 0 bolt 100 Nm 74 ft lb To replace C...

Page 306: ...e joint The balls will fall out it the hub is pivot ed too far TRAILING ARMS 9 Pack each CV joint and rubber boot with the specified amount of the lubricant supplied in the boot kit Apply adhesive to the large end of the boot and mount it on the joint Secure the boot with the clamps Then apply sealer to the joint end coverts and install them NOTE BMW recommends Bostik t513 or Epple 485t eone sive ...

Page 307: ... remove the trailing arm from the car See Fig 15 11 II removing the right side trailing arm unbolt the diago nal SUppOr1 arm from the connecting link then loosen the other end of the arm and swing it out of the way See Fig 16 Installation is the reverse of removal Always use new self locking nuts When installing the trailing arm mounting bolts install the inner bolt nrst Tighten the mounting bolts...

Page 308: ...evelling rear suspension system called LAD Load Absorption Dampening uses mechanical and hydrau lic components to monitor and adjust the rear suspension ride height based on load and driving conditions The system is in operation whenever the engine is running and the vehicle load is changed NOTE To identily LAD equipped cars inspect the power steering system reservoir On cars without LAD the plast...

Page 309: ...the power steering LAD pump drive belt is in good condi tion and properly tensioned 1 Raise the rear of the car WARNING Make sure that the car is firmly supported on jack stands designed for the purpose Place the jack stands beneath a structural chassis point Do not place jack stands under suspension parts 2 Connect the gauge between the pump and the pump output fitting Use new sealing washers NOT...

Page 310: ... Moving Ihe le ver rearward lowers the car When the lever is in the center position the ride height is maintained 5 If necessary loosen the locknuts and adjust the control link length so that the link end fits correctly into the le ver Tighten the lock nuts 6 Using a new self locking nut install the link and then re move the drill bit To fill and bleed LAD system 1 With the engine ott fill the pow...

Page 311: ...egulator valve with mounting bracket to rear axle subframe self locking nuts M6 bolts 9 Nm 80 in Ib M8 bolts 22 Nm 16 ft lb 9 Fill and bleed the hydraulic system as described earlier under To liII and bleed LAD system 10 Adjust the LAD system ride height as described earlier under To adjust ride height cars with LAD To replace LAD fluid accumulator 1 Raise the rear of the car WARNING Make sure tha...

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Page 313: ...acing 331 2 Final Drive Oil Seals 331 3 Final drive flange oil seal replacing 331 3 Final drive input shaft oil seal replacing 331 3 Final drive oil draining and filling 331 4 caution when working beneath the car and lowering the final drive See010 Fundamentals for the Do it youself Owner The final drive is mounted to the rear suspension cross member and is easily removed using ordinary hand tools...

Page 314: ...maximum speed Tightening Torques Final drive to subframe 123 Nm 91 It Ib Final drive to rubber mounts 77 Nm 57 1t lb Drive axle to final drive M10 83 Nm 61 ft lb M10 with locking teeth always replace bolts and washers 96 Nm 70 ft Ib Driveshalt to final drive flange See 260 Drives halt Speedometer sender to final drive 10 Nm 89 in Ib Oil drain and fill plug 70 Nm 52 ft lb Final drive rubber mounts ...

Page 315: ...ng when removing the seat 5 Dip new seal in final drive lubricant and drive seal into place unlil fully seated 6 Install new snap ring in groove of final drive housing Make sure both ends of ring are fully seated in groove 7 install drive lIange by pressing it in by hand until snap ring engages It may be necessary to turn drive flange slightly while pushing B3 5 DRI B Fig 4 Drive flange snap ring ...

Page 316: ...inal drive fluid 2 Place a drain pail below final drive and remove drain and fill plug from final drive See Fig 6 001174 001174 Fig 6 Final dnve drain plug Al and fill plug 8 FINAL DRIVE SERVICE NOTE Use a 14 mm allen bil socket to remove the drain plug Alternatively cut approximately 30 mm 1 2 in from an allen key and use an open end wrench on tne key stub If the caris raised in the air it should...

Page 317: ...AL 340 10 To adjust brake pedal height except cars with M60 engine 340 10 PARKING BRAKE 340 10 To adjust parking brake 340 10 To remove and install parking brake shoes 340 11 To replace parking brake cable 340 12 ANTILOCK BRAKE SYSTEM ABS 340 12 ABS System Inspection 340 12 To replace ABS pulse sensor 340 12 TABLES a Brake System Troubleshooting 340 2 b Rotor Reconditioning Specifications 340 7 Ai...

Page 318: ...azed or oil soaked b c Vacuum booster or vacuum hose connections to booster aully 1 a 4 Pedal feels spongy or brakes work only after pedal is pumped 6 Brakes pulsate chatter or grab 5 Excessive braking effort 7 Uneven braking car pulls to one side rear brakes lock 8 Brakes drag bind or overheat a Incorrect tire pressures or worn tires b Brake pads on one side of car heat glazed or oil soaked c Cal...

Page 319: ...requently to prevent it from emptying during brake bleeding 4 Close the bleeder screw Refill the brake fluid reservoir and proceed to the next wheel in the order given above To manually bleed brakes except cars with ASC T 1 Top oHthe brake fluid in the reservoir and replace the reservoir cap Connect the bleeder hose and waste bottle to the right rear bleeder screw 2 Have a helper pump the brakes s...

Page 320: ...w s 3 If applicable disconnect the brake pad wear sensor connector and remove the wiring from its holder 4 Remove the anti rattle clip from the caliper See Fig 3 5 Pull the caliper straight oHthe rotor See Fig 4 CAUTtON Do not let the brake caliper hang Irom the brake hose Support it from the chassis with strong wire BRAKE PADS CALIPERS AND ROTORS Fig 3 Brake pad anti rattle clip being unhooked fr...

Page 321: ...htly coat the contact points of the new pads with Plastilube or an equivalent Place the outer brake pad onto the caliper Place the inner brake pad with its lo cating spring onto the brake caliper piston Route the pad wear sensor wiring through the caliper opening and bleeder dust cap 00 11257 Fig 6 Brake caliper piston being pressed into caliper Use a rag to protect caliper piston and seals 12 The...

Page 322: ... reverse of removal Bleed the entire brake system before driving the car See Bleeding Brakes Tightening Torques Front brake caliper to strut assembly 110 Nm 81 fHb Rear brake caliper to trailing arm 67 Nm 50 ft Ib Brake fluid hose to caliper Ml0 coupling 14 Nm 10 ft Ib M12 coupling 17 Nm 1 3 ft Ib Road wheel to hub 100 10 Nm 74 7 ft Ib To remove and install brake rotor Always replace rotors in pai...

Page 323: ...or loosened the entire brake system must be bled as described above under Bleeding Brakes Once the brake assembly is installed depress the brake pedal several times to adjust the caliper and pads 0 05 mm 0 002 m 0 20 mm 0 008 in front rear 20 4 mm 0 803 in 8 4 mm 0 331 in 0 05 mm 0 002 in 0 20 mm 0 008 in Axial runout max rotor removed rotor installed Wearlimit min thickness Fig 10 Brake rotor mou...

Page 324: ...eservoir cap 8 Connect all brake fluid lines and bleed the entire brake system as described above under Bleeding Brakes 3 On cars with manual transmission remove the clutch master cylinder supply hose from the side of the fluid reservoir 4 Disconnect the brake fluid lines from the master cylin der Unscrew the mounting nuts and remove the mas ter cylinder from the brake booster See Fig 12 Tightenin...

Page 325: ... ring is being re placed disconnect the booster from the master cylinder 10 Make sure all nuts fluid couplings thread bores and mating surfaces are clean 11 If necessary mount the master cylinder to the vacuum booster using a new O ring and new sell locking nuts CAUTION Use care not over torque the master cylinder mounting bolts This could damage the brake booster and prevent proper vacuum build u...

Page 326: ...moving the pedal cluster trim panel as described in 513 Interior Trim Once the trim panel is removed loosen the lock nut on the pushrod clevis and slowly turn the pushrod until the correct dimension is obtained See Fig 14 00 11 751 Dimension a 245 255 mm 9 65 10 00 in 001 175 1 Fig 14 Brake pedal assembly Adjust pedal heiqht to dimension a PARKING BRAKE The parking brake is a dual drum system inte...

Page 327: ...as the lever is pulled up 9 Install the parking brake lever boot Install the road wheel lug bolts Tightening Torque Road wheel to hub 100 10 Nm 74 7 ft lb To remove and install parking brake shoes 1 Raise the rear of the car WARNfNG Make sure the car IS firmly supported on jack stands designed for the purpose Place the jack stands be neath a structural chassis point Do not place jack stands under ...

Page 328: ...und and the ASS light remains on have the system diagnosed by an authorized SMWdealer Carefully inspect the entire ASS wiring harness particularly the pulse sensor harnesses and connectors near each wheel Look for chafing or damage due to incorrectly routed wires Remove the pulse sensors and clean the sensor tips In spect the toothed pulse rings for missing teeth or other dam age Check the rings f...

