BMW 3 E36 serieS Workshop Manual Bentley Publishers

94,418 views 184 slides Sep 04, 2013
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Bmw
3Series
M3,3181,3231,3251,3281
Sedan,CoupeandConvertible
1992,1993,1994,1995,1996,1997,1998
Bentley,Publishers
Cambridge,Massachusetts

B-1ROBERTBENTLEY,INC.IAUTOMOTIVEPUBLISHERS
Informationthatmakes

1734MassachusettsAvenue
thedifferenceo Cambridge, MA02138USA
800-423-45951617-547-4170
www.rb.com

e-mail:[email protected]
WARNING-Important SafetyNotice
TechnicalContactInformation
Wevalueyourfeedback.Technicalcommentsand
suggestionsarehelpfultous.Pleasesendyour
commentsandthoughtstoBentleyPublishers
e-mail:[email protected]
Fromtimetotime,updatesmaybemadetothis
manual.Alistingofupdatescanbefoundontheweb
Iat www.rb.com/updates
Donotusethismanualunlessyouarefamiliarwithbasicautomotiverepairproceduresandsafeworkshoppractices.Thismanual
illustratestheworkshopproceduresrequiredformostservicework.Itisnotasubstituteforfui¡andup-to-dateinformationfromthe
vehiciemanufacturerorforpropertrainingasanautomotivetechnician.Notethatitisnotpossibleforustoanticipateal¡oftheways
orconditionsunderwhichvehiclesmaybeservicedortoprovidecautionsastoallofthepossiblehazardsthatmayresult.
Thevehiciemanufacturerwillcontinuetoissueserviceinformationupdatesandpartsretrofitsaftertheeditorialclosingofthis
manual.Someofthoseupdatesandretrofitswillapplytoproceduresandspecificationsinthismanual.Weregretthatwecannot
supplyupdatestopurchasersofthismanual.
Wehaveendeavoredtoensuretheaccuracyoftheinformationinthismanual.Pleasenote,however,thatconsideringthevast
quantityandthecomplexityoftheserviceinformationinvolved,wecannotwarranttheaccuracyorcompletenessoftheinformation
containedinthismanual.
FORTHESEREASONS,NEITHERTHEPUBLISHERNORTHEAUTHORMAKESANYWARRANTIES,EXPRESSORIMPLIED,THATTHEINFORMATIONIN
THISBOOKISFREEOFERRORSOROMISSIONS,ANDWEEXPRESSLYDISCLAIMTHEIMPLIEDWARRANTIESOFMERCHANTABILITYANDOFFITNESS
FORAPARTICULARPURPOSE,EVENIFTHEPUBLISHERORAUTHORNAVEBEENADVISEDOFAPARTICULARPURPOSE,ANDEVENIFA
PARTICULARPURPOSEISINDICATEDINTHEMANUAL.THEPUBLISHERANDAUTHORALSODISCLAIMALLLIABILITYFORDIRECT,INDIRECT,
INCIDENTALORCONSEQUENTIAL DAMAGESTHATRESULTFROMANYUSEOFTHEEXAMPLES,INSTRUCTIONSOROTHERINFORMATIONINTHIS
BOOK.INNOEVENTSHALLOURLIABILITYWHETHERINTORT,CONTRACTOROTHERWISEEXCEEDTHECOSTOFTHISMANUAL.
Yourcommonsenseandgoodjudgmentarecrucialtosafeandsuccessfulservicework.Readproceduresthroughbeforestarting
them.Thinkaboutwhethertheconditionofyourcar,yourleve¡ofmechanicalskill,oryourleve¡ofreadingcomprehensionmight
resultinorcontributeinsomewaytoanoccurrencewhichmightcauseyouinjury,damageyourcar,orresultinanunsaferepair.
lfyouhavedoubtsfortheseorotherreasonsaboutyourabilitytoperformsaferepairworkonyourcar,havetheworkdoneatan
authorizedBMWdealerorotherqualifiedshop.
Partnumberslistedinthismanualareforidentificationpurposesonly,notforordering.AlwayscheckwithyourauthorizedBMW
dealertoverifypartnumbersandavailabilitybeforebeginningserviceworkthatmayrequírenewparts.
BeforeattemptinganyworkonyourBMW,readthewamingsandcautionsonpagesvi¡andvi¡¡,andanywamingorcautionthat
accompaniesaprocedureintheservicemanual.Reviewthewarningsandcautionsonpagesvi¡andviüeachtimeyouprepareto
workonyourBMW.
Specialtoolsrequiredtoperformcertainserviceoperationsareidentifiedinthemanualandarerecommendedforuse.Useoftools
otherthanthoserecommendedinthisservicemanualmaybedetrimentaltothecar'ssafeoperationaswellasthesafetyofthe
personservicingthecar.
CopiesofthismanualmaybepurchasedfrommostautomotiveaccessoriesandpartsdealersspecializinginBMWautomobiles,from
selectedbooksellers,ordirectlyfromthepublisherbymail.
Thepublisherencouragescommentsfromthereaderofthismanual.Thesecommunicationshavebeenandwillbecarefullyconsideredin
thepreparationofthisandothermanuals.PleasewritetoRobertBentley,Inc.,Publishersattheaddresslistedonthetopofthispage.
ThismanualwaspublishedbyRobertBentley,Inc.,Publishers.BMWhasnotreviewedanddoesnotvouchfortheaccuracyofthetechnical
specificationsandproceduresdescribedinthismanual.
LibraryofCongressCataloging-in-PublicationData
BMW3SeriesServiceManualM3,318i,323i,3251,328i,Sedan,CoupeandConvertible:
1992,1993,1994,1995,1996,1997,1998.
p.cm.
Includesindex.
ISBN0-8376-0326-9
1.BMW3Seriesautomobile--Maintenanceandrepair--Handbooks,manuals,
etc.I.RobertBentley,inc.
TL215.132513561999
629.28'722--cic21

99-17179
CIP
BentleyStockNo.B398
Editorialclosing01/99
03020100991098765432
ThepaperusedinthispublicationisacidfreeandmeetstherequirementsoftheNationalStandardforInformationSciences-
PermanenceofPaperforPrintedLibraryMaterials.O
©Copyright1999RobertBentley,Inc.
Allrightsreserved.Allinformationcontainedinthismanualisbasedontheinformationavailabletothepublisheratthetimeofeditorial
closing.Therightisreservedtomakechangesatanytimewithoutnotice.Nopartofthispublicationmaybereproduced,storedinaretrieval
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ManufacturedintheUnitedStatesofAmerica

GeneralDataand

010FundamentalsfortheDo-lt-YourselfOwner
Maintenance

020MaintenanceProgram
Engine
Transmission
Suspension,
Steeringand
Brakes
4Body
100Engine-General
110

EngineRemovalandInstallation
113

CylinderHeadRemoval
andInstallation
116

CylinderHeadandValvetrain
117

CamshaftTimingChain
119

LubricationSystem
200Transmission-General
210Clutch
230ManualTransmission
510

ExteriorTrim,Bumpers

520

Seats
BoyEquipment

512
DoorWTdws

540

nrt
513

InteriorTrim

541

ConvertibleTop
515

CentralLockingandAnti-Theft
600

ElectricalSystem-General

620

Instruments
ElectricalS

stem
610ElectricalComponentLocations

630ExteriorLighting
611

WipersandWashers

640

HeatingandAirConditioning6

612

SwitchesandElectricalAccessories

650

Radio
Equipmentand

720SeatBelts
Accessories

721AirbagSystem(SRS)
ElectricalWiring
Diagrams
Foreword...............................................................................................................v
WarningsandCautions........................................................................................vii
Index...................................................................................................backofbook
300

Suspension,Steeringand

330

RearSuspension
Brakes-General

331

FinalDrive
310

FrontSuspension

340

Brakes
320

SteeringandWheelAlignment
400Body-General

411Doors
410

Fenders,EngineHood

412

TrunkLid
120

IgnitionSystem
121

Battery,Starter,Alternator
130

Fue¡Injection
160

FuelTankandFuelPump
170

RadiatorandCoolingSystem
180

ExhaustSystem
240

AutomaticTransmission
250

GearshiftLinkage
260Driveshaft

BMW SERVICEMANUUAS
BMW7SeriesServiceManual:1988-1994
7351,735iL,740i,740iL,750iL
RobertBentleyISBN0-8376-0328-5
BMW3SeriesServiceManual:1992-1998
M3,3181,323i,325i,328i,Sedan,Coupeand
ConvertibleRobertBentley
ISBN0-8376-0326-9
GloryDays:WhenHorsepowerand
BMWZ3ServiceManual:1996-1998

PassionRuledDetroit
4-cylinderand6-cylindermodels

JimWangersISBN0-8376-0208-4
RobertBentleyISBN0-8376-0327-7

AlfaRomeoOwner'sBibleTM
BMW3-SeriesServiceManual:1984-1990

PatBradenwithforewordbyDonBlack
3181,325,325e(es),325i(is),and325i

ISBN0-8376-0707-9
ConvertibleRobertBentley
ISBN0-8376-0325-0

FordF-SeriesPickupOwner'sBibleTM
MosesLudelISBN0-8376-0152-5
BMW5-SeriesServiceManual:1989-1995
5251,530i,535i,540iincludingTouring
RobertBentleyISBN0-8376-0319-6
BMW5-SeriesServiceManual:1982-1988
528e,5331,535i,535isRobertBentley
ISBN0-8376-0318-8
ENTHUSIASTTITLES
CompleteRoundel1969-1998:30Yearsof
theMagazineoftheBMWCarClubof
America(CD-ROM)ISBN0-8376-0322-6
AFrenchKissWithDeath:Steve
McQueenandtheMakingofLeMans
MichaelKeyserISBN0-8376-0234-3
TheSpeedMerchants:AJourneyThrough
TheWorldofMotorRacing,1969-72
MichaelKeyserISBN0-8376-0232-7
Mustang5.0TechnicalReference&
PerformanceHandbook
AlKirschenbaumISBN0-8376-0210-6
MaximumBoost:Designing,Testing,and
InstallingTurbochargerSystems
CorkyBellISBN0-8376-0160-6
VolkswagenSportTuning
forStreetandCompetition
PerSchroederISBN0-8376-0161-4
SportsCarandCompetitionDriving
PaulFrérewithforewordbyPhilHill
ISBN0-8376-0202-5
AutomotiveBooksFromRobertBentley
GTI,Golf,andJettaServiceManual:1985-
TheDesignandTuningofCompetition

1992Gasoline,Diesel,andTurboDiesel,
EnginesPhilipH.Smith,6theditionrevisedby

including16VRobertBentley
DavidN.WennerISBN0-8376-0140-1

ISBN0-8376-0342-0
GoingFaster:TheSkipBarberRacing

CorradoOfficialFactoryRepairManual:
SchoolCarlLopezISBN0-8376-0227-0

1990-1994VolkswagenUnitedStates
9M-f,Ir-Winn
onAlexanderwithforeword

ISBN0-8376-0387-0
byMarkMartínISBN0-8376-0070-7

PassatServiceManual:1990-1993,
TheTechniqueofMotorRacingPiero

includingWagonVolkswagenUnitedStates
TaruffiwithforewordbyJuanManuelFangio

ISBN0-8376-0378-1
ISBN0-8376-0228-9

CabrioletandSciroccoServiceManual:
RaceCarAerodynamics

1985-1993,including16V
JosephKatzISBN0-8376-0142-8

RobertBentleyISBN0-8376-0362-5
TheScientificDesignofExhaustand

VolkswagenFoxServiceManual:1987-
IntakeSystemsPhilipH.SmithandJohnC.

1993,includingGL,GLSportandWagon
MorrisonISBN0-8376-0309-9

RobertBentleyISBN0-8376-0363-3
VolkswagenModelDocumentation

Rabbit,Scirocco,JettaServiceManual:
JoachimKuchISBN0-8376-0078-2

1980-1984GasolineModels,including
VolkswagenBeetle:PortraitofaLegend

PickupTruck,Convertible,andGTIRobert
EdwinBaaskeISBN0-8376-0162-2
BentleyISBN0-8376-0183-5
JeepOwner'sBibleTM
MosesLudelISBN0-8376-0154-1
EurovanOfficialFactoryRepairManual:

MANUUAS
VolkswagenInspection/Maintenance
(I/M)EmissionTestHandbook:1980-1997
VolkswagenofAmericaISBN0-8376-0394-3
Rabbit,JettaServiceManual:1977-1984
DieselModels,includingPickupTruck
andTurboDieselRobertBentley
ISBN0-8376-0184-3
SuperBeetle,BeetleandKarmannGhia
OfficialServiceManualType1:1970-1979
VolkswagenUnitedStatesISBN0-8376-0096-0
BeetleandKarmannGhiaOfficialService
ManualType1:1966-1969Volkswagen
UnitedStatesISBN0-8376-0416-8Harley-DavidsonEvolutionVTwin
Owner'sBibleTMMosesLudel
ISBN0-8376-0146-0
Audi100,A6OfficialFactoryRepair
Manual:1992-1997,includingS4,S6,
quattroandWagonmodels.
ToyotaTruck&LandCruiserOwner's

AudiofAmerica.ISBN0-8376-0374-9
BibleTMMosesLudelISBN0-8376-0159-2

Audi80,90,CoupeQuattroOfficial
AUDISERVICEMANUUAS
TheRacingDriverDenisJenkinson

FactoryRepairManual:1988-1992
ISBN0-8376-0201-7

including80Quattro,90Quattroand
20-valvemodelsAudiofAmerica
UnbeatableBMW:EightyYearsof

FUELINJECTION

ISBN0-8376-0367-6
EngineeringandMotorsportSuccess

FordFuelInjectionandElectronicEngine

Audi100,200OfficialFactoryRepair
JeremyWaltonISBN0-8376-0206-8

CharlesOProbst,SAE

Manua1:1988-1991AudiofAmericaControl:1788-1993 .
BMW6SeriesEnthusiast'sCompanionTM

ISBN0-8376-0301-3

ISBN0-8376-0372-2
JeremyW.11 ISBN0-8376-0149-5
FordFuelInjectionandElectronicEngine

Audi500055000CSOfficialFa,ctory
BMWEnthusiast'sCompanionTMBMW

Control:1980-1987CharlesO.Probst,SAE

RepairManual:1984-1988Gasoline,
CarClubofAmericaISBN0-8376-0321-8

ISBN0-8376-0302-1

Turbo,andTurboDiesel,includingWagon
BMWNotecardsSeries1Photographyby

BoschFuelIn1ectionandEngne

andQuattroAudiofAmericaISBN0-8376-
i
KlausSchnitzerISBN0-8376-0211-4

ManagementCharlesO.Probst,SAE

0370-6
ISBN0-8376-0300-5

Audi5000,50005OfficialFactoryRepair
Manual:1977-1983GasolineandTurbo
VOLKSWAGEN OFFICIALSERVICE

Gasoline,DieselandTurboDiesel
MANUUAS

AudiofAmericaISBN0-8376-0352-8
NewBeetleServiceManual:1998-1999

Audi40005,4000CS,andCoupeGT
RobertBentleyISBN0-8376-0385-4

OfficialFactoryRepairManual:1984-1987
includingQuattroandQuattroTurboAudi
Jetta,Golf,GTI,CabrioServiceManual:

ofAmericaISBN0-8376-0373-0
1993-early1999,includingVR6andTDI
RobertBentleyISBN0-8376-0366-8

SAABOFFICIALSERVICE
1992-1999VolkswagenofAmerica

Saab90016ValveOfficialServiceManual:
ISBN0-8376-0335-8

19851993RobertBentl

ISBN0837603129-ey---
Saab9008ValveOfficialServiceManual:
1981-1988RobertBentleyISBN0-8376-0310-2
PassatOfficialFactoryRepairManual:

VOLVOSERVICEMANUAL
1995-1997VolkswagenofAmerica

Volve240ServiceManual:1983-1993
ISBN0-8376-0380-3

RobertBentleyISBN0-8376-0285-8
RobertBentleyhaspublishedservice
manualsandautomobilebookssince
1950.PleasewriteRobertBentley,Inc.,
Publishers,at1734Massachusetts
Avenue,Cambridge,MA02138,visit
ourwebsíteathttp://www.rb.com,or
call1-800-423-4595forafreecopyofour
completecatalog,includingtitlesand
servicemanualsforJaguar,Triumph,
Austin-Healey,MG,andothercars.

Foreword
Thisservicemanualcovers1992through1998BMW3Seriesmodels,andisspecificallyde-
signedtocoveronlythosemodelsbuiltforsaleintheUnitedStates.
BMW,andmostaccessoriesandpartssellersspecializinginBMWs,refertothe3Seriescars
coveredbythismanualastheE36model.Thecode"E36"isBMW'sinternalcodeforthebasicplat-
formsharedbyal¡ofthecarscoveredbythismanual.Exceptfortheengineandafewothercompo-
nents,themodelscoveredbythismanualsharemanyofsamecomponentssuchassuspension
parts,bodypanels,andtheinteriorpieces.Whenorderingparts,especiallybodyparts,knowingthe
E36codemaybehelpful.
BMWalsousesaninterna¡codefortheenginesusedinthe3Seriesmodels.Consultthetextin
the100Engine-Generalrepairgroupofthismanualforacompletelistingofenginecodes.Engine-
codeinformationisprimarilyusedinternallybyBMW,butmaybehelpfulifyouhaveaccesstoBMW
technicalinformation.
FortheBMWownerwithbasicmechanicalskills,thismanualgivesdetailedmaintenanceandre-
pairinformation.Inaddition,theBMWownerwhohasnointentionofworkingonhisorherowncar
willfindthatowningandreadingthismanualwillmakeitpossibletobebetterinformedandtodis-
cussrepairsmoreintelligentlywithaprofessionaltechnician.Thismanualhasbeenpreparedfrom
therepairinformationthatBMWprovidestoitsfactory-trainedtechniciansandhasbeendeveloped
primarilywiththedo-it-yourselfBMWownerinmind.Theaimthroughouthasbeenclarityandun-
derstandingwithpracticaldescriptions,step-by-stepprocedures,andaccuratespecifications.
TheBMWownerintendingtodomaintenanceandrepairshouldhaveasetoftoolsincludingaset
ofmetricwrenchesandsockets,screwdrivers,atorquewrench,andfeelergauges,sincetheseba-
sictoolswillbeusedtodothemajorityofthemaintenanceandrepairproceduresdescribedinthis
manual.Thismanualincludesdetailedinformationonthesebasictoolsandothertipsforthebegin-
nerinthefirstsectionofthemanual,entitled010FundamentalsfortheDo-It-YourselfOwner.
Forsomeoftherepairsdescribedinthismanual,BMWtechniciansusespecialtools.Thetextwill
notewhenarepairrequiresthesespecialtoolsand,wherepossible,willrecommendpractica¡alter-
natives.

Wehaveendeavoredtoensurethehighestdegreeofaccuracypossible.Whenthevastarrayof
datapresentedinthemanualistakenintoaccount,however,noclaimtoinfallibilitycanbemade.
Wethereforecannotberesponsiblefortheresultofanyerrorsthatmayhavecreptintothetext.The
publisherencouragescommentsfromthereadersofthismanualwithregardtoanyerrorsand,al-
so,suggestíonsforimprovementinthepresentationoftechnicalmaterial.Thesecommunications
havebeenandwillbecarefullyconsideredinthepreparationoffutureprintingsofthisandother
manuals.PleasecontactRobertBentley,Inc.usingthecontactinformationonthecopyrightpage
atthebeginningofthismanual.
BMWoffersextensivewarranties,especiallyoncomponentsofthefueldeliveryandemissions
controlsystems.Therefore,beforedecidingtorepairaBMWthatmaystillbecoveredwhollyorin
partbyanywarrantiesissuedbyBMWofNorthAmerica,consultyourauthorizedBMWdealer.You
mayfindthathecanmaketherepaireitherfreeoratminimumcost.
Regardlessofitsageandwhetherornotitisstillprotectedbywarranty,yourBMWisaneasycar
togetserviced.Soifatanytimearepairisneededthatyoufeelistoodifficulttodoyourself,a
trainedBMWtechnicianisreadytodothejobforyou.EachauthorizedBMWdealersenricedepart-
menthasmadeasignificantinvestmentinserviceanddiagnostictestequipment,specialstools,
andBMWoriginalparts.Itisalsothebestsourceofthemostup-to-daterepairandservicetech-
niques,whichincludesfactorytrainingandtechnicalliterature.ServicingyourBMWthroughanau-
thorizedBMWdealerwillinsurethatyourinvestmentwillbeprotectedwhilemaintainingthehighest
degreeofservicestandards.
RobertBentley

Pleasereadthesewarningsandcautions
beforeproceedingwithmaintenanceandrepairwork.
WARNING-

"Frictionmaterials(suchasbrakepadsorshortsorclutchdiscs)
containasbestosfibersorotherfrictionmaterials.Donotcreate
"SeealsoCautionsonpageviü

dustbygrinding,sanding,orbycleaningwithcompressedair.
"Somerepairsmaybebeyondyourcapability.Ifyoulackthe

Avoidbreathingdust.Breathinganyfrictionmaterialdustcanlead
skills,toolsandequipment,orasuitableworkplaceforanyproce-

toseriousdiseasesandmayresultindeath.
duredescribedinthismanual,wesuggestyouleavesuchrepairs

"
Batteriesgiveoffexplosivehydrogengasduringcharging.
toanauthorizedBMWdealerservicedepartmentorotherquali-

Keepsparks,lightedmatchesandopenflameawayfromthetop
fiedshop.

ofthebatteryIfhydrogengasescapingfromthecapventsis
"Donotre-useanyfastenersthatarewornordeformedinnormal

ignited,itwillignitegastrappedinthecellsandcausethebattery
use.Manyfastenersaredesignedtobeusedonlyonceand

toexplode.
becomeunreliableandmayfailwhenusedasecondtime.This

"Connectanddisconnectbatterycables,jumpercablesorabat-
includes,butisnotlimitedto,nuts,bolts,washers,self-lockingnuts
orbolts,circlipsandcotterpins.Alwaysreplacethesefasteners
withnewparts.
"Donotquick-chargethebattery(forbooststarting)forlonger
"Neverworkunderaliftedcarunlessitissolidlysupportedon

thanoneminute.Waitatleastoneminutebeforeboostingthebat-
standsdesignedforthepurpose.Donotsupportacaroncinder

teryasecondtime.
blocks,hollowtilesorotherpropsthatmaycrumbleundercontin-
uousload.Neverworkunderacarthatissupportedsolelybya

"Donotallowbatterychargingvoltagetoexceed16.5volts.Ifthe
jack.Neverworkunderthecarwhiletheengineisrunning.

batterybeginsproducinggasorboilingviolently,reducethecharg-
ingrate.Boostingasulfatedbatteryatahighchargingratecan
"Ifyouaregoingtoworkunderacarontheground,makesure

causeanexplosion.
thatthegroundislevel.Blockthewheelstokeepthecarfromroll-
ing.Disconnectthebatterynegative(-)terminal(groundstrap)to

"Theair-conditioningsystemisfilledwithchemicalrefrigerant,
preventothersfromstartingthecarwhileyouareunderit.

whichishazardous.TheA/Csystemshouldbeservicedonlyby
trainedtechniciansusingapprovedrefrigerantrecovery/recycling
"Neverruntheengineunlesstheworkareaiswellventilated.

equipment,trainedinrelatedsafetyprecautions,andfamiliarwith
Carbonmonoxidekills.

regulationsgoverningthedischarginganddisposalofautomotive
"Fingerrings,braceletsandotherjewelryshouldberemovedso

chemicalrefrigerants.
terychargeronlywiththeignitionswitchedoff,topreventsparks.
Donotdisconnectthebatterywhiletheengineisrunning.
thattheycannotcauseelectricalshorts,getcaughtinrunning

"DonotexposeanypartoftheA/Csystemtohightemperatures
machinery,orbecrushedbyheavyparts.

suchasopenflame.Excessiveheatwillincreasesystempressure
"Tielonghairbehindyourhead.Donotwearanecktie,ascarf,

andmaycausethesystemtoburst.
looseclothing,oranecklacewhenyouworknearmachinetoolsor

"Someaerosoltireinflatorsarehighlyflammable.Beextremely
runningengines.Ifyourhair,clothing,orjewelryweretogetcaught

cautiouswhenrepairingatirethatmayhavebeeninflatedusing
inthemachinery,severeinjurycouldresult.

anaerosoltireinflator.Keepsparks,openflameorothersources
"Donotattempttoworkonyourcarifyoudonotfeelwell.You

ofignitionawayfromthetirerepairarea.Inflateanddeflatethetire
increasethedangerofinjurytoyourselfandothersifyouaretired,

atleastfourtimesbeforebreakingthebeadfromtherim.Com-
upsetorhavetakenmedicationoranyothersubstancethatmay

Pletelyremovethetirefromtherimbeforeattemptinganyrepair.
keepyoufrombeingfullyalert.
"Illuminateyourworkareaadequatelybutsafety.Useaportable
safetylightforworkinginsideorunderthecar.Makesurethebulb
isenclosedbyawirecage.Thehotfilamentofanaccidentallybro-
kenbulbcanignitespilledfueloroil.
"Catchdrainingfuel,oil,orbrakefluidinsuitablecontainers.Do
notusefoodorbeveragecontainersthatmightmisleadsomeone
intodrínkingfromthem.Storeflammablefluidsawayfromfirehaz-
ards.Wipeupspillsatonce,butdonotstoretheoilyrags,which
canigniteandburnspontaneously.
"Alwaysobservegoodworkshoppractices.Weargoggleswhen
youoperatemachinetoolsorworkwithbatteryacid.Glovesor
otherprotectioeclothingshouldbewornwheneverthejobrequires
workingwithharmfulsubstances.
"Greases,lubricantsandotherautomotivechemicalscontain
toxicsubstances,manyofwhichareabsorbeddirectlythroughthe
skin.Readthemanufacturer'sinstructionsandwarningscarefully.
Usehandandeyeprotection.Avoiddirectskincontact
"Carscoveredbythismanualareequippedwithasupplemental
restraintsystem(SRS),thatautomaticallydeploysanairbag(s)in
theeventofafrontalímpact.Theairbag(s)isinflatedbyanexplo-
sivedevice.Handledimproperlyorwithoutadequatesafeguards,
canbeaccidentlyactivatedandcauseseriousinjury.
"Theignitionsystemproduceshighvoltagesthatcanbefatal.
Avoidcontactwithexposedterminalsanduseextremecarewhen
workingonacarwiththeenginerunningortheígnitionswitchedon.
"Placejackstandsonlyatlocationsspecifiedbymanufacturer.
Thevehicleliftingjacksuppliedwiththevehicleisintendedfortire
changesonly.Aheavydutyfloorjackshouldbeusedtoliftvehicle
beforeinstallingjackstands.See010FundamentalsfortheDo-.
it-YourselfOwner.
"Batteryacid(electrolyte)cancausesevereburns.Flushcontact
areawithwater,seekmedicalattention.
"Aerosolcleanersandsolventsmaycontainhazardousordeadly
vaporsandarehighlyflammable.Useonlyinawellventilated
area.Donotuseonhotsurfaces(engines,brakes,etc.).
"Disconnectthebatterynegative(-)terminal(Groundstrap)

"Donotremovecoolantreservoirorradiatorcapwiththeengine
wheneveryouworkonthefuelsystemortheelectricalsystem.Do

hot.Dangerofbumsandenginedamage.
notsmokeorworknearheatersorotherfirehazards.Keepan
approvedfireextinguisherhandy.

continuedonnextpage
vii

Pleasereadthesewarningsandcautions
beforeproceedingwithmaintenanceandrepairwork.
CAUTION-
"SeealsoWarningsonpagevi¡

"BeforedoinganyelectricalweldingoncarsequippedwithABS,
disconnectthebatterynegative(-)terminal(groundstrap)andthe
"Ifyoulacktheskills,toolsandequipment,orasuitablework-

ABScontrolunitconnector.
shopforanyproceduredescribedinthismanual,wesuggestyou
leavesuchrepairstoanauthorizedBMWdealerorotherqualified

"Oncarsequippedwithanti-theftradios,makesureyouknowthe
shop.

correctradioactivationcodebeforedisconnectingthebatteryor
removingtheradio.lfthewrongcodeisenteredintotheradio
"BMWisconstantlyimprovingitscarsandsometimesthese

whenpowerisrestored,thatradiomaylockupandberendered
changes,bothinpartsandspecifications,aremadeapplicableto

inoperable,evenifthecorrectcodeisthenentered.
earliermodels.Therefore,partnumberslistedinthismanualare
forreferenceonly.AlwayscheckwithyourauthorizedBMWdealer

"Alwaysmakesureignitionisoffbeforedisconnectingbattery.
partsdepartmentforthelatestinformation.
"Labelbatterycablesbeforedisconnecting.Onsomemodels,
"Beforestartingajob,makecertainthatyouhavealltheneces-

batterycablesarenotcolorcoded.
sarytoolsandpartsonhand.Readal¡theinstructionsthoroughly,
donotattemptshortcuts.Usetoolsappropriatetotheworkand

"Disconnectingthebatterymayerasefaultcode(s)storedincon-
useonlyreplacementpartsmeetingBMWspecifications.Make-

trolmodulememoryUsingspecialBMWdiagnostícequipment,
shifttools,partsandprocedureswillnotmakegoodrepairs.

checkforfaultcodespriortodisconnectingthebatterycables.Ifthe
CheckEnginelightisilluminated,see100Engine-Generalfor
"Usepneumaticandelectrictoolsonlytoloosenthreadedparts

On-BoardDiagnostics(OBD)faultcodeinformation.lfanyother
andfasteners.Neverusethesetoolstotightenfasteners,espe-

systemfaultshavebeendetected(indicatedbyanílluminated
ciallyonlightalloyparts.Alwaysuseatorquewrenchtotighten

warninglight),seeanauthorizedBMWdealer.
fastenerstothetighteningtorquespecificationlisted.
"Ifanormalorrapidchargerisusedtochargebattery,thebattery
"Bemindfuloftheenvironmentandecology.Beforeyoudrainthe

mustbedisconnectedandremovedfromthevehicleinorderto
crankcase,findouttheproperwaytodisposeoftheoil.Donot

avoiddamagingpaintandupholstery
pouroilontotheground,downadrain,orintoastream,pondor
lake.DisposeofinaccordancewithFederal,StateandLocallaws.