Page 329: ...he E34 chassis was introduced in North America in 1989 It replaced the 1982 1988 E28 S Series while retaining many of the typical BMW visual accents such as the twin kidney cen ter grille and the trademark dual round headlights The aero dynamically efficientS Series with a coefficient of drag CD of 0 31 achieves unprecedented levels of performance and han dling The E34 S Series is 18 more efficien...

Page 330: ...d prevented from sliding back in an accident by retaining hooks The hood trunk front doors and rear doors open to extremely wide angles 64 90 68 and 66 respectively The trunk lid opening extends almost down to the bumper for easy loading and unloading These bolt on components including the front fenders are easily re placed The unitized body forms a very rigid passenger compart ment with large cru...

Page 331: ...ical repairs to the instrument cluster are covered in 620 In struments The electronically controlled heating and air conditioning system provides separate controls for the driver and front pas senger An extra large infinitely variable radial blower motor provides perfect distribution of air Fresh air enters through the grille below the engine hood and into the passenger com partment via the dashbo...

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Page 333: ...s and Washers 3 Remove ventilation grille s at base of windshield Re move two piece plastic retaining clips to remove grille See 611 Wipers and Washers 4 Peel up rubber strip at top of fender 5 Working inside the wheel housing remove wheel hous ing trim and seal between fender and trim 6 Open front door fully Working at leading edge of door remove two screws from fender Working at rocker pan el re...

Page 334: ...ling 1 Raise hood Remove hood insulation from rear of hood panel by carefully removing plastic retaining clips ENGINE HOOD 2 Unclip hoses and wiring from hood and set aside Re move ground wire from hood if applicable 3 Disconnect left and right engine hood holders from hood See Fig 4 0011626 Fig 4 Remove hood trom holder by removing re 3 n g pu clip and rernovmq pin tAl NOlO plastic spacer 1 8 4 W...

Page 335: ...tely 1mm 0 04 in be low top of fenders Close hood 10 check adjustment 7 Unscrew rubber stops at front until hood lightly touches stops and hood is flush with the top of the fenders 8 Adjust hood rear height by loosening rear catch mount ing bolts See Fig 8 With the hood closed the top sur face of the hood should align with the top surface of the fender 00 116 13 Fig B Hood rear catch mounting bolt...

Page 336: ...rom hood lock 4 Working within the passenger compartment remove the lower dashboard trim panel knee bolster See 513 Interior Trim 5 Remove bolt from hood lock latch and detach cable from latch 6 Pull cable out from engine compart ment 7 Installation is reverse of removal ENGINE HOOD Hood gas pressure strut replacing 1 Open hood fully 2 Pry up end of retaining clip on strut and pull strut end from ...

Page 337: ...ner clip from door check pin on body pil lar Drive out door check pin See Fig 2 Front outside door handle with door lock cylinder removing and installing 411 4 Rear outside door handle removing and installing 411 5 Front door lock removing and installing 411 5 Rear door lock removing and installing 411 6 Door check replacing 41 1 6 Door striker replacing 411 6 00 11651 Fig 2 Door check pin being r...

Page 338: ...leeve Arrow Indicates bearing removal direction NOTE If replacing the upper bearing sleeve first unbolt the hinge half from the door Mark the position of the hinge before removing On the lower hinge the hinge half with the sleeve is on the body 2 Remove hinge pin from hinge half See Fig 4 NOTE A special BMW service tool BMW tool no 41 5 0 10j is used to install the bearing sleeve into the bearing ...

Page 339: ... plastic parts clips Check that the rubber seal and the vapor barrier are correctly positioned and not damaged Rear door panel removing and installing 1 Open door and pry out power window switch Discon nect harness connector 2 Remove ash tray Remove trim cover from door open ing latch Remove concealing plug from arm rest Re move door panel retaining screws See Fig 8 00 1165 1 Fig 7 Door panel lock...

Page 340: ...arrows 2 Lock cylinder 3 Lock heater 4 Microswitch door lock contacts 4 Working from inside of door disconnect locking linkage from door lock 00 68 Fig 9 Insert screwdnver into access hole and push locking plate forward to unlock and release handle trim 3 Pry out access plug in end of door Use screwdriver through access hole to slide exterior trim locking plate into released position See Fig 9 5 R...

Page 341: ...ving and installing 1 Remove front door panel as described earlier 2 Close door window completely Disconnect harness connector from window motor to prevent accidental op eration 3 Working from inside of door peel back rubber window guide from guide rail Using T30 torx driver remove guide rail mounting bolt See Fig 13 Remove lower rail from door NOTE The top of the lower guide rait is hooked to the...

Page 342: ...e installing the door panel DOORS Door check replacing 1 Remove interior door panel as described earlier 2 Close door window completely Disconnect harness connector from window motor to prevent accidental op eration 3 Remove locking clip and washer from door check pivot pin Then drive pin from bracket See Fig 17 001 1651 Fig 17 Door check pin being driven out P n locking clip shown at A 4 Remove b...

Page 343: ...id A 3 Disconnect wiring from electrical components and re move complete wiring harness from trunk lid 4 Remove plastic cover from left hinge arm TAILGATE TOURING MODELS 41 2 2 Tailgate removing and installing 412 2 Tailgate support strut removing and installing 412 2 Tailgate window support strut removing and installing 41 2 3 5 While supporting trunk lid loosen top hinge bolts and remove lower b...

Page 344: ...ides of trim cov er Remove screws from below pads See Fig 5 Re move trim cover from body by lifting upwards NOTE The body is painted at the factory aher assembly Re alignment of body panels may expose unpainted metal Paint all exposed metal once me work is complete Tailgate removing and installing 1 Raise complete tailgate 2 Remove insulatlnq liner from tailgate and disconnect wiring Disconnect ma...

Page 345: ...erse of removal Replace any trim retaining clips damaged during removal 0011668 Fig 8 Strut bracket mounting bolt arrow at tailgate end Tailgate window support strut removing and installing The support strut for the tailgate window is concealed within the vehicle roof cavity The concealed end of the strut is in stalled on a ball stud BMW calls for special tools to remove and install the strut onto...

Page 346: ... Move hose aside to access screws 6 Remove retaining clip from end of support strut and dis connect end of strut from hinge arm See Fig 12 7 Pry end of strut off of ball stud within roof cavity See Fig 13 TAILGATE TOURING MODELS 001167 Fig 12 Remove retaining clip from end of support strut and pull off of hinge arm Grommet f 0 l o J 0011675 Fig 13 Tailgate window support stru ball end arrow Instal...

Page 347: ...arefully pry out emblem See Fig 1 0011723 Fig 1 BMW emblem being removed Pry up emblem carefUlly on ai tner side a rrows Note lape on screwdnver tip Mirror glass replacing 510 2 Center radiator grille removing and installing 510 2 Side radiator grille removing and installing 510 3 BUMPERS 51 0 3 Front or rear bumper removing and installing 510 4 CAUTlON Use care to protect painted surfaces Install...

Page 348: ...removal Check mirror function before installing covering parts EXTERIOR TRIM Mirror glass replacing 1 Insert screwdriver to engage tab on mirror glass lock ing ring Turn locking ring to unlock mirror glass See Fig 5 oo l172S Fig 5 Screwdriver inserted into opening in mirror 110USlng Pivot screwdriver away Irom door to unlock glass Pivot screwdnv er towards door to lock glass 2 Lift glass from mirr...

Page 349: ...e of removal Attach left and right front panel retaining clips first then attach center grille retain ing clips Side radiator grille removing and installing 1 Remove center grille See Center grille removing and installing 2 Remove screws from front of grille See Fig 9 0011734 Fig 9 Left raoator grille mounting screws arrows 3 Remove grille 4 Installation is the reverse of removal BUMPERS Front or ...

Page 350: ... 11 I sP Jr 1 2 C 7_ 14 16 I I 13 I 15 1 _ _ 4 567 A 4 3 I 2 1 Guard right 2 Nut tighten to 42 Nm 31 ft lb 3 Member 4 Bracket 5 Allen head bolt lighten to 73 Nm 53 tt lh 6 Impact absorber 7 Mounting bolt tighten to 50 Nm 36 ft lb 8 Impact box 9 Mounting bolt lighten to 9 Nm 80 in lb 10 Nut tighten to 9 Nm 80 ln lb 11 Mounting plug 12 Bracket 13 Slide 14 Sleeve 15 a ring 16 Retaining cap 17 Plug 18...

Page 351: ... Plug I I I I 14 13 1 15 6 Guard left 7 Cover tow hook 8 Cover trailer hitch 9 Clip 10 Member _ 11 Nut tighten to 42 Nm 30 fl Ib 12 Bracket 13 Nut tighten to 22 Nm 16 It Ib 14 Bracket 15 Screw tighten to 9 Nm 80 in tb 16 Impact absorber 0011658 Fig 12 Exploded view 01rear bumper assembly BUMPERS ...

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Page 353: ...the door cavity Use a blunt screwdriver to clean out any remaining glass pieces from the window guide rails 00 11695 WINDOW SERVICE Front door window removing installing 1 Remove outside mirror See 510 Exterior Trim Bumpers 2 Remove interior trim panel See 411 Doors 3 Lower front window Remove retaining clips from win dow slides See Fig 1 NOTE Once window is lowered disconnect harness connec tor f...

Page 354: ...off exterior trim cover from rear window guide Pull rubber window channel from door frame 6 Remove screws from interior of rear window guide See Fig 6 1 1 I 0011699 Fig 5 Remove InSide widow trim pieces IA and B by prying pulling off of door trame 0011698 Fig 4 Remove screws from window tnm cover arrows and re move cover 8 Remove outside trim cover mounting screws and re move trim cover by sliding...

Page 355: ...from switch 2 Remove interior trim panel See 411 Doors 3 Remove retaining clips from window slides See Fig 8 0011696 Fig 8 Retaining clips for winoow slides arrowsl 4 Pry window lifting arms out of left and right slides 5 Remove regulator mounting bolts or rivets See Fig 9 0011 703 Fig 9 Window regulator mounting bolts or rivets arrows NOTE On some models the regulator is mounted to the door W ith...

Page 356: ...should be checked The glass should contact the top of the window squarely and should seat against the win dow seal uniformly NOTE II the window seal does not contact the door glass uni formly wind noise will result 1 Remove interior trim panel See 411 Doors 2 Adjust window to window frame by repositioning sup port bracket See Fig 10 001 1705 Fig 10 Adjust window to door frame by loosening bolt arr...

Page 357: ...as described in 721 Airbag System SRS WARNING SRS is complex and dangerous Special precautions must be observed when servicing cars equipped with SRS Serious injury may result if system service is attempted by persons unfamiliar with the BMW SRS and its approved service procedures 2 Remove lower instrument panel trim from below steer ing column See Lower instrument panel trim re moving and install...

Page 358: ...e carpeted trim panel from left and right sides of center console Remove center console mounting screws at left and righl sides See Fig 6 GEN RAL 0011 712 Fig 5 Rernove heater control panel by PI IIlg out trorn lett side tar row 0011713 Fig 6 Center console mounts sc ew on gil SIde ot console tar row Also remove screw on lef se e 14 Separate center console from right side and remove console NOTE O...

Page 359: ... panel mounting screws arrow s 11 Peel back door seals on left and right sides in area of A pillar Lift off A pillar trim panels from left and right sides See Fig 8 12 Remove mounting screws from lower corners of A pil lars See Fig 9 13 Remove mounting bolts from underneath left and right sides of instrument panel See Fig 10 NOTE Wire ties may need 1 0 be cut and main harnesses moved out of the wa...

Page 360: ...move trim covers from left and right side of steering column and remove screws from behind covers See Fig t2 3 On cars without SRS airbaq remove screw concealing caps and remove screws securing lower instrument panel trim 4 Lower and then lift off lower instrument panel trim 5 Installation is reverse of removal GENERAL Fig 12 Lower mstrurnent panel trim cover tJe ng removed on cars witll SRS airba...

Page 361: ...roswitch and deactivates the alarm system 00 11762 Fig 1 Door lock cylinder key positions The door lock microswitches are integrated in the front door handle door lock assembly See 411 Doors for removal and replacement of the front door handle NOTE If just one of the central locking drives does not oper ate the locking linkage could be frozen or stiff enough to prevent actuation of the drive Remov...

Page 362: ...cedure until the locking system is synchronized NOTE This procedure can also be used il the locks become unsynchronized This mighl happen il a door which is not completely closed is locked or a door handle is lift ed betore the interior lock button is raised GENERAL Front door locking drive replacing 1 Remove interior door panel See 411 Doo rs 2 Disconnect harness connector from locking drive by p...

Page 363: ...inkage rod to locking drive and install locking drive so that mounting screws are centered in elongat ed mounting holes 2 Connect drive harness connector to locking drive 3 Mount drive on outside door and attach screws loosely 4 Push locking drive into locked position 5 Push back locking drive as far as possible Compress the central lock drive by hand to relieve pressure from the locking pawl 6 Ti...

Page 364: ... and tighten screws See Fig 9 0011769 Fig 8 Trunk lock drive mounting screws arrows 4 Installation is the reverse of removal Make sure there is no play in the linkage by turning the ball socket on the lock and adjusting the central lock drive See Trunk lid locking drive adjusting GENERAL 001 1752 00 11752 Fig 9 Compress locking drive into locked position arrow prior to adjusting 5 Check function T...

Page 365: ...e il from its reo lainers 3 Move seat to full forward position Remove two bolts at rear of seat rails See Fig t 00 11770 Fig 1 Front seat mounting bolts arrow s Rear seat cushion and backrest removing and installing sedan models with fold down rear seat 520 5 Rear seat backrest side section Touring removing and installing 520 5 Rear seat cushion and backrest Touring removing and installing 520 5 4...

Page 366: ...ngular seat drive regulator 2 Forward backward seat drive regulator 3 Backrest drive regulator 4 Head rest and up down seat drive regulator 5 Oval head screw 6 Headrest gearbox 7 Intermediate muffler Fig 5 Exploded VIt 1 J of sea frame and tram motor assembly Fig 6 Reill seat rail mounting pins al ned With bole In outer seat rail arrows 2 Unscrew nuts and remove armrest See Fig 4 00 11773 1 Slide ...

Page 367: ... A and drive out seal ra lmounting pin arrow NOTE BMW Special too 52 1 700 can be used to remove the seat rail mounting pins A ways use new seat mounting pins These pins should not be reused NOTE II replacing motors on seat rail assembly it may be necessary to remove the support plate Irom the seat rail assembly Remove the plate by drilling out the riv ets and removing the screws Irom the plate Se...

Page 368: ...ent gearbox screw being removed GENERAL 11 Remove screws from headrest adjustment motor mov ing seat cover out of the way as necessary See Fig 13 00 11781 Fig 13 Headrest adiustmeru motor screws arrows 12 On seats with memory unscrew potentiometer from motor 13 Partially loosen seat cover from seat bottom 14 Remove screws from backresVseat height adjustment motor bracket Pull drive cables out of b...

Page 369: ...at cushion and backrest removing and installing sedan models without fold down rear seat Fig 17 Rear seat bottom cushion release strap A 2 Compress both seat cushion locking levers and lift cushion forward and out See Fig 18 1 Pull front of cushion up and out of clips 3 Tilt backrest forward and use flat screwdriver to unlock retainers See Fig 19 Lift out backrest 0011761 001176 1 o Fig 18 Rear se...

Page 370: ...Remove backrest side section by lifting up a and out b Left rear seat side section shown 2 Installation is the reverse of removal Rear seat cushion and backrest Touring removing and installing 1 Remove backrest side section See procedure given earlier 2 Fold both backrests forward Pull up locking plate be tween backrests 3 Remove bolts from lower outside corners of left and or right backrest See F...

Page 371: ...I 15 0011800l NOTE Be sure to check the drains in the front corners of the sunroof carrier if water is entering the car through the headliner The dual panel tilting sunroof used on Touring models is not covered in this repair group The electrically operated single panel sunroof is controlled by a set of cables that move the sunroof panel along guide rails when the motor is operated The sunroof can...

Page 372: ...set shows clip det ul as viewed from above SINGLE PANEL SUNROOF 3 Lock sunroof guides in closed position on left and right sides This will ensure that sunroof panel is squarely positioned in opening See Fig 5 Lift channel lnternal hex head wrench Rear guide 6593 Fig 5 Hex key wrench Inserted through rear gUide to lock guide and panel in closed poston Lock left and right guides 4 Loosen screws on l...

Page 373: ...8 Sunroof panel retaining clip arrow as viewed from above Pry back clip to release sunroof panel Right side clip shown Sunroot panel shown removed Tightening Torque Sunroof panel to sunroof drive gate 3 5 Nm 31 in lb 1 Remove sunroof panel See Sunroof panel remov ing and installing 2 Remove sunroof motor See Sunroof moto r remov ing and installing 3 Working from above push left and right drive cab...

Page 374: ...1 8 Nm 17 in Ib M5 screw 2 8 Nm 25 in Ib Sunroof motor removing and installing The sunroof should be in the closed position before remov ing or installing the sunroof motor If necessary manually close the sunroof panel as described under Sunroof panel emergency closing 1 With ignition switch off remove access panel from be low sunroof motor See Fig 2 2 Remove sunroof motor mounting screws See Fig ...

Page 375: ... are mounted on the fuse relay panel in the engine compartment although later models are equipped with additional auxiliary relay panels beneath the rear seat For information on fuse and relay locations see 610 Fuses and Relays To measure voltage 600 4 To check for a voltage drop 600 4 Checking for Continuity 600 5 Checking for Short Circuits 600 5 To check for a short circuit using an ohmmeter 60...