"Donotquick-chargethebattery(forbooststarting)forlonger
thanoneminute.Waitatleastoneminutebeforeboostingthebat-
eIfbatterypowerislostorthebatteryhasbeendisconnected,the

teryasecondtime.
powerwindowsmustbere-initialized.Bothonetouchup/down
andpinch-protectionwillbeinactiveuntilwindowsarere-initial-

"Connectanddisconnectabatterychargeronlywiththebattery
ized.See512DoorWindows.

chargerswitchedoff.
"Thecontrolmodulefortheanti-lockbrakesystem(ABS)cannot
withstandtemperaturesfromapaint-dryingboothoraheatlamp
inexcessof203°F(95°C)andshouldnotbesubjectedtotemper-
aturesinexcessof185°F(85°C)formorethantwohours.
"Sealedor"maintenancefree"batteriesshouldbeslow-charged
only,atanamperageratethatisapproximately10%ofthebat-
tery'sampere-hour(Ah)rating.
"Donotallowbatterychargingvoltagetoexceed16.5volts.Ifthe
batterybeginsproducinggasorboilingviolently,reducethecharg-
ingrate.Boostingasulfatedbatteryatahighchargingratecan
causeanexplosion.

GENERAL
FUNDAMENTALS FORTHEDO-ITYOURSELFOWNER

010-1
010Fundamentalsforthe
Do-lt-YourselfOwner
GENERAL.............................010-1

TOOLS...............................010-8
BasicToolRequirements................010-8
HOWTOUSETHISMANUAL ...........010-2

JackStands...................

......010-9
Warnings,CautionsandNotes............010-2

OilChangeEquipment..................010-9
GETTINGSTARTED....................010-2

TorqueWrench.......................010-10
FeelerGauges.......................010-10
Safety

..........

....................010-2

DigitalMultimeter

.....................010-10
LíftingtheCar..........................010-3

gMWSpecialTools....................010-11
Raisingcarsafely.........

.............010-3
Workingundercarsafely...................010-4

EMERGENCIES ......................010-11
ADVICEFORTHEBEGINNER ..........010-4

ChangingaTire......................010-11
CarWillNotStart.....................010-11
PlanningAhead........................010-4

JumpStartingCar.....................010-12
Cleanliness............................010-4

Overheating

.........................010-12
Non-reusableFasteners..................010-5

LowOilPressure.......................010-13
TighteningFasteners....................010-5

BrakeFluidLevel

.....................010-13
GasketsandSeals......................010-5

CheckEngineWarningLight............010-13
ElectricalTesting.......................010-6

pimLights...........................010-13
WireRepairs

..........................010-6

Towíng

.............................010-13
BUYINGPARTS

.......................010-6

SparePartsKit.......................010-14
GenuineBMWParts....................010-6
Non-returnableParts....................010-7

TABLES
InformationYouNeedtoKnow............010-7

a.GeneralBoltTighteningTorques
SERVICE ..............................010-7
AlthoughtheBMWisasophisticatedandcomplexmachine,
basicmaintenancecanbeaccomplishedbyaninterestedown-
erwithmechanicalskillsandtherightinformation.Mostofthe
preventivemaintenancethatisrequiredinthelifetimeoftheav-
erageBMWisweilwithinthecapabilitiesofthedo-it-yourseifer.
WARNING-
Donotusethismanualunlessyouarefamiliarwith
basicautomotiverepairproceduresandsalework-
shoppractices.Thismanualillustratesthework-
shopproceduresrequiredformostservicework;it
isnotasubstituteforfullandup-to-dateinformation
fromthevehiclemanufacturerorforpropertraining
asanautomotivetechnician.Notethatitisnotpos-
sibleforustoanticipateal¡ofthewaysorconditions
underwhichvehiclesmaybeservicedortoprovide
cautionsastoallofthepossiblehazardsthatmay
result '
inNm(max.permissible)....................010-5
WARNING-
Yourcommonsenseandgoodjudgmentarecrucial
tosaleandsuccessfulservicework.Readproce-
duresthroughbeforestartingthem.Thinkabout
whethertheconditionofyourcar,yourleve¡ofme-
chanicalskill,oryourleve¡ofreadingcomprehen-
sionmightresultinorcontributeinsomewaytoan
occurrencethatmightcauseyouinjurydamage
yourcar,orresultinanunsaferepair.lfyouhave
doubtsfortheseorotherreasonsaboutyourabilíty
toperformsalerepairworkonyourcar,havethe
workdoneatanauthorizedBMWdealerorother
qualifiedshop.
Thissectionofthemanualisintendedtohelpthebeginner
getstarted.TobeginwiththereisadiscussiononHowToUse
ThisManual.Tipsonmechanicasskillsandworkshoppractic-
esthatcanhelpthebeginnerdoafasterandmorethoroughjob
canbefoundunderGettingStarted.Thebasictoolsneeded
todomostoftheproceduresinthismanualarefoundunder
Tools.ThesectionendswithaquickreferenceguidetoEmer-
gencies,includingbasictroubleshootingandinformationon
howtogaugetheseriousnessofaproblem.
GENERAL

010-2

FUNDAMENTALS FORTHEDO-ITYOURSELF OWNER
HOWTOUSETHISMANUAL
Anotecontainshelpfulinformation,tipsthatwillhefpin
Themanualisdividedintoninesections:

doingabetterjobandcompleting!tmoreeasíly.
0GENERALDATAANDMAINTENANCE
1ENGINE
2TRANSMISSION
3SUSPENSION,STEERINGANDBRAKES
4BODY
5BODYEQUIPMENT
6ELECTRICALSYSTEM
7EQUIPMENTANDACCESSORIES
ELECTRICALWIRINGDIAGRAMS
0GENERALDATAANDMAINTENANCE coverstherec-
ommendedmaintenanceschedulesandserviceprocedures
neededtoperformBMWscheduledmaintenancework.Also
withinthissectionisthe010FundamentalsfortheDo-It-
YourselfOwnersection,whichcontainsbasicinstructions,
tipsandhelpfulhintsfordo-it-yourselfmaintenanceandrepair.
Thenextsevensections(1through7)arerepairbasedand
arefurtherbrokendownintothreedigitrepairgroups.Eachma-
jorsectionbeginswithaGeneralrepairgroup,e.g.100En-
gine-General.These"00"(doublezero)groupsaremostly
descriptiveinnature,coveringtopicssuchastheoryofopera-
tionandtroubleshooting.Theremainderoftherepairgroups
containthemoreinvolvedrepairinformation.Thelastmajor
sectioncontainsdetailedelectricalwiringdiagramschematics.
Amasterlistingofthe9majorsectionsandthecorrespond-
ingindividualrepairgroupscanbefoundontheinsidefront
cover.
EachrepairgroupbeginswithaTableofContentslistingthe
majossubjectheadingswithinthegroup.Pagenumbers
throughoutthemanualareorganizedaccordingtotherepair
groupsystem.Forexample,youcanexpecttofindrepairinfor-
mationonbrakes(RepairGroup340)beginningonpage340-
1.Acomprehensiveindexcanbefoundatthebackoftheman-
ual.
Warnings,CautionsandNotes
Throughoutthismanualaremanypassageswiththehead-
ingsWARNING,CAUTION,orNOTE.Theseveryimportant
headingshavediflerentmeanings.
WARNING-
Thetextunderthisheadingwarnsofunsafepractic-
esthatareverylikelytocauseínjury,eitherbydírect
threattotheperson(s)pertormingtheworkorbyin-
creasedriskofaccidentormechanfcalfallurewhíle
driving.
CAUTION-
Acautioncallsattentiontoimportantprecautions
tobeobservedduringtherepairworkthatwillhelo
preventaccidentallydamagingthecaroritsparts.
GETTINGSTARTED
Safety
NOTE-
PleasereadeveryWARNING,CAUTION,andNOTEatthe
frontofthemanualandastheyappearinrepairprocedures.
Theyareveryimportant.Readthembeforeyoubeginany
maintenanceorrepairjob.
SomeWARNINGsandCAUTIONsarerepeatedwherever
theyapply.Readthemall.Donotskipany.Thesemessages
areimportant,eventotheownerwhoneverintendstoworkon
thecar.
GETTINGSTARTED
Mostofthenecessarymaintenanceandminorrepairthatan
automobilewillneedcanbedonewithordinarytools,evenby
ownerswithlittleornoexperienceincarrepair.Belowissome
importantinformationonhowtoworksafely,adiscussionof
whattoolswillbeneededandhowtousethem.
Althoughanautomobilepresentsmanyhazards,common
senseandgoodequipmentcanheloensuresafety.Manyacci-
dentshappenbecauseofcarelessness.Payattentionandstick
tothesefewimportantsafetyrules.
WARNING-
"Neverruntheengineintheworkareaunlessit
iswell-ventflated.Theexhaustshouldbevented
totheoutside.Carbonmonoxide(CO)intheex-
haustkilts.
"Removeallneckties,scarts,looseclothing,or
jewelrywhenworkingnearrunningenginesor
powertools.Tuckinshirts.Tielonghaírandse-
cureitunderacap.Severeinjurycanresultfrom
thesethingsbeíngcaughtinrotatingparts.
"Removeríngs,watches,andbracelets.Asíde
fromthedangersofmovingparts,metallicjew-
elryconductselectricityandmaycauseshorts,
sparks,bums,ordamagetotheelectricalsys-
temwhenaccidentallycontactingthebatteryor
otherelectricalterminals.
"Disconnectthebatterynegative()cablewhen-
everworkingonornearthefuelsystemorany-
thlngthatiselectricallypowered.Accidental
electrícalcontactmaydamagetheelectrical
systemorcauseafire.

WARNING-
"Neverworkunderaliftedcarunlessitissolidly
supportedonjackstandsthatareintendedfor
thatpurpose.Donotsupportacaroncinder
blocks,bricks,orotherobjectsthatmayshiftor
crumbleundercontinuousload.Neverworkun-
deracarthatissupportedonlybytheliftingjack.
"Fuelishighlyflammable.Whenworkingaround
fuel,donotsmokeorworknearheatersorother
firehazards.Keepanapprovedfireextinguisher
handy.
"llluminatetheworkareaadequatelyandsafely.
Useaportablesafetylightforworkinginsideor
underthecar.Afluorescenttypelightisbestbe-
causeitgivesofflessheat.Ifusingalightwitha
normalincandescentbutb,useroughservice
bulbstoavoidbreakage.Thehotfilamentofan
accidentallybrokenbulbcanignitespilledfuelor
oil
"Keepsparks,lightedmatches,andanyopen
llameawayfromthetopofthebattery.Hydrogen
gasemittedbythebatteryishighlyflammable.
Anynearbysourceofignitionmaycausethe
batterytoexplode.
"Never¡aytoolsorpartsintheenginecompart-
mentorontopofthebattery.Theymayfallinto
confinedspacesandbedifficulttoretrieve,be-
comecaughtinbeitsorotherrotatingparts
whentheengineisstarted,orcauseelectrical
shortsanddamagetotheelectricalsystem.
"Thefuelsystemisdesignedtoretainpressure
evenwhentheignitionisoff.Whenworkingwith
thefuelsystem,loosenthefuelfinesslowlytoal-
lowtheresidualpressuretodissipategradually.
Takeprecautionstoavoidsprayingfuel.
LiftingtheCar
FUNDAMENTALS FORTHEDO-ITYOURSELF OWNER 010-3
Forthoserepairsthatrequireraisingthecar,theproperjack-
ingpointsshouldbeusedtoraisethecarsafelyandavoiddam-
age.Therearefourjackingpointsfromwhichthecarcanbe
safelyraised.ThejacksuppliedwiththecarbyBMWcanonly
beusedatthefoursidepointsjustbehindthefrontwheelor
justinfrontoftherearwheel.SeeFig.1.
WARNING-
"Whenraisingthecarusingafloorjackorahy-
drauliclift,carefullypositionthejackpadtopre-
ventdamagingthecarbody.Asuitableliner
(wood,rubber,etc.)shouldbeplacedbetween
thejackandthecartopreventbodydamage.
"Watchthejackclosely.Makesureftstaysstable
anddoesnotshiftortilt.Asthecarisraised,the
carmayrol¡slightlyandthejackmayshift.
Fig.1.

3-Seriesjackingpoints(arrows).
Raisingcarsafely
1.Parkcaronflat,leve¡surface.
2.Removetheroundcoverfromjackmountusinga
screwdriver.SeeFig.2.
0013126
Fig.2.

Jackmountcoverbeingremovedfromrockerpanel.
3.Placejackfullyintoposition.SeeFig.3.Makesurejack
isrestingonflat,solidground.Useaboardorothersup-
porttoprovideafirmsurfaceforthejack,ifnecessary.
4.Raisecarslowlywhileconstantlycheckingpositionof
jackandcar.
5.Oncecarisraised,blockthewheelthatisoppositeand
farthestfromjacktopreventcarfromunexpectedlyroll-
ing.
GET77NGSTARTER

010-4

FUNDAMENTALS FORTHEDO-ITYOURSELF OWNER
Fig.3.

BMWsuppliedjackcorrectlypositionedinfrontjackingpoint.

Mostoftherepairsandmaintenancetasksdescribedinthis
manualcanbesuccessfullycompletedbyanyonewithbasic
toolsandabilities.Topreventgettingintoodeep,knowwhat
WARNING-

thewholejobrequiresbeforestarting.Readtheprocedurethor-
"Donotrelyonthetransmissionortheemergen-

oughly,frombeginningtoend,inordertoknowjustwhattoex
cybraketokeepthecarfromrolling.Theyare

pectandwhatpartswillhavetobereplaced.
notasubstituteforpositivelyblockingtheoppo-
sitewheel.
"Neverworkunderacarthatissupportedonlyby
ajackUsejackstandsthatareproperlyde-
signedtosupportthecar.SeeTools.
Workingundercarsafely
1.Disconnectnegative(-)cablefrombatterysothatno
oneelsecanstartthecar.Letothersknowwhatyouwill
bedoing.
CAUTION-
Priortodisconnectingthebatteryreadthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevüi.
2.Raisecarslowlyasdescribedabove.
3.Useatleasttwojackstandstosupportthecar.Ajack
isatemporaryliftingdeviceandshouldnotbeused
alonetosupportthecarwhileyouareunderit.Usejack
standsdesignedforthepurposeofsupportingacar.
Formoreinformationonjackstands,seeToolsbelow.
WARNING-
Donotusewood,concreteblocks,orbrickstosup-
portacar.Woodmaysplit.Blocksorbricks,while
strong,arenotdesignedforthatkindofload,and
maybrakkorcollapse.
ADVICEFORTHEBEGINNER
4.Placejackstandsonfirm,solidsurface.Ifnecessary,
useaflatboardorsimilarsolidobjecttoprovideafirm
footing.
5.Lowercarslowlyuntilitsweightisfullysupportedby
jackstands.Watchtomakesurethatthejackstandsdo
nottiporleanasthecarsettlesonthem.
6.Observealljackingprecautionsagainwhenraisingcar
toremovejackstands.
ADVICEFORTHEBEGINNER
Thetipsintheparagraphsthatfollowaregeneraladviceto
helpanydo-it-yourselfBMWownerperformrepairsandmain-
tenancetasksmoreeasilyandmoreprofessionally.
PlanningAhead
Cleanliness
Keepingthingsorganized,neat,andcleanisessentialtodo-
ingagoodjob.Whenworkingunderthehood,fendercovers
willprotectthefinishfromscratchesandotherdamage.Make
surethecarisrelativelycleansothatdirtunderthecoverdoes
notscratchthefinish.
Anyrepairjobwillbelesstroublesomeifthepartsareclean.
Forcleaningoldparts,therearemanysolventsandparts
cleanerscommerciallyavailable.
Forcleaningpartspriortoassembly,commerciallyavailable
aerosolcansofpartscleanerorbrakecleanerarehandytouse,
andthecleanerwillevaporatecompletely.
WARNING-
Virtuallyallsolventsusedforcleaningpartsare
highlyflammable,especiallyinaerosolform.Use
wíthextremecare.Donotsmoke.Donotusethese
productsnearanysourceofheat,sparksorflame.
Letanysolventorcleaningproductdrycompletely.Low-
pressure,drycompressedairishelpfulifavailable.Also,use
onlylint-freeragsforcleaninganddrying.

FUNDAMENTALSFORTHEDO-ITYOURSELFOWNER

010-5
WARNING-
Avoidgettingtoolsorclothingnearthebattery.Bat-
teryelectrolyteisacorrosiveacid.Becarefulwith
brakefluid,asitcandamagethecarspaintFinally,
keeprubberpartssuchashosesandboltsfree
fromoilorgasoline,astheywillcausethematerial
tosoftenandfailprematurely.
Non-reusableFasteners
Manyfastenersusedonthecarscoveredbythismanual
mustbereplacedwithnewosesoncetheyareremoved.These

Fig.4.Generalsequenceforalternatelytighteningmultiplefasten-
includebutarenotlimitedto:bolts,nuts(self-locking,nylock,

ers.
etc.),cotterpins,studs,brakefittings,rol¡pins,clipsandwash-
ers.GenuineBMWpartsshouldbetheonlyreplacementparts

NOTE-
usedforthispurpose.

"Metricboltclassesorgradesaremarkedonthebolt'
head.
Someboltsaredesignedtostretchduringassemblyandare
permanentlyalteredrenderingthemunreliableonceremoved.
Theseareknownastorque-to-yieldfasteners.Alwaysreplace
fastenerswhereinstructedtodoso.Failuretoreplacethese
fastenerscouldcausevehicledamageandpersonalinjury.
SeeanauthorizedBMWdealerforapplicationsandordering
information.
TighteningFasteners
Whentighteningtheboltsornutsthatattachacomponent,it
isalwaysgoodpracticetotightentheboltsgraduallyandevenly
toavoidmisalignmentoroverstressinganyoneportionofthe
component.Forcomponentssealedwithgaskets,thismethod
helpstoensurethatthegasketwillsealproperlyandcomplete-
ly.
Wheretherearesevera¡fasteners,tightentheminase-
quencealternatingbetweenoppositesidesofthecomponent.
Fig.4showssuchasequencefortighteningsixboltsattaching
atypicalcomponent.Repeatthesequenceuntilal¡theboltsare
evenlytightenedtotheproperspecification.
"Donotconfusewrenchsizewithboltdiametersize.
Foralistingofthecommonwrenchesusedonvari-
ousboltdiameters,seeBasicToolRequirements.
Tablea.GeneralBoltTighteningTorquesinNm
(max.permissible)
BoltClass(accordingtoDIN267)
Bolt
diameter 5.6 5.8 6.8 8.8 10.912.9
M5 2.5 3.5 4.5 6 8 10
M6

4.5

6

7.5

10

14`17
M8

11

15-

18

24

34

40
M10 23 30 36 47 66 79
M12 39 52 62 82 115 140
M14 62 82 98 130 180 220
M16 94 26 150 200 280 340
M18 130 174 210 280 390 470
Forsomerepairsaspecifictighteningsequenceisneces-
sary,oraparticularorderofassemblyisrequired.Suchspecial

GasketsandSeals
conditionsarenotedinthetext,andthenecessarysequenceis
describedorillustrated.Wherenospecifictorqueislisted,Ta-

Thesmoothestmetalmatingsurfacesstillhaveimperfec
bleacanbeusedasageneralguidefortighteningfasteners.

tionsthatcanallowleakage.Topreventleakageatcritica¡
joints,gasketsofsoft,form-fittingmaterialareusedtofillinthe
WARNING-

imperfections.
Tableaisageneralreferenceonly.Thevalueslist-
edinthetablearenotintendedtobeusedasasub-

Tobemosteffective,gasketsaredesignedtocrushandbe-
stitutefortorquesspecificallycalledoutinthetext

comethinnerasthematingpartsareboltedtogether.Oncea
throughoutthismanual.

gaskethasbeenused,itisnolongercapableofmakingas
goodasea¡aswhennew,andismuchmorelikelytoleak.For
thisreason,gasketsshouldnotbereused.Alwaysplantouse
newgasketsforanyreassembly.Somegaskets-suchas
headgaskets-aredirectional.Makesurethatthesearein-
stalledcorrectly.Thissamelogicappliestoanypartusedfor
sealing,includingrubberO-ringsandcoppersealingwashers.
ADVICEFORTHEBEGINNER

010-6

FUNDAMENTALS FORTHEDO-ITYOURSELF OWNER
Inplaceswhereashaftmustpassthroughahousing,flexible
lipsealsareusedtokeepthelubricatingoilorgreasefromleak-
ingoutpasttherotatingshaft.Sealsshouldneverbereused
oncetheyhavebeenremoved.Whenremovingaseal,becare-
fulnotloscratchorotherwisedamagethemetalsurfaces.Even
minordamagetosealingsurfacescancausesea¡damageand
leakage.
Thekeytosea¡installationistogetthesea¡instraightwithout
damaging¡t.Useasea¡driverthatisthesamediameterasthe
sealhousingtogentlyandevenlyinsta¡Iintoplace.Ifaproper
sizesealdriverisnotavailable,asocketoftherightsizewilldo.
Wheninstallingaseal,¡tagoodideatocoatthesea¡witho¡I
toaidinstallation.Somesealsaredirectionalandspecialinstal-
lationinstructionsapply.Makesure¡tisinstalledwiththelipfac-
ingthecorrectway.Normallythelipfacestheinside.Notethe
installationdirectionoftheoldsea¡beforeremoving¡t.
ElectricalTesting
Manyelectricalproblemscanbeunderstoodandsolvedwith
onlyalittlefundamentalknowledgeofhowelectricalcircuits

Insulatethefinishedconnection.Electronicsstorescansup-
function.

plyheat-shrinkableinsulatingtubingthatcanbeplacedonto
thewirebeforeconnectiog,slidoverthefinishedjoint,and
Electriccurrentonlyflowsinacompletecircuit.Tooperate,

shrunktoatightfitwithaheatgunorhairdryer.Thenextbest
everyelectricaldeviceinthecarrequiresacompletecircuitin-

alternativeiselectricaltape.Makesurethewireiscleanand
cludingavoltagesourceandapathtoground.Thepositive(+)

freeofsolderfluxorothercontamination.Wrapthejointtightly
sideofthebatteryistheoriginalvoltagesource,andgroundis
tosea¡outmoisture.See600Electrical-Generalformorein-
anyretumpathtothenegative
()
-sideofthebattery°whetherli

formation.
throughthewiringharnessorthecarbody.Exceptforportions
ofthechargingsystem,al¡electricalcurrentinthecarisdirect
current(DC)andflowsfrompositive(+)tonegative(-).

BVYINGPART$
Switchesareusedtoturncomponentsonoroffbycomplet-
ingorinterrupting#hecircuit.Aswitchis"open"whenthecircuit

Manyofthemaíntenanceandrepairtasksinthismanualcal¡
isínterrupted,and"closed"whenthecircuitiscompleted.Fig.5

fortheinstallationofnewparte,ortheuseofnewgasketsand
showsabasiccircuitschematic.See600ElectricalSystem-

othermaterialswhenreinstallingparts.Mostoften,theparts
Generalforelectricaltroubleshooting.

thatwillbeneededshouldbeonhandbeforebeginningthejob.
Readtheintroductorytextandthecompleteproceduretode-
terminewhichpartswillbeneeded.
B029ELG
Fig.5.

Schematicrepresentationofsimplecircuitforlightbulb.Igni-
tionswitchisshownclosed,makingcircuitcomplete.
BVYINGPARTS
WireRepairs
Repairstoawiringharnessrequirespecialcaretomakethe
repairpermanent.Thewireendsmustbeclean.lffrayedoroth-
erwisedamaged,cutofftheend.Ifthewireistooshort,splicein
anewpieceofwireofthesamesizeandmaketwoconnec-
tions.
Useconnectorsthataredesignedforthepurpose.Crimped-
onorsoldered-onconnectorsarebest.Crimpconnectorsand
specialcrimpingpliersarewidelyavailable.Ifsoldering,use
needlenoseplierstoholdthewirenearthesolderjointandcre-
atea"heatdam".Thiskeepstheheatandthesolderfromtrav-
elingupthewire.Alwaysuseasoldermadespecificallyfor
electricalwork(rosincore).
NOTE-
Twistingwirestogethertomakearepairisnotrecom-
mended.Corrosionandvibrationwilleventuallyspoil
theconnectionandmayleadtoirreparabledamageto
sensitiveelectroniccomponente.
NOTE-
Forsomebiggerjobs,partialdisassemblyandinspec-
tionarerequiredtodetermineacompletepartslist.
Readtheprocedurecarefullyand,ifnecessary,make
otherarrangementstogetthenecessarypartswhile
yourcarisdisassembled.
GenuineBMWParts
GenuineBMWreplacementpartsfromanauthorizedBMW
dealeraredesignedandmanufacturedlothesamehighstan-
dardsastheoriginalparts.Theywillbethecorrectmaterial,
manufacturedtothesamespecifications,andguaranteedlofit
andworkasintendedbytheengineerswhodesignedthecar.
SomegenuineBMWpartshavealimitedwarranty.

Non-returnableParts
FUNDAMENTALSFORTHEDO-ITYOURSELFOWNER 010-7
Manyindependentrepairshopsmakeapointofusinggenu-

Originalbodypaneisandotherlargecomponentsareidenti-
ineBMWparts,eventhoughtheymayattimesbemoreexpen-

fiedbyalabelbearingtheVINandtwoBMWroundellogos.Re-
sive.Theyknowthevalueofdoingthejobrightwiththeright

placementpartshaveasimilarlabel,bearingoneBMWroundel
parts.Partsfromothersourcescanbeasgood,particularlyif

logoandthelettersDOT-R.SeeFig.6.Partsorassemblies
manufacturedbyoneofBMWsoriginalequipmentsuppliers,

bearingthelabelaretheengine,transmission,frontandrear
butitisoftendifficulttoknow.

bumpers,frontfenders,rearquarterpaneis,hood,trunklidand
doors.Theselabelsshouldnotberemovedastheywilltear
BMWisconstantlyupdatingandimprovingtheircars,often

apart.
makingimprovementsduringagivenmodelyear.BMWmay
recommendanewer,improvedpartasareplacement,and
yourauthorizeddealer'spartsdepartmentwillknowaboutit
andprovideit.TheBMWpartsorganizationisbestequippedto
dealwithanyBMWpartsneeds.
Somepartscannotbereturnedforcredit,eveniftheyarethe
wrongpartsforthecar.Thebestexampleiselectricalparts,
whicharealmostuniversallyconsiderednon-returnablebe-

,..
causetheyaresoeasilydamagedinternally.
Buyelectrícalpartscarefully,andbeassureaspossiblethat P-DOT~R
areplacementisneeded,especiallyforexpensivepartssuch
aselectroniccontrolunits.Itmaybewisetoletanauthorized

B328FUN
BMWdealerorotherqualifiedshopconfirmyourdiagnosisbe-
forereplacinganexpensivepartthatcannotberetuned.

Fig.6.

Labelsusedtoidentiyparts.Originalequipmentlabelwith
VINnumberandroundellogos(top)andreplacementpartla-
belwithoneroundellogos
InformationYouNeedtoKnow
Engine.3-Seriescarscoveredinthismanualarepowered
Model.Whenorderingpartsitisimportantthatyouknowthe

byeithera4-or6-cylinderengine.Forinformation-onengine
correctmodeldesignationforyourcar.Modelscoveredinthis

codesandengineapplications,see100Engine-General.
manualareE363Seriesinboth4-and6-cylinderconfigura-
tions.

Transmission.Thetransmissiontypewithitsidentifying
codemaybeimportantwhenbuyingclutchparts,seals,gas
Moda¡Year.Thisisnotnecessarilythesameasdateof

kets,andothertransmission-relatedparts.Forinformationon
manufactureordateofsale.A1997modelmayhavebeen

transmissioncodesandapplications,see200Transmission
manufacturedinlate1996,andperhapsnotsolduntilearly

General.
1997.Itisstilla1997model.Modelyearscoveredbythisman-
ualare1992to1998.
SERVICE
DateofManufacture.Thisinformationishelpfulwhenor-
deringreplacementpartsordeterminingifanyofthewarranty

BMWdealersareuniquelyqualifiedtoprovideservicefor
recallsareapplicabletoyourcar.Thelabelonthedriver'sdoor

BMWcars.TheirauthorizedrelationshipwiththelargeBMW
belowthedoorlatchwillspecifythemonthandyearthatthecar

serviceorganizationmeansthattheyareconstantlyreceiving
wasbuilt.

newtoolsandequipment,togetherwiththelatestandmostac-
curaterepairinformation.
VehicleIdentificationNumber(VIN).Thisisacombination
oflettersandnumbersthatidentifytheparticularcar.TheVIN
appearsonthestateregistrationdocument,andonthecarit-
self.Onelocationisintherearoftheenginecompartment,en-
otherinthelowerleftcomerofthewindshield.
TheNationalHighwayTrafficSafetyAdministration(NHT-
SA)requirespassengercarswithahightheftratetohavethe
VINmarkedonspecificpartsofthecarwhenmanufactured.On
BMWcars,thesepartsareidentifiedbyanadhesivelabel.
)WBADK00000000
00000
TheBMWdealersservicetechniciansarehighlytrainedand
verycapable.Unfkemostindependentrepairshops,autho-
rizedBMWdealersareintenselycommittedtosupportingthe
BMWproduct.TheysharetheownersinterestinBMWvalue,
performance,andreliability.Ontheotherhand,therearemany
independentshopsthatspecializeinBMWserviceandareca-
pableofdoinghighqualityrepairwork.Checkingwithother
BMWownersforrecommendationsonservicefacilitiesisa
goodwaytoleamofreputableBMWshopsinyourarea.
SERVICE

010-8

FUNDAMENTALSFORTHEDO-ITYOURSELFOWNER
TOOLS
Mostmaintenancecanbeaccomplishedwithasmallselec-
tionoftherighttools.Toolsrangeinqualityfrominexpensive
junk,whichmaybrakkatfirstuse,toveryexpensiveandwell-
madetoolsfortheprofessional.Thebesttoolsformostdo-it
yourselfBMWownersHesomewhereinbetween.

O
Manyreputabletoolmanufacturersoffergoodquality,mod-
eratelypricedtoolswithalifetimeguarantee.Theseareyour
bestbuy.Theycostalittlemore,buttheyaregoodqualitytools
thatwilldowhatisexpectedofthem.Sears'Craftsman®lineis
onesuchsourceofgoodqualitytools.
Someoftherepairscoveredinthismanualrequiretheuseof
specialtools,suchasacustompullerorspecializedelectrical
testequipment.Thesespecialtoolsarecalledoutinthetext
andcanbepurchasedthroughanauthorizedBMWdealer.As
analternative,somespecialtoolsmentionedmaybepur-
chasedfromthefollowingtoolmanufacturersandlordistribu-
tors:
"AssenmacherSpecialtyTools
6440OdellPlace,Boulder,CO80301
(303)530-2424
"BaumToolsUnlimited.Inc.
PO.Box87,LongboatKey,FL34228
(800)848-6657
"SchleyProductsInc.
5350E.HunterAve.,AnaheimHills,CA92807
(714)693-7666
"ZelendaMachineandToolCorp.
66-02AustinStreet,ForestHills,NY11375
(718)896-2288
BasicToolRequirements
Thebasichandtoolsdescribedbelowcanbeusedtoaccom-
plishmostofthesimplemaintenanceandrepairtasks.
Fig.8.