Page 376: ...ronics work because they are generally more accurate than analog meters The numerical display is also less likely to be misread since there is no nee dle position to be misinterpreted by reading at an angle An LED test light is a safe inexpensive tool that can be used to perform many simple electrical tests that would other wise require a multimeter The LED indicates when voltage is present betwee...

Page 377: ...lways moving from the voltage source toward ground Keeping this in mind electrical faults can be located through a process of elimination When troubleshooting a complex circuit separate the circuit into smaller parts The general tests outlined below may be helpful in finding electrical problems The information is most helpful when used with the wiring diagrams Be sure to analyze the problem Use th...

Page 378: ...use the resistances in volved are often too small to measure with most ohm meters For example a resistance as small as 0 02 ohms would results in a 3 Volt drop in a typical tSO amp starter circuit 150 amps x 0 02 ohms 3 volts Keep in mind that voltage with the key on and voltage with the engine running are not the same W th the ig nition on and the engine 011 ballery voltage voltage should be appr...

Page 379: ... When checking continuity the ignition should be olf On cir cuits that are powered at all times the battery should be dis connected Using the appropriate wiring diagram a circuit can be easily tested for faulty connections wires switches re lays and engine sensors by checking for continuity Fig 3 shows continuity test being made on a brake light switch CAUTION On circuits protected with large fuse...

Page 380: ...r or the wire insulation for further inspection Repair any faults found To check for a short circuit using a voltmeter 1 Remove the blown fuse from the circuit 2 Disconnect the harness connector from the circuit s load or consumer 3 Using a voltmeter connect the test leads across the fuse terminals See Fig 5 Make sure power is present in the circuit if necessary turn the key on 4 If voltage is pre...

Page 381: ...ter pump relay 9 Unloader relay K 15 10 Hazard flasher relay 11 Check control module 12 Crash control unit 13 Lamp control module 0011842 Fig 1 1989 1990 Front power distribulion box 9 Unloader relay K 15 10 Auxiliary water pump relay 11 Horn relay 12 Hazard flasher relay 13 Check control module 14 Crash control module 15 Lamp control module 1 Jumper plug for horn phone 2 Starter relay 3 Unloader ...

Page 382: ... Auxiliary Relay Panel 001 635 Fig 5 Electronics be iE be in r 1 1Hear corner 01engine com partrnent CAUTION Relay positions are suaject to change and may vary trom car to car fI questions arise an autho rized BMW dealer is the best source for the most accurale and up to oete information A good way 10 verify a relay posuion is 10 compare file wiring colors et tne relay socket to the colors indicat...

Page 383: ...entral body electronics ZKE see also Fuses 4 5 17 24 30 47 4 7 5amp Parkitail underhood lights see also Fuses 5 15 20 Lamp monitor see also Fuses 1 2 3 5 7 I 10 11 13 14 1 5 Power mirrors see also Fuses 5 12 Headlight washer Canada see also Fuses 3 5 17 22 24 Central body electronics ZKE see also Fuses 3 5 17 24 30 47 5 10 amp Headlights Fog lights see also Fuses 2 3 7 10 11 13 14 Headlight washer...

Page 384: ...mp Fuel injection see also Fuse 23 Charging system Starting E box fan see also Fuse 28 Electronic Transmission control see also Fuses I 12 ABSlTraction see also Fuse 1 Door lock heating see also Fuse 30 Power windows see also Fuses 30 31 47 Power sunroof see also Fuses 30 31 47 Headlight washer Canada see also Fuses 3 4 5 22 24 Instrument cluster check control see also Fuses 1 17 20 29 Lamp monito...

Page 385: ...7 5 amp Central locking see also Fuses 30 47 Power windows see also Fuses 17 30 47 Power sunroof see also Fuses 17 30 47 Cellular telephone see also Fuses 9 18 32 I 7 5 amp Vacant 34 20 amp Electric steering column adjust 36 30 amp Central locking 37 20 amp Rear window wiperlwasher control Touring 40 15 amp Vacant 41 30 amp Radio CD player see also Fuse 18 Heated seats 42 I 30 amp Power seats see ...

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Page 387: ...an alcohol or ammonia solution or a non abrasive cleanser Bon Ami to clean the windshield Wiper blade chatter may be caused by dirty or worn blades or by wiper arms that are out of alignment Clean the blades and windshield as described above Adjust the wiper arm so that there is even pressure along the blade and so that the TAILGATE WIPER CONSOLE AND WIPER MOTOR 611 5 Tailgate wiper console removi...

Page 388: ...uides slightly using needle nose pliers 3 Pull old insert from wiper arm guides 4 Remove metal support strips from old insert and install into slots in new insert noting installation direction of cutouts in support strips NOTE The notched cutouts in the retaining strips should en gage the molded tangs in the inserts 5 Slide new insert through wiper blade guides Lock in sert in place at end guides ...

Page 389: ... key on and off with the air controVvolume lever in the off position to operate the lIap motor 1 Disconnect negative H battery cable 2 Remove heater blower motor See 640 Heating and Air Conditioning Fig 5 Wiper arm retaining nut arrow 3 On cars with ADV wiper arm remove the wiper arm clamping screw and remove the wiper arm NOTE If necessary use a screwdriver to spread clamping gap in wiper arm 4 I...

Page 390: ...ate harness connector at wiper motor 12 Push wiper arm shafts down into cowl area and maneu ver wiper console out of cowl WINDSHIELD WIPER CONSOLE AND WIPER MOTOR 001 788 Fig 8 Wipe console mounting bolts rarrow sj 00 ti B Fig 9 Moulding g lIe retaining clips arrows Remove clip cel1le pece tAl from outer piece IBI 13 Installation is the reverse of removal Tightening torques are given below Install...

Page 391: ... the wiper motor and other linkage parts can be repaired or re placed The rear wiper motor circuit is electrically interrupted when the tailgate window is opened A microswitch is positioned in the tailgate window lock The lockpin in the base of the win dow operates the microswitch 00 11791 Fig 11 Attach wiper arm crank to parked motor so thai crank is in straight line W ith linkage Tailgate wiper ...

Page 392: ...large washers are used with rubber mounts Note location of large bolts and short bolts as they must be reinstalled in the original locations 7 Partially lift out wiper assembly and loosen wire strap from holder 8 Unplug harness connector from wiper motor TAILGATE WIPER CONSOLEAND WIPER MOTOR p J A nv C l f 1O J m l 1 Cl p O _ _ a 0 0 tip 001 1736 Fig 15 Tail panel trim retaining clips arrows 00117...

Page 393: ... harness connector for nozzle heater I 3 Depress nozzle retaining clips and push nozzle up wards out of hood See Fig 20 4 Installation is reverse of removal 001 1792 Fig 20 Windshield washer spray nozzle being removed from hOOd Headlight spray nozzle removing and installing t a I 0011749 If necessary adjust the lock pin height See Fig 17 0011737 Fig 18 Tailgate window lockpin and wiper arm crank e...

Page 394: ...ent The headlight washer fluid pump is mounted in the head light washer fluid reservoir The headlight washer fluid reser voir is mounted on top of the windshield washer fluid reservoir On Touring models the rear wiper washer fluid reservoir and washer pump is located behind the right rear trim panel in the luggage compartment WINDSHIELD CLEANING SYSTEM 1 Open hood or tailgate as applicable 2 On To...

Page 395: ...ew s Loosen reservoir from mount and pull up slightly to access washer fluid level switch 4 Unplug harness connectors for washer fluid level switch and pump CAUTION Be careful when pulling harness connector off washer ffuid pump The pump can eaSIly puff out of the rubber grommet resulting in spilled washer ffuid 5 Empty washer fluid reservoir 6 Pull fluid level switch out from rubber grommet See F...

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Page 397: ...xtreme caution when removing the airbag unit from the steering wheel and be sure to follow the airbag removal procedure given in 721 Airbag System SRS Im proper handling of the airbag could cause serious injury Light switches removing and installing 612 3 Power window switch assembly removing and installing 612 3 Outside mirror switch removing and installing 612 4 INTERIOR LIGHTS 612 4 Dome light ...

Page 398: ...d only once Tightening Torques Steering wheel to steering column spindle self locking nut always replace 80 Nm 59 ft Ib bolt 63 Nm 46 ft Ib INTERIOR SWITCHES Ignition switch removing and installing 1 Disconnect negative battery cable and cover termi nal with an insulating material 2 Remove lower left dash panel 3 Remove screws retaining lower steering column cover and remove cover See Fig 1 4 Pres...

Page 399: ...h 1 Push switch to right and insert a thin strip of metal 1 0 mm feeler gauge to disengage switch frame locking tab See Fig 6 2 Remove switch frame with switches from instrument panel 3 Disconnect harness connector from appl icable switch and push switch forward out of switch frame 4 Installation is reverse of removal Engage switch frame using a feeler gauge as shown earlier 0011809 Fig 6 Feeler g...

Page 400: ...11855 Fig 10 Rear IIg11t assembly shown removed INTERIOR LIGHTS 3 Use a screwdriver to carefully pry off trunk light lens and replace the bulb See Fig 11 0011856 i __ 1 Fig 11 Trunk lighl lens being removed Dome light map lights rear lights trunk lights replacing bulbs 1 Pry dome light out from lell side Release the locking blade and swing back reflector Spread apart the con tact blades to remove ...

Page 401: ...eplacing cars built Feb 1989 and later 620 5 Vehicle speed sender replacing 620 5 On board computer removing and installing 620 6 TABLE a Instrument Cluster Self Test Diagnostics cars built Feb 1989 and later 620 2 NOTE If the battery has failed or become disconnected it may be necessary to reset the language designation of Check Control display to English U S Whenever the battery is disconnected ...

Page 402: ...orn pad lacmg up I stored lacmg down scaaemet deployment could propel It violently into the air causing inlury 1 Disconnect negative ballery cable and cover termi nal with an insulating material 2 On cars with driver s side airbag remove airbag unit from steering wheel See 721 Airbag System SRS Store the airbag unit in a safe place J _ I _ J 0 1 1 3 With front wheels pointed straight ahead remove ...

Page 403: ... See Fig 4 4 Unhook base plate from instrument carrier and discon nect wiring connector if applicable 5 Remove screws from perimeter of cluster Carefully lift off cluster cover from instrument carrier CAUTION LCD module can fall out once cluster cover is separated from instrument carrier 6 Remove individual instruments by carefully pulling them straight out of instrument carrier 7 Instrument clust...

Page 404: ...ocated in the brown harness connector at the rear of the cluster 1 Remove instrument cluster 2 Record mileage of vehicle 3 Remove rear portion of brown connector X17 See See Fig 7 00 11841 Fig 7 Coding plug on earlier model cars built up to Feb 19a9 in strument cluster 4 Insert special removing tool supplied with replacement coding plug into backside of plug releasing the coding plug retaining tan...

Page 405: ...g levers on con nector and disconnect connector See Fig 9 0011600 Fig 9 Vehicle speed sender harness connector Aj and sender B 2 Remove vehicle speed sender retaining screws and re move sender from differential cover 3 On installation replace O ring and coat with oil 9QW oil Install O ring up to first land on sender Install sender into differential and tighten mounting bolts evenly in stages until...

Page 406: ...minated by two bulbs It must be removed to replace the bulbs 1 Remove radio See 650 Radio and Alarm 2 Slide lever forward to release On Board Computer from instrument panel See Fig 11 0011802 Fig 11 On Board Computer release lever arrow 3 Installation is the reverse of removal INSTRUMENT CLUSTER ...

Page 407: ...e hood 2 Remove black plastic protective cover from back of headlight assembly See Fig 1 NOTE I replacing driver s side headlight bulb remove the alter nstor cooling duct as necessary before removing the protective cover behind the headlight Front side marker assembly and bulb replacing 630 4 REAR LIGHTING 630 4 Taillight bulb replacing 630 4 Taillight assembly removing and installing 630 4 Rear s...

Page 408: ...bly front mounting screws arrow s 5 Remove screws from rear of headlight assembly See Fig 4 6 Remove headlight assembly from front 7 Installation is reverse of removal FRONT LIGHTING 0011830 Fig 4 Heae flight assembly rear mounting screws arrows Headlight lens unit removing and installing t Remove side radiator grill See 510 Exterior Trim Bumpers 2 Using a hot air blower heat plastic sleeves on fr...

Page 409: ...ulb fail ure If necessary clean bulb using a clean cloth dampened with rubbing alcohol 4 Installation is the reverse of removal Check electrical connector for corrosion Spray with contact cleaner if necessary Front turn signal assembly removing and installing The following procedure also includes turn signal bulb re placement 1 Remove black plastic protective cover from back of headlight assembly ...

Page 410: ...remove side liner retainer Pull back liner to access rear of tail light Bulb Specification Side marker bulb 5 wan 2 Disconnect harness connector from rear of tail light lens assembly and remove nuts See Fig 11 3 Installation is reverse of removal REAR LIGHTING Tail light bulb replacing The procedure given below applies to the tail light bulbs in the lens assembly on the body The procedure for repl...

Page 411: ...trunk lid 2 Locate bulb socket on the under side of the parcel shelf below center brake light assembly 3 Turn socket counterclockwise 90 and remove from center brake light assembly Remove bulb from socket and replace 4 Installation is the reverse of removal License plate light removing and installing 1 Open trunk lid 2 Remove screws retaining license plate light assembly 3 Remove bulb and install ...

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Page 413: ...R II 1992 1995 6 cylinder cars IHKRIII 1994 1995 8 cylinder cars IHKA NC compressor replacing M50 engine 640 9 NC compressor replacing M60 engine 640 10 NC condenser replacing 640 10 NC receiver drier replacing 640 1 1 NC evaporator and expansion valve removing and installing 640 11 NC evaporator temperature sensor replacing 640 13 NC microfilter replacing 640 13 NC control module removing and ins...

Page 414: ...blower motor retaining strap from blower motor See Fig 3 001186 1 Fig 3 Awl beulg useo to disengage blower 1l1Otor retauunq strap P y up on strap 0 release HEATER AND CONTROLS Blower series resistance replacing IHKR II IHKR III 1 Remove carpeted trim panel from left side of center console Trim panel is retained by a single screw in side of panel 2 Disconnect harness connector from series resistor ...

Page 415: ...only Heater valve replacing The heater valve is located in the rear of the engine com partment on the driver s side 1 Drain engine coolant See 170 Radiator and Cooling System 2 Disconnect two coolant supply heater hoses at rear bulkhead in engine compartment See Fig 8 A Coolant return B Coolant supply passenger C Coolant supply driver 0011869 Fig B Heater hoses to be disconnected lA B G 3 Disconne...

Page 416: ...ional coolant circulation to the heater core The pump is located in the rear of the engine compartment directly below the heater valve 1 Drain engine coolant See 170 Radiator and Cooling System 2 Disconnect two coolant supply heater hoses from rear bulkhead in engine compartment See Fig 8 3 Disconnect coolant hose from auxiliary coolant pump 4 Remove harness connector and mounting nuts from heater...

Page 417: ...insulation from sensor harness 7 Install heat shrink tubing on finished w iring splice Con nect wires from new sensor to harness wires and sol der in place NOTE To minimize danger of a short circuit reconnect and solder the sensor wiring so that wire splices are offset from each a her 8 Installation is reverse of removal Outside temperature sensor test values are listed in Table c Table c Outside ...

Page 418: ...se of removal Distribution control panel cables replacing IHKR cars only 1 Remove glove box See 513 Interior Trim 2 Remove carpeted trim cover at right side of center con sole 3 Remove plastic trim cover at left of glove box See Fig 5 4 Remove heating and air conditioning distribution panel See Distribution panel removing and installing 5 Disconnect bowden cablets from air distribution le vers See...

Page 419: ...jor components of the AlC system WARNING Work in a well ventilated area Avoid breathing refrigerant vapors Exposure may irritate eyes nose and throat Switch on exhaustJventilation systems when working on the refrigerant system Always be careful that refrigerant does not come in contact with your skin Always wear hand and eye protection gloves and goggles when work ing around the AlC system If refr...

Page 420: ... to both vehicle and service equipment will result from R 12 contamination of R 134a The mixture of refrigerant oil PAG oil and refrig erant R 134a attacks some metals and alloys for example copper and breaks down certain hose materials Use only hoses and lines that are iden lified with a green mark stripe or the lettering R 134a Immedialely plug open connections on AlC com ponents to prevent dirt...

Page 421: ...g damage to the vehicle and personal injury may result Read warnings and cautions given under AlC sys tem warnings and cautions 2 Disconnect negative ballery termi nal 3 Remove engine splash guatd from under engine 4 Remove drive belt from AlC compressor See 020 Maintenance Program 5 Disconnect suction and pressure hose and set aside Discard O rings See Fig 19 6 Disconnect electrical connector and...

Page 422: ...r ant lines Always replace Q rings 8 Before recharging evacuate the system for at least 30 min Recharge system following the equipment manu tacturer s instructions AIR CONDITIONING Tightening Torques M60 engine NC compressor to engine block 22 Nm 1 7 fHb NC line flange to NC compressor self locking nut 20 Nm 1 5 ft Ib A C condenser replacing 1 Following the manufacturer s instructions connect an a...

Page 423: ...tery terminal 3 Remove protective cover from rear of right headlight assembly 4 Disconnect harness connectors from windshield wash er container and remove container from mount 5 Disconnect switch electrical harness connector s and re move mounting bolts from receiver drier See Fig 23 6 Remove refrigerant pressure lines from receiver drier See Fig 23 7 Remove receiver drier complete with safety swi...

Page 424: ...e refrigerant lines mounting nut and screws arrow s 7 Remove center console and glove box See 513 Inte rior Trim 8 Remove screws retaining ventilation duct and remove duct See Fig 25 9 Cut wire ties holding wire harness to right side of heater housing and disconnect and move wiring to gain ac cess to evaporator cover 10 On cars with IHKR I and IHKA unclip air distribution motor from right side of ...