Typesofwrenchheads.Fromleft,open-end,12-pointbox-
Screwdrivers.Thecommonfíat-bladetypeandthePhillips

end,6-pointbox-end,fiarenut.
typewillhandlealmostallscrewsusedonBMWs.Twoorthree
differentsizesofeachtypewillberequired,sinceascrewdriver

Thecómbinationwrenchisthemostuniversal.Ithasone
ofthewrongsizewilldamagethescrewhead.SeeFig.7.

open-endandonebox-end.10mmand13mmwrenchesare
themostcommonsizesneeded.Amorecompletesetof
AcompletesetofscrewdriversshouldalsoincludeTorx@

wrencheswouldinciude6mmthrough19mmsizes.
typescrewdrivers.
Wrenches.Wrenchescomeindifferentstylesfordifferent
uses.Fig.8showsseveral.Thebasicopen-endwrenchisthe
mostwidelyused,butgripsononlytwosides.Itcanspread
apartandslipoffmoreeasily.Thebox-endwrenchhasbetter
grip,onal¡sixsidesofanutorbolt.
A12-pointbox-endcanloosenanutorboltwherethereis
lessroomformovement,whilea6-pointbox-endprovidesbet-
tergrip.Forhexfastenersonfluidlines,likebrakelinesandfuel
lines,afiare-nutwrenchofferstheacivantagesofabox-end
wrenchwithaslotthatailowsittofitovertheline.
TOOLS
B005FNG
Fig.7.

Commonflat-blade(top)andPhillips(bottom)screwdrivers.
Offsetscrewdríver(right)isusedforscrewswithlimitedac-
cess.
B002FNG
Sockets.Socketsperformthesamejobasbox-endwrench-
es,butoffergreaterflexibility.Theyareusedwitharatchethan-
dleforspeedandconvenienteandcanbecombinedwith
extensionsanduniversaljoints(swivels)toreachfasteners
moreeasily.Socketscomewithdifferentsizeconnectionsto
drivehandiesorextensions,calledthedrivesize.Themost
commondrivesizesare1/4in.,318in.,and1/2in.
Socketscomein6-pointand12-pointstyles.Forusewitha
ratchet,the6-pointoffersabettergripontightnutsandbolts.
6mmto19mmsocketsarethemostneededsizes.Belowisa
listoftypicalboltdiametersandthecorrespondingwrenchsiz-
es.

SoltDiameterandWrenchSize
"M5..................................8mm
"M6.................................10mm
"M8.........................12mmor13mm
"M10................................17mm
"M12................................19mm
"M14...:............................22mm
SparkPlugSocket.Aspecialsocketforsparkplugsisthe
correctsize,isdeepenoughtoaccommodateasparkplug's
length,andincludesarubberinserttobothprotectthespark
plugfromdamageandgripitforeasierremoval.SeeFig.9.
Fig.9.

Sparkplugsocket.
FUNDAMENTALSFORTHEDO-ITYOURSELFOWNER 010-9
B003FNG
Pliers.AfewofthemanytypesofpliersareshowninFig.10.
Mostareusedforholdingirregularobjects,bending,orcrimp-
ing.Somehavespecialapplications.
Aneedlenoseplierisusedforgrippingsmallandpoorlyac-
cessibleobjects,andisusefulforwiringandotherelectrical
work.AlockingpliersuchastheVise-Grip®isusefulbecause
ofitstightgrip.
Snap-ringandcirclipplierswithspecialtippedjacasareused
loremoveandinstallsnap-ringsorcirclips.AChannel-lock®or
waterpumpplierhasadjustablejacasthatcanbequickly
changedtomatchthesizeoftheobjectbeingheldtogivegreat-
erleverage.
Anadjustablewrenchcanbeausefuladditiontoasmalltool
kit.SeeFig.11.Itcansubstituteinapinch,iftwowrenchesof
thesamesizeareneededloremoveanutandbolt.Useextra
carewithadjustablewrenches,astheytendtoloosen,slip,and
damagefasteners.
Fig.11.Adjustablewrench.
B008FNG
Comparedtoawrenchofthecorrectsize,anadjustable
wrenchisalwayssecondbest.Theyshouldonlybeusedwhen
thecorrectsizewrenchisnotavailable.Chooseoneofaverage
sizerange,about6to8inchesinlength.
JackStands
Strongjackstandsareextremelyimportantforanyworkthat
isdoneunderthecar.Useonlyjackstandsthataredesigned
forthepurpose.Blocksofwood,concrete,bricks,etc.arenot
safeorsuitablesubstitutes.
WARNING-
Ajackshouldbeusedonlytoraisethevehicleand
shouldnotbeusedtosupportthecarforalongpe-
riod.Alwaysusejackstandstosupportaraisedve-
hicle.
Jackstandsareavailable1nsevera¡styles.Atypicaljack
standisshowninFig.12.Thebestonesaremadeofheavyma-
terialforstrength,haveawidebaseforstability,andare
equippedlopositivelylockintheirraisedpositions.Getthebest
onesavailable.
OilChange Equipment
Changingengineoilrequiresa17mmsocketorwrenchto
BOO6FNG-

loosenandtightenthedrainplugandadrainpan(atleast8qt.
capacity).Anoilfilterwrenchisnotrequired.Theseitemsare
Fig.10.Pliers.Fromleft,snap-ring,

needlenose,adjustable-joint

showninFig.13.Awide,locadrainpanwíllfitmoreeasilyunder
(Channellock©),slip-joint,andlocking(Vise-Grip®).

thecar.Useafunnellopourthenewoilintotheengine.
TOOLS

010-10

FUNDAMENTALS FORTHEDO-ITYOURSELFOWNER
TOOLS
TorqueWrench
B021FNG
Fig.12.Jackstandforsafelysupportingcartoworkunderneath.
B022FNG
Fig.13.Oilchangeequipmentincludesdrainplugwrench(17mm),
8qt.drainpan,andfunnel.
Atorquewrenchisusedtopreciselytightenthreadedfasten-

Fig.15.Feelergaugeset.
erstoapredeterminedvalue.Manyoftherepairproceduresin
thismanualincludeBMW-specifiedtorquevaluesinNewton-
meters(Nm)andtheequivalentvaluesinfoot-pounds(ft-Ib).

DigitalMultimeter
Atorquewrenchwitharangeuptoabout150Nm(185ft-lb)
hasadequatecapacityformostoftherepairscoveredinthis
manual.Forrecommendedtorquevaluesof10Nmorbelow,
theEnglishsystemequivalentisgivenininch-pounds(in-lb).
Thesesmallvaluesmaybemosteasilyreachedusingatorque
wrenchcalibratedininch-pounds.Toconvertinch-poundsto
foot-pounds,divideby12.
Fig.14.Torquewrenches.Inexpensivebeam-type(top)isadequate
butmustbereadvisually.Ratchet-type(bottom)canbepre-
settoíndicate(click)whentorquevaluehasbeenreached.
FeelerGauges
B018FNG
Feelergaugesarethinmetalstripsofprecisethickness,
usedtomeasuresmallclearances.Theyarenormallyavailable
asaset,coveringarangeofsizes.SeeFig.15.
Severaltypesoftorquewrenchesareavailable.Theyal¡do

ManyoftheelectricaltestsinChismanualcal¡forthemea-
thesamejob,bu¡ófferdifferentconveniencefeaturesatdiffer-

surementofresistance(ohms)orvoltagevalues.Forsafeand
entprices.TwotypicaltorquewrenchesareshowninFig.14.

accuratetestsofignition,fuelinjection,andemissioncontrol
Themostconvenientoneshaveabuilt-inratchet,andcanbe

systems,themulti-meter,showninFig.16,shouldbedigital,
presettoindicatewhenaspecifictorquevaluehasbeen

withhigh(atleast10,000ohms)inputimpedance.Some
reached.Followthewrenchmanufacturer'sdirectionsforuse

metershaveautomotivefunctionssuchasdweilandpulse
toachievethegreatestaccuracy.

widththatareusefulfortroubleshootingignitionandfuelinjec-
tionproblems.
CAUTION-
TheDMEsystem,centralbodyelectronics,and
otherelectronicsystemsmaybedamagedbythe
highcurrentdrawofatestfightwithanormalin-
candescentbulb.Asageneralrule,useahighím-
pedancedigitalmultimeteroranLEDtestfightfor
allelectrfcaltestfng.
B020FNG

Fig.16.MultimeterorDigitalVolt/Ohmmeter(DVOM).
BMWSpecialTools
FUNDAMENTALS FORTHEDO-ITYOURSELF OWNER 010-11
0012223
Someofthemorechallengingrepairscoveredinthismanual
cal¡fortheuseofBMWspecialtools.This,however,doesnot
automaticallymeanthatthejobistoocomplicatedoroutof
reachofthenovice.
ManyoftheBMWspecialtoolsmentionedinthismanualare
simplythebestthingtousetodothejobcorrectly.Inthesecas-
es,thetoolisidentifiedwithaBMWpartnumber.Seeyourau-
thorizedBMWdealerpartsdepartmentforinformationonhow
toorderspecialtools.
Therearesomejobsforwhichexpensivespecialtoolsare
essential,andnotacost-effectivepurchaseforone-timerepair
bythedo-it-yourselfowner.Thismanualincludessuchrepairs
forthebenefitofthesewiththenecessaryexperienceandac-
cesstotools.Forthedo-it-yourselfer,theneedforspecialtools
isnotedinthetext,andwhetherornotBMWdealerserviceis
recommended.
EMERGENCIES
ChangingaTire
Stopthecaronasflatasurfaceaspossible,inaplacewhere
youcanbeeasilyseenbyotherdrivers.Avoidstoppingjust
overthecrestofahill.Turnontheemergencyflashers,andset
out(laresoremergencymarkerswellbehindthecar.Chockthe
wheel(wheelchocklocatedintrunk)diagonallyoppositetothe
onebeingchanged.Passengersshouldgetoutofthecarand
standwellawayfromtheroad.Removethesparetirefromthe
sparetirestoragetray,asdescribedlater.
WARNING-
Ifatiregoesfíatwhiledrtving,pullwellofftheroad.
Changingatireonabusystreetorhighwayisvery
dangerous.Ifnecessary,driveashortdistanceon
thefíattiretogettoasaleplace.ttismuchbetterto
ruinatireorrimthantoriskbeinghit.
Takethejackandtoolsfromthetoolareabeneaththetrunk
mat.Removethesparetirefromthetirestoragetray.
Loosenthewheelboltswhilethecarisontheground,but
leavethemalittlesnug.Placethejackintheliftingpointnearest
thewheelbeingchanged,liftingpointsareshowninFig.1and
Fig.2).Useaboardtoprovideafirmfootingforthejackifthe
groundissoft.Raisethecaronlylarenoughsothatthewheelis
fullyoffthegroundandthenremovethewheelnutsandthe
wheel.
Insta¡¡thesparewheel.Installthewheelnutsandtighten
thembyhand,thenlowerthecar.Withallwheelsonthe
ground,fullytightenthenutsinacrisscrosspattern.Torquethe
wheelnutswheninstallingthewheel.Checktheinflationpres-
sureofthesparetire.
Tighteningtorques
"Wheeltowheelhub.....100t10Nm(74t7ft-Ib)
CarWillNotStart
Iftheenginetucosoverslowlyornotatall,especiallyoncold
mornings,thebatterymaynotbesufficientlycharged.Jump-
startingthebatteryfromanothercarmayhelp.
WARNING-
Oncarswithmanualtransmisston,pushstarting(or
towstarting)acartsnotrecommendedbyBMW.
NOTE-
BesuretoreadthecautionsunderJumpStartingCar
priorboostingalowbattery.Fatluretofollowthecau-
tionsmayresultindamagetotheelectroniccompo-
nentsinthecar.
Iftheengineisturningoveratnormalspeedwiththestarter
motor,thebatteryandstarterarefine.Checktomakesurethat
thereisfuelinthetank.Donotrelyonthefuelgauge,itmaybe
faulty.Instead,removethegasfillercapandrockthecar.If
thereisgasinthetank,youshouldhearasloshingsoundatthe
fillerneck.lfthereisplentyoffuelinthetank,see100Engine-
Generalforin-depthdiagnosticsandtroubleshootingproce-
dures.
EMERGENCIES

010-12

FUNDAMENTALSFORTHEDO-ITYOURSELFOWNER
JumpStartingCar
Carswithdischargedordeadbatteriescanbejump-started
usingthegoodbatteryfromanothercar.Whenjump-starting
theengine,alwaysnotethefollowingwarnings.
WARNING-
"Batteryacid(electrolyte)cancausesevere
burns,andwilldamagethecarandclothing.lf
electrolyteisspilled,washthesurfacewithlarge
quantitiesofwater.lfitgetsfintoeyes,flushthem
withwaterforsevera¡minutesandcal¡adoctor.
"Batteriesproduceexplosiveandnoxiousgas-
ses.Keepsparksandflamesaway.Donot
smokenearbatteries.
"Donotjump-starttheengineifyoususpectthat
thebatteryisfrozen.Trappedgasmayexplode.
Allowthebatterytothawfirst.
"Donotquick-chargethebattery(forbooststart-
ing)forlongerthanoneminute,anddonotex-
ceed15voltsatthebatterywiththeboosting
cablesattached.Waitatleastoneminutebefore
boostingthebatteryasecondtime.
"Someelectricalsystem'comfort"featuresmaynot
functioncorrectlyoncebatterypowerisrestored.
Forexample,thefrontwindowone-touch-upfunc-
tionmaybedisabled.Someelectricalsystemswill
needtobereinitializedConsulttheappropriatere-
pairgroupformorespecificinformation.
1.Placecarsclosetogether,butdonotallowthemto
'toucheachother.Turnofftheengineofthecarwiththe
goodbattery.
2.Connectoneendofthepositive(+)cabletothepositive
(+)postofthegoodbattery.Removethecoverfromthe
positive(B+)junctionpostintheenginecompartment
ofthedeadcarandconnecttheotherendoftheposi-
tive(+)cabletothejunctionpost.SeeFig.17.
EMERGENCIES
3.Connectoneendofthenegative(-)cabletothenega-
tive(-)batterypostofthegoodbattery.Connectoppo-
siteendofthenegativecable(-)totheengineblockof
thecarwiththedeadbattery.
4.Startthecarwiththegoodbatteryandruntheengine
atabout2,000rpm,thenstartthecarwiththedeadbat-
tery.
5.Withtheengineat¡dle,switchontheheadlights,blower
motorandrearwindowdefoggertoavoiddamagingthe
carselectricalsystem.Carefullydisconnectthejumper
cables,startingwiththenegativecableontheengine
block.Turnallelectricalconsumersoff.
NOTE-
Theengineshouldberunforatleastanhourtore-
chargethebattery.
Overheating
lfthetemperaturegaugeneedlegoesintotheredbandon
thegaugeface,thecoolanttemperatureistoohigh.Findasafe
placetostopandturntheengineoff.Openthehoodandallow
theenginetocooluntilthetemperaturegaugeneedleisatthe
lowerthirdofthescale.Continuingtodriveanoverheatedcar
cancauseextensiveenginedamage.
WARNING-
Donotremovethecoolantreservoirorradíatorcap
withtheenginehot.Undoingeithercouldsprayhot
coolantandcauseburnsordamagetheengine.
CAUTION-
Donotaddcoldwaterorcoolanttoahotengine.
Enginedamagecouldresultfromthesuddentem-
peraturechange.
NOTE-
Iftheenginecannotbesafelytumedoff,makesurethe
aircondifionerisoffandturntheheatertohigh.This
willhelocooltheengineuntilasalestoppingplacecan
bereached.
Overheatingmaybecausedbylowcoolantleve¡oradam-
agedenginedrivebelt.Visuallycheckthecoolantleve¡anden-
ginebeltsasdescribedin020MaintenanceProgram.lfthe
coolantleve¡islow,checkthefillercap,hoses,clampsandra-
diatorforsignsofleakage.Checkforleaksatthewaterpump
onthefrontoftheengine.
lfnoleaksarefound,addcoolantaftertheenginehas
cooled.Thecarcanbedriven,buthavethecoolingsystem
thoroughlycheckedassoonaspossible.lfreplacementcool
0013245

-

antisnotavailable,thenplainwatercanbeused,butthecool-
antshouldlaterbedrainedandrefilledwiththepropermixture
Fig.17.Batteryjumpstartingposts(arrows)behindrightfrontstrut

ofanti-freezeandwater.
tower.Liftcovertoaccesspositivepost.

Ifsteamiscomingfromtheenginecompartmentthenthereis

Withtheengineandignitionoff,checkforlooseorcorroded
mostlikelyaburstcoolanthoseoralargeleakinthecooling

batterycablesorwiresatthebatteryorthealtemator.Discon-
system.Tofindtheleak,lookforsignsofcoolantleakageon

necting,cleaning,andreinstallingcorrodedwiresandconnec-
hoses,athoseconnections,orontheradiator.Lettheengine

torsmaysolvetheproblem.Alsocheckdrivebelttensionas
coolthoroughly,thenaddcoolantorwatertofillthesystemand

describedin020MaintenanceProgram.
starttheengine.Ifagreatdealofwaterorcoolantflowsoutof
thehole,thenthecarshouldnotbedrivenuntilrepairsare
made.lfthereisslightseepage,thenitmaybepossibletodrive

TOWing
ashortdistance,addingcoolantasneeded.
Thecarscoveredbythismanualshouldbetowedwithatow
truckusingwheelliftorflatbedequipment.Donottowthecar
onallfourwheelsexceptforveryshortdistancestomoveittoa
safeplace.
Iftheredengineoilpressurewarninglightilluminates,imme-
diatelystopthecarandturnofftheengine.Havethevehicle

Atowingeyeisprovidedintheluggagecompartmenttoolkit.
flat-beddedortowedtoanauthorizedservicecenterandhave

Thetowingeyecanbescrewedintothefrontorrearbumper.
theengineoilpressurechecked.

SeeFig.18andFig.19.
LowOilPressure
NOTE-
Detafedinformationoncheckingtheoilpressureis
coveredín119LubricationSystem.
BrakeFluidLeve¡
Thebrakefluidleve¡warninglightmaybeanindicatorof
brakefluidloss.Problemswiththebrakesystemshouldbe
checkedandrepairedimmediately.See340Brakesformore
information.
CheckEngineWarningLight
DimLights
FUNDAMENTALSFORTHEDO-ITYOURSELFOWNER

010-13
Ifthe"CHECKENGINE"warninglightcomesonorflashes,it
indicatesthatanemissions-relatedfaulthasoccurred.Faults
suchasafailedoxygensensororafaultyfuelinjectorcantum
thelighton,causingtheexhaustorevaporativeemissionsto
exceedaspecifiedlimit.Theenginecanbesafelydrivenwith
thelighton,althoughtheemissionsystemsshouldbechecked
assoonaspossible.See100Engine-Generalformoreinfor-
mationontheCheckEngineLightandtheOn-boarddiagnostic
system.
Headlightsandinstrumentpanelilluminationthataredimor
graduallygettingdimmergenerallyindicateaproblemwiththe
batteryorchargingsystem.Thebatterychargeindicatorlight
maycomeonasthelightsaredimming.Ineithercase,theen-
gineandaccessoriesarerunningoffofthebatteryalone,and
willsoondischargeitaltogether.
Ifpossible,donotstoptheengineunlessyouhavethecapa-
bilitytojumpstart¡t.Theremaynotbeenoughpowerinthe
startingsystemtorestarttheengine.Instead,turnoffasmany
electricalconsumersaspossible.Thiswillreducethecurrent
drainandwillallowthecartobedrivenfartherbeforeyoulose
allbatterypower.
Fig.18.Pryopenreartowlúgaccesspanel.
Whentowingthecarfromthefrontwiththerearwheelson
theground,amaximumdistanceof20milesisacceptable.If
thecarneedstobetowedfurther,havetherearwheelsplaced
ondollies.
CAUTION-
"Donottowwithsling-typeequipmentThefront
spoilersandbumpercoversmaysustaindam-
age.
"TowíngaBMWwithanautomatictransmission
withtherearwheelsonthegroundcanresuftin
transmissiondamageduetolackoflubrication
andshouldbeavoided.
0013128
EMERGENCIES

010-14

FUNDAMENTALSFORTHEDO-ITYOURSELFOWNER
Fig.19.Instafreartowlugintothreadedhole.
ifabsolutelynecessary,carswithautomatictransmissions
canbetowedwiththerearwheelsontheground,butthetow
shouldnotexceed25miles(40km),atspeedsatorbelow30
mph(35km/h).Besurethetransmissionfluidhasbeentopped
offbeforestartingthetow.Alwaystowthecarwiththetransmis-
sionleverin"N"(neutral).Ifthetowmustexceed25miles(40
km),addonequartofATFtothetransmission,orbetteryet,re-
movethedriveshaft.Besuretodrainorpumpouttheaddedflu-
idoncethetowhasbeencompleted.
NOTE-
"ATFdrainingandfillingiscoveredin240Automatic
Transmission.
"Driveshaftremovaliscoveredin260Driveshaft.
EMERGENCIES
úo1W¿b
SparePartsKit
Carryingabasicsetofsparepartscanpreventaminor
breakdownfromturningintoamajorannoyance.Manyofthe
followingitemswon'tallowyoutodomajorrepairworkonthe
car,buttheywillhelpintheeventofthefailureofsomethingthat
candisablethecarorcompromiseitssafety.
SparePartsKit-BasicContents
"Drivebelt(V-beltorpoly-ribbed)
"Engineoil(oneortwoquarts)
"Enginecoolant(1gallonofpremixed50/50anti-freeze
andwater)
"Fuseassortment(7.5A,10A,15A,20A)
"Radiatorhoses(upperandlower)
SparePartsKit-AdditionalContents
"Exteriorlightingbulbs(headlight,brakelight,turnsignal,
andtaillight)
"Wiperbiades
"Brakefluid(newunopenedbottle,DOT4specification)
"MainrelayforDMEsystem

020MaintenanceProgram
GENERAL............................020-2
BMWServiceIndicator....................020-2
OilService..............................020-2
InspectionIandInspectionII...............020-2
ResettingServiceIndicator.................020-3
MAINTENANCE TABLES...............020-3
FLUIDANDLUBRICANT
SPECIFICATIONS.....................020-8
ManualTransmissionFluid...............020-8
AutomaticTransmissionFluid.............020-8
FinalDriveGearOil....................020-9
BrakeFluid.........................020-9
EngineCoolant(Anti-freeze)..............020-9
PowerSteeringFluid....................020-9
ENGINEOILSERVICE.................020-9
Engineoil,checkingleve¡..................020-9
Engineoilandfilter,changing..............020-9
ENGINECOMPARTMENT
MAINTENANCE ......................020-10
Airfilter,replacing.......................020-11
Sparkplugs,replacing...................020-11
¡dleSpeed.............................020-12
Battery,checkingandcleaning............020-12
Battery,replacing.......................020-12
AcceleratorandThrottleLinkage...........020-13
EngineDriveBelts......................020-13
V-belt,replacing
(4-cylinderenginesbuiltupto1/94).......020-13
Poly-ribbedbelt,replacing
(4-cylinderenginesbuiltfrom1194
andall6-cylinderengines)..............020-13
CoolingSystemService..................020-14
Powersteeringfluid,checkingleve¡.........020-14
OxygenSensors...............

........020-15
MAINTENANCE PROGRAM

020-1
UNDER-CAR MAINTENANCE ..........020-16'
Fuelfilter,replacing.....................020-16
Tires,checkinginflationpressure...........020-17
Tires,rotating...........................020-17
Wheels,aligning........................'020-17
Brakesystem,inspecting.................020-17
Brakepad/rotorwear,checking............020-17
Brakefluid,replacing............

....

.020-17
Parkingbrake,checking..................020-17
Exhaustsystem,inspecting................020-18
ManualTransmissionSenrice..............020-18
Manualtransmissionfluida
checkingandfilling.........

..........020-18
AutomaticTransmissionService............020-18
Frontsuspensionandsteeringlinkages,
inspecting...:........................020-18
Rearsuspension,inspecting...............020-18
Finaldriveoilleve¡,checking...............020-18
Fueltankandfuellines,inspecting..........020-19
Clutchfluid,checking.....................020-19
Driveaxlejointboots,inspecting............020-19
BODYANDINTERIOR
MAINTENANCE .......................020-19
WindshieldWiperBladeMaintenance......020-19
Bodyandhinges,lubricating...............020-19
SeatBelts..............................020-20
ExteriorWashing........................020-20
Waxing................................020-20
Polishing...............................'020-20
WashingChassis........................020-20
SpecialCleaning.........

..............020-20
InteriorCare...............

............020-20
LeatherUpholsteryandTrim...............020-20
TABLES
a.OilService............................---020-4
b.Inspection1Service........................020-5
c.Inspection11Service.......................020-6
d.ScheduledMaintenance-Time/MileageIntervals..020-7
e.FluidsandLubricants.......................020-8

020-2

MAINTENANCE PROGRAM
GENERAL
Theinformationgiveninthisrepairgroupincludestheroutine
checksandmaintenancestepsthatarebothrequiredbyBMW
underthetermsofthevehiclewarrantyprotectionandrecom-
mendedbyBMWtoensurelongandreliablevehicleoperation.
GENERAL
NOTE-
Asidefromkeepingyourcarinthebestpossiblecondi-
tion,propermaintenanceplaysaroleinmaintainingfull
protectionunderBMWsnew-carwarrantycoverage.If
indoubtaboutthetermsandconditionsofyourcark
warranty,anauthorizedBMWdealershouldbeableto
explainthem.
NOTE-
BMWisconstantlyupdatingtheirrecommendedmain-
tenanceproceduresandrequirements.Theinforma-
tioncontainedhereisasaccurateaspossibleatthe
timeofpublication.Ifhhereisanydoubtaboutwhatpro-
ceduresapplytoaspecificmodelormodelyear,or
whatintervalsshouldbefollowed,rememberthatan
authorizedBMWdealerhasthelatestinformationon
factory-recommendedmaintenance.
BMWServiceIndicator
TheBMWServiceIndicatornotifiesthedriverwhenmainte-
nanceisrequired.Theserviceindicatorconsístsofmultiple
lightemittingdiodes(lEDs)-typicallyfivegreen,oneyellow,
andonered-aswellasOILSERVICEandINSPECTIONindi-
cators.
Whentheignitionistumedon,thegreenLEDscomeon.
Theygooutwhentheengineisstarted.AftertheServiceIndi-
catorisreset,al¡greenLEDswillbeilluminatedwiththekeyon.
Asthecarisdriveninnormaluse,fewerandfewergreenLEDs
willbeilluminatedbeforestart-up,indicatingthatthenextmain-
tenanceintervalisapproaching.
Whenthecarhasaccumulatedsufficientusetorequirethe
nextmaintenanceinterval,theyellowLEDwillcomeonalong
witheithertheOILSERVICEindicatorortheINSPECTIONin-
dicator.TheseLEDswillstayonaftertheengineisstarted.If
maintenanceserviceisdelayed,theredLEDwillalsoilluminate
asareminderthatmaintenanceserviceisoverdue.
AnOILSERVICEintervalwillalwaysbefollowedbyanIN-
SPECTIONinterval,whichwillthenbefollowedbyanOILSER-
VICEinterval,andsoon.SeeFig.1.
'80
100/
60
II
"
1
,

ló1,4`20 140s

#
X120
100 leo
AO
,

80

km/h
`F

*101
200,
,~60
BMWhastakenauniqueapproachtoestablishingmainte-
nanceintervals.BMW'sServiceIndicatorSystemcomputes
maintenanceintervaisbasednotonlyonelapsedmileage,but

Fig.1.

Serviceindicatordisplayinlowersectionofspeedometer.
alsoonsuchinputsasenginespeed,enginetemperature,
numberofstarts,andlengthoftrips.Attheappropriatetime,the
systemindicates,throughlightsintheinstrumentcluster,when

OilService
thenextroutinemaintenanceisdue.
TheOilServiceindicatorsignalstheneedforthemostbasic
levelofroutinemaintenance.BMW'srequiredoilservicespeci-
fieschangingtheenginelubricatingoilandtheengineoilfilter
aftertheenginehasbeenwarmedup.BMW-recommendedad-
ditionalmaintenanceforthisserviceislistedinTablea.
NOTE-
Forreference,theBMWOilServicerequirementsare
approximatelyequivalenttothemaintenancethat
otherEuropeanmanufacturersspecifyatintervals
withamaximumofevery7,500milesor6months.
CAUTION-
Besuretofollowtheínstructionsforresettingthe
OilServiceindicatorfight.TheInspectionindica-
torcanbeaccidentallyresetrenderingitsfunction
inaccurate.
InspectionlandInspectionII
TheInspectionindicatorsignalstheneedformorecompre-
hensivemaintenanceandInspection.Therearetwosetsofin-
spectionrequirements,InspectionIandInspectionll.These
inspectionsalternatethroughoutacar'smaintenancehistory.If
thelastInspectionintervalwasInspectionI,thenextInspection
interval(followinganOilService)willbeInspectionll,thenext
afterthatwillbeInspectionI,andsoon.
InspectionItasksarelistedinTableb.InspectionIIin-
cludesmostofthetasksfromInspectionIwithadditionalIn-
spection11tasks.AcompletelistingofInspectionIItasksare
listedinTablec.

NOTE-

Aftermarketresettoolscanbepurchasedfromoneofthefol-
liftowngmanuacurers:
Forreferente,theBMWInspection1andInspection11
requirementsareapproximatelyequivalenttothemain-
tenancerequirementsthatotherEuropeanmanufac-

Assenmacher
Bos
turersspecify.InspectionIisnormallydueatintervals

lder,CO80301
SpecialtyTools
withamaximumof15,000milesor12months.lnspec-

(303)530-2424
tion11isnormallydueatintervalswithamaximumof
30,000milesor24months.

PeakeResearch,AutomotiveProductsDivision
P.O.Box28776
SanJose,CA95159
ResettingServiceIndicator

(408)369-0406
Whenthespecifiedmaintenancehasbeencarriedout,the
serviceindicatormemoryshouldbereset.

MAINTENANCE TABLES
Thesenriceindicatorisresetusingaspecialtool.Thetoolis
pluggedintothediagnosticconnectorintheenginecompart-
ment.SeeFig.2.
iii
Fig.2.