Page 425: ...onsole remove carpeted trim panel 3 Disconnect electrical connector from evaporator tem perature sensor and pull sensor straight out of evapo rator housing See Fig 29 4 Installation is reverse of removal Table e lists evapo rator temperatu re sensor test values 0011 925 Fig 29 Evaporator temperature sensor shown removed arrow Table e Evaporative Temperature Sensor Test Values Test temp Resistance ...

Page 426: ...ve AlC control module electrical connector from left side of control unit if necessary 4 Remove screws retaining trim panel above glove box and remove trim panel disengaging from clip at rear 5 Remove two screws retaining ventilation duct and re move duct See Fig 25 6 Separate all electrical connectors from AlC control module and push aside wiring harness 7 Depress control module retaining clip an...

Page 427: ...adios amplifiers speakers etc are beyond the scope of this manual Servicing of et termerket sound equipment should be referred to an authorized agent of the equipment in question Do not remove radio or disconnect the battery without obtaining the anti theft code 1 Swing open small square covers at left and right sides of radio 2 Using hex key turn screw counterclockwise to loosen See Fig 1 3 Pull ...

Page 428: ...ng and installing 1 Remove door seal at edge of speaker cover and turn retainer screws 90 2 Pull speaker trim panel away from body and then pull panel back towards rear of car Pull off speaker con nector and remove the nuts retaining speaker to panel 3 Installation is the reverse of removal RADIO SERVICE Rear speaker removing and installing 1 Remove speaker cover by prying up inner edge See Fig 4 ...

Page 429: ...he rear of the radio on 1991 and later cars Use this along with Table a to identify the vari ous terminals Term inals 1 17 G 0011850 Fig 6 Connector designations on 1991 and later radio Use togeth er with Table a RADIO 650 3 Table a Radio Connector Terminal Designation 1991 and later I Connector Connector Signal Terminal 1 Speaker left Iront 2 Speaker right front 3 Speaker left rear 4 Telephone mu...

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Page 431: ... FRONT SEAT BELT ASSEMBLY Fig 2 shows an exploded view of the front seat belt assern bly Note that the front seat belt lock assembly varies depend ing on model year WARNfNG On late models cars an automatic seat belt lock tensioner is used on the Iront seats A mechanical impact sensor activates the tensioner in the case of a head on collision and retracts the seat belt ap proximately 55 mm 2 in Thi...

Page 432: ...ndow Front seat belt lock tensioner deactivating 1 Working at side of seat pry up concealing flap on ten sioner Tightening Torque Front seat belt lock mounting bolt 48 Nm 36 It Ib 0012290 I I 3 4 2 1 4 1 Bolt 5 Nut 12 Height adjuster cable assembly 2 Belt lock with tensioner 6 Bushing 13 Seat belt height adjuster late cars 7 Thrust washer 14 Socket head screw always deactivate B Sliding piece 15 S...

Page 433: ...im panel from B pillar See Fig 1 1 Remove rear seat and back rest See 520 Seats 4 Remove door lock latch mounting screws at B Pillar and partially remove latch 2 Remove seat belt anchor bolt from beneath rear seal 5 Remove seat belt guide bolt on B pillar and remove guide Remove two bolts holding cross bracket to B pil lar 3 Remove retaining clips and partially lift up parcel shelf See Fig 5 6 Rem...

Page 434: ...TS 4 Remove seat belt reel mounting bolt and remove seat bell and reel See Fig 6 00 11859 Fig 6 Seal belt reel mounting bolts arrows Tightening Torque Rear seal bell reel 10 body 48 Nm 36 ft Ib REAR SEAT BELTASSEMBLY ...

Page 435: ...he neq ative ballel terminal with an insulator before starting diagnostic troubleshooting or service work not associated with SRS and before doing any welding on the car Passenger s side airbag removing and installing Airbag II 721 3 Airbag contact ring replacing 721 4 Airbag crash sensor replacing Airbag I 721 5 WARNfNG o Always replace any airbag system component that has been mechanically damag...

Page 436: ...e fore removing the airbag from the steering wheel This will allow the system capacitor to discharge reducing the possibility of a trigger pulse being gen erated to the airbag 2 Remove lower steering column trim mounting screws and remove the lower trim 3 Remove orange SRS connector from its holder and carefully separate connector See Fig 2 Airbag I 1 Driver s side airbag unit 2 Airbag control mod...

Page 437: ...Store the removed airbag unit with the horn pad facing up If stored lacing down accidental oe ployment could propel it violently into the air causing injury Fig 3 Driver s side airbaq unit mounting screws arrows Fig 4 Driver s side airbag unit harness connector arrow Do not connect the battery with the airbag discon nected A fault code will be stored causing the SRS indication SRS light Special to...

Page 438: ...ing light goes out If the light stays on the SRS system will not lunction as designed Have the system diagnosed and repaired by an authorized BMW dealer Airbag contact ring replacing The airbag contact ring is mounted to the rear of the steer ing wheel and is made up of a wire ribbon that coils and un coils as the steering wheel is turned The contact ring assures continuous electrical contact to t...

Page 439: ...ng mounting screws shown at A Airbag crash sensor replacing Airbag I The Airbag I system uses two crash sensors mounted in the engine compartment on the left and right wheel arches The sensors are identified by their orange color 1 Disconnect negative battery cable and cover nega tive terminal with an insulating material 2 Remove lower steering column trim mounting screws and remove the lower trim...

Page 440: ...This page intentionally left blank ...

Page 441: ...rbag equipped car refer to the warnings and cautions in 69 Seatbells Airbags Headlights Foglights EWD 161 Heated Seats EWD 200 Horns EWD 140 Instrument Panel EWD 152 Interior Lights Illumination EWD 180 Lamp MonitorlWarning EWD 159 Memory Mirror EWD 196 Memory Seat EWD 201 Power Distribution EWD 2 Power Door Locks EWD 186 Power Mirrors EWD 194 Power Seats EWD 198 Power Sunroof EWD 203 Power Window...

Page 442: ...0 O lfll UI euTIO llflO_ QADi I f L Il ltl l l un I 1 sA I __ J CD 1 10 0 0 0 0 1 I r 1 1 L 2 e r I I LaC lOt _ T OC sO LOC aT I _ c _ 3 __ c _ 1 __ c J_ J J r Gil O L V Ll VIO i I 1 i 1i r I I J I I 1 I 1 _1 1 _ I I I I _I Q O QPl04 V O O n I 1 I I _ vrc u OADi 0 1 t L f t U fI L 1 1 0 1 J J J I 1 1 I 1 1 1 1 1 1 I I I I I I I I I _ I _I _ _I 1 __ I _I I _I 0 01 1 0 HJor 0 G IUO 11 110 0 00 1 0 C...

Page 443: ..._I _ 0 1 1 1 1 J 0 IE FUS Ull U l U USI 0 A 0 n n I lu L JI G c w a ta D 1 1 a t U 1l l Il O1 I OLIQ01 0 1 000 f tI Q e t 1 1 J il I In Ill S f u l j hOlT fo T 81 QA u t LI P 0 lit AO t i 1 1 1 1 _ I COOl e CO j OL U OlO ll L ID O1 O l l ll U U C u T l I ro f II O O OV I l tll l II Ul I O j 1 0_ r H I _ 0 l j t l t I I O T O OOU LI L o J ro e 1 1 1 L _ 1t T IHI E I t C US Te ll G r L 1 1 tL 1 I I ...

Page 444: ..._ _ J PlEDI G rol OA IW Q M r U OI l1 0 l I 1 10 110 r u O l c l J 10 I 11 0 Aro Rr DI REO I IE0 AI D YOO Y O OA G I I I 1 I 1 I 1 1 1 __I _I _I _ _I _I _I 1 _ ____ 1 a fA Pora Sf reet f TfilE T W I f l l P IE A UIEC T I C f1 UI CONTROL HrGH tJ llI l CO h l t Ol O lu OR f L A t OH Oa oEA AOI tChO WITC a W Te a T W ITC AU _ A IE rfto I W __ ut I I tlt I II U I Olli lt O O Fl1 I _ _ J Q JU t l OA IJ...

Page 445: ...UO P ll vto o Flr CIQ Alll Uo u tr 0 1 0 1 Ul f 1 0 1111 0 0 0 I A I 0 Tn 0 0 0 i i I L 1 1 1 I I 1 1 1 1 _ _I _ _I __ 1 _ __ _1 1 __1 __I C I C I 1I0 AAD CIIlV o UI luM C vlli r f CO PO l r o u r COti T Ol C S TI IoI OL u a IoI ODu l lOO UU 5 WITI w e U lo n I l IIll L 1 1 111 1 1 1 I 1 1 __ 1 r vo 0 1 0 f11 10L DUll I lr Co 10 l r l 0 V U r 1 1 L G l l 1 1 I _ I __I 0 0 STI lUM G f L O 110 0 l u...

Page 446: ...Rl l nD l F A O f POlo EPo I PIS I O I 11 0 1 1 1 1 1 I 0 1 I N L z z z o 0 1 1 1 1 _ I rA tlD O Qf l l U l O M I RO N T O W Q 0 10 1111 11 0 1 0 U O D Ul l tI U I OJ I __ J o s o r 1 1 L FU L V U I CI j 0 0 _ nEl 0 LO Ol A HO N I IE L EL r I L 1 1 O 1 r 1 1 I I 1 1 1 I 1 1 I I 1 1 1 1 1 __ 1 _ _I __I 1 _ _ 1 __I ti I O r Q I II O r I G I I O IQ 1IO IG OO COIL CO I 0 O L I a TO U 1 I I I __I o U I...

Page 447: ... L LIS r 1 I 1 L ro ro f EL I lIlO tlf Col ll III U 0 r IC FlIO on Arc FlU I ti L r l oy T 1 1 1 1 1 1 1 1 1 _1 1 __ 1 1 1 I 1 _ I _I Dl I ULIC 1 1 11 lfn II Li n 1110 0 cow r Co a M Of In lC DL T EM I L GIi T Hl lJ L I7o tl L I I r j I 1 J z O L l I AU oil CO TAOl OOULE D G I I L U 1 1 1 1 1 1 1 1 1 1 _ I _I U o t T ClUS Te R ECOl eo T Ol L l DUL i I r 9 I 1 1 1 __ 1 a 1 1 01 PLD 1 0 w 1 t p v 2 ...

Page 448: ...1 1 1 1 1 1 I 1 I I I 1 1 1 _ _I _ _I 1 _ _ 1 1 _ _ _ __ 1 _I 1 __1 0 111 13 lEA h lC TIII I I o llVe t l T I r t I n A l l CO l O r G lIUl I OIl I 1ll0 CflO C O l ol l UIll O IliT tWltc r e tA c r e 0 I o OAl ON 1 RO 0 VII 1 111 10 11 1110 0_ 17 O A 0 _ _ MID r r a r SU fl I OR T O L f 1 I1 l I I O T 1 I f u n n 1 0 o r IJ __I r to _ 1II1n a r 1 L _ us Y D AO T O t f UI E I P lo T luTlO 1 0 f n I...

Page 449: ... us ItuS n o o I _ _ J o 1 0 n I n U NI e l u S 1 1 1 1 1 1 ow G fIO plO I fC I G 0 It CI 0 on le 1 1 1 1 1 1 1 1 1 1 1 1 1 I I 1 1 _ _ _ _ _ 1 _ I _I 1 __ 1 _I U lO OIf l AIt C f C 0 0 0 v SE 11 lo A l 1 CO II Ol CO Uf f l l O OL C OUl l e Ou l f I UI G o o e CO N 1II0l OOUl a r G to OR 0 1 1 1 n r 1 1 L 0 GJII lO o l 1 1 1 1 _ _ 1 u eo 0 1 0 If AUlo e e lU ODUl l 0 11 11 II S I O 10 1 1 W He IlJ...

Page 450: ... H L II HE RE l _ 1 1 __ I I AUIoI 1 5 CLV EA COotH IDl OO Ul l 0 1 uS D 1 J 1 n I lilR 1 1 1 1 1 1 1 1 1 1 1 1 1 I 1 _I 1 __1 _ _I __I _I 1 _ _1 I NI O IeU t IO 00 1 0 I IT IO I I O 11011 COIL COOL C lIl eO L COoL 1 CO L 1 O R N R V n O T t o ul a ll l t o US 1 1 e U r D U E F o 1 0 111 CO 1110L IlIIO D U L 0 1 o 0 1 1 1 1 _I o e 1 I 1 _ _ 1 r IF lIiSO C C O O l I L e I 1 __ 1 l 1 I J 1 1 _I I 1 ...

Page 451: ...TlO o u t VII D t CO O l H l CIU f Z O lol S PI J 1 ILII f l 10 lW H I I I I I I _ _I J I us I ut i I Bt tI AOlilh f f 1 u US 1 l Ow B L OLIO Ol C I _ _I OC O UL C U B Oh SI f l s t 0 0 COwU L 1 o JlO f A O IU UO f OX r 0 __ l i 1 r D I f a 1 1 0 QII O LA I I C O T A O l OOULl L J 0 to fO Il k l 11 1 I 1 u lV I I J _I Ie I C lIlOl ODu Lf 0 9 I _I I P O 11 1 0 1 0 1 I 1 I I I __I I I _ _I _I _I 0 1...

Page 452: ... 01 00 01 _ I n THI OIllf 14a IIl ON f IJ II LI r L i or D 0 M a LIN_ D fl O u ti IH E D t h U r u o no O I A U I Ol H lI UTIO SO H I __ _ J T lI D I U S D a U f r I I L 11 0 li fO a IlII D 0 E D lil t ti l G a 0 _L1 0 0 1 1 1 1 1 1 1 1 1 _ _ 1 __I __ __ _ 1 1 __ 1 1 __ 1 lO l t J III IG r f At U J t l l n S l A U l E A CO F10 L CO I lOL CO 0 t HIQ I I U O 0 0 1 1 1 s Wlt e S lt e S lIIo tel un tO...

Page 453: ...jt C n u l UIjlRl S U OAl SW I CIO _I O ljl 10 11110 S lfC 0 0 owr u I tl la r _ltlVtlC It e e1l C _ 0 PJ 0 V l 0 n IJ 1 1 1 I I _ _ _ _ 1 1 _1 I 1 n Ulilf C RU I to _ Cl Ja tl ll t O I O C 0 1 0 0 1 1 1 1 I I 1 _ _ _I 1 _1 __I C_ 1ll1li er e O _ D C_ tlllI O O OL C U U II co r OL r U Q O U l l 3 0 Ul I r I c u uQ IO T h OV 0 ln r 0 t VIOl 0 1 w 11 0 l IC LiQ IIlI Q A _ Uf 0 l l lfM r 0 I U i I O ...

Page 454: ... 0 f L A till A L A R n A MO W r lCi IC IoI GI ll r I I L U US l Q MII 1 1 1 r l f I 0 0 1 US5 I OI lIul O itO 11 1 I 0 r O G P 4 RN CI _El H 1 1 1 1 I I I I I _ _I __I _ I _ I OA 1 Tl loIf I I LI4 T C 0 1I1 IOi o Y I I iIL G IIC 1 tlo wu c c co a OIOO f IC O 0 c QA AED QlUII ll IE 0 0 UU I 0 0 101 0 1 0 1 kI r 1 1 1 I I I _ I 1 _ _ 1 _ _I _ I AI Ill AUTo 0 11 0 1 0 O L CLIJt U IIl Ott C O r UT R ...

Page 455: ...I 1 __ 1 LOIlOl IE L 1 11 n loa 1 0 ol OL oau l O I l 1 r I I L OC r H oc Io o e 10 oc S fA _ _ J _ _ _ J __ c J r Q 1 I l r n A I 1 vso 1 1 1 1 __ 1 I _ _I fJWa ot CII O IIII ODtl LL ell I 1 __ HfA 1IEo o rG PlSO z o r 1110 a Ul l DllIi Ul l O I i L _ J s o 1 1 I I 1 __ l Cl t J U l D U f TO U t lo v r TOhl U l 1 tnrlJ I I I __I 0 0 0 O u III L 0 0 0 0 0 0 1 1 1 1 1 I I I I I I I I I I _I __I 1 _...

Page 456: ... III LA l D 1 1 1 1 __ 1 _ _ I U U r i 1 J JIIfG G r l 0 D w D U l VEL F USI D 1 I _I on ill iG LI c ow ow 10 Ill y Cl u L C If I E 1 A OllG r O lG Olln f O L B 0 uti I II D I C O I IIlIOL OCl D 1 I O D 1 no Oll of DI fM IIIVltO 1I0_ I I r r 7 lii i I Irol AVO I 1 I I I ee e r o I U L I I J I t il IiL 1 I QA LU 0 L 0 R D 1 l P n I L z 1 1 1 1 II u CU I f r A 1 1 1 __ I C H C II CO IIIIOL OOUU D w ...

Page 457: ...O A OOU L O T fIlOl N ODU U 0 5 h f G r L 1 I lII10 lIlEO o _10 t o IJI IJ o o I I 1 1 1 1 1 1 _I _I _ _ 1 __I 1 _____ 1 0 NA DIO u n A T I E ElU flint 0 JI C G 1 Jl flll li C O TAOt Otf eTIC OOVr l l ll I C U UC f UHG COLli O Il uI 011 1 r j J 1 1 1 _ _ 1 t Q u c Nl t C II II0 0l T 0 uSt I OII U V l I0 1 0 U 1 ___ J 1 1 _ _I un u CO L I l C 1 0 I 0 u Hot AlO lUI 11I 1 0 U Sf u m r R D 0 1 VIC W I...