Serviceindicatorresettoolinstalledindiagnosticconnector
(aftermarkettoolshown).
CAUTION-
Followthemanufacturer'sdirectionswhenreset-
tingtheserviceIndicator.Iftheresetprocedures
aredoneincorrectly,theresettoolortheelectron-
icserviceindicatormaybedamaged.
MAINTENANCE PROGRAM 020-3
Tablea,b,c,anddonthefollowingpageslisttheroutine
maintenancetasksspecifiedbyBMW.Theintervalsformostof
thesetasksaredeterminedbytheServiceIndicator.Themain-
tenanceintervalsforafewadditionalitemsarebasedoneither
elapsedmileageortime.Theseintervalsareindicatedinsepa-
ratetables.
Exceptwherenoted,themaintenanceitemslistedapplytoall
modelsandmodelyearscoveredbythismanual.Thecolumns
ontherightsitieofeachtablegivequick-referenteinformation
aboutthejob.Theboldtextreferencestherepairgroupswhere
additionalrepairinformationcanbefound.
MAINTENANCE TABLES

020-4

MAINTENANCE PROGRAM
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Maintenanceítem

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Enginecompartmentmaintenance
Changeoilandoilfilter
Checkfluidlevels(coolant,steering,brake/clutch,ATF)
Undercarmaintenance
Checksteeringrackandsteeringlinkagesforleaksandexcessplay.RepairGroup320
Inspectbrakesystem.Checkbrakecalipers,rotors,andbrakepadthíckness.Inspectfordam-
agedhosesandlines,leaksordamage.Checkhandbrake,adjustcableifnecessary.Repair
Group340
Checkandadjusttirepressures,includingspare
Bodyandinteriormaintenance
Checkoperationofexteriorandinteriorlights,includinggloveboxlight,enginecompartment
light,trunklight,instrumentpanellights,horns,headlightflasheranddimmerswitch.Check
headlightanddrivinglightaiming.6ElectricalSystem
Checkfunction/conditionofseatbelts.RepairGroup720
Checkwindshieldwasherfluidlevelandconcentration,addasnecessary.Checkoperationof
washersystem.Checkconditionofwiperblades.RepairGroup611
RoadTest
Checkbrakingperformance,steering,heatingandventilation,manualorautomatictransmis-
sion,andmirrors
ServiceIntervalReset
Resetserviceindicatorusingspecialresettool.
MAINTENANCE TABLES
Tablea.OilService

Tableb.InspectionIService
MAINTENANCE PROGRAM 020-5
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Maintenanceítem

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Enginecompartmentmaintenance
Changeoilandoilfilter.
Checkbrake/clutchfluidleve¡
Checkbatteryacidleve¡andcorrectasnecessary.RepairGroup121
Checkenginecoolantlevelandanti-freezeprotectionandaddasnecessary.
Inspectforcoolingsystemleaks.RepairGroup170
Lubricatethrottielinkage
Undercarmaintenance
Checktransmissionforexterna¡leaks.
Checkmanualtransmissionoilleve¡andaddasnecessary.RepairGroup230
Checkfinaldrivelubricantandaddasnecessary.
Checkfue¡tank,fuellines,andallconnectionsforleaks.
Inspectexhaustsystem.RepairGroup180
Checksteeringrackandsteeringlinkages.Checkpowersteeringsystemforleaks.Check(luid
leve¡.RepairGroup320
Inspectbrakesystemfordamagedhosesandfines,leaksordamage.Removecalipersand
checkbrakepadwear.Checkbrakerotorsforscoringdamage.RepairGroup340
Checkparkingbrakeoperation,adjustcableifnecessaryRepairGroup340
Inspectfrontandrearsuspension,includingwheelbearings,forplay.RepairGroup320/330
Inspectwheelsandtires,includingspare,checktirepressureandcondition
BodyandInteriorMaintenance
Lubricatedoorhingesandhoodlatch,hoodhinges
Checkheadlightanddrivinglightaimingandadjustasnecessary.
Checkoperationofheadlights,parkinglights,back-upfights,licenseplatelights,interiorlights,
gloveboxlight,enginecompartmentlight,trunklight,instrumentpanellights,turnsignals,emer-
gencyflashers,stopfights,horas,headlightflasheranddimmerswitch
Replaceventilation/A/Cmicro-filter.Checkfunctionofairconditioning.RepairGroup640
Checkfunctionofseatbelts.RepairGroup720
Checktightnessofmountfngscrewsonairbagfrontcrashsensors(AirbagI).RepairGroup721
Checkwindshieldwasherfluidleve¡andconcentration,addasnecessaryCheckoperationof
washersystem.Checkconditionofwiperblades.RepairGroup611
Tightennutsandboltsfordoorlocksandstrikerplates
Replacebatteriesforalarm/remotecontrolinmasterkey(whereapplicable).
RoadTest
Checkbrakingperformance,steering,HVAC,manualorautomatictransmission,andmirrors
ServiceIntervalReset
Resetserviceindicatorusingspecialresettool.
MAINTENANCE TALES

020-6

MAINTENANCEPROGRAM
Group310/330
Tablec.InspectionIIService
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Maintenanceítem

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Enginecompartmentmaintenance
InspectV-belt/Poly-ribbeddrivecondition.CheckV-belttension,ifapplicable.
Lubricatethrottlelinkage.
Replaceairfilter.
Changeoilandoilfilter.
Replacesparkplugs.RepairGroup120
Checkbrake/clutchfluidleve¡.
Checkbatteryacidleve¡andcorrectasnecessary.RepairGroup121
Checkenginecoolantleve¡andanti-freezeprotectionandaddasnecessary.
Inspectforcoolingsystemleaks.RepairGroup170
Undercarmaintenance
Changeautomatictransmissionfluid.RepairGroup240
Changemanualtransmissionoil.RepairGroup230
Checkclutchplateforwear.RepairGroup210
Checkdriveaxlebootsforleaks.RepairGroup330
Changefinaldrivefluid(1995andlatermodels:changesyntheticoilevery2ndInspectionII).
Replacefuelfilter.
Checkfueltank,fuellines,andafconnectionsforleaks.
Inspectexhaustsystem.RepairGroup180
Checksteeringgearandsteering¡inkages.Checkpowersteeringsystemforleaks.Checkfluid
leve¡.RepairGroup320
Inspectbrakesystemfordamagedhosesandlines,leaksordamage.Removecalipersand
checkbrakepadwear.Checkbrakerotorsforscoringdamage.RepairGroup340
Checkparkingbrakeoperation,adjustcableifnecessary.Checkthicknessofparkingbrakelin-
ings.RepairGroup340
Inspectfrontandrearsuspension,includingfrontandrearwheelbearings,forplay.Repair
Inspectwheelsandtires,includingspare,checktirepressureandcondition.
BodyandInteriorMaintenance
Lubricatedoorhingesandhoodlatch,hoodhinges.
Checkheadlightanddrivinglightaimingandadjustasnecessary.
Checkoperationofheadlights,parkinglights,back-uplights,licenseplatelights,interiorlights,
gloveboxlight,enginecompartmentlight,trunklight,instrumentpanellights,turnsignals,emer-
gencyflashers,stoplights,horns,headlightflasheranddimmerswitch.
Checkactivecheckcontrolpanelforfauits(whereapplicable).6ElectricalSystem
MAINTENANCE TABLES
Continuedonnextpage

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Maintenanceítem

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BodyandInteriorMaintenance(cont.)
Replaceventilation/A/Cmicro-filter.Checkfunctionofairconditioning.RepairGroup640
Checkfunctionofseatbelts.RepairGroup720
Checkwindshieldwasherfluidlevelandconcentration,addasnecessary.Checkoperationof
washersystem.CheckconditionofwiperbladesRepairGroup611
Tightennutsandbeltsfordoorlocksandstrikerplates.
Replacebatteriesforalarm/remotecontrolinmasterkey(whereapplicable).
Checkgroundconnection(mountingscrews)ofSRS(airbag)frontsensortobody,ifapplicable.
RepairGroup721
RoadTest
Checkbrakingperformance,steering,HVAC,manualorautomatictransmission,andmirrors
ServiceIntervalReset
Resetserviceindicatorusingspecialresettool.
Maintenanceítem
Replaceoxygensensor.RepairGroup180
1992-1994
1995-on
Flushandreplacebrakefluid/clutchfluid.RepairGroup340
Drainandflushcoolingsystemandreplacecoolant.Repair
Group170
1992-1996
1997-1998
Anti-corrosionwarrantyinspection.
Tablec.InspectionIIService(continued)
Cabled.ScheduledMaintenance-Time/MileageIntervais
MAINTENANCE PROGRAM 020-7
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MAÍNTENANCE TABLES

020-8

MAINTENANCE PROGRAM
FLUIDANDLUBRICANTSPECIFICATIONS
ThefluidsandlubricantespecifiedbyBMWarelistedinTa-
blee.Shownbelowisengineoilviscosity(SAEgrade)vs.oper-
atingtemperaturerangefortheBMWenginescoveredinthis
manual.
EngineOilViscosityRequirements
vs.Temperature
`SEAVic
P
Q
SAE
swao
YCO
0
N
M42engine

1.1I(1.2USqt.)
M44engine

1.1l(1.2USqt.)
M50engine

1.11(1.2USqt.)
M52engine

1.21(1.3USqt.)
S50USengine

1.21(1.3USqt.)
S52USengine

1.21(1.3USqt.)
°F
80
-
1o-0-30-----20
WARNING-
TheuseoffluidsthatdonotmeetBMWsspecifica-
tionsmayimpairperformanceandrefability,and
mayvoidwarrantycoverage.
Tablee.FluidsandLubricants
0013227
Fluid Approximate Specification
capacity
Engineoilwithfilterchange
M42engine

5.01(5.3USqt.)
M44engine

5.0I(5.3USqt.)
M50engine

6.5I(6.9USqt.)

APIserviceSHor
M52engine

6.51(6.9USqt.)

si
S50USengine

6.51(6.9USqt.)
S52USengine

6.0I(6.3USqt.)
Manualtransmissionoil
FLUIDANDLUBRICANT SPECIFICATIONS
See230Manual
Transmissionfor

NOTE-
fluidspecification
Tablee.FluidsandLubricants(continued)
Fluid Approximate Specification
capacity
Automatictransmissionfluid(ATF)(drainandfill)
(additionalfluidrequiredwheninstallingadrytorqueconverter)
A4S310R

See240AutomaticTransmissionforfluid
A4S270R

specificationinformation
A5S310Z
Finaldrive(drainandfill)
(Lifetimefluid;nofluidchangerequired)
4-cylinder

1.1I(1.2USqt.)

BMWSAF-XO
6-cylinder

1.7l(1.8USqt.)

synthetic

oil

(ex.
limitedslip)
BMWSAF-X1-S
syntheticoil(limit-
edslip)
Powersteeringfluid
Al¡modeis

permanentlysealed

DexronIIPATF
nodrainplug
rakefluid
Allmodeis

- ~ SAEDot4
Enginecoolant
M42engine

6.51(6.9USqt.)
M44engine

6.51(6.9USqt.)
M50engine

10.51(11.1USqt.)

50%BMWanti-
M52engine

10.51(11.1USqt.)

freezel50%water
S50USengine

10.751(11.4qt.)
S52USengine

10.75I(11.4qt.)
CAUTION-
Multi-viscosityengineoilsshouldnotbeusedin
themanualtransmission.Useofsuchanoilcould
shortentheservicelifeofthetransmission.
ManualTransmissionFluid
ThemanualtransmissionsinstalledintheE36modeisare
normallyfilledwithautomatictransmissionfluid(ATF),although
alternativesyntheticlubricantsmayhavebeenusedfrom-the
factory,dependingontransmissiontypeandmodelyear.Con-
sult230ManualTransmissionforadditionalinformationon
identifyingthetypeoffluidinstalled.
AutomaticTransmissionFluid
TheautomatictransmissionsinstalledintheE36modeis
arenormallyfilledwithDexron111automatictransmissionfluid
(ATF),althoughalternativefluidshavebeeninstalledfromthe
factory,dependingontransmissiontypeandmodelyear.
SometransmissionarefilledwithaspecialBMW"life-time"
automatictransmissionfluid,whíchdoesnotrequireperiodic
fluidchanges.Consult240AutomaticTransmissionforad-
ditionalfluidspecificationinformation.
information

1

The

11-

11lubrican typecanbefoundonti¡e
`Yypeplate"onthesideofthetransmission.Consultan
authorizedBMWdealerforalternatefluiduseandthe
Continued

most-up-to-dateinformationregardingtransmissionop-
eratingfluids.

FinalDriveGearOil
BMWrecommendsusingonlyaspeciallyformulatedsyn-
theticgearoilthatisavailablethroughanauthorizedBMW
dealerpartsdepartment.Foradditionalinformationonthis¡u-
bricantandanyotherlubricantsthatmaybecompatible,con-
tactanauthorizedBMWdealersenricedepartment.See331
FinalDrive.
BrakeFluid
Brakefluidabsorbsmoistureeasily,andmoistureinthefluid
affectsbrakeperformanceandreliability.Thisiswhybrakefluid
shouldbeflushedfromthesystemeverytwoyears.Whenre-
placingoraddingbrakefluid,useonlynew(luidfrompreviously
unopenedcontainers.Donotusebrakefluidthathasbeenbled
fromthesystem,evenifitisbrandnew.UseonlyDOT4brake
fluid.See340Brakesformoreinformation.
EngineCoolant(Anti-freeze)
BMWrecommendscoolantthatisa50/50mixtureofdistilled
waterandphosphate/nítratefreeanti-freezecontainingethyl-
eneglycol.Anti-freezeraisestheboilingpointandlowersthe
freezingpointofthecoolant.Italsocontainsadditivesthathelp
preventcoolingsystemcorrosion.
PowerSteeringFluid
ThepowersteeringfluidisDexronII]®ATF,orequivalent.
Thesystemispermanentlyfilledanddoesnothaveadrain.
RoutinelyaddingATFisnotrequiredunlessthesystemisleak-
ing,
WARNING-
Besuretocheckthefluidspecificationsonthepow-
ersteeringreservoirtoconfirmthefluidtypein-
stalledinthesystem.Insomeinstances,thepower
steeringsystemmaybefilledwithanalternativehy-
draulicfluiddesignatedCHF7.1.
MAINTENANCE PROGRAM 020-
ENGINEOILSERVICE

Engineoilandfiiter,changing
Fig.3.

Engineoilleveldipsticklocationon4-cylinderengine(arrow).
Dipsfckismarkedwithmínimumandmaximumlevelmarks.
Fig.4.

Oilfillercap(arrow).6-cylinderengineshown.
0012202
Engineoii,checkingleve¡

Acompleteoilchangerequiresnewoil(seeTablee),anew
oilfilterinsertkit,andanewdrainplugsealingwasher.The
Theengineoilleve]ischeckedwithadipstickintheengine

toolsneeded,adrainplugsocketorboxwrench(17mmor19
block.Checktheoiileve¡withthecanonalevelsurface,after

mm)andadrainpan(8-10USqt.capacity),aredescribedin
theenginehasbeenstoppedforatleastafewminutes.Check

010FundamentalsfortheDo-It-YourselfOwner.
theleve¡bypullingoutthedipstickandwipingitclean.Reinsert
itallthewayandwithdrawitagain.Theoilleve¡iscorrectifitis

NOTE-
betweenthetwomarksneartheendofthestick.SeeFig.3.

Ifusinga"fast-lube"servicefacilityforoilchanges,
makesurethetechnicianhand-startsandtorquesthe
Addoilthroughthefillercaponthetopofthecylinderhead.

engineoildrainplugusinghand-tools.Powertoolscan
SeeFig.4.Addonlytheamountneededtobringtheoilleve¡to

stripthethreadsoftheplugandtheoilpan.
theMAXmarkonthedipstick,usinganoilofthecorrectviscos-
ityandgrade.Toomuchoilcanbejustasharmfulastoolittle.
ENGINEOILSERVICE

020-10

MAINTENANCE PROGRAM
1.Runengineforafewminutestowarmengineoil.Shut

5.Whenoilflowhasdiminishedtoanoccasionaldrip,re-
engineoff.

installdrainplugwithanewmetalsealingwasherand
torqueplug.
2.Withcaronlevelground,placedrainpanunderoildrain
plug.SeeFig.5.

TighteningTorques
"Engineoildrainplug
M12bolt(17mmwrench)........25Nm(18ft-Ib)

-
M22bolt(19mm.wrench)........60Nm(44ft-Ib)
Fig.5.

Engineoildrainplug(arrow)inoilpan.
3.Removefilterhousingcover.Removefiltercartridge
anddiscardanyO-rings.SeeFig.6.
CAUTION-
Pulíthelooseplugawayfromtheholequicklyto
avoidbeingbumedbyhotoil.Itwíllrunoutquickly
whentheplugísremoved.Ifpossible,usegloves
toprotectyourhands.
ENGINECOMPARTMENT MAINTENANCE
0012460
Fig.6.

Engineoilfiltercartridge.NoteO-ringlocationswhenremoving
coverandfilter.
4.Usingasocketorboxwrench,loosendrainplugatoil
drainpan.Byhand,removeplugandletoildraininto
pan.
6.LubricateandinstallnewO-rings.Installanewfilter
cartridgeandhousingcover.Tightencover.SeeFig.7.
7

«a~.~~ fT~
iII~IIIi~.
Fig.7.

Oilflterhousingon6-cylínderengine.4-cylinderengineis
similar.
TighteningTorque
"Engineoilfiltercovertooil
filterhousing...................25Nm(18ft-Ib)
7.Refillcrankcasewithoil.'Approximateoilcapacityislist-
edinTablee.Usedipsticktocheckcorrectoillevel.
8.Startengineandcheckthatoilpressurewarninglight
immediatelygoesout.
9.Allowenginetorunforafewminutestocírculatenew
oil,thencheckforleaksatdrainplugandoilfilter.Stop
engineandreclieckoillevel.
ENGINECOMPAR

ENTMAINTENANCE
Theinformationunderthisheadingdescribesroutinemainte-
nance-otherthanoilchange-doneintheenginecompart-
ment.Itisnotnecessaryforthecartoberaisedandsupported
offtheground.Informationonoilchangeisgivenearlierunder
EngineOilChange.

Airfilter,replacing

Sparkplugs,replacing
Thespecifiedmaintenanceintervalsfortheairfilterare

Toaccessthesparkplugson4-cylinderengines,removethe
basedonnormaluse.Ifthecarisoperatedprimarilyindusty

coverfromatopthesparkplugs.SeeFig.10.Usingthespecial
conditions,theairfiltershouldbeservicedmorefrequently.

sparkplugwireremovaltool(attachedtorearofcylinderhead
beneathenginecover),gentlypullthesparkplugwirefromthe
Toreplacetheairfilteron6-cylinderengines,unclipandsude

sparkplug.SeeFig.11.Blowawayanydirtfromaroundthe
thefiltercartridgeassemblyoutoftheairboxandremovethe

baseoftheplugtopreventitfromenteringtheengine.Remove
filterfromtheframeassembly.SeeFig.8.

andinstallthesparkplugsoneatatime.
0012625
Fig.8.

Toremoveairfiltercartridgeon6-cylinderengines,releasefil-
tercartridgeatsides(arrows)andthenremovefilterelement
insertfromcartridge.
Toreplacetheairfilterelementon4-cylinderengines,sepa-
ratetheupperairfilterhousingsectionfromthelowersectionby
unfasteningthespringclips.Removetheairfilterelementfrom
theairfilterhousing.SeeFig.9.Wipetheinsideoftheairfilter
housingcleanandinstallthenewelement.Reinstalltheupper
airfilterhousing,makingsurethatthetwohalvesaremated
correctly.Refastenthespring-clips.
Fig.9.

Airfilterelementbeingremovedon4-cylinderengine.
MAINTENANCE PROGRAM

020-11
NOTE-
Sparkplugapplicationsareoftenupdatedandsuper-
sededfromtheoriginalplugspecification.Consuffan
authorizedBMWpartsdepartmentforthelatestparts_'
information.Thesparkplugfistedintheownersmanu-
almaynotbethelatestrecommendsparkplug,espgp
ciallyonoldercars.
0012631
Fig.10.Toremoveenginecoverabovesparkpiugson4-cylinderen-
gine,turnretainers90°counterclockwiseandliftcoveroff.
0012630
Fig.11.Toremovesparkplugwirefromsparkplugon4-cylinderen-
gine,sudespecialremovaltooloversparkplugwireend(ar-
row)andpullstraightoff.Useascrewdriverforadded
leverage.Specialtoolisstoredatrearofcylinderheadbelow
topcover.
ENGINECOMPARTMENT MAINTENANCE

020-12

MAINTENANCEPROGRAM
6-cylinderenginesuseacoil-on-plugconfiguration,andre-

Batterycablesshouldbetight.Theterminals,thecable
movalofthetopenginecover(betweenthecamshafts)andig-

clamps,andthebatterycaseshouldbefreeofthewhitedeposits
nitioncofsarenecessary.SeeFig.12.Blowawayanydustor

thatindicatecorrosionandacidsalts.Evenathin¡ayerofdust
dirtaroundtheignitioncoils,andthenremovethecoils.Blow

containingconductiveacidsaltscancausebatterydischarge.
awayanydustordirtaroundthesparkplugs.Removethespark
plugs.

Toremovebatterycorrosion,beginbydisconnectingtheca-
bles.Disconnectthenegative(-)cablefirst.Cleantheterminal
postsandthecableclampswithawirebrush.Cleanthemain
chassisgroundterminalnexttothebattery.Corrosioncanbe
washedawaywithabakingsodaandwatersolutionthatwill
neutralizetheacid.Applythesolutioncarefully,though,sinceít
willalsoneutralizetheacidinsidethebattery.Reconnecttheca-
bleclamps,positive(+)cablefirst.Lightlycoattheoutsideofthe
terminals,holddownscrews,andclampswithpetroleumjelly,
grease,oracommercialbatteryterminalcorrosioninhibitor.
Fig.12.IgnitioncoilbeingremovedfromsparkplugonM52engine.
NOTE-
Ifnecessary,see120IgnitionSystemformoredetails
oncoilremoval.
B11004
Lightlylubricatethenewsparkplugthreadswithasmall
amountofanti-seizecompound.Threadtheplugsintothecyl-
inderheadbyhandtopreventcross-threading.
TighteningTorque
"Sparkplugtocylinderhead.......25Nm(18ft-ib)
IdieSpeed
Engine¡dlespeedcanchangeduetoanumberoffactors,in-
cludingnormalwear.Theidlespeediselectronicallyadaptiveand
non-adjustable.See130FuelInjectionformoreinformation.
Battery,checkingandcleaning
Thebatteryislocatedintherightsideoftheluggagecom-
partment.Simplemaintenanceofthebatteryanditsterminal
connectionswillensuremaximumstartingperformance,espe-
ciallyinwinterwhencoldertemperaturesreducebatterypower.
ENGINECOMPARTMENT MAINTENANCE
WARNING-
"Priortodisconnectingthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
"Batteryacidisextremelydangerous.Takecare
tokeepitfromcontactingeyes,skin,orclothing.
Weareyeprotection.Extinguishallsmokingma-
terialsanddonotworknearanyoyenflames.
Batteryelectrolyteshouldbemaintainedatthecorrectlevel
justabovethebatteryplatesandtheirseparators.Thecorrect
leve¡isapproximately5mm(1/4in.)abovethetopofbattery
platesortothetopoftheindicatormarks(ifapplicable).The
batteryplatesandtheindicatormarkscanbeseenoncethefill-
ercapsareremoved.Iftheelectrolytelevelislow,replenishit
byaddingdistilledwateronly.
Battery,repiacing
Batteriesareratedbyamperehours(Ah),thenumberof
hoursaspecificcurrentdraíncanbesustainedbeforecomplete
discharge,orbycoldcrankingamps(CCA),thenumberof
ampsavailabletocranktheengineincoldweatherconditions.
Ingeneral,replacementbatteriesshouldalwaysberatedequal
orhigherthantheoriginalbattery.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthls
manualonpageviii.
Thebatteryisheldinplacebyasinglehandscrewandpíate.
Asecurebatteryhold-downisimportantinordertopreventvi-
brationsandroadshockfromdamagingthebattery.
NOTE-
NOTE-
"Alwaysdisconnectthenegative()cablefirst,and
Designcharacteristicsoftheconvertiblebodycausevi-

connectftlastWhilechangingbatteries,cleanaway
brationsinthetrunkarea.Therefore,E36convertibles

anycorrosioninoraroundthebatterytray.
requireaspecialbatterydesignedforconstantvibra-
tion.Whenrepiacingthebattery,besurethereplace-

"Designcharacteristicsoftheconvertiblebodycause
mentisdesignedspecfficallyfortheconvertible.

vibrationstooscillateinthetrunkarea.Therefore,the
convertiblemodelusesaspecialbatterydesignedfor
thisconstantvibration.

AcceleratorandThrottleLinkage
Theacceleratorandthrottielinkageshouldbelubricatedpe-
riodically.Useageneralpurposeoilonthejointsandbearings
ofthelinkage.Useamultipurposegreaseonthebearingpoints
ofthethrottieplate.
EngineDriveBelts
Drivebeltsandpulleystransferpowerfromtheenginecrank-
shafttovariousaccessories.SeeFig.13.Dependingonmodel
andmodelyear,enginedrivenaccessoriesaredrivenbyV-
belts,poly-ribbed(serpentine)belts,oracombinationofthe
two.Forexample,early4-cylinderengines,usetwoV-beltsand
onepoly-ribbedbelt.
Inspectdrivebeltswiththeengineoff.lfthebeltshowssigns
ofwear,cracking,glazing,ormissingsections,itshouldbere-
placedimmediately.
Vbelt,replacing
(4-cylinderenginesbuiltupto1194)
0012472
Fig.13.Drivebeltandtensionerassemblyforlate4-cylinderengine
wíthpoly-ribbeddrivebelt.
V-beltsshouldbeinspectedduringregularmaintenancein-
tervais.Incorrecttensioncandecreasethelifeofthebeltand
thecomponentitdrives.TheV-belttensionisadjustedthrough
atoothed-rackmechanism.
Inspectbeltswiththeengineoff.Twistthebelttoinspectits
sidewallsandbottom.Beltstructuraldamage,glazedorshiny
sidewaljscausedbyaloosebelt,orseparationareal¡reasons
toreplaceabelt.
ReplacementoftheV-beltseveryfouryearsisrecommend-
ed.Loosenthemountingboltsandadjustthebelt-drivenunit
untilthebelttensionisaslooseaspossible.Removethebeltby
slippingitoverthepulleys.Insomecasesitmaybenecessary
toremoveoneV-belttogettoanother.Useatorquewrenchand
acrowfootwrenchtoturnthetensioninggearboltandsetbelt
tension.Holdthewrenchsteadyandtightenthelocknutonthe
rearofthetensioninggearbolt.Tightenal¡othermountingnuts.
MAINTENANCE PROGRAM

020-13
NOTE-
"Forthemostaccuratecheck,V-belttensionshouldbe
checkedusingaV-belttensiongauge.
"Beltsquealingisnormallycausedbyloosebeltten-
sion.Beltdressingsshouldnotbeused.
TighteningTorques
"Tensioninggear(alternator
belttensioning)..................7Nm(62in-lb)
"Tensioninggear(powersteering
belttensioning)........8to8.5Nm(71to75in-lb)
"Tensioninggearlockingnut.......24Nm(18ft-Ib)
NOTE-
Whenbeltsarereplacedwithnewones,storetheold
setintheluggagecompartmentforemergencyuse.
Wheninstallinganewbelt,gentlypryitoverthepulleys.Too
muchforcemaydamagethebeltortheaccessory.Tensionthe
belt(s),runtheengineforafewminutes(atleast1500rpm),
thenrecheckthebelttension.
CAUTION-
DonotovertightentheV-belts.Overtighteningwill
causeshaftbearingstofailprematurely.
Poly-ribbedbelt,replacing
(4-cylinderenginesbuiitfrom1194
andall6-cylinderengines)
Anautomaticbelttensionerisusedtokeepthebeltsten-
sionedproperly.Unlessthetensionermechanismmalfunc-
tions,thepoly-ribbedbeltsdonotrequiretensionadjustment.
Toreducethechanceofbeltfailurewhiledriving,replace-
mentofthebeltseveryfouryearsisrecommended.Markdrive
beltrotationdirectíonifremovingandreusinganoldbelt.
Toremovethebelt,itisnecessarytoretracttheself-tension-
er.Usingabreakerbarorotherlongsocketassembly,rotate
thetensionertoloosenthebelt.SeeFig.14orFig.15.On4-cyl-
inderengines,itwillbenecessarytoremovetheA/Ccompres-
sorbelttoremovethemaindrivebelt.
WARNING-
Observecarewhenreplacingthebelt.Personalin-
jurycouldresultifthetensionerspringsbackinto
positionuncontrollably.
Withthebeltremovedfromthepulleys,inspectthepulleys
forwearordamagethatmaycauseearlyfailureofthenewbelt.
Thisisalsoagoodopportunitytoinspectthebelt-drivenacces-
sories,checkingforbearingwearandexcessplay.Drivebelt
routingisshowninFig.16andFig.17.
ENGINECOMPARTMENT MAINTENANCE

020-14

MAINTENANCE PROGRAM
uu11989
Fig.14.Enginedrivebelttensíonerbeingreleasedonlate4-cylinder
engine.Pryofftensionercoverandthenlevertensionerin
clockwisedirection(asfacingengine)andslipbeltoffpulleys.

Fig.17.Enginedrivebeltroutingforlate4-cylinderenginewithpoly-
ribbeddrivebelts.
CAUTION-
UseonlyBMWapprovedphosphate-freeanti-
freezewhenfillingthecoolingsystem.Useofanti-
B11177

freezecontainingphosphates!sconsideradtobe
Fig.15.Enginedrivebelttensionerbeingreleasedon6-cylinderen-

harmfultothecoolingsystem.
gine.Pryofftensionercoverandthenlevertensionerinclock-
wisedirection(asfacingengine)andslipbeltoffpulleys.

Atranslucentexpansiontank,oroverflowresenroir,provides
monitóringofcoolantleve¡.Becausetheexpansiontankis
translucent,thecoolantlevelcanbecheckedvisuallywithout
openingthesystem.Alwayscheckthecoolantleve¡withtheen-
ginecold.Thecoolantleve¡shouldbeatthemaximummarkon
O

o'~I

theexpansiontank,asshowninFig.18.
OO

Hoseconnectionhld btihtssoueg

anddry.Coolántseepage
indicateseitherthatthehoseclampisloose,thattheposeis
ENGINECOMPARTMENT MAINTENANCE
0012470
Fig.16.Enginedrivebeltroutingfor6-cylinderengine.A/Ccompres-
sordrivebeltnotshown.
'92
irá
Alternator
belt
Coolant~
0
pp

o0o

Belttensioner
CoolingSystemService
0013000
Coolingsystemmaintenanceconsistsofmaíntainingthe
coolantleve¡,inspectinghoses.Becausethecoolant'santi-cor-
rosionandanti-freezeadditivesgraduallylosetheireffective-
ness,replacementofthecoolanteverytwoyearsupto1996
models,andeverythreeyearsfrom1996isrecommended.As
apreventivemeasure,replacementofthecoolingsystemhos-
eseveryfouryearsisalsorecommended.
damaged,orthattheconnectionisdirtyorcorroded.Driedcool-
anthasachalkyappearance.Hosesshouldbefirmand
springy.Replaceanyhosethatiscracked,thathasbecome
softandlimp,orhasbeencontaminatedbyoil.SeeFig.19.
Powersteeringfluid,checkingleve¡
Checkthepowersteeringfluidlevelinthefluidreservoir.
Parkthecaronleve¡groundwiththeengineoff.Theleveliscor-
rectifitisbetweentheMINandMAXmarksonthedipstick.See
Fig.20.Iftheleve¡isbelowtheMINmark,starttheengineand
addfluidtothereservoirtobríngtheleve¡up.Stoptheengine
andrechecktheleve¡.Hand-tightenthereservoircap.

Fig.18.Fillmarkoncoolantexpansiontank.Coolantlevelshouldbe
atmarkwhenengineíscold.
...e...-..

~...-.
OzoneDamagedHose
0012476
Fig.19.Examplesofdamagetocoolanthoses.Anyofconditions
showniscauseforreplacement.CourtesyofGatesRubber
Company,Inc.
Specification
"Powersteeringfluid..............DexronIII®ATF
OxygenSensors
1996andlaterenginesareequippedwithmultipleoxygen
sensors.SeeFig.21.Aregulatingsensorismountedbefore
eachcatalyticconverterandamonitoringsensordownstream
ofeachconverter.Theregulatingsensormonitorsenginecom-
bustionefficiencyandhelpstocontrolthefuelinjectionsystem
andexhaustemissions.Themonitoringsensorisusedbythe
On-boarddiagnosticsystemtomonitorthefunctionofthecata-
lyticconverter.
MAINTENANCE PROGRAM

020-15
NOTE-
5pecialsocketsforreplacingtheoxygensensorare
availablefrommostautomotivepartsstores.Thesock-
ethasagroovecutdownonesidetoallowthesensor
tobeinstalledwithoutdamagingthewirehamess.
Fig.20.PowersteeringfluiddipstickshowingMINandMAXmarks.
OBDIIenhancedemissionstandardsrequiretheengine
controlmodule(ECM)tomonitortheoxygencontentintheex-
haustbothbeforeandafterthecatalyticconverter.Thisallows
fortightercontrolofthetailpipeemissionsandalsoallowsthe
ECMtodiagnoseconverterproblems.lftheDMEdetectsthat
catalyticconverteroroxygensensorefficiencyhasdegraded
pastacertainpre-programmedlimit,itwillturnontheCheck
Enginelight,andstoreadiagnostictroublecode(DTC)inthe
ECM.
Replacementofoxygensensorsatthespecifiedintervalsen-
suresthattheengineandemissioncontrolsystemwíllcontinue
tooperateasdesigned.Extendingthereplacementinterval
mayvoidtheemissioncontrolwarrantycoverage.See180Ex-
haustSystemforinformationonreplacingtheoxygensen-
sors.
TighteningTorque
"Oxygensensorto
exhaustsystem.............55±5Nm(40±4ft-Ib)
ENGINECOMPARTMENT MAINTENANCE

020-16

MAINTENANCEPROGRAM
Fuelfilter,replacing
Oxygensensor
(regulating)\Catalytic

Oxygensensor
convertor (monitoring)
Fig.21.Typical1996andlaterexhaustsystemshowingoxygensensorlocations.
UNDER-CARMAINTENANCE
convertor
Onearly4-cylíndercars,thefuelfilterismountedunderthe
carontheleftfrontbulkhead.Onearly6-cylíndercars,thefuel
filterismountedtothefrontleftmotormountintheenginecom-
partment.SeeFig.22.
0013139
Fig.22.Fuelfilterlocation(arrow)onbulkheadunderleftsideofvehi-
cle.FilterforM42engineshown.
Onlatercars,thefuelfilterislocatedbeneaththecenterof
thecar,approximatelyunderthedriver'sseat.SeeFig.23.A
protectivecoverisinstalledoverthefuelfilter,whichmustbere-
movedtoaccessthefilter.
UNDER-CARMAINTENANCE
Exhaustflap
actuator
(monitoring)
NOTE-
Drainthefuelfiltertromtheinletsideintoacontainer
andinspectthedrainedfuel.Checkforrust,moisture
andcontamination.
WARNING-
Fuelwillbeexpelledwhenthefilterisremoved.Do
notsmokeorworknearheatersor'otherfirehaz-
ards.Keepatireextinguisherhandy.
CAUTION-
Cleanthoroughlyaroundthefilterconnectionsbe-
foreremovingthem.
0012726
Fig.23.Fuelfilterlocationundercenterofcar(arrow).FilterforM52
engineshown.
Catálytic\Oxygensensor
Whenreplacingthefuelfilter,disconnectthebatterynegative
(-)cableandclampthefilterinletandoutlethosestolessen
fuelspillage.Loosenthecenterclampingbracketandthetwo
hoseclampsoneitherendofthefilter.Notethearrowormark-
ingsindicatingdirectionofflowonthenewfilter.Installthefilter
andusenewhoseclamps.

Tires,checkinginflationpressure

Brakepad/rotorwear,checking
Correcttirepressuresareimportanttohandlingandstability,

Al¡E36carsarefittedwithdiscbrakesatal¡fourwheels.See
fueleconomy,andtirewear.Tirepressureschangewithtemper-

Fig.24.Althoughthebrakesareequippedwithabrakepad
ature.Pressuresshouldbecheckedoftenduringseasonaltem-

warningsystem,thesystemonlymonitorsonewheelperaxle.
peraturechanges.Correctinflationpressurescanbefoundon

Itisrecommendedthatpadthicknessshouldbechecked
thedriver'sdoorpillarandintheowner'smanual.Notethattire

wheneverthewheelsareofforbrakeworkisbegggdone.
pressuresshouldbehigherwhenthecarismoreheavilyloaded.
WARNING-
Donotinflateanytiretoahigherpressurethanthe
tiressmaximumínflationpressurelistedontheside-
wall.Usecarawhenaddlngairtowarmtires.Warm
tirepressurescanincreaseasmuchas4psi(0.3
bar)overtheircoldpressures.
Tires,rotating
BMWdoesnotrecommendtirerotation.Duetothecarssus-
pensiondesign,thefronttiresbegintowearfirstattheouter
shoulderandthereartiresbegintowearfirstatthemiddleof
thetreadorinnershoulder.Rotatingthetiresmayadverselyaf-
fectroadhandlingandtiregrip.
NOTE-
Themainpurposeoftirerotationistopromoteeven
wearandmaximumtirelife.Tirelifemaybedecreased
slightlyifthetiresarenotrotated.
Wheels,aligning
Routinemaintenanceofthebrakesystemincludesmaintain-
ingthebrakefluidinthereservoir,checkingbrakepadsfor
wear,checkinghandbrakefunctíon,andinspectingthesystem
forfluidleaksorotherdamage.
Checkthatbrakehosesarecorrectlyroutedtoavoidchafing
orkinkíng.Inspectunionsandbrakecalipersforsignsoffluid
leaks.Inspectrigidfinesforcorrosion,dents,orotherdamage.
Inspectflexiblehosesforcracking.Replacefaultyhosesor
linesasdescribedin340Brakes.
WARNING-
Incorrectinstallationorovertighteninghoses,fines,
andunionsmaycausechafingorleakage.Thiscan
leadtopartíalorcompletebrakesystemfailure.
MAINTENANCE PROGRAM

020-17
B323
Fig.24.Discbrakepadwearcancheckedthroughopeningincaliper.
Thebrakecalipershouldbeunboltedfromthesuspension
struttoproperlyinspectthebrakepadsandtherotors.SeeFig.
25.Brakecaliperremovalandinstallationproceduresaregiven
in340Brakes.
BMWrecommendscheckingthefrontandrearalignment
onceayearandwhenevernewtiresareinstalled.See320
SteeringandWheelAlignmentforamoredetaileddiscus-
sionofalignmentrequirementsandspecifications.
BrakePadLiningMinimumThickness
(DimensionA)
Brakesystem,inspecting

"Frontandreardiscbrakepads....3.0mm(0.12in)
Brakefluid,replacing
BMWstrictlyrecommendsreplacingthebrakefluidevery
twoyears.Thiswillhelpprotectagainstcorrosionandtheef-
fectsofmoistureinthe(luid.See340Brakesforbrakefluid
flushingprocedures.
Parkingbrake,checking
Theparkingbrakesystemisindependentofthemainbraking
systemandmayrequireperiodicadjustmentdependingon
use.Adjusttheparkingbrakeifthebrakelevercanbepulledup
morethan8clicks.Checkthatthecablemovesfreely.Ade-
scriptionoftheparkingbrakeandparkingbrakeadjustment
canbefoundin340Brakes.
UNDER-CAR MAINTENANCE

020-18

MAINTENANCE PROGRAM
Fig.25.Inspectbrakepadswiththecaliperremoved.Minimumbrake
padthicknessshownbydimension(A).
NOTE-
Theparkingbrakemaylosesomeofitseffectivenessif
itisnotusedfrequently.Thisisduetocorrosionbuild-
upontheparkingbrakedrum.Toremovecorrosion,ap-
plytheparkingbrakejustuntilitbeginstogrip,thenpulí
theleveruponemorestop(click).Drivethecarapprox-
imately400meters(1,300ft.)andreleasethebrake.To
rechecktheadjustmentoftheparkingbrakesee340
Brakes.
UNDER-CAR MAINTENANCE
0011920
Manualtransmissionfluid,
checkingandfilling
Themanualtransmissionfluidleve¡shouldbecheckedat
specifiedintervals.Checkandfillthetransmissionwiththecar
onaleve¡surface.Transmission(luidleve¡checkingandre-
placementproceduresarecoveredin230ManualTransmis-
sion.
AutomaticTransmissionService
Theautomatictransmissionisnotequippedwithadipstíck.
Therefore,checkingtheATFlevelisanínvolvedprocedure,
whichincludesmeasuringandmaintainingaspecifiedATF
temperatureduringthecheckingprocedure.
FormorecompleteATFservice,includingcheckingATFlev-
e¡andATFfilterreplacementprocedures,see240Automatic
Transmission.
Frontsuspensionandsteeringlinkages,
inspecting
Inspectionofthefrontsuspension'andsteeringincludesa
checkofallmovingpartsforwearandexcessiveplay.Alsoin-
specttherubbersealsandbootsforcracksortearsthatcould
allowtheentryofdirt,water,andothercontaminants.See310
FrontSuspension.
Exhaustsystem,inspecting

Rearsuspension,inspecting
Exhaustsystemlifevarieswidelyaccordingtodrivinghabits

Finaldriveandreardriveaxleserviceconsistsofchecking
andenvironmentalconditions.Ifshort-distancedrivingpre-

andchangingthegearoil,inspectingforleaks,andchecking
dominates,themoistureandcondensationinthesystemwill

thereardriveaxlerubberbootsfordamage.
notfullydryout.Thiswillleadtoearlycorrosiondamageand
morefrequentreplacement. Theareaswhereleaksaremostlikelytooccurarearound
thedriveshaftanddriveaxlemountingflanges.Formoreinfor
Scheduledmaintenanceoftheexhaustsystemislimitedlo

mationonídentifyingoilleaksandtheircauses,see330Rear
inspection.Checkforrestrictionsduetodentsorkinks.Check

Suspension.
forweaknessorperforationduetorust.Checkloseethatallthe
hangersareinplaceandproperlysupportingthesystemand
thatthesystemdoesnotstrikethebody.Alignmentofthesys-

Finaldriveoilleve¡,checking
temandthelocationofthehangersaredescribedin180Ex-
haustSystem.

Checkthelubricantleve¡withthecarlevel.Removetheoil
fillerplug.Theleve¡iscorrectwhenthefluidjustreachesthe
edgeofthefillerhole.Installandtightentheoilfillerplugwhen
ManualTransmissionService

theoilleveliscorrect.SeeFig.26.
Manualtransmissionserviceconsistsofinspectingforleaks

ThefinaldriveshouldbefilledwithaspecialBMWlubricant
andcheckingandchangingthefluid.

availablethroughanauthorizedBMWdealer.Inaddition,the
lubricanttypevariesdependingonwhetherornotalimited-slip
Evidenceoftransmissionleaksisfkelytobeseenaroundthe

differentialisfitted.
driveshaftmountingflangeandatthebottomofthebellhousing.
Formoreinformationonidentifyingoilleaksandtheircauses,
see230ManualTransmissionand210Clutch.

TighteningTorque
"Finaldrivefillerplugtofinal
drivehousing..................70Nm(52ft-Ib)

NOTE-
Usea14mmor17mmalíenbitsockettoremovethe
drainplug.
"Ifthecarisraisedintheair,itshouldbeleve¡.
Fueltankandfuelfines,inspecting
0012474
Inspectthefueltank,fuellines,andfuelsystemfordamage
orleaks.Checkforfuelleaksintheenginecompartmentor
fuelodorsinthepassengercompartment.Checkforfaultyfuel
linesbybendingthem.Ifanyleaksarepresent,fuelshouldbe
expelled.Checkforanyevaporativeemissionshosesthat
mayhavebecomedisconnected,checkingcarefullyatthe
charcoalcanisterandevaporativeemissionspurgesystem.
See130FuelInjectionand160FuelTankandFuelPump
forcomponentlocationsandadditionalinformation.
WARNING-
Whencheckingforfuelleaks,theenginemustbe
cold.Ahotexhaustmanifoldorexhaustsystem
couldcausethefueltoigniteorexplodecausingse-
riouspersonalinjury.Uentilatetheworkareaand
cleanupspilledfuelimmediately.
Clutchfluid,checking
Thehydraulicclutchandthebrakesystemsharethesame
reservoirandthesamebrakefluid.Clutchfluidleve¡andbrake
fluidlevelarecheckedatthesametime.See340Brakesfor
moreinformation.See210Clutchforinformationontheclutch
andthehydraulicclutchoperatingsystem.
MAINTENANCEPROGRAM

020-19
Driveaxiejointboots,inspecting
100Engine-General
Theprotectivebootsmustbecloselyinspectedforcracks
andanyotherdamagethatwillallowcontaminantstogetínto
thejoint.Iftherubberbootsfaf,thewateranddirtthatenterthe
jointwillquicklydamage¡t.Replacementofthedriveaxlejoint
bootsandinspectionofthejointsaredescribedin330Rear
Suspension.
BODYANDINTERIORMAINTENANCE
WindshieldWiperBiadeMaintenance
Commonproblemswiththewindshieldwipersinclude
streakingorsheeting,waterdropsafterwiping,andbladechat-
ter.Streakingisusuallycausedwhenwiperbladesarecoated
withroadfilmorcarwashwax.Cleanthebladesusingsoapy
water.Ifcleaningthebladesdoesnotcuretheproblemthen
theyshouldbereplaced.BMWrecommendsreplacingthewip-
erbladestwiceayear,beforeandafterthecoldseason.Onold-
ercars,checkthetensionspringthatholdsthewipertothe
glass.Replacethewiperarmifthespringsareweak.
Dropsthatremainbehindafterwipingarecausedbyoil,road
film,ordieselexhaustcoatingthewindshield.Useanalcoholor
ammoniasolution,oranon-abrasivecleansertocleanthe
windshield.
Wiperbladechattermaybecausedbydirtyorwornblades,
byadirtywindshield,orbybentortwistedwiperarms.Clean
thebladesandwindshieldasdescribedabove.Adjustthewiper
armsothatthereisevenpressurealongtheblade,andsothat
thebladeisperpendiculartothewindshieldatrest.Lubricate
thewiperlinkagewithalightoil.Thelinkageislocatedunder
thehoodonthedriversside.Iftheproblempersists,theblades
areexcessivelyagedorwornandshouldbereplaced.See611
WipersandWashers.
Bodyandhinges,lubricating
Thedoorlocksandlockcylinderscanbelubricatedwithan
oilthatcontainsgraphite.
Thebodyanddoorhinges,thehoodlatch,andthedoor
checkrodsshouldbelubricatedwithSAE30orSAE40engine
oil.Lubricatetheseatrunnerswithmultipurposegrease.Donot
applyanyoiltorubberparts.Ifdoorweatherstripsaresticking,
lubricatethemwithsiliconesprayortalcumpowder.Thehood
releasecableshouldbelubricatedaswell.
Theuseofwinterlockde-icerspraysshouldbekepttoanab-
soluteminimum,asthealcoholinthede-icerwillwashthe
greaseoutofthelockassemblies,andmaycausethelocksto
corrodeinternally,orbecomedifficulttooperate.
ENGINE-GENERAL 100-1

020-20

MAINTENANCEPROGRAM
SeatBelts

WashingChassis
Dirtandotherabrasiveparticleswilldamageseatbeltweb-

Periodicwashingoftheundersideofthecar,especiallyin
bing.If¡tisnecessarytocleanseatbelts,useamildsoapsolu-

winter,willhelppreventaccumulationofroadsaltandrust.The
tion.Bleachandotherstrongcleaningagentsmayweakenthe

besttimetowashtheundersideisjustafterthecarhasbeen
beltwebbingandshouldbeavoided.

driveninwetconditions.Spraythechassiswithapowerfuljetof
water.Commercialorself-servicecarwashesmaynotbebest
WARNING-

forthis,astheymayrecyclethesalt-contaminatedwater.
Donotcleantheseatbeltwebbingusingdryclean-
ingorotherchemicals.Allowwetbeltstodrybefore
allowingthemtoretract.

SpeeialCleaning
Theconditionofthebeltwebbingandthefunctionofthere-
tractormechanismsshouldbeinspected.See720SeatBelts
forseatbeltinspectioninformation.
ExteriorWashing
Thelongerdirtisleftonthepaint,thegreatertheriskofdam-
agingtheglossyfinish,eitherbyscratchingorbythechemical
effectdirtparticlesmayhaveonthepaintedsurface.
Donotwashthecarindirectsunlight.Iftheenginehoodis
warm,allowittocool.Beadsofwaternotonlyleavespotswhen
driedrapidlybythesunorheatfromtheengine,butalsocanact
assmallmagnifyingglassesandburnspotsintothefinish.
Washthecarwithamixtureoflukewarmwaterandacarwash
product.Rinseusingplentyofclearwater.Wipethebodydry
withasoftclothtowelorchamoistopreventwater-spotting.
Waxing
Foralong-lasting,protective,andglossyfinish,applyahard
waxafterthecarhasbeenwashedanddried.Usecarnaubaor
syntheticbasedproducts.Waxingisnotneededafterevery
washing.Youcantellwhenwaxingisrequiredbylookingatthe
finíshwhenitiswet.Ifthewatercoatsthepaintinsmooth
sheetsinsteadofformingbeadsthatrol¡off,anewcoatofwax
isneeded.Waxshouldnotbeappliedtoblacktrimpieces,rub-
ber,orotherplasticparts.
Polishing
Usepaintpolishonlyifthefinishassumesadulllockafter
longservice.Polishcanbeusedtoremovetarspotsandtar-
nish,butafterwardsacoatofwaxshouldbeappliedtoprotect
thecleanfinish.Donotuseabrasivepolishorcleanersonalu-
minumtrimoraccessories.
BODYANDINTERIORMAINTENANCE
CylinderHeadandValvetrain
Thealuminumcylinderheaduseschain-drivendouble
overheadcamshaftsandfourvalvespercylinder.SeeFig.1.
Tharvfinriarhandnmnlnvenernceflnierrineinnfnrnronter
Tarspotscanberemovedwithabugandtarremover.Never
usegasoline,kerosene,nailpolishremover,orotherunsuitable
solvents.Insectspotsalsorespondtotarremover.Abitofbak-
ingsodadissolvedinthewashwaterwillfacilitatetheirremoval.
Thismethodcanalsobeusedtoremovespottingfromtreesap.
InteriorCare
Dirtspotscanusuallyberemovedwithlukewarmsoapywa-
teroradryfoamcleaner.Usespotremoverforgreaseando¡I
spots.Donotpourthe(quiddirectlyonthecarpetorfabric,but
dampenacleanclothandrubcarefully,startingattheedgeof
thespotandworkinginward.Donotusegasoline,naptha,or
otherflammablesubstances.
LeatherUpholsteryandTrim
Leatherupholsteryandtrimshouldbeperiodicallycleaned
usingaslightlydampcottonorwoolcloth.Theideaistogetrid
ofthedirtinthecreasesandporesthatcancausebrittleness
andprematureaging.Onheavilysoiledareas,useamilddeter-
gent(suchasWoolite®)orotherspeciallyformulatedleatherr
cleaners.Usetwotablespoonstoonequartofcoldwater.Dry
thetrimandupholsterycompletelyusingasoftcloth.Regular
useofagoodqualityleatherconditionerwillreducedryingand
crackingoftheleather.
1.Camshafts
2.Rockerarms
3.Hydraulicvalveadjusters(HVA)
4.Valveandconicalvalvespring

GENERAL ............................100-1
CylinderBlockandCrankshaft............100-1
ConnectingRodsandPistons.............100-1
CylinderHeadandValvetrain.............100-2
VANOS(VariableValveTiming)...........100-2
DISA(DualResonanceIntakeSystem).....100-3
EngineManagementSystem.............100-3
Ignition..............................100-5
FuelDelivery..........................100-5
CoolingSystem........................100-5
LubricationSystem.....................100-5
MECHANICAL TROUBLESHOOTING ....100-5
WarningsandCautions..................100-5
Cylindercompression,checking...........100-6
EngineMechanicalTroubleshootingTable...100-7
DRIVEABILITYTROUBLESHOOTING ...100-8
GENERAL
Therearevariousengíneconfigurationsusedinthe1992-
1998E36cars.SeeTablea.
Onbothfour-and6-cylinderengines,thecylinderblockis
cast¡ronwithintegralcyiinders.Thecyiindersareexposedon
allsidestocirculatingcoolant.
Thefullycounterweightedcrankshaftrotatesinreplaceable
split-shellmainbearings.Oiiwaysdrilledintothecrankshaftpro-
videbearinglubrication.O¡Isealspressedintoalloysea¡hous-
ingsareinstalledatbothendsofthecrankshaft.
100Engine-General
Tablea.EngineSpecifications
ENGINE-GENERAL 100-1
On-BoardDiagnostics(OBD)..............100-8
BasicRequirements....................100-11
PreventiveMaintenance................100-11
BasicEngineSettings..................100-11
OxygenSensors......................100-11
AirFlowMeasurementandVacuumLeaks..100-12
BatteryVoltage.......................100-12
WiringandHarnessConnections.........100-13
GroundConnections...................100-13
Fue¡Supply..........................100-14
TABLES
a.EngineSpecifications.......................100-1
b.EngineManagementSystems.................100-5
c.EngineMechanicalTroubleshooting............100-8
d.OBD1Fault(Blink)Codes
(1992-1995modelsonly).....................100-9
e.EngineDriveabilityTroubleshooting............100-15
Model

Enginecode

No.of

Dispiacement

Compression

Horsepower
cyiinders

liters(cu.in.)

ratio

SAEnet@rpm
318i/is/¡C
1992-1995

M42

4

1.8(109.6)

10.0:1

100@6000
1996-1998

M44

4

1.9(115.6)

~
10.0:1

103@6000
323ís/iC
1998

M52

6

2.5(152.2)

10.5:1

168@5,500
325i/is/iC
1992-1995

M50

6

2.5(152.2)

10.0:1

110@5,900
328i/is/iC
1996-1998

M52

6

2.8(170.4)

10.2:1

190@5,300
M3
1995

S50US

6

3.0(182.5)

10.5:1

240@6,000
1996-1998

S52US

6

3.2(192.3)

10.5:1

240@6,000
CylinderBlockandCrankshaft

ConnectingRodsandPistons
Theforgedconnectingrodsusereplaceablesplit-shell
bearingsatthecrankshaftendandsolidbushingsatthepis-
tonpinend.Thepistonsareofthethree-ringtypewithtwoup-
percompressionringsandalowerone-pieceo¡iscraperring.
Fui¡-floatingpistonpinsareretainedwithcirclips.
GENERAL

100-2 ENGINE-GENERAL
CylinderHeadandValvetrain
Thealuminumcylinderheaduseschain-drivendouble
overheadcamshaftsandfourvalvespercylinder.SeeFig.1.
Thecylinderheademploysacrossflowdesignforgreater
powerandefficiency.Intakeairentersthecombustioncham-
berfromonesidewhileexhaustgassesexitfromtheother.
Oílwaysintheheadprovidelubricationforthecamshafts)
andvalvetrain.
Fig.1.

M52twin-cam,4-valve-per-cylinderenginewithhydraulíclift-
ers.
OnallenginesexcepttheM44engine,valveclearanceisby
seif-adjustinghydrauliclifters.OnM44engines,insteadofhy-
drauliclifters,hydraulicpedestaisareusedincombination
withrollerrockerarmstoactuatethevalves.Hydraulicpedes-
talshavethesamefunctionashydrauliclifters,whichísto
maintainzerovalveclearance,reducevalvenoise,andelimí-
nateroutíneadjustment.SeeFig.2.
VANOS(VariableValveTiming)
GENERAL
1.Camshafts
2.Rockerarms
3.Hydraulicvalveadjusters(HVA)
4.Valveandconicalvalvespring
4
Fig.2.

CrosssectionofM44twin-cam,4-valve-per-cylinderhead.
Notefunctionofhydraulícpedestalincombinationwithrock-
erarm(withrollerbearingforreducedfriction).
ThemaincomponentsoftheVANOSsystemarethepiston
housingwithintegralspoolvalveandsolenoid,andthemodi-
fiedintakecamshaftandsprocketassembly.SeeFig.3.
1993andlater6-cylinderenginesareequippedwithavari-

B11001
ableintakevalvetimingsystem,knownasVANOS(fromthe
GermanwordsVariableNockenwellenSteuerung).The

Fig.3.VANOS(variableintakevalvetiming)systemusedonM52en-
VANOSsystemelectro-hydraulicallyadjustsintakevalvetim-

gine.Whensolenoidisactuated,oílpressureisdirectedto
ingforenhancedmid-rangeperformance.TheVANOSsys-

frontsideofgearcuppiston.Thisforcesgearcupfintocam
temiscontrolledbytheenginecontrolmodule(ECM),using

shafttoadvanceintakevalvetiming.
enginespeed,engineloadandenginetemperatureasthepri-
maryinputs.

Whentheengineisrunning,thepistonhousingissupplied
withpressurizedengineoilvíathesolenoid-actuatedspool
Atlowspeeds,theintakevalvesopenlatetoensuresmooth

valve.Dependingonthepositionofthespoolvalve,oilisdi
engineoperation.Atmid-rangespeeds,thevalvesopenearly

rectedtoeitherthefrontorbacksideofthegearcuppiston.
(valvetimingadvanced,VANOSactuated)forincreased
torque,improveddriveability,andreducedemissions.Andat

Whenthesolenoidisintheoffposition,engineoílisdirect-
highspeeds,thevalvesagainopenlateforoptimumpower

edtothebacksideofthepiston.Thisholdsthegearcupfor-
andperformance.

wardandvalvetimingismaintainedatthenormal"late"
position.Whenthesolenoidisenergized,thespoolvalveis
movedforwardandoilpressureisdirectedtothefrontsideof
thepiston.Thisinturnmovesthegearcupfurtherintothe

camshaftsecondarydrive,causingthecamshaftto"advance"
12.5°.Thehelicalgearsarecutsothatforwardmotionofthe
gearcupistransiatedintorotationalmotionofthecamshaft.
See117CamshaftTimingChainfortestingandrepairinfor-
mationontheVANOSsystem.
DISA(DualResonanceIntakeSystem)
DISA,usedon4-cylinderengines,isadualintakerunner
systemthateffectivelyprovidestheadvantagesofbothshort
andlongintakerunnerswithinthesameengine.Forbestper-
formance,longintakerunnersaremostbeneficialatlow-and
mid-enginespeeds(below4,200rpm),andshortintakerun-
nersenhancetorqueathighenginespeeds(above4,200
rpm).
NOTE-
ThetermDISAcomesfromtheGermanwordsDiffer-
enzierteSauganlage,andcanroughtybetransiatedas
adifferingintakemanifoldconfiguration.
TheDISAsolenoidvalveiscontrolledbytheDMEcontrol
module,usingenginespeedastheprimaryinput.Themain
componentsofthesystemarethemodifiedtwin-sectionin-
takemanifoldwithchange-overvalve,thetwin-barrelthrottle
body,andtheelectrical/pneumaticactuatingcomponents.
SeeFig.4.
r
I
I
I
?,in
UpPer,
take-1
manifold
1-1
Throttlehousing
(Heated)
q:lZU
Fig.4.

DISAsystemcomponents.DISAchangestheintakerunner
lengthbasedonenginespeed.
TheDISAsystemelectro-pneumaticallychangestheintake
runnerlengththroughthetwin-sectionintakemanifoldanda
change-overbutterflyvalve.Thechange-overvalveislocated
atapointintheintakemanifoldwherefourpipescomeinto
two.Whenthechange-overvalveisclosed,the4-wayprimary
intakemanifoldandthe2-wayramairmanifoldareconnected
tomakethe"long"configuration.Whenthechange-overvalve
opens,intakeairflowisredirectedthroughonlytheshort4-
wayprimaryintakemanifold.
Thechange-overvalveisheldinthenormallyopenposition
byaspring.Thisallowsforanopenvalveintheeventofsys-
temfailure.Duringlowandmidenginespeeds,theDMEcon-
trolmodulesuppliespowertothesolenoidvalve,whichinturn
allowsvacuumtobeappliedlothevacuumdiaphragm.This
causesthevalvetoclose(long-pipeconfiguration).Whenen-
ginespeedreachesapproximately4,800rpm,theDMEcon-
trolmoduleelectricallysignalsthesolenoidvalveandthe
valveopens,creatingtheshortpipeconfiguration:
FurtherdetafsonDISAcanbefoundin130FuelInjection.
EngineManagementSystem
Al¡enginescoveredbythismanualuseanadvancedengine
managementsystemcalledDigitalMotorElectronics(DME).
IntheDMEsystem,advancedOn-BoardDiagnostics(OBD),
fuelinjection,ignition,andotherfunctions,arecombinedunder
thecontroloftheEngineControlModule(ECM).SeeFig.5.
-

Lowerintakemanifold
DISA
vacuum
'~servo
EíY1z
ENGINE-GENERAL 100-3
le-DISAsolenoidvalve
0012591
/ withbutterflyva¡
GENERAL

100-4 ENGINE-GENERAL
'

TEMP
PRECAT

POSTCAT

OXYGENSENSOR
HEATING
#
.THROTTLE
POSITION

FUELINJECTORCONTROL
(SEQUENTIAL)
OPERATINGPOWER

00
CAMSHAFT POSITIONSENSOR
ECM

IMAINGROUND
RELAY

J_

-

ACCOMPRESSOR
RELAYCONTROL
TERMINAL15
MEMORY POWER
FUELPUMP
RELAYCONTROL
AUXGROUND
P
CRANKSHAFT
POSITION
dESENSOR
INTAKE
AIR
ENGINE
COOLANT
TEMP
FUELTANKPRESSURE SENSOR
S-EML
S-MSR
ASC S-ASC
VEHICLESPEED
LOWFUELLEVEL
A/CSWITCHON(AC)
E36
IHKACOMPRESSOR"ON"
SIGNAL(KO)
INDIVIDUALSERIALNUMBER
MS41.1
SECONDARY AIR
1NJECTIONAIRPUMP®
RELAYCONTROL
IDLECONTROLVALVE

'M
FUELINJECTION(TI)
ENGINESPEED(TD)
Fig.5.

SiemensMS41.1OBDIIenginemanagementsystemusedon1996andlaterM52engines.
GENERAL
IGNITIONCOILS
CONTROL
Lr"Qif~CIYVFIYC

CHE
AMPCONTROL
ENGINE
THROTTLEPOSITION
6
ECM
RELAY
CONTROL
ASC
THROTTLE
..:....-11

1Q\\POTENTIOMETER
POWER
CAN

TCM
II

SCAN(DES
;
ER
DIAGNOSIS
OBDII III
GENERICSCANTOOL

0012596

ignition
Tableb.EngineManagement Systems

enginehashighmileage.
Engine

1System
4-cylinderengines
M42(1992-1995)

BoschDMEMl.7
M44(1996-1998)

BoschDMEM5.2(OBDII)
6-cylinderengines
M50(1992)

BoschDMEM3.1
M50VANOS(1993-1995)

BoschDMEM3.3.1
M52(1996-1998)

SiemensMS41.1(OBDII)
S50US(1995)

BoschDMEM3.3.1
S52US(1996-1998)

SiemensMS41.1(OBDII)
Boththe4-cylinderand6-cylinderenginesuseadistributor-
lessignitionsystemwithindividualignitioncoilsforeachcylin-
der.
FuelDelivery
Pressurizedfuelfromthein-tankfuelpumpisinjectedvia
solenoid-typefuelinjectors.TheECMcontrolstheopening
andclosingoftheinjectorsbyswitchingthegroundsideof
eachinjectorcircuit.Theexactamountoffuelinjectedisde-
terminedbytheamountoftimetheinjectorsareopen.
CoolingSystem
Whenevertheengineisrunning,acoolantpumpcirculates
coolantthroughtheengineand,ifeitherheatercontrolvalves
areopen,throughtheheatercoreinthepassengercompart-
ment.Thecoolantabsorbsexcessheatandcarriesittothera-
diatorwhereitistransferredintothepassingairstream.A
thermostatcontrolstheflowofcoolantthroughtheradiator
basedonenginetemperature.
LubricationSystem
Thelubricationsystemispressurizedwhenevertheengine
isrunning.Theoilpumpdrawsoilthroughapickupinthebot-
tomoftheoilpan,thenforcesitthroughareplaceableoilfilter
andfintotheengineoíipassages.
On4-cylinderengines,theoilpumpismountedtothefront
enginecover.On6-cylinderengines,thechain-drivenoil
pumpisboltedtothebottomofthecylinderblock.
Apressurereliefvalvelimitsthemaximumsystempres-
sure.Abypassvalvepreventstheoilfilterfromburstingand
insuresenginelubricationshouldthefilterbecomeplugged.
See119LubricationSystemforadditionalinformation.
ENGINE-GENERAL 100-5
VariousversionsofDMEsystemsareusedonthecarscov-

MECHANICAL TROUBLESHOOTING
eredbythismanual.SeeTableb.Eachsystemishighly
adaptivetocompensateforthingssuchasenginewearand

Whentroubleshootinganenginethatfailstostartorruns
vacuumleaks.

poorly,firstcheckitsmechanicalcondition-particularlyifthe
WarningsandCautions
Forpersonalsafety,aswellastheprotectionofsensitive
electroniccomponents,thefollowingwarningsandcautions
mustbeadheredtoduringalltroubleshooting,maintenance,
andrepairwork.
WARNING-
"Theignitionsystemproduceshighvoltagesthat
canbefatal.Avoidcontactwithexposedtermi-
nalsanduseextremecautionwhenworkingon
acarwiththeignitionswitchedonortheengine
running.
"Donottouchordisconnectanyhighvoltageca-
blesfromthecoil,distributor,orsparkplugs
whiletheengineisrunningorbeingcrankedby
thestarter
"Connectanddisconnecttheenginemanage-
mentsystemwiringandtestequipmentleads
onlywhentheignitionisswitchedoff.
"Gasolineishighlyflammableanditsvaporsare
explosive.Donotsmokeorworkonacarnear
heatersorotherfirehazardswhendiagnosing
andrepairingfuelsystemproblems.Haveafire
extínguisheravailableincaseofanemergency.
"Disconnectingthebatterymayerasefaultcode(s)
storedincontrolmodulememory.Usingspecial
BMWdiagnosnncequipment,checkforfaultcodes
priortodisconnectingthebatterycables.Ifthe
CheckEnginelightisilluminated,seeOn-
BoardDiagnostics(OBD)forfaultcodeinfor-
mation.Ifanyothersystemfaultshavebeende-
tected(indicatedbyanilluminatedwarning
light),seeanauthorizedBMWdealer.
CAUTION-
"Priortodisconnectingthebattery,readthebat-
terydisconnectioncautionsgívenatthefrontof
thismanualonpageviii.
"Donotconnectanytestequipmentthatdelivers
a12-voltpowersupplytoterminal15(+)ofthe
ignitioncoil.Thecurrentflowmaydamagethe
ECM.Ingeneral,connecttestequipmentonly
asspecifiedbyBMW,thismanual,ortheequip-
mentmaker.
"Donotdisconnectthebatterywiththeengine
running.Donotruntheenginewithanyofthe
sparkplugwiresdisconnected.
MECHANICAL TROUBLESHOOTING

100-6 ENGINE-GENERAL
Cylindercompression,checking
Acompressiontesterisneededtomakeacompressiontest.
Toobtainaccuratetestresults,thebatteryandstartermustbe
capableofcrankingtheengineat250-300rpm,andtheen-
gineshouldbeatnormaloperatingtemperature.Usecom-
pressedairtocleanaroundthesparkplugsbeforeremoval.
1.Disabletheignítionsystembyremovingtheengine
managementsystemmainrelayandthefuelpumpre-
¡ay.SeeFig.6.
WARNING-
Theignítionsystemproduceshighvoltagesthatcan
befatal.Avoidcontactwithexposedtermínalsand
useextremecautionwhenworkingonacarwíththe
ignítionswitchedonortheenginerunning.
Fuel

DME
pump main
reay

relay
ooaooa
.,o00oao
Fig.6.

Enginemanagementrelaysinpowerdistributionboxinleft
rearofenginecompartment.
CAUTION-
"OnOBD11cars,makingacompressiontestmay
causeafaulttosetintheECMandmayalsoil-
luminatetheCheckEnginelight.Thelightcan
onlybetumedoutusingspecialscantoolequip-
ment,usingeíthertheBMWspecialservícetool
orusinga"generic"OBD11scantool.Discon-
nectingthebatterywillnoterasethefaultmem-
orynorturnoutthelight.
0013034,
0012630
Fig.7.

Removesparkplugwiresfromsparkplugson4-cylinderen-
gineusingspecialtool.Toolisstoredundercoveratrearof
cylinderhead(arrow).
Fig.8.

Removeenginecoveron6-cylinderenginebypryingoffnut
coversandremovingnuts(A).Becarefulnottoletrubberin-
sulatorsfalloffascoverisremoved(arrows).
4.On6-cylinderengines,disconnecttheharnessconnec-
torsfromtheignítioncoilsbyliftingtheretainingclip.
Removethecoilmountingnutsandremovethesix
coils.SeeFig.9.Removethesparkplugs.
"Failuretoremovethemainrelayorattemptingto
disabletheignítionsystembyothermethodsmay
resultindamagetotheenginecontrolmodule.

NOTE-
Usedsparkplugsshouldbereinstalledinthesamecyl-
2.On4-cylinderengine:Removeplasticenginecoverfrom

inderfromwhichtheywereremoved.
topofcylinderhead.Disconnectsparkplugwiresandre-
movesparkplugs.SeeFig.7.

5.Insta¡¡thecompressiongaugeinthefirstcylinder's
3.On6-cylinderengine:Removetopenginecoverbypry-

sparkplughole,tightenoughtoformagoodseal.
ingoffnutcoversandremovingmountingnuts.See
Fig.8.
MECHANICAL TROUBLESHOOTING

eiioo4
Fig.9.

Removeignitioncoilson6-cylinderenginebydisconnecting
harnessconnectorandremovingmountingbolts(arrows).
NOTE-
"Thecompressiongaugereadingshoutdincreasewith
eachcompressionstrokeandreachnearitsmaxi-
mumreadinginabout4-6strokes.
"Allcylindersshoutdreachmaximumcompressionin
thesamenumberofstrokes.Ifacylinderneedssig-
nificantlymorestrokestoreachmaximumcompres-
sion,thereisaproblem.
7.Releasethepressureatthecompressiongaugevalve,
thenremovethegaugefromthesparkplughole.Re-
peatthetestforeachoftheothercylindersandcom-
paretheresultswiththevaluesgivenbelow.
ENGINE-GENERAL 1:00-7
CompressionPressure
"Minimum................10-11bar(142-156psi)
"Maximumdifference
betweencylinders................0.5bar(7psi)
Reinstallthesparkplugsandsparkplugwiresorignition
cofs.Theremainderofinstallationisthereverseofremoval.Be
suretoreihstallal¡wiresdisconnectedduringthetest,especial-
¡ygroundwiresatthecoilsandcylinderheadcover(whereap-
plicable).
TighteningTorque
"Sparkplugtocylinderhead.......25Nm(18ft-Ib)
Lowcompressionindicatesapoorlysealedcombustion
6.Withtheparkingbrakeset,thetransmissioninParkor

chamber.Relativelyevenpressuresthatarebelowspecification
Neutral,andtheacceleratorpedalpressedtothefloor,

normallyindicatewornpistonringsand/orcylinderwalls.Erratic
cranktheenginewiththestarter.Recordthehighest

valuestendtoindicatevalveleakage.Dramaticdifferencesbe
valueindicatedbythegauge.

tweencylindersareoftenthesignofafailedheadgasket,
bumedvalve,orbrokenpistonring.
EngineMechanicalTroubleshootingTable
Tablecliststhesymptomsofcommonenginemechanical
problems,theirprobablecausesandthesuggestedcorrective
actions.Theboldtypeindicatestherepairgroupswhereappli-
cabletestandrepairprocedurescanbefound.
MECHANICAL TROUBLESHOOTING

100-8 ENGINE-GENERAL
Symptom

1

Probablecauseandcorrectiveaction
1.Enginewillnotstartorrun.Startercranks

a.

Nofuelreachingengine.Checkforfuelintank.
engineatnormalspeed.

Fuelpumpnotoperating.RepairGroup160
b.Nospark.Checkignitionsystem.RepairGroup120
c.Incorrectvalvetiming.Checktimingchain.RepairGroup117
2.CheckEnginewarninglightilluminated.

a.DMEenginemanagementsystemself-diagnosticfaultdetected.Seaanauthorized
BMWdealerorotherqualifiedshopforOBDIIfaultcodediagnosis.SeealsoOn-
boardDiagnostics(OBD),givenlaterinthisrepairgroup.
3.Whiteexhaustsmoke(steam).

a.Failedcylinderheadgasket(probablyaccompaniedbylowcompressionreadings).
Replacegasketandresurfacecylinderheadifnecessary.RepairGroup113
4.Blue-grayexhaustsmokeandoilyspark

a.Contaminatedorgasoline-dilutedengineoil.Changeengineoilandreplaceoilfilter.
plugs.Indicatesoiiburningincombustion.

RepairGroup020
b.Faultyvalveguidesealsorvalveguides.Replacevalveguideoilsealsoroverhaul
cylinderhead.RepairGroup116
5.Pingingorrattlingwhenunderload,

a.Ignitiontimingtooadvanced.Ignitionknocksensorsfaulty(CheckEnginelight
travelinguphill,oraccelerating,especially

illuminated).RepairGroup120
fromlowspeeds.Indicatespre-ignitionor

b.Fueloctaneleve¡toolow.
detonation.

c.Enginerunningtoohotoroverheating.Checkcoolingsystem.RepairGroup170
6.Lightmetallictappingthatvariesdirectly
withenginespeed.Oilpressurewarning
lightnotilluminated.
7.Lightmetallicknockthatvariesdirectlywith
enginespeed.Oilpressurewarninglight
blinkingorfullyilluminated;maybemost
noticeableduringhardstopsorcornering.
8.Screechingorsquealingunderloadthat

a.Loose,worn,ordamageddrivebelt.Inspectbelt(s).RepairGroup020
goesawaywhencoasting.
9.Growlingorrumblingthatvarieswithengine

a.Removedrivebelt(s)toidentifyfaultycomponent.Checkforplay,bearingroughness,
rpm.Indicatesabadbearingorbushingin

andloosemountings.Refertoappropriaterepairgroupforrepairprocedures.
anengine-drivenaccessory.
DRIVEABILITY TROUBLESHOOTING

On-Board Diagnostics (OBD)
On-BoardDiagnosticsisincorporatedintoal¡engineman-

TwogenerationsofOBDareusedonthecarscoveredby
agementsystemsusedonthecarscoveredbythismanual.

thismanual:
Therefore,checkingforfaultcodesshouldbethefirststepin
troubleshootingadriveabilityproblem.Foradditionalinforma-

On-BoardDiagnostics
tiononenginemanagementandrepairsee130FuelInjec-
tion.

"1992-1995models.....................OBDI
"1996-1998models.....................OBDII
DRIVEABILITYTROUBLESHOOTING
Tablec.EngineMechanicalTroubleshooting
b.Warpedorcrackedcylinderhead.Resurfaceorreplacecylinderhead.RepairGroup113
c.Crackedcylinderblock.Replaceengineorshortblock.
c.Wornpistonrings.Overhaulorreplaceengine.
d.Failedcylinderheadgasket.Replacegasket.RepairGroup113
d.Air/fuelmixturetoolean(CheckEnginelightilluminated).RepairGroup130
a.Valveclearancesexcessive.Checkhydraulicvalveadjusters.RepairGroup116
b.Lowoilpressureorpossiblydefectivewarninglightcircuit.Checkoilpressureand
warninglightcircuit.RepairGroup119
c.Dirtyoil.Changeoil.RepairGroup020.
a.Lowoilleve¡.Checkandcorrectoilleve¡.
b.Lowoilpressure/wornorfaultyoilpump.Oilpumppickuprestricted/clogged.Check
oilpressure.RepairGroup119
TheOBDsystemdetectsemissions-relatedenginemanage-
mentmalfunctionsandtucosontheCheckEngínelightinthein-
strumentcluster.TheCheckEnginelightwillstayonuntilthe
code(s)arecalledupandthememoryiserased.Whenfaultyare
detected,theOBDsystemstoresaDiagnosticTroubleCode
(DTC)inthesystemECM.Inaddition,theCheckEnginewarn-
inglightwillcomeonifanemissions-relatedfaultisdetected.

NOTE-
"OncarswithOBD ti,specializedOBD 11scantool
equipmentmustbeusedtoaccesstheDTCs,either
usingtheBMWspecialtoolora`generic"OBD 11scan
tool.See130FuelInjection.
"The08D 11faultmemory(includinganiiluminated
CheckEnginelight)canonlyberesetusingthespe-
cialscantool.Removingtheconnectorfromthe
ECM
ordisconnectingthebatterywillnoterasethefault
memory.
Tabled.OBD1Fault(Blink)Codes
(1992-1995modeisonly)
GraphicrepresentationofflashingCheckEnginelightfaultcode:1221
5Seconds.:-

2.5~-
--05--
Faultcodeandmeaning

1Correctiveaction
Code1216:Throttlepotentiometer
Code1218:Outputstage,group#1(DME3.3.ionly)
Code1219:Outputstage,group#2(DME3.3.1only)
Code1221:Oxygensensor#1
Code1224:Airtemperaturesensor(NTC)
Code1226:Knocksensor#2(DME3.3.1only)
130
ENGINE-GENERAL 100-9
2.5seconds,thengoofffor2.5seconds.Atthispoint,thefault
codeswillbegintoflash.SeeTabled.
Ifmorethanonefaulthasbeendetected,eachcodewillbe
separatedbya2.5secondpause.Whenal¡faultcodeshave
beendisplayed,therewillbe0.5secondflashandthenthe
lightwillremainoff.Toreadthecodesagain,turnthekeyoff
andthenonagain.Depresstheacceleratorpedaltothefloor
fivetimesquickly(within5seconds).Thecodeswillbeginto
repeat.
OncarswithOBDI,faultcodescanbereadbyturningthe

Toerasethefaultcodememory,firstmakesurethefault
ignitionkeyonandfullydepressingtheacceleratorpedalto

code1000(shortblinkandthenlightgoesoutforlongperiod)
thefloorfivetimeswithinfiveseconds.TheCheckEngine

ispresent,thendepressthethrottlefullyforatleast10sec-
lightwillthenremainonforfiveseconds,blinkoff,comeonfor

onds.Readthefaultcodesasdescribedearlierandcheckfor
the1444code(nofaultsstored).
-,--------------CheckEnginelighton
CheckEnginelightoff
Code1211:DMEControlModule

DMEcontrolmodulemaybefaulty.Thiscodeappearsifthecontrol
modulefailstheselftest.Checkinputstocontrolmodule.Repair
Group130
Code1215:Massairflowsensor

Checkairflowormassairflowsensorandwiringtosensor.Repair
Group130
Testthrottlepotentiometerresistanceandwiring.RepairGroup130
TestDMEcontrolmoduleinput/outputs.RepairGroup130
TestDMEcontrolmoduleinput/outputs.RepairGroup130
ChecksensoroutputsignaltoDMEcontrolmodule.RepairGroup
Code1222:Oxygensensorlean/richcontrolstop

Checkforintakeairleaksorreasonsforrichmíxture.SeeDriveabil-
ityTroubleshootinggivenearlierinthisrepairgroup
Code1223:Coolanttemperaturesensor(NTC)

1Testcoolanttemperaturesensor.RepairGroup130
Testintakeairtemperaturesensor.RepairGroup130
Code1225:Knocksensor#1(DME3.3.1only)

1Checkknocksensorandsensorwiring.RepairGroup120
Checkknocksensorandsensorwiring.RepairGroup120
Code1231:Batteryvoltagemonitor

Testbatteryvoltageandbatterycheckchargingsystemandstarter.
RepairGroup121
Code1234:Speedometer"A"signal(DME3.3.1only)

CheckwiringbetweeninstrumentclusterandDMEcontrolmodule.
ElectricalWiringDiagrams
Code1237:A/Ccompressorcutoff(DME3.3.1only)

TestDMEcontrolmoduleinputs/outputsfromA/Csystem.Repair
Group130
Code1242:A/Ccompressorsignal(DME3.3.1only)

TestDMEcontrolmoduleinputs/outputsfromA/Csystem.Repair
Group130
DRIVEABILITYTROLIBLESHOOTING

100-10 ENGINE-GENERAL
Tabled.OBDIFault(Blink)Codes(continued)
(1992-1995modeisonly)
GraphicrepresentationofflashingCheckEnginelightfaultcode:1221
-;5Seconds.;--~2.5r
----------------CheckEnginelighton
Faultcodeandmeaning

Correctiveaction
CheckEnginelightoff
Code1243:Crankshaftpositionsensor(DME3.3.1only)

Testcrankshaftposition/rpmsensorandwiringfromsensorloDME
controlmodule.RepairGroup120
Code1244:Camshaftpositionsensor(DME3.3.1only)

TestcamshaftpositionsensorandwiringfromsensortoDMEcon-
trolmodule.RepairGroup130
Code1245:Electronictransmissioncontrolintervention(DME3.3.1

CheckwiringbetweenDMEcontrolmoduleandauto.transmission
only)

controlmodule
Code1247:Ignitionsecondarymonitor(DME3.3.1only)

Checksecondaryvoltageloignitioncoils.Checkwiringatignition
coils.RepairGroup120
Code1251:Fuelinjector#1(DME3.113.3.1only)

1Testinjectoroperation/signalloinjector.Repairgroup130
Code1252:Fuelinjector#2(DME3.113.3.1only)

Testinjectoroperation/signalloinjector.Repairgroup130
Code1253:Fuelinjector#3(DME3.1/3.3.1only)

Testinjectoroperation/signaltoinjector.Repairgroup130
Code1254:Fuelinjector#4(DME3.1/3.3.1only)

Testinjectoroperation/signaltoinjector.Repairgroup130
Code1255:Fuelinjector#5(DME3.1/3.3.1only)

Testinjectoroperation/signaltoinjector.Repairgroup130
Code1256:Fuelinjector#6(DME3.1/3.3.1only)

Testinjectoroperation/signalloinjector.Repairgroup130
Code1261:Fuelpumpcontrol

Testfuelpumprelayandfuelpumpcircuit.Repairgroup160
Code1262:Idlespeedcontrol

Testidleaircontrolvalveandsignaltovalve.RepairGroup130
Code1263:Fueltankevaporative(EVAP)system

TestEVAPpurgevalve.RepairGroup160
Code1264:Oxygensensorheater

1Testoxygensensorheaterandheaterrelay.Repairgroup130
Code1265:Checkenginelamp(DME3.3.1only)

1Testforfaultybulborwiring.ElectricalWiringDiagrams
Code1266:VANOS(DME3.3.1only)

1TestVANOSsolenoid.CheckforsignaltoVANOSsolenoid.
Code1267:Airpumprelaycontrol(DME3.3.1only)

Testairpumprelayandwiring(whereapplicable)ElectricalWiring
Diagrams
Code1271:Ignitioncoil#1(DME3.3.1only)

Testignitioncoilandwiringtoignitioncoil.RepairGroup120
Code1272:Ignitioncoil#2(DME3.3.1only)

Testignitioncoilandwiringloignitioncoil.RepairGroup120
Code1273:Ignitioncoil#3(DME3.3.1only)

Testignitioncoilandwiringloignitioncoil.RepairGroup120
Code1274:Ignítioncoil#4(DME3.3.1only)

Testignitioncoilandwiringtoignitioncoil.RepairGroup120
Code1275:Ignitioncoil#5(DME3.3.1only)

Testignitioncoilandwiringloignitioncoil.RepairGroup120
Code1276:Ignitioncoil#6(DME3.3.1only)

Testignitioncoilandwiringloignitioncoil.RepairGroup120
Code1281:DMEcontrolmodulememorysupply(DME3.3.1only)

CheckvoltagesupplyfrombatteryloDMEcontrolmodule.Electri-
Code1282:Faultcodememory(DME3.3.1only)

CheckDMEcontrolmoduleinputs/outputs.Controlmodulemaybe
faulty.RepairGroup130
Code1283:Fuelinjectoroutputstage(DME3.3.1only)

CheckDMEcontrolmoduleinputs/outputs.Controlmodulemaybe
faulty.RepairGroup130
DRIVEABILITYTROUBLESHOOTING
calWiringDiagrams

GraphicrepresentationofflashingCheckEnginelightfaultcode:1221
-;5Seconds.~-

2.5;-
Faultcodeandmeaning

Correctiveaction
Code1286:Knockcontroltestpulse(DME3.3.1only)

CheckDMEcontrolmoduleinputs/outputs.Controlmodulemaybe
faultyRepairGroup130
Code1000(lightremainsoff):

Endoffaultcodeoutput-allfaultcodeshavebeendisplayed.No
~
correctiveactionnecessary.Repeattestifnecessary
Code1444:

Nomorefaults.Nocorrectiveactionnecessary.Thiscodemustbe
presentloerasefaultmemory
BasicRequirements

PreventiveMaintenance
Thefollowinglistcontainsbasicchecksthatshouldbe
madewhenexperiencingdriveabilityproblems.
1.Checkintake(induction)systemforleaks.Checkfor
cracked,loose,ordisconnectedhosesandductwork.
Checkthatallhoseclampsaretight.
NOTE-
Anairleakallowsunmeasuredairtoentertheengine,
offenresultinginaninoverlyleanfuelmixtureand
causingdriveabilityproblemswhichwillcausethe
CheckEnginelighttocomeon.
Tabled.OBDIFault(Blink)Codes(continued)
(1992-1995modelsonly)
7-1--------------CheckEnginelighton
ENGINE-GENERAL 100-11
CheckEnginelightoff
Theconditionofthefuel,ignitionandemissioncontrolsys-
temcomponentshasadirecteffectonengineperformance
anddriveability.BMWspecifiesmaintenanceofcertainparts
atregularintervalslokeeptheengineinpropertune.Extend-
ingmaintenanceintervalsbeyondthetimeormileagerecom-
mendedbythemanufacturercanadverselyaffectthewaythe
engineruns.Whentroubleshootingdriveabilityproblems,a
goodstartingpointistoperformamajorengineservice,par-
ticularlyifoneisoverdue.Formaintenanceschedules,major
engineserviceandotherdriveability-relatedmaintenance
procedures,see020MaintenanceProgram.
BasicEngineSettings
2.Checkthatthebatteryisingoodcondition.Checkthat
thecablesaretightandfreeofcorrosionatbothends.

Idlespeed,idlemixture(%CO),andignitiontimingarenot
Checkthatallrelatedgroundpointsarefirmlyconnect-

adjustable.Theadaptiveenginemanagementsystemisde-
edandingoodcondition.Checkal¡harnessconnectors

signedloautomaticallycompensateforchangesinengineop-
fordamageandcorrosion.

eratingconditions,althoughtheadaptiverangeislimited.
Oncetheselimitsareexceeded,driveabilityproblemsusually
3.CheckforprwerandgroundattheEngineControl

becomenoticeable.
Module(ECM).CheckthemaingroundsfortheECM.
See130FuelInjection.

NOTE-
IftheDMEadaptivelimitsareexceeded,theCheckEn-
4.Checkthefuses.Checkforsufficientfuelinthetank.If

ginelightwillcomeon,indicatinganemissionrelated
theengineranoutoffuel,itwilltakealittletimetore-

fault.See130FuelInjection,
storefuelpressure.See160FuelTankandFuel
Pump.
OxygenSensors
5.Checkforsparkatthesparkplugs.Ifthetachometer
needlebounceswhiletheengineiscrankedbythe

Ahighoxygenlevelintheengineexhaustindicatesalean
starterthentheignitionsystemisprobablyworkingcor-

air-fuelmixtureandalowoxygenlevelindicatesarichmix
rectly.See120IgnitionSystem.

ture.Theoxygensensor,showninFig.10,measurestheoxy-
gencontentintheexhaustgasandgeneratesavariable
6.CheckforanyfaultsthroughtheOn-BoardDiagnostics

voltagesignal.Usingthatfeedbacksignalasaninput,the
system.SeeOn-BoardDiagnostics(OBD).

DMEcontrolmodulefinetunestheair-fuelmixture.
DRIVEABILITYTROUBLESHOOTING

100-12ENGINE-GENERAL
NOTE-
Theoxygensensorsignalisignoreduntiltheengine
reachesaspecifiedminimumtemperature.Therefore,

Theprimaryinputusedbythefuelinjectionsystemtodeter-
whentroubleshootingcoldenginedriveabilityprob-

minehowmuchfuelshouldbedeliveredisthesignalfromthe
lems,theoxygensensorcanberuledoutasapossible

massairflowsensorintheintakeairductwork.
cause.
Astheoxygensensorages,itsabilitytoreactquicklyto
changingconditionsdeteriorates,anditmayeventuallycease
toproduceanysignalatall.Tochecktheoperationoftheoxy-
gensensor,see130FuelInjection:
NOTE-
On1996andlatercars,OBD11enhancedemission
standardsrequiretheenginecontrolmodule(ECM)to
monitortheoxygencontentintheexhaustbothbefore
andafterthecatalyticconverter.Thisallowsfortighter
controlofthetailpipeemissionsandalsoallowsthe
ECMtodiagnoseconverterproblems.IftheDMEde-
tectsthatcatalyticconverteroroxygensensorefficien-
cyhasdegradedpastacertainpre-programmedlimit,
itwillturnontheCheckEnginelight,andstoreadiag-
nostictroublecode(DTC)intheECM.
DRIVEABILITYTROUBLESHOOTING
Catalytic
B9506
AirFlowMeasurementandVacuumLeaks
Becauseproperfuelmeteringdependsonaccuratemea-
surementoftheincomingair,anyunmeasuredairthatenters
theenginedownstreamofthemassairflowsensorwillcause
aleanair-fuelmixtureandpossiblyaffectdriveability.
NOTE-
Fig.10.Regulatingoxygensensormeasuresoxygencontentofex-

gatteryVoltage
hausYgasasindicatorof.¡_fi.1ratioand"-k,.E-effi-
ciency.Monitoríngoxygensensor(notshown)monitors
Ifalargeairleakiscausingdriveabilityproblems,the
CheckEnginelightwillusuallybeilluminatedanda
faultwillbestoredinthefaultcodememory.SeeOn
BoardDiagnostics(OBD).
Therearemanyplacesforunmeasuredairtoentertheen-
gine.First,inspectallhoses,fittings,ducts,seals,andgaskets
intheintakeairtractforcracksorlooseness.Itmaybeneces-
sarytoremovepartsthatcannotbefullycheckedintheirin-
stalledpositions.Alsomakesurealloftheintakemanifoldand
throttlebodymountingnutsaretight.
Inadditiontoairleaks,airrestrictionscanalsocausedrive-
abilityproblems.Removetheairfilterandholdituptoastrong
lightsource.Ifthefilterdoesnotpasslight,itisrestrictedand
shouldbereplaced.Also,removetheintakeairductworkand
checkforoilydepositsatthethrottleplate.Buildupinthisarea
cancauseanerraticidle.Cleanawayanydepositsusinga
clothwettedwithcarburetorcleanerandreinstalltheductwork.
CAUTION-
Donotspraycarburetorcleanerdirectlyinthethrot-
tleanea.Sprayingcleanermayforceitintothethrot-
tlepositionswitchorsensorandcausedamage.
catalyticconverteroperation.

Alloftheelectricalcomponentsinthefuelinjectionandigni-
tionsystemsrequireaminimumvoltagetooperateproperly.
Whentroubleshootingenginedriveabilityproblems,oneof
Replacementofoxygensensorsatthespecifiedintenralsen-

thefirstchecksshouldbetomakesurethebatteryisfully
suresthattheengineandemissioncontrolsystemwilicontinue

chargedandcapableofdeliveringallitspowertotheelectrical
tooperateasdesigned.Astheoxygensensorages,itsabilityto

system.
reactquicklytochangingconditionsdeteriorates,anditmay
eventuallyceasetoproduceanysignalatall.

Tomakeaquickcheckofbatterycharge,measurethevolt-
ageacrossthebatteryterminalswithallcablesattachedand
Astheoxygensensorages,itsabilitytoreactquicklyto

theignitionoff.Afullychargedbatterywillmeasure12.6volts
changingconditionsdeteriorates,anditmayeventuallycease

orslightlymore,comparedto12.15voltsforabatterywitha
toproduceanysignalatall.Tochecktheoperationoftheoxy-

25%charge.
gensensor,see130FuelInjection.
Evenafullychargedbatterycannotdeliverpowerunlessit
isproperlyconnectedtotheelectricalsystem.Checkthebat-
teryterminalsforcorrosionandloosecableconnections.Ifthe
batterydoesnotmaintainthepropervoltage,thecharging
systemmaybeatfault.See121Battery,Starter,Alternator.

Ifabatterycableconnectionhasnovisiblefaults,butisstill
suspect,measurethevoltagedropacrosstheconnection.A
largedropindicatesexcessiveresistance,meaningthecon-
nectioniscorroded,dirty,ordamaged.Cleanorrepairthe
connectionandretest.
NOTE-
Forinstructionsonconductingavoltagedroptest,and
othergeneralelectricaltroubleshootinginformation,
see600ElectricalSystem-General.
WiringandHarnessConnections
Theelectronicfuelinjectionandignitionsystemsoperateat
lowvoltageandcurrentvalues,makingthemsensitiveto
smallincreasesinresistance.Theelectricalsystemisroutine-
lysubjectedtocorrosion,vibrationandwear,sofaultsorcor-
rosioninthewiringharnessandconnectorsarecommon
causesofdriveabilityproblems.
Visuallyinspectallwiring,connectors,switchesandfuses
inthesystem.Looseordamagedconnectorscancauseinter-
mittentproblems,especiallythesmallterminalsintheECM
connectors.Disconnectthewiringharnessconnectorsto
checkforcorrosion;anduseelectricalcleaningspraytore-
movecontaminants.Often,simplydisconnectingandrecon-
nectingadirtyconnectorseveraltimeswillcleantheterminals
andhelptoreestablishgoodelectricalcontact.
Ifawiringharnessconnectorhasnovisiblefaults,butisstill
suspect,measurethevoltagedropacrosstheconnector.A
largedropindicatesexcessiveresistance,meaningthecon-
nectoriscorroded,dirtyordamaged.Cleanorrepairthecon-
nectorandretest.
GroundConnections
Foranyelectricalcircuittowork,itmustmakeacomplete
path,beginningatthepositive(+)batteryterminalandending
atthenegative(-)terminal.Thenegative(-)batterycableis
attachedtothecar'schassis.Therefore,anywireormetal
partattachedtothechassisprovidesagoodgroundpathback
tothenegative(-)batteryterminal.
Poorgroundconnectionsareamajorsourceofdriveabílity
problems.Ifanyofthemaingroundconnectionsfortheigni-
tionsystemorthefuelinjectionsystemarefaulty,thein-
creasedresistanceinthatcircuitwillcauseproblems.
Visuallyinspectal¡groundwiresandconnectionsfor
breaks,loosenessorcorrosion.Becarefulbecausewires
sometimesbreakinternallyorinareasnoteasilyvisible.The
maingroundsfortheDMEsystemareshowninFig.11,Fig.
12,andFig.13.Alsocheckthemainfuelpumpgroundinthe
centerconsole,belowtheemergencybrakehandle.
Ifagroundconnectionhasnovisiblefaults,butisstillsuspect,
measurethevoltagedropacrosstheconnection.Alargedrop
indicateshighresistance,meaningtheconnectioniscorroded,
dirtyordamaged.Cleanorrepairtheconnectionandretest.
ENGINE-GENERAL 100-13
UU,~uyi
Fig.11.Mainground(arrow)forenginemanagementsystem.
Groundsareinrightrearofenginecompartment.
Fig.12.MaingroundforignitioncoilsonMS41.1enginemanage-
mentsystem(arrow).
DRIVEABILITYTROLIBLESHOOTING

100-14ENGINE-GENERAL
0013131
Fig.13.Mainchassisground(arrow)inleftfrontofenginecompart-
ment.
FuelSupply
Fortheenginetostartandrunproperly,theinjectionsys-
temmustdeliverfuelinpreciseproportiontotheamountofair
enteringtheengine.Todothis,theinjectionsystemrequires
anunrestrictedsupplyoffuelfromthefuelpump.
Ifthefuelpumpisnotworking,theenginewillnotrun.Ifthe
fuelfilterorafuellineisrestricted,theenginemayrunpoorly.
Iftherestrictionissevereenoughtheenginewillnotstart.lf
fueldeliveryproblemsaresuspected,performthetestsde-
scribedin160FuelTankandFuelPump.
Thefuelpressurecreatedbythefuelpumpiscontrolledbya
pressureregulatorthatreturnsexcessfueltothetank.Any
changeinfuelpressurewillcauseachangeinthebaseair-fuel
mixturedeliveredtotheengine.Ifthefuelpressureistoolow,the
baseair-fuelmixturewillbelean.lfthefuelpressureistoohigh,
thebasemixturewillberich.Fuelpressuretestsaredescribed
in160FuelTankandFuelPumpand130FuelInjection.
NOTE-
Fuelpressuretestsrequireapressuregauge.Ifthis
toolísnotavaílable,thetestscanbeperformedbyan
authorizedBMWdealerorotherqualifiedshop.
DRIVEABILITYTROUBLESHOOTING
Properlyoperatingfuelinjectorsplayamajorroleinfuelde-
livery.TheDMEECMswitchestheinjectorsonandoffatthe
negative(-)orgroundsideoftheconnectors.Posítíve(+)bat-
teryvoltageisalwayspresentattheconnectorswhentheen-
gineisrunning.Aninjectorthatfailsorlosespowerwillnot
open,creatingaleanair-fuelmixtureandcausingtheengineto
runpoorlywhencoldorstumbleonacceleration.Aninjector
thatshortstogroundwillremainopenconstantlywhentheen-
gineisrunning,creatingarichair-fuelmixturethatcandilute
engineoil,foulthesparkplugs,causearoughidle,anddamage
thecatalyticconverter.
Tableelistsadditionalsymptomsofcommonenginedrive-
abilityproblems,theirprobablecauses,andthesuggested
correctiveactions.Theentriesinboldtypeinthecorrective
actioncolumnindicatetherepairgroupswhereapplicabletest
andrepairprocedurescanbefound.
NOTE-
MostofthesymptomsfistedinTableewillalsocause
theCheckEnginelighttocomeon.Ifthelightison,
checkforanystoredfaultsasthefirststepíntrouble-
shootingdriveabilitycomplaints.

al Icld
Tablee.EngineDriveabilityTroubleshooting
cl

1

I

f

I

IOxygensensorfaulty

Testoxygensensor.
ENGINE-GENERAL 100-15
SYMPTOMS
a.Enginefafstostart
b.Enginestartsbutstopsimmediately
c.Erraticengineidle
d.Poorengineresponseonacceleration
e.Erraticengineoperationinal¡speedranges
f.Excessivefuelconsumption
g.Poorenginepower,failstorevup
h.COcontenttoolow
i.COcontenttoohigh
CAUSES

CORRECTIVEACTION
a

Fuelpumpfaulty

Testfuelpump.RepairGroup160
a

e

Ignitionsystemfaulty

Testignitionsystem.RepairGroup120
a

Mainrelayorfuelpumprelayfaulty

Testmainrelay.RepairGroup130
a

Crankshaft/rpmpositionsensorfaulty

Testcrankshaft/rpmsensor.120
b

c

h

i

ldlespeedcontrolvalvefaulty

Testidlespeedcontrolvalve.
c

d

e

Throttlepositionsensorfaultyoridlesignalto

Testthrottlepositionsensor.
DMEcontrolmodulemissing.
c

d

h

i

Massairflowsensorfaulty

TestmassairflowsensorRepairGroup130
a

b

c

d

e

h

Largeairintakesystemleak

Checkformajorintakeairleaksdownstreamof
massairflowsensor.
a

c

d

e

g

h

Fuelpressuretoolow

Testfuelpressure.RepairGroup130
?

I

Fuelpressuretoohigh

Testfuelpressure.RepairGroup130
d

e

g

h

Fuelpumpdeliveryvolumetoolow

Testfuelpumpdeliveryvolume.RepairGroup
160
a

c

e

f

hqC
oolanttemperaturesensorfaulty

--]
Testcoolanttemperaturesensor.
c

e

~

f

i

~Fuelinjectorsleaking

Checkfuelinjectorsandreplaceleakinginjectors.
~
RepairGroup130
Throttleplatebindingorincorrectlyadjusted

Checkthrottleplateandadjustifnecessary.
a

c

Electricalconnectionsloose,broken,orcor-

Visuallyinspectconnectorsandcorrectany
roded

faults.RepairGroup600
Groundconnectionsloose,broken,orcorroded

Visuallyinspectgroundconnectionsandcorrect
anyfaults.RepairGroup600
c

e~

f

COcontenttoohigh

Testairflowormassairflowsensor.Repair
~
Group130
a

b

c

d

e

COcontenttoolow

Testmassairflowsensor.
g
b

c

d

e

f

g

h

i

InputsignalstoECMmissing,ECMinlimp

MakeelectricaltestsatDMEECMrelay.Repair
homemode

Group130
a~b~c~d

e]

f

g

h

i

ECMfaulty

TestDMEECMinputs.Ifallinputsarecorrect,
replaceECM.
DRIVEABILITYTROUBLESHOOTING

110EngineRemovalandInstallation
GENERAL............................110-1

Engine,removingandinstalling
(4-cylinderengines).....................110-1
ENGINEREMOVALANDINSTALLATION110-1

Engine,removingandinstalling
(6-cylinderengines).....................110-4
GENERAL
Somespecialtoolsarerequiredforremovalandinstallation
oftheengine.Besuretohavethenecessaryequipmenton
handbeforestartingthejob.
CAUTION-
"Engineremovalrequiresdisconnectingthebat-
tery.Thismayeraseanysystemfaultcode(s)
thathavebeenstoredincontrolunitmemories.
Checkforfaultcodespriortodisconnectingthe
batterycables.
"IftheCheckEnginelightisilluminatedwiththe
enginerunning,see100Engine-Generalfor
On-BoardDiagnostics(08D)faultcodeinfor-
mation.
"Ifanyothersystemfaultshavebeendetected,as
indicatedbyanilluminatedANTILOCK,SRSor
ASTwarninglight,seetheappropriaterepair
groupinthismanualoranauthorizedBMW
dealerformoreinformationonfaultcodes.
ENGINEREMOVALANDINSTALLATION
Engine,removingandinstalling
(4-cylinderengines)
Coveral¡paintedsurfacesbeforebeginningtheremoval
procedure.Asanaidtoinstallation,labelal¡components,
wires,andhosesbeforeremovingthem.Donotreusegas-
kets,O-ringsorsealsduringreassembly.
WARNING-
Duetoriskofpersonalinjury,besuretheengineis
coldbeforebeginningtheremovalprocedure.
1.Disconnectnegative(-)cablefrombatteryinluggage
compartment.

0011969
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
ENGINEREMOVALANDINSTALLATION

110-1
2.Removetransmissionfromcar.See230Manual
Transmissionor240AutomaticTransmission.
3.Removeenginehoodorplacehoodinservicepositíon.
See410Fenders,EngineHood.
NOTE-
ttisnotnecessarytoremovetheenginehood,butitis
helpfulandwillmakeengineremovalandinstallation
easier.
4.Removesplashguardunderengine,ifapplicable.
5.Unboltignitioncoilassemblyfrombracketonstruttow-
er.Disconnectwiringtoignitioncofs,thenplacecoil
assemblyonengine.
6.Disconnectal¡cablesandharnessconnectorsatthrot-
tlehousing.
7.Unboltandremovecompleteaircleanerhousingwith
massairflowsensor,disconnectingandlabelingcon-
nectors,ductingandhosesasnecessary.SeeFig.1.
Fig.1.

Intakeairducthoseclamp(A),massairflowsensorconnec-
tor(B),andaircleanertoairflowsensorclips(C)onM44en-
gine.
ENGINEREMOVAL ANDINSTALLATION

110-2

ENGINEREMOVALANDINSTALLATION
8.Drainenginecoolantandremovecoolanthosesat-

10.Removeradiatorcoolingfanandradiatorasdescribed
tachedtocylinderhead.

in170RadiatorandCoolingSystem.
"Drainradiatorandengineblock.See170Radiator
andCoolingSystem.

NOTE-
"Disconnecthosesfromthermostathousingatfrontof

Somelate4-cylindermodelsuseanelectricprímary
cylinderhead.

coolingfan.
"Disconnectheaterhosesatrearofengine.SeeFig.2.
CAUTION-
NOTE-

Oncarswithviscous-typecoolingfans,theradia-
"Theblockdrainplugislocatedontheexhaustsideto-

torfanhaslefthandthreads.
wardsrearofengine.
"Removesmallplasticlockclíptopullradiatordrain

11.Removeupperintakemanifold,unfastencableduct
plugoutcompletely.

fromlowerintakemanifold,crankcaseventvalvehose
(M44engineonly)
0012687
Fig.2.

Coolanthosesatheatervalveandheatercoretobediscon-
nected(arrows).
9.Removeairshroudfromtopofradiator.SeeFig.3.
ENGINEREMOVAL ANDINSTALLATION
12.Disconnectfuelsupplyandfuelreturnlines,mainen-
gineelectricalconnectors,andlowerintakemanifoldas
describedin113CylinderHeadRemovalandInstal-
lation.SeeFig.4.
0012504
Fig.4.

Crankcaseventvalve(A)ontopoflowerintakemanifoldof
M44engine.FueldeliveryandretumlinesshownatB.Engine
harnessandsensorconnectorsshownatC.
WARNING-
"Fuelmaybeexpelledunderpressure.Donot
smokeorworknearheatersorotherfirehaz-
ards.Keepafireextinguisherhandy.Beforedis-
connectingfuelhoses,wrapaclotharoundfuel
hosestoabsorbanyleakingfuel.Plugallopen
fuellines.
"Alwaysunscrewthefueltankcaptoreleasepres-
sureinthetankbeforeworkingonthetankor
lines.
CAUTION-
0013137

IStuffcleanragsintotheopenintakeportstopre-
Fig.3.

Frontairshroudmountingscrews(arrows).

ventanypartsfromfallingintotheengineintake.
13.Disconnectvacuumhosefrombrakeboosteronbulk-
head.Coverbothholeinboosterandplughoseend.

14.Unboltpowersteeringfluidreservoirfromítsmounting
bracket.Usestiffwiretohangreservoirtooneside.Do
notdisconnectfluidlines.
15.Removepowersteeringpumpdrivebeltandremove
pumpfromitsmountingbracket.Usestiffwiretohang
pumpfrombody.
16.Oncarswithautomatictransmissionremovefrontand
rearbracketsholdingautomatictransmissioncooler
linestoengine.
17.RemoveA/Ccompressorfromitsmountingbracket
withoutdisconnectinganyrefrigerantlines.SeeFig.5.
ENGINEREMOVALANDINSTALLATION

110-3
21.Removefrontexhaustpipefromexhaustmanifold.See
Fig.6.
22.Installanengineliftingdeviceandraiseengineuntilits
weightissupported.Removenutsandgroundstrap
fromleftandrightenginemounts.
0011967
Fig.6.

Frontexhaustpipetoexhaustmountingnuts(arrows),as
viewedfrombelowon4-cylinderengine.
23.Carefullyraíseengineoutofcar,checkingforanywir-
ingharnesses,fuellines,ormechanicalpartsthat
mightbecomesnaggedasengineisremoved.
24.Installationisreverseofremoval,notingthefollowing:
"Replaceallgaskets,O-ringsandseals.
"Changeengineoilandfilterandcheckal¡otherfluid
levels.See020MaintenanceProgram.
"Refillandbleedcoolingsystem.See170Radiator
andCoolingSystem.
"Insta¡¡thefrontexhaustpipesusingnewgasketsand
self-lockingnuts.Usecopperpasteonthreads.See
180ExhaustSystem.
TighteningTorques
"Coolantdrainplugtocylinderblock.25Nm(18ft-Ib)
Fig.5.A/Ccompressormountingbolts(arrows).

"Enginemounttosubframe
M8......:...............,:..22Nm(17ft
-1b),
18.MoveA/Ccompressoroutofwaywithoutdistortingor

M10.....

..................45Nm(33ft'-Ib)
damaginganylines.Supportcompressorbyhangingit

"Intakemanifoldtocylinderhead
fromchassisusingstiffwire.

M7..........................15Nm(11ft-Ib)
M8..........................22Nm(16ft-Ib)
19.Disconnectwiringfromstarterandalternator.Move

`"Radiatorcoolingfantocoolantpump40Nm(30ft-Ib)
wiringharnessoutofway.See121Battery,Starter,

"Radiatordrainscrewtoradiator...2.5Nm(22in-lb)
Alternator.

"Wiringtoalternator(M8nut)........12Nm(9ft-1b)
"Wiringtostarter
20.Removeoildipstickguidetube.NoteO-ringatbaseof

M6nut........................:5Nm(44in-lb)
tubewhenremoving.

M8nut........................12Nm(9ft-Ib)
ENGINEREMOVALANDINSTALLATION

110-4

ENGINEREMOVALANDINSTALLATION
Engine,removingandinstalling
(6-cylinderengines)
Engineremovalproceduresforthevarious6-cylinderen-
ginesarecoveredinthissection.Moststepsintheproce-
duresaresimilarorthesameforal¡engines.Specific
differencesthatapplyarenotedatthebeginningofeachstep.
Besuretocoverallpaintedsurfacesbeforebeginningthe
removalprocedure.Asanaidtoinstallation,labelallcompo-
nents,wires,andhosesbeforeremovingthem.Donotreuse
gaskets,O-ringsorsealsduringreassembly.
WARNING-
Duetoriskofpersonalinjury,besuretheengineis
coldbeforebeginningtheremovalprocedure.
1.Disconnectnegative(-)batterycableinluggagecom-
partment.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
2.Removeenginehoodorplacehoodinserviceposition.
See410Fenders,EngineHood.
NOTE-
1tisnotnecessarytoremovetheenginehood,butitis
helpfulandwillmakeengineremovalandinstallation
easier.
3.Removesplashguardunderengine,ifapplicable.
4.Removetransmissionfromcar.See230Manual
Transmissionor240AutomaticTransmission.
5.Removevacuumhosefrombrakeboosteronbulkhead.
Coverholeinboosterandplughoseend.
6.Removeintakeairplenumpanelinrearofenginecom-
partment.See640HeatingandAirConditioning.
7.Removegroundstrapfromtimingcasecover,ifappli-
cable.
8.Removetopenginecoversanddisconnectignitioncoil
harnessconnectors.Workingatfuelinjectors,pryopen
smallwireclipsateachinjector.Removemainharness
hold-downnutsandliftcompleteharnessaway.See
Fig.7.
ENGINEREMOVALANDINSTALLATION
Fig.7.

Removemainharnessfromtopengineandplaceatbaseof
windshield.
0012703
Fig.8.

Massairflowsensorconnectorairducthoseclamp,andair
cleanerhousingmountingbolts(arrows).
9.Unboltandremovecompleteaircleanerhousingwith

10.Oncarswithautomatictransmission,removefrontand
massairflowsensor,disconnectingandlabelingcon-

rearbracketsholdingtransmissioncoolerlinestoside
nectors,ductingandhosesasnecessary.SeeFig.8.

ofengine.

11.DraínenginecoolantandRmovecoolanthosesat-
tachedtocylinderhead.
"Drainengineblockbyremovingblockdrain.
"Disconnecthosesfromthermostathousinginfrontof
cylinderhead.
"Disconnectheaterhosesatrearofengine.SeeFig.9.
"Drainradiatorbyremovingthreadedplasticplugfrom
lowerleftcomer.
NOTE-
"Theblockdrainplugislocatedohtheexhaustsideto-
wardsrearofengine.
"Removesmallplasticlockcliptopulíradiatordraín
plugoutcompletely.
NOTE-
CAUTION-
Radiatorfanhaslefthandthreads.
ENGINEREMOVALANDINSTALLATION

110-5
Fig.9.

Coolanthosesatheatervalveandheatercoretobediscon-
nected(arrows).
12.Removeradiatorcoolingfanandradiatorasdescribed
in170RadiatorandCoolingSystem.
13.Labelanddisconnectcoolanthoses,cables,andhar-
nessconnectorsfromthrottlehousing.SeeFig.10.
14.Workingatrearofintakemanifold,labelandthenre-
movefuelsupplyandfuelretumlines.Disconnectfuel
linesfromsupportbracketonmanifold.SeeFig.11.
uu12ivu
Fig.10.ThrottlehousingassemblyonM52engine.Disconnecthos-
es,cablesandharnessconnectorsatandaroundhousing.
0012699
Fig.11.SpecialfuellinefittingatfuelrailonM52/S52USengine.Use
BMWspecialtool161050toreleaselockingfittingsatends
offuellines.
WARNING-
"Fuelmaybeexpelledunderpressure.Donot
smokeorworknearheatersorotherfirehaz-
ards.Keepafireextinguísherhandy.Beforedis-
connectingfuelhoses,wrapaclotharoundfuel
hosestoabsorbanyleakingfuel.Plugalloyen
fuelfines.
"Alwaysunscrewthefueltankcaptoreleasepres-
sureínthetankbeforeworkingonthetankor
lines.
OnM52andS52USengines,specialfittingsareused
toretainthefuellinestothefuelrail.UseBMWspecial

16.Removeintakemanifoldfromenginebyremovingsev-
toolno.161050tocompressthelockingclipinsidethe

enmountingnutsfromaboveandtwomountingbracket
endofthefuellinefittingstoreleasethefine.

boitsfrombelow.SeeFig.12.
15.Unboltpowersteeringfluidreservoirfromitsmounting

CAllTION-
bracket.Usestiffwiretohangreservoirtooneside.Do

Stuffcleanragsintotheopenintakeportstopre-
notdisconnectfluidfines.

ventanypartsfromfallingintotheengineintake.
ENGINEREMOVAL ANDINSTALLATION

110-6

ENGINEREMOVALANDINSTALLATION
Fig.12.Intakemanifoldmountingnutson6-cylinderengine.Alsore-
movetwoboltsfromsupportbrackets(arrows).
17.Workingbelowintakemanifold,disconnectharness
connectors.Cutwiretiesholdingengineharnessto
bulkheadanddisconnectmainengineharnesscon-
nectoratrearofenginecompartment.SeeFig.13.
0013132
Fig.13.Mainengineharnessconnectorsinrearofenginecompart-
ment(arrow).
18.Removepoly-ribbeddrivebelt(s).
19.Removeenginedrivebelt.See020MaintenancePro-
gram.
20.Removepowersteeringpumpfromitsmountingbrack-
et.SeeFig.14.Usestiffwiretohangpumpfrombody.
ENGINEREMOVAL ANDINSTALLATION
Fig.14.Powersteeringpumpmountingbolts(arrows).M52engine
shown.
21.RemoveA/Ccompressorfromitsmountingbracket
withoutdisconnectinganyrefrigerantlines.SeeFig.
15.
Fig.15.A/Ccompressormountingbolts(arrows).

22.MoveA/Ccompressoroutofthewaywithoutdistorting

26.Carefullyraiseengineoutofcar,checkingforanywir-
ordamaginganylines.Supportcompressorbyhanging

ing,fuellines,ormechanicalpartsthatmightbecome
itfromchassisusingstiffwire.

snaggedasengineisremoved.
23.Disconnectwiringfromstarterandalternator.Move

27.Installationisreverseofremoval,notingthefollowing:
wiringharnessoutoftheway.See121Battery,Start-
Replaceal¡gaskets,O-ringsandseals.
er,Alternator.

"Changeengineoilandfilterandcheckallotherfluid
24.RemoveFontexhaustpipefromexhaustmanifold.See

levels.See020MaintenanceProgram.
"Refillandbleedcoolingsystem.See170Radiator
Fig.16.

andCoolingSystem.
"Checkthatenginedrivebeltsproperlyengagethepul-
leygrooves.
"InstalltheFontexhaustpipesusingnewgasketsand
seif-lockingnuts.Usecopperpasteonthreads.See
180ExhaustSystem.
0012525
Fig.16.Frontexhaustpipetoexhaustmanifoldsmountingnutson6-
cylinderengine(arrows).
25.Installanengineliftingdeviceandraiseengineuntilits
weightissupported.Removenutsandgroundstrap
fromleftandrightenginemounts.
ENGINEREMOVALANDINSTALLATION

110-7
TighteningTorques
"Coolantdrainplugtocylinderblock.25Nm(18ft-Ib)
"Enginemounttosubframe
M10.........................45Nm(33ft-Ib)
M8..........................22Nm(16ft-Ib)
"Intakemanifoldtocylinderhead
M7..........................15Nm(11ft-Ib)
M8..........................22Nm(16ft-Ib)
"Radiatorcoolingfantocoolantpump40Nm(30ft-Ib)
"Radiatordrainscrewtoradíator...2.5Nm(22in-lb)
"Wiringtoalternator(M8nut)........12Nm(9ft-Ib)
"Wiringtostarter
M6nut

........................5Nm(44in-lb)
M8nut........................12Nm(9ft-Ib)
ENGINEREMOVALANDINSTALLATION

113CylinderHeadRemovalandInstallation
GENERAL............................113-1

CYLINDERHEAD,6-CYLINDER.......113-10
Cylinderhead,removing(6-cylinderengine)..113-10
CYLINDERHEAD,4-CYLINDER........113-1

Cylinderhead,installing(6-cylinderengine)...113-15
Cylinderhead,removing(4-cylinderengine)...113-1

ECylinderhead,installing(4-cylinderengine)...113-6
GENERAL

CYLINDERHEAD,4-CYLINDER
Theinformationgiveninthisrepairgroupassumesthatthe
engineisinstalledintheenginebay.Forcylinderhead,cam-

Cylinderhead,removing
shaft,andvalvetraindisassemblyandreconditioninginforma-

(4-cylinderengine)
tion,see116CylinderHeadandValvetrain.
Foreaseofusethisremovalprocedureisbrokenintosub-
Intheproceduresgivenbelow,enginesarereferredtoby

sections,asfollows:
enginecode.Ifnecessary,see100Engine-Generalforen-
ginecodeandapplicationinformation.
NOTE-
Ifaheadgasketproblemissuspected,acompression
testwillusuallydetectthefault.See100Engine-Gen-
eralforcompressiontestinginformation.
SpecialBMWservicetoolsarerequiredtoproperlyremove
andinstallthecylinderheadonboththe4-cylinderand6-cyl-
inderengines.Thespecialtoolsareusedtotimetheval-
vetraintothecrankshaftandtoremovetheTorx(El2)head
bolts.Readtheprocedurethroughbeforebeginningthejob.
Coveral¡paintedsurfacesbeforebeginningtheremoval
procedure.Asanaidtoinstallation,labelallcomponents,
wires,andhosesbeforeremovingthem.Donotreusegas-
kets,O-ringsorsealsduringreassembly.
WARNING-
Duetoriskofpersonalinjury,besuretheengineis
coldbeforebeginningtheremovalprocedure.
CYLINDER HEADREMOVAL ANDINSTALLATION

113-1
General
Coolingsystem,draining
Cylinderheadcover,removing
Intakemanifold,removing
Timingchains,uncoupling
Cylinderheadassembly,removing
WARNING-
Allowenginetocoolbeforebeginningthisproce-
dure.
General
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
"Disconnectingthebatterymayerasefault
codees)
storedincontrolmodulememory.Checkforfault
codesusingspecialBMWdiagnosticequipment.
NOTE-
Thebatteryismountedintheluggagecompartment
behindtherightsidetrimpanel.
2.Workingunderneathvehicle,removefrontexhaustpipe
fromexhaustmanifold.SeeFig.1.
3.Disconnectvacuumhosefittingfrombrakeboosteron
rearbulkhead.Plugopeninginboosterandhoseend.
CYLINDERHEAD,4-CYLINDER

113-2

CYLINDERHEADREMOVALANDINSTALLATION
0011s6i

-
0
Fig.1.

Frontexhaustpipetoexhaustmanifoldmountíngnuts
(arrows).
-1

~~ 0013023
4.Removeairfilterhousingcompletewithmassairflow

Fig.3.

CoolanthoseconnectionbeneathintakemanifoldonM42
sensorandattachedhosesandducting.SeeFig.2.

engine(arrow).
0011969
Fig.2.

Airfilterhousing/airintakeconnectionsonM44enginewith
tractioncontrol.Clampatthrottlehousing(A);massairflow
sensorconnector(B);andclipsatupperairfilterhousing(C).
Coolingsystem,draining
5.Draincoolantfromengineblockandradiator.See170
RadiatorandCoolingSystem.
NOTE-
"Theblockdrainisontheexhaustsideoftheengine,
nearcylinderno.4.
6.Disconnecthosesfromcoolantflange/thermostathous-
ingonfrontofcylinderhead.Unboltthermostathousing
fromcylinderhead.
CYLINDERHEAD,4-CYLINDER
7.OnM42engines,disconnecthosefromcoolantpipeon
leftsideofengine.SeeFig.3.
8.Disconnectheaterhosesfromcoolantflangeonrearof
cylinderhead.
Cylinderheadcover,removing
9.Removeignitioncoilpackfromrightstruttower.See
Fig.4.
0011995
"Theradiatordrainplugisonthebottomoftheradiator

Fig.4.

Cylinderheadcovershowinglocationofenginebreatherhose
onthedriver'sside.Removesmallplasticlockclipto

(A),wiringharnessduct(B),andignitioncoilpack(C).M44
pullradiatordrainplugoutcompletely.

engineshown.CoveronM42engineissimilar.
10.Disconnectenginebreatherhosefromcylinderhead
cover.

11.Detachwiringharnessductatrearbulkheadpaneland
pullcompleteductforwardanduptoallowaccessto
rearofcylinderheadcover.
12.Removesparkplugsandsparkplugwireloom.
"Removeplasticcoverfromtopofcylinderhead.
"Disconnectsparkplugwiresfromsparkplugsandre-
movesparkplugs.
"Unboltsparkplugcableharnessandheatshieldfrom
rightsideofcylinderheadcoverandsetaside.
13.Unscrewandremovecylinderheadcovercapscrews
andremovecover.SeeFig.5.
CAUTION-
Twoofthecoverhold-downscrewsareunderthe
sparkplugcableduct.
NOTE-
Makenoteofthearrangementofcapscrews,washers
andrubbergrommetsholdingthecylinderheadcover
inplace.
Fig.5.

Cylinderheadcovermountingpoints(arrows).
Fig.7.

M44fuelrailairconnection(A)andfuelsupplyandreturnlines
Intakemanifold,removing

(B).
14.Onlateengines,disconnectinjectorairshroudinghose
fromfittingatcenterofupperintakemanifold.

18.Disconnectfuelsupplyandreturnlinesfromfuelrail.
15.Removeuppersectionofintakemanifold.
"Disconnectalicablesharnessconnectorsfromthrottle
housingandintakemanifold.
"Disconnectfueltankventhosefromventvalveonlow-
ersitieofmanifold.
"Removemanifoldsupportbrackets.SeeFig.6.
"Removeupper-to-lowermanifoldfasteners(1bolt,2
nuts)andseparateuppermanifoldfromlowermani-
fold.
Notelocatingdoweisleevesonlowertouppermanifold
mountingstuds.Removedowelsandsetaside.SeeFig.8.
CYLINDERHEADREMOVALANDINSTALLATION

113-3
0012686
Fig.6.

Intakemanifoldsupportbracketsandmountinghardware.
ManifoldforM44engineshows.
16.Disconnectoildipsticktubebracketfromlowermanifold
section.
17.OnM44engine,relievefuelpressureusingcom-
pressedair(maximum3barpressure)atschroeder
valveonfuelrail.Brieflyapplyairpressuretoforcefuel
backintofueltank.SeeFig.7.
WARNING-
"Thefuelsystemretainsfuelpressurewhenthe
engineisoff(upto75psi).Usecarewhendis-
connectingfuellines.Unscrewthefueltankcap
toreteasepressureinthetank.Wrapaclean
shoptowelaroundthefittingwhenloosening.
"Fuelishighlyflammable.Whenworkingaround
fuel,donotdisconnectanywiresthatcouldcause
electricalsparks.Donotsmokeorworknear
heatersorothertirehazards.Placeatireextin-
guisherinthevicinityoftheworkarea.
19.Disconnectcoolanthosesfromventvalveonlowerintake
manifold.Removecrankcaseventvalvefrommanifold.
CYLINDERHEAD,4-CYLINDER

113-4

CYLINDERHEADREMOVALANDINSTALLATION
20.Disconnectmainenginewiringharnessconnector.La-
belanddisconnectharnessconnectorsforcrankshaft
andcamshaftsensors.SeeFig.8.
0012504
Fig..Crankcaseventvalve(A),camshaftandcrankshaftsensor
harnessconnectors(B),locatingbushings(C),mainengine
wiringharnessconnector(D).M44engineshown.
NOTE-
Earlyenginesdonothaveamaíndisconnectatthe
lowerintakemanifoldharness.lfnecessary,remove
thecableductingboltsandsetharnessductingaside.
21.Removélowersectionofintakemanifold.
"RemoveYshapedsupportbracketfromundersideof
manifold.(SeeFig.6.)
"Unboltsupportbracketsfromalternatorandstarter.
"Removenutsholdingmanifoldtocylinderheadand
pullmanifoldbackuntilharnessconnectorsforoil
pressureswitchandcoolanttemperaturesensorare
accessible.Labelanddisconnectconnectors,thenre-
movemanifoldandsetaside.
Timingchains,uncoupling

26.LockcrankshaftinTDCpositionbyinsertíngBMWspe-
22.OnM42engines,removethermostathousingfromup-

cialtoolno.112300throughboreandintoholeinfly-
pertimingchaincover.

wheelordriveplate.SeeFig.11.
23.OnlateM44engines(January1997andlater),remove

NOTE-
secondaryairinjectioncheck-valvefromfrontofengine

"Ifnecessary,removeplugfromlocatingboreinlower
andlayaside.

edgeofbellhousingtoinsertlockingtool.
24.Removecylinderidentificationsensorfromuppertim-
ingchaincover.Removeuppertimingchaincover.See
Fig.9.
25.SetenginetoapproximateTDCbyrotatinginnormal
operatingdirectionuntilcamshaftlobesatcylinderno.
1arefacingeachother.SeeFig.10.
CYLINDERHEAD,4-CYLINDER
Fig.9.

Uppertimingchaincoverbolts(arrows).Removesecondary
airinjectioncheckvalvefromhose(A)onM44engine.Re-
movecylinderidentificationsensorfromchaincover(B).
0011998
Fig.10.EnginesettoapproximateTDC.Cylinderno.1camshaft
lobesfaceinandarrowsonsprocketspoíntup(arrows).
"Confirmthatthelockingtoolhasbeencorrectlyin-
stalledbytryingtorotatethecrankshaft.
27.LockcamshaftsatTDCbymountingBMWspecíaltool
no.113240oversquareendsofcamshafts.SeeFig.12.
NOTE-
Checkthattoolissquarelyseatedoncylinderhead
gasketsurface.Ifnecessary,rotatecamshaftsslightly
usinganopen-endwrenchathexoncamshafts.

Fig.11.BMWspecialtoolno.112300installedthroughbellhousin
andfintoflywheel(arrow)tolockcrankshaftatTDC.
Fig.12.BMWspecialtoolno.113240installedonrearofcamshafts
toholdthematTDC.(M44engineshown.Otherengínesare
similar.)
CAUTION-
ThecamshaftsmustbelockedintheTDCposition
usingthespecialservicetool,orequivalent,be-
foreremovingthetimingchaín.Thetoolholdsthe
camshaftsparalleltoeachotherandperpendicu-
lartothevalvecovergasketsurface.
CYLINDERHEADREMOVALANDINSTALLATION

113-5
6011966
28.Removehydraulicchaintensionesfromrightsideofcyl-
inderhead.SeeFig.13.
Fig.13.Hydraulicchaintensioner(arrow).
NOTE-
Itisnotnecessarytoremovethecamsprocketsfrom
thechainuntessthesepartsarebeingreptaced.tire
tieeachsprockettothechaintokeepthesprockets
timedtoeachother.Keepingthesprocketstimedwill
símplífyinstaftation.
uu11999
Fig.14.Chainguideandguideadjustingsleeve(arrow).Allen-head
retainingscrewhasbeenremoved.Useslottedscrewdriverto
loosenadjustingsleeve.
29.Removemountingboltsfromleftandrightcamshaft
sprockets.Thenremovecamshaftsprocketsfromcam-

_

Cylinderheadassembly,removing
shafts.OnM44engines,noteorientationofsensor

31.Removecrankshaftlockingtool(BMWspecialtoolno.
wheel.

112300).Usingthecrankshaftvibrationdamperbolt,
30.Removeupperboltfromleftchainguide.Loosenchain

turnengineoppositeitsnormaldirectionofrotation
guideadjustingsleeveapproximatelytwoturns.See

(counterclockwiseasviewedfromthefront)approxi
Fig.14.

mately45°.Thispreventsaccidentalcontactbetween
valvesandpistonsduringinstallation.
CYLINDERHEAD,4-CYLINDER

113-6

CYLINDERHEADREMOVALANDINSTALLATION
32.UsingTorxE12socket,removecylinderheadboltsin

2.Checkgasketsurfaceofcylinderheadandcylinder
thesequenceindicated.SeeFig.15.Removecylinder

blockforwarpageusingastraightedge.
headandheadgasket.Discardheadboits.

3.OnM42engine:Besureoilfeedcheckvalveandspac-
erarecorrectlypositionedinblock.SeeFig.16.
0012502
Fig.15.Cylinderheadboltlooseningsequence.UseTorxEl2socket.
Cylinderhead,installing
(4-cylinderengine)
CAUTION-
Ifthecamshaftswereremovedrínstalledwhilethe
cylinderheadwasoff,aminimumwaftingtimeís
requíredafterinstallingthecamshafts.Whenthe
camshaftsareremoved,thehydrauliclifterscan
expand.Thisexpansioncancausefncreased
valvelift,resultínginopenvalvesandpfstoncon-
tact
Cylinderheadinstallationwaitingtimes
"Atorabove68°F(20°C)...............10minutes
"50-68°F(10-20°C)...................30minutes
"32-50°F(0-10°C)....................75minutes
1.Cleancylinderheadandgasketsurfacesofcylinder
blockandal¡timingchaincovers.
"Removeal¡foreignmatterandany¡¡quidfrombolt
holes,thencleanwithathreadchaser.
CAUTION-
Donotuseametalscraperorwirebrushtoclean
thealumfnumcylinderheadorpistons.Ifneces-
sary,useahardwoodenorplasticscraper.Also
availableareabrasivediscstobeusedínconjunc-
tionwíthanelectricdril¡.Besuretousethecorrect
discforthetypeofmetalbeingcleaned.
CYLINDERHEAD,4-CYLINDER
Fig.16.OilfeedcheckvalveandspacerusedonM42engine.Install
checkvalvewíthcollar(arrow)facingdown.
CAUTION-
Ifthecheckvalveisnotinstalledcorrectly,oilflow
tothecylinderheadwouldberestrícted.
4.Placenewcylinderheadgasketonsurfaceofcylinder
block.Checkthattwolocatingdowelsarecorrectlypo-
sitionedinblockandnotdamaged.
CAUTION-
Theword"OBEN",prfntedonthegasket,should
faceup.
5.Placenewrubberprofilegasketingrooveoffrontcover.
6.WithcamshaftslockedinTDCpositionwithBMWspe-
cialtoolasdescribedearlier,setcylinderheadinposi-
tion.
CAUTION-
"ThecamshaftsmustbefockedintheTDCposi-
tionattherearofthecylinderheadwithBMW
specfaltoolno.113240beforeinstallingthecyl-
inderhead.
"Makesurethecrankshaft,whichhadbeenrotat-
edapproximately45°oppositethedfrectionof
enginerotation,isstillinthatpositionbeforelow-
eringthecyffnderheadíntoposition.
"Torx-typecylinderheadboltsshouldnotbere-
used.Theyarestretch-typeboltsandmustal-
waysbereplacedwheneverloosened.

7.Lightlylubricatenewcylinderheadbolts.Looselyinstan
boltsandtheirwashers,thenthreadtheminuntilthey
arefingertight.
NOTE-
Checkthatallwashersforthecylinderheadboltsarein
placebeforeinstallingthebolts.
8.Tightencylinderheadboltsincorrectsequence.See
Fig.17.
UU125U2
Fig.17.Cylinderheadbolttighteningsequencefor4-cylinderen-
gines.Noteoilsupplytubeseal(arrow)onM44engine.
WARNING-
Theboltsshouldbetightenndinthreestagesaslíst-
edbelow.Thefinalstagesrequiretheuseofaspe-
cialtool(BMWtoolNo.112110)orasuitable
protractortotightentheboltstoaspecifiedtorque
angle.SeeFig.18.
TighteningTorques
"Cylinderheadtoengineblock(TorxEl2M10bolts)
Stage1

......................30Nm(22ft-Ib)
Stage2

...............................+90°
Stage3................................+90°
9.Carefullyrotatecrankshaftindirectionofenginerota-
tionandlockitatTDCbyinsertingBMWspecialtool
no.112300throughtransmissionbellhousing.See
Fig.19.
CYLINDERHEADREMOVALANDINSTALLATION

113-7
Fig.18.Protractorandpointerbeingusedtotightenboltstospecified
torqueangle(6-cylinderengineshown).
Fig.19.BMWspecialtool112300insertedthroughbellhousinghole
andfintoflywheel(arrow)tolockcrankshaftatTDC.
10.Turnleftchainguideadjustingsleeveinuntilitjustcon-
tactsthecylinderhead(SeeFig.14.).Insertchain
guideretainingscrewandtighten.
CAUTION-

11.Placechainsprocketswithchainsoncamshaftssothat
Besuretimingchaindoesnotbindoncrankgear
whenturningcrankshaft.

arrowsonsprocketspointupandelongatedholesin
sprocketsarecenteredtotappedholesincamshafts.
SeeFig.20.
CYLINDERHEAD,4-CYLINDER

113-8

CYLINDERHEADREMOVALANDINSTALLATION
IW? - L
'/~f
W

~
4
r
"
-"

;,s
1
12.OnM44engine:Placesensorwheelonintakecam-
shaftsprocketsothatarrowonsensorwheelpointsup.
13.Instanandhand-tightensprocketmountingbolts.
CAUTION-
Differenthydraulicchaintensionerswereused
duringmanufacture,dependingonenginetype.
SeeFig.21.Notethatthelatestyletensionercan
beretrofittedtotheearlierengine,sobesureto
identifytheversionoftensionerinstalledasinsta-
lationinstructionsvarybetweenthetwo.
14.OnM42engine:Disassemblechaintensionerbystrik-
ingoutersleeveagainstasolidobject.Thiswillrelease
snapringandtensionerwillseparate.SeeFig.22.
M42Engine
upandcamshaftthreadedholescenteredinsiottedholes.
CYLINDERHEAD,4-CYLINDER
0013024a
Outersleve

Detent
ring
Sprig
Fig.22.DisassembledchaintensionerforM42engine.
15.OnM42engine:Clamptensionerpistoninvice(soft
jaws).Slowlycompresspiston,makingsuredetentring
fitsintotaperofoutersleeve.Ifnecessary,pressends
ofdetentringtogether.Slowlycontinuepressingten-
sionertogetheruntilsnapringaudiblyclicksintoouter
sleeve.Measureoveralllengthoftensionertoconfirm
correctassembly:68.5mm(2.7in.).
NOTE-
i
Snap
ring
/0
.13024
Thelate-styletensionerontheM44engínecanberet-
rofittedtotheM42engine.
TighteningTorque
"Chaintensionerplug
tocylinderhead......-~..........40Nm(30ft-Ib)
16.OnM44engíne:Clamptensionerpístoninvice(soft
jaws)andsqueezeoilfromit.Slowlycompresspiston
onlyuptoendcirclip.Repeatproceduretwicetoensure
alloilisexpelled.SeeFig.23.
17.Instanhydraulicchaintensionertocylinderhead.Usea
newsealingwasherontensionerwheninstalling.
18.OnM42engine:Unlockchaintensionerbypressing
chainrailagainsttensioneruntilitexpandsout.
19.Checkthatchainisfreeofslack.Tightensprocket
mountingbolts.
Fig.21.Twoversionsofhydraulicchaintensioners.Originalchainten-
sioneronM42engine(top)canbedisassembled.Chainten
sioneronM44engine(bottom)cannotbedisassembled.

TighteningTorque
Notedifferencesinoutersleeve.Also,theM42tensionerde-

"Chainsprockettocamshaftflange...10Nm(89in-lb)
tentringgroove(arrow)isvisiblewhentensionerisextended.
20.Removecrankshaftlockingtoolfrombellhousingand
camshaftlockingtoolfromrearofcylinderhead.

Fig.23.WhenreinstallingchaintensioneronM44engine,oldoilin
tensionerpistonmustbeexpelledbycompressingpistonin
vise.Whencompressingpiston,onlycompressuptoendcir-
clip(arrow).
21.Turnengineoverbyhandindirectionofrotationatleast
twofui¡rotations.Reinstallcamshaftandcrankshaft
lockingtoolstocheckengínetiming.Removelocking
toolsifnofaultsarefound.
22.Insta¡¡uppertimingchaincover.
"Installgasketsandinstancoverusingtwomounting

TighteningTorque
bolts.Usingascrewdriver,leverdownonfrontcover

"Cylinderheadcover
untilcovergasketsurfaceisflushwithcylinderhead

tocylinderhead(M6screws).......10Nm(89in-lb)
gasketsurface.SeeFig.24.Tightentwobolis.
"Insta¡¡andtightenremainderofbolis.
23.Installcylinderheadcover.
CYLINDERHEADREMOVALANDINSTALLATION

113-9
0012507
Fig.24.Installuppertimingcasecoverwithtwobolis,thenpress
downoncoversothattopsurfaceisflushwithcylinderhead
(arrow).Holdcoverinpositionandtightenbolis.
"Cleanoldgasketgluefromsealingsurfaces.Usea
smallamountof3-Bond®1209adhesiveorequivalent
atcornersofhalf-mooncut-outsatbackofcylinder
head.SeeFig.25.
NOTE-
OnM44engines,reptacesea¡foroilsupplytube.See
Fig.17.)
Fig.25.Rearofcylinderheadcovershowingareawheresealant(ar-
rows)shouldbeapplied.Insetshowscylinderheadcover
mountingboltandinsulatorassembly:M6screw(1),rubber
damper(2),washer(3).
24.Installationofremainingpartsisreverseofremoval,
notingthefollowing:
"Makesureal¡sealingsurfacesarecleanandfreeofold
gasketmaterial.Installnewintakemanifoldgasket.
"OnM44engine:Replacesealsaboveandbelow
crankcaseventvalve.
"Wheninstallinglowerintakemanifold,makesurehol-
lowlocatingbushingsareontwolowerstuds.
"Reinstallharnessconnectorsforoilpressureswitch
andcoolanttemperaturesensorbeforeinstallingin-
takemanifold.Tightenmanifoldnutsinstages.
"Refillcoolingsystemasdescribedin170Radiator
andCoolingSystem.
"Changeengineoilandfilterasdescribedin020Main-
tenanceProgram.
"Ifnecessary,adjustacceleratorcable.
"Runengineatapprox.3,500rpmforabout20seconds
toallowhydraulicchaintensionertofillwithoil.
"Reconnectbatterylast.
CYLINDERHEAD,-CYLINDER

113-10

CYLINDERHEADREMOVALANDINSTALLATION
TighteningTorques
"Coolantdrainplugtocylinderblock..25Nm(18ft-1b)
"Intakemanifoldsupporttomanifold..15Nm(11ft-Ib)
"Lowerintakemanifold
tocylinderhead.................

15Nm(11ft-Ib)
"Lowerintakemanifold
touppermanifold................15Nm(11ft-Ib)
"Radiatorcoolingfantocoolantpump.40Nm(30ft-Ib)
"Radiatordrainscrewtoradiator....2.5Nm(22in-lb)
CYLINDERHEAD,6-CYLINDER
Foreaseofusethisprocedureisbrokenintosubsections,
asfollows:
General
Coolingsystem,draining
Cyiinderheadcover,removing
Intakemanifold,removing
Timingchains,uncoupling
Cylinderheadassembly,removing
WARNING-
Allowtheenginetocoolbeforebeginningthispro-
cedure.
General
1.Workinginsideluggagecompartment,disconnectneg-
ative(-)batterycable.
CAUTION-
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpagevi¡¡.
"Disconnectingthebatterymayerasefaultcode(s)
storedincontrolmodulememory.Checkforfault
codesusingspecialBMWdiagnosticequipment
2.Removefrontexhaustpipesfrommanifolds.Discard
nuts.
3.Removeairfilterhousingcompletewithmassairflow
sensorandintakeairducting.Disconnectvacuumhos-
esfromthrottlehousing.
4.OnM52andS52USengines:Removesecondaryair
injectioncheck-valvefromfrontofengineandset
aside.
CYLINDERHEAD,6-CYLINDER
Coolingsystem,draining
5.DrainenginecoolantandRmovecoolanthosesfrom
thermostathousing.Drainengineblockbyremoving
blockdrain.See170RadiatorandCoolingSystem.
NOTE-
Theblockdrainisontheexhaustsideoftheengine,
nearcylinderno.5.
6.Removeradiatorcoolingfanandfanshroud.See170
RadiatorandCoolingSystem.
NOTE-
Theradiatorcoolingfannut(32mmwrench)hasleft-
handthreads.
Cylinderhead,removing
(6-cylinderengine)

7.Disconnectheaterhosesatrearofcylinderhead.See
Fig.26.
'i
8.Removealternatorcoolingduct.
Cylinderheadcover,removing
0012687
Fig.26.Disconnectheaterhosesatheatervalve(A)andheatercore
(B).
9.Removeairplenumfromrearofenginecompartment.
See640HeatingandAirConditioning.
10.Removeplasticcylinderheadcoversfromabovefuel
injectorsandignitioncoils.Pulllargercoverforward
whenremoving.SeeFig.27.
11.Disconnectcrankcaseventílationhosefittingfromcyl-
inderheadcover.
12.Disconnectignitioncoilharnessconnectorsfromcoiis.
Removeignitioncoiisandsparkplugs.See120Igni-
tionSystem.

Fig.27.Removetopenginecoversbypryingoutplugsandremoving
nuts(A).Makesurerubberinsulatorsoneithersideoflarge
coverdonotfalloffduringcoverremoval(B).
Fig.28.Fuelinjectionharnessbeíngliftedoffenginetobeplacedat
baseofwindshield(A).Ignitioncoilsarealsovisible(B).M50
engineshown,other6-cylinderenginesaresimilar.
14.Removecylinderheadcovermountingboltsandre-
movecylinderheadcover.
CYLINDERHEADREMOVALANDINSTALLATION

113-11
15.Removeoilbafflecoverfromaboveintakecamshaft.
SeeFig.29.
Fig.29.Camshaftoilbafflecoverbeingremoved.
NOTE-
Thecylinderheadcovermountingboltinsulatorsand
13.Removeholddownnuts/boltsfromfuelinjectionhar-

gasketsshouldbereinstalledinthesameorder.Make
ness.Prybackinjectorconnectorretainingclipsandlift

noteoftheirarrangementduringremoval.
entireharnessoffengine.SeeFig.28.
Intakemanifold,removing
811119
16.Disconnectvacuumhosefrombrakesystemvacuum
booster.Plugopeninginbooster.
17.Removethrottlehousingmountingboltsandremove
throttlehousing.Setthrottlehousingasidewithoutdis-
connectingcablesorcoolanthoses.SeeFig.30.
Fig.30.Remove4comerbolts(arrows)fromthrottlehousingand
unboltcompleteassemblyfromintakemanifold.Remove
completethrottleassemblywithoutdisconnectingconnec-
tors,hosesorcables.(M50engineshown.)
CYLINDERHEAD,6-CYLINDER

113-12

CYLINDERHEADREMOVALANDINSTALLATION
18.Workingfromundersideofintakemanifold,disconnect

21.Detachoildipstickguidetubefrommanifold.Discon
harnessconnectors,venthoses,andairbypass

nectventhoseatbaseofdipstick.
hoses).
22.Removeintakemanifoldfromenginebyremovingsev-
19.Workingatrearofintakemanifold,labelanddisconnect

enmountingnutsfromaboveandtwosupportbracket
fuelsupplyandfuelreturnlines.Removefuellinehold

boltsfrombelow.SeeFig.32.
downbrackettofreelines.SeeFig.31.
NOTE-
OnM52IS52USengines,aspecialfittingisusedtore-
tainthefuelfinestothefuelrail.UseBMWspecialtool
no.161050toexpandthelockingclipinsidetheend
ofthefuellínefittings.
WARNING-
"Thefuelsystemisdesígnedtoretanpressure
evenwhehtheignitionisoff.Whenworkingwith
thefuelsystem,loosenthefuellinesslowlytoal-
lowresidualfuelpressuretodissipategradually.
Avoidsprayingfuel.
"Fuelishighlyflammable.Whenworkingaround
fuel,donotdisconnectanywiresthatcouldcause
electrfcalsparks.Donotsmokeorworknear
heatersorotherfirehazards.
"Alwaysunscrewthefueltankcaptoreleasepres-
sureinthetankbeforeworkingonthetankor
lines.
20.Removemountingscrewsandreleasewiringharness
ductatrearbulkheadandmoveaside.Removewiring
harnessbracketsfrombulkhead.
CYLINDERHEAD,6-CYLINDER
Fig.32.Intakemanifoldnutsandsupportbracketbolts(arrows).
CAUTION-
Stuffcleanragsintotheopenintakeportstopre-
001269s

ventanyportsfromfalfingintotheengine.
Fig.31.FuellinesatintakemanifoldonM52/S52engine.UseBMW
specialtool161050toreleaselockingfittingsatendsoffuel
enes.

1

Timingchains,uncoupling
23.RemoveVANOSunitfromfrontofcylinderhead.See
VANOSsectionin117CamshaftTimingChain.
24.SetenginetoapproximateTDCbyrotatinginnormal
operatingdirectionuntilcamshaftlobesatcylinderno.
1arefacingeachother.Arrowsoncamshaftsprockets
shouldbepointingup.
NOTE-
ToconfirmthatthecrankshaftissettotheTDCposi-
tion,checkthattheOITmark(0°TDC)onthefrontlow-
ertimingchaincoverísalignedwiththevíbration
damperSeeFig.33.
25.LockcrankshaftatTDC.
"InsertBMWspecialtoolno.112300throughtransmis-
sionbellhousingandfintoholeinflywheelordrive
plate.SeeFig.34.

Fig.33.CrankshaftispositionedatTDCwhennotchohfronttiming
chaincoverisalignedwith0/Tmarkonvíbrationdamper.
CYLINDERHEADREMOVALANDINSTALLATION

113-13
Fig.35.Camshaftlockingtool(BMWspecialtoolno.113240)in-
stalledonrearofcamshafts.(M44engineshown.Otheren-
ginesaresimilar.)
CAUTION-
ThecamshaftsmustbelockedintheTDCposition
usingthespecialservicetoolbeforeremovingthe
timingchain.Thearrowsonthesprocketsshould
notbeusedtoaccuratelysettheenginetoTDC.
Thetoolholdsthecamshaftsparalleltoeachoth-
erandperpendiculartothecylinderheadcover
gasketsurface.
27.Depresssecondarytimingchaintensionerandlockt
downbyinsertingBMWspecialtoolno.113292.Alter-
natively,astiffpieceofwirecanbeused.SeeFig.,36.
Fig.34.Crankshaftlockingtool(BMWspecialtool112300)inserted

Fig.36.Presssecondarytensionerdownfullyandinsertwirethrough
throughbellhousingholeandfintoflywheel(arrow).

holes(arrow)tolock.Timingchaintensionervariesdepend-
ingonengine(M52enginetensionershown).
26.LockcamshaftsatTDC.
"Removethreecylinderheadcovermountingstuds

28.Removemountingnutsfromfrontofintakecamshaft
fromacrossrearofhead,ifapplicable.

sprocket.Removecamshaftsprocket,thrustwasher(s),
"MountBMWspecialtoolno.113240oversquare

andwhereapplicable,springplate.
endsofcamshafts.Checkthattoolissquarelyseated
oncylinderheadgasketsurface.Ifnecessary,rotate

NOTE-
camshaftsslightlyusinga24mmwrenchathexon

Whereapplicable,makenoteofthrustwasherpositions.
camshaft(s).SeeFig.35.

Thethicker(0.4mm)washerismountedoutermost.
CYLINDERHEAD,6-CYLINDER

113-14

CYLINDERHEADREMOVALANDINSTALLATION
29.Removemountingnutsfromfrontofexhaustcamshaft
sprocket.Removesecondarysprocketstogetherwith
timingchainfromfrontofcamshafts.
CAUTION-
Thecrankshaftmustnotbeallowedtorotateonce
thecamshafttimingchainisremoved.Thepistons
cancontactthevalves.
NOTE-
Donotremovethesprocketsfromthechainunless
thesepartsarebeingreplaced.Wiretieeachsprocket
tothechaintokeepthesprocketstimedtoeachother.
30.Unboltsecondarytimingchaintensionerfromtopof
cylinderhead.
31.Removeprimarytimingchaintensionerfromsideof
cylinderhead.SeeFig.37.
Fig.37.Primarytimingchaintensioner(arrow).
WARNING-
Removetensionerslowly-¡tísunderspringpres-
sure.
32.Removetimingchainguíde(TonoE8socket).SeeFig.
38.
33.Liftprimarychainsprocketoffexhaustcamshaft.Re-
movesprocketfromchain.Suspendchainusingstiff
wire.
Cylinderheadassembly,removing
34.Removetwomountingboltsholdingcylinderheadto
lowertimingchaincover(TorxE8socket).SeeFig.39.
CYLINDERHEAD,6-CYLINDER
Fig.38.Timingchainguidemountingbolts(arrows).M50engine
shown.
Fig.39.Cylinderhead-to-timingchaincovermountingboits(arrows).
(BoltAalsoretainssecondarychaintensioner.)
35.UsingBMMIspecialtoolno.112250oranequivalent
tool,loosencylinderheadboltsinseveralstages.See
Fig.40.Discardheadboits.
CAUTION-
Torx-typecylinderheadboltsshouldnotbere-
used.Theyarestretch-typeboltsandmustatways
bereplacedwheneverloosened.

NOTE-
Cylinderhead,installing
(6-cylinderengine)
CAUTION-
Ifthecamshaftswereremovedandinstalledwhile
thecylinderheadwasoff,aminimumwaitingtime
isrequiredafterínstallingthecamshafts.When
thecamshaftsareremoved,thehydraullclifters
canexpand.Thisexpansioncancauseincreased
valveliftwhenthecamshaftsarebolteddown,re-
sultinginopenvalves.
Cylinderheadinstallationwaitingtimes
"68°F(20°C)andhigher...............10minutes
"50-68°F(10-20°C)...................30minutes
"32-50°F(0-10°C)....................75minutes
CYLINDERHEADREMOVALANDINSTALLATION

113-15
1.Cleancylinderheadandgasketsurfacesofcylinder
blockandal¡timingchaincovers.
"Removeallforeignmatterandany¡¡quidfrombolt
holes,thencleanwithathreadchaser.
CAUTION-
Donotuseametalscraperorwirebrushtoclean
thealuminumcylinderheadorpistons.Ifneces-
sary,useahardwoodenorplasticscraper.Also
availableareabrasivediscstobeusedinconjunc-
tionwithanelectricdrill.Besuretousethecorrect
discforthetypeofmetalbeingcleaned.
2.Checkgasketsurfaceofcylinderheadandcylinder
blockforwarpageusingastraightedge.
NOTE-
Fig.40.Cylinderheadboltlooseningsequence.

Ifthecylinderheadhasbeenmachined,aspecial0.3
mmthickergasketshouldbeinstalled.Thethickergas-
ketisavailablefromanauthorizedBMWdealer.
BMWspecialtoolno.112250isathin-walledTorxE12
socketwíthanextendedreach.Thecylinderheadbolts

3.Placenewcylinderheadgasketoncylinderblock.
arerecessedfintotheheadbelowthecamshafttowers

Checkthattwolocatingdowelsarecorrectlypositioned
wíthliffleworkingspace.

inblockandarenotdamaged.
36.Removecrankshaftlockingtool(BMWspecialtoolno.

NOTE-
112300).Usingthecrankshaftvibrationdamperbolt,

Theword"OBEN",printedonthegasket,shouldface
turnengineoppositeitsnormaldirectionofrotation

up.Thecylinderheadgasketwillfitcorrectlyinonlyone
(counterclockwiseasviewedfromthefront)approxi-

orientation.
mately45°.Thispreventsaccidentalcontactbetween
valvesandpistonsduringinstallation.

4.WithcamshaftslockedinTDCpositionwithBMWspe-
cialtoolsasdescribedearlier,setcylinderheadinpo
NOTE-

sition,guidingprimarychainthroughcylinderhead
Guidecamchaintokeepitfromjammingwhenturning

opening.
thecrankshaft.
CAUTION-
"ThecamshaftsmustbelockedintheMCposi-
tionattherearofthecylinderheadwithBMW
specialtoolno.113240beforeinstallingthecyl-
inderhead.
"Makesurethecrankshaft,whichhadbeenrotat-
edapproximately45°oppositethedirectionof
enginerotation,isstillinthatpositionbeforelow-
eringthecylinderheadintoposition.
5.Lightlylubricatenewcylinderheadbolts.Looselyinstan
boltsandtheirwashers,thenthreadtheminuntilthey
arefingertight.Installcylinderhead-to-lowertiming
chaincoverboitsfingertight.
CAUTION-
Tonc-typecylinderheadboltsshouldnotbere-
used.Theyarestretch-typeboltsandmustalways
bereplacedwheneverloosened.
CYLINDER HEAD,6-CYLINDER

113-16

CYLINDERHEADREMOVALANDINSTALLATION
NOTE