Page 458: ...f illo AH A FIlO t Or IC ALI I I 100 M IQ 11 10 W If CH 0 AO P OW f1 U I O I A I II Ll Itl H 8 0 _ 1 1 n 7 0 n c s on JI 1 I I I I I 1 _ __ _ _I I 91 10 C Il IJI E Ct V lt T A CO IH FlOt n a n CH 0 10 VIC 1 110 n n I 0 I I I I 1 1 I I I 1 I I I I _I _I 1 __ 1 _I L 1 4 1 1 0 FI I O O l Ii O C F k Ill U O I C O I O co C O IJt llll HT u ODVU MODVH NU C 1 uar 1 0 0 0 10 1 0 m l n IPllE l IIO llD 1 I I...

Page 459: ...Jo I _I tI LeA D 1I0 L Ml DIH I 1 1J IO I n I H I IlII e Olll s c 1 I S 1 I L _ O O f f I U tl T O J I n _ __ J 011I D G U 1 I P 1 o r a n u u 1 1 1 I I I I I I 1 _I _I _I _I _I 0 1 L r LI 0 8 Q1 o Q II CO P10L W T e T C IllI Te 00 1 DI DDlE OOULI IC O I c QI Ill O O IIII D 0 uno H 0 1 fO 1 1 1 1 1 1 1 I 1 1 1 1 _I _ _I _I __ 1 11 utO I 0 Q O 0 CLUS T S Q CO 1Il tlu f wITe I G 110 1 Il TC 0 0 0 I ...

Page 460: ... o U I 1 11 t o U SE I O F OI I COIll IIlIOL htOOULE lOu r o C H 1 o I InD 1110I 15 0 C J Of OVEIII LVIi IQ H TIO COIL IQ ll IO COil ft OI co tlO OOULI o 1 _ _I _ _I O CO OL a OULl 0 11 __I o f I I OO OI S I OI l lO I I f to e OH 1OI0l MODULE lII l C U O ly Q 10 OWl I I DUU AI IlUTlO l oa _ J o o o s i o r I L J U L 0 1 0 0 0 0 n 0 II n n 1 1 1 1 I I I I o r L I I I CO I C t O _ ___1 _ I _ I __I _...

Page 461: ... 1 I 1 1 1 10 1 0 C S CO I OL ODul t f EO 0 L I III L OE l c I ll I 1 1 1 1 _ I _I 1 _ _ 1 u I 1 1 1 J fo D oEC 1 0 A Do ilL U l1 T O C M IG IIf _ IA oLI t U EO n t o C W OO D Ll rr UG Ill PUG e I Ll nu U T t QM C N O N Ii Il l II OL Q 0 1 0 1 e c Ee 1 1 1 I _ I _ I 11 n CO OL tHu V LIC MODULI If AO 11I 0 flO w 1 I N Ol TlII V UO l Oll r r E D C EC AI E C C J C 10 IUti 1 LAIlI I I O t O L Wl ODUL ...

Page 462: ..._ ___ _ O _ USE US E l I 4Q l O till Utl l f D fA C J I US Lf 11 r l _ 1 1 10 FU l IB L f 1 1 f I T S I A 0 0 S Wlr c lO r T loll r SU N O 0 LE IoE CO llll I FlOl wIre R E D o li ED m 0 t C e T U P l CI H u D lUS WEtj Il H r j J f O m f l U Oh See E 1 1 0 I Po f O 111 0 f O r 0 D l I D JI J_ e 1 1 1 1 _I __I 1 __ 1 1 __ ___ 1 CO JIo O D 5 II H f tc O U ll U L CO OL A CH C la O n LJ 1 I LA AO 1 20 ...

Page 463: ...o UP AU O IH IC 1 I 140J l 0 l n n fo O CO IO l lie H ew IN 1 1 TC C s o J I rl l U 0 0 _ I 1 l l I 3 0 0 t OU lt LO Df L f I v e vro 0 fUll to L I v 1 LEf M U u o LIii 1 10 1 1 1 _I L I C fOOC O It 1 liD U CO H AO OCu LI o N I f 1II Af l v u I 1 _ _ 1 C l 1 1 CO 1D L lN lt C c UN N CU ll 1 1 1 1 VIC 1 0 U M I OIII Uf OA CO 1I 0 l or l l 1 1 _I VIO A E l OO L 0 0 roll I 1 I _I 1 1 UT O 11t 1 C fl ...

Page 464: ...I101 I s r 11 D h AO 0 11 10 lu u I CH v r 1 1 L F U lIIE US E F1 S I Ott po w FUS I 0 1 1 0 0 1 If I r ___ J G I nu 0 1 1 ca 0 r O 0 G R I IILU 1 D Oh 1 C U ll G ill n u n u 1 I 1 1 1 1 I _ _I __ I __I __ I __I DII v t 101 IE L LIO LIO 0 Tl0 u G G C O O 9 WITC tJ CH lfC tOO i G O O Df lIl0 QULf IC ilUi O U D O NI 0 r I IU lIol IE T c u a 1l D Oh UT O C W SS IO 0 IE IIIt C I W E G 1 1 __ 1 0 O U D...

Page 465: ..._1 0 0 0 10 11 0 0 110101 0 0 1 0 COil t CO CO COt cO COlo 1 1 1 _I W I 0 uI ro 2 1 1 I 0 1 __1 r U l C U I a lll 1 I t 1 1 _I 1 __1 U O OI J u 1 V L 0 r O U r 9 O A O I 0 t o U fit ID A IIl Y O Go B O f U f J 1 0 1 G O 10 U51 1 IO G s O Q u 10 U 17 0 11 I 0 1 1 1 0 0 ___ I 110 0 10 1 0 Oo u I IOII 1 70 z z z z z 0 e c c e ll CO OI M O D U LE 0 11I 1 1 o o c 10 1 1 1 1 I G CO 01 MODUl I n S S IQ f...

Page 466: ... O NT 0 fJl D IU AltiU O O 1 1 1 1 I 1 1 I I I I I 1 1 I I F S E us C A A cO lIlO WOti ULI 1 fD C l w 0 1 111 rI 10 I I I 1 I I 1 1 __ 1 __ I of n r 1 1 J f 1l1 0 JlE D 0 GA LU W 1 1 n 0 L L A 6 D 0 f E u G 0 LE n t LI o G c f Ht OL lli n OL u r ClLlO ULtG Ilf D 0 0 0 110 D O lJ i S 11o PDiN r v 0I Il 0 o1 0 1 11 110 1 0 K I l 0 I I I U I l i r c r 1 _ l 1 I I I CO TJlO UOOULl L I J o I I 1 __I YO...

Page 467: ...valve replacing 240 18 output shaft replacing 240 17 torque converter replacing 240 17 B Battery starter alternator alternator brushes inspecting and replacing 121 5 alternator removinglinstalling 121 4 battery charging 121 3 load voltage test 121 2 open circuit voltage test 121 2 charging system checking 121 3 quick check 121 1 static current draw test 121 2 general information 121 1 solenoid swi...

Page 468: ...ngine 116 13 general information 116 1 height 116 16 reconditioning 116 15 cam followers hydraulic M50 M60 engines 116 17 camshaft 116 16 cylinder head 116 15 rocker arms M20 M30 engines 116 17 rocker arm shafts M20 M30 engines 116 17 valves 116 18 valve guides 116 18 valve seats 116 19 valve springs 116 20 valve stem oil seals 116 18 testing hydraulic cam followers 116 17 valves leakage 116 18 va...

Page 469: ...ad and valvetrain VANOS Variable Valve Timing 100 2 See also Camshaft timing chain Engine removal and Installation engine removinglinstalling M20 engine 110 1 M30 engine 110 9 M50 engine 110 4 M60 engine 110 12 general information 110 1 Evaporator See Heating and air conditioning Exhaust system components 180 1 general information 180 1 manifolds M20 M30 M50 engines removing installing 180 4 M60 e...

Page 470: ...ntake air temperature sensor 130 7 throttle position sensor M50lM60 engines 130 8 warnings and cautions 130 3 Fuel filter See Maintenance program Fuel pump See Fuel tank and fuel pump Fuel tank and fuel pump general information 160 1 pump current 160 7 electrical circuit checking 160 6 fuse and relay 160 5 power consumption checking 160 7 pressure and rate checking 160 6 pressure specifications 16...

Page 471: ...isabling system 120 2 distributor cap M20 M30 engines replacing 120 4 testing 120 3 firing order 120 6 general information 120 1 knock sensors 120 6 rotor M20 M30 engines replacing 120 4 testing 120 3 rpm sensor testing 120 5 schematics circuit 120 7 service 120 3 spark plug wires M20 M30 engines replacing 120 4 specifications M20 M30 engines 120 4 testing 120 3 troubleshooting basic principles 12...

Page 472: ... 020 18 Manual transmission general information 230 1 oil checking and replacing 230 1 removinglinstalling 230 5 seals input shaft replacing transmission removed 230 4 output shaft replacing transmission installed 230 2 selector shaft replacing transmission installed 230 3 service 230 1 technical data 200 2 Map light See Switches and electrical accessories Master cylinder See Brakes See also Clutc...

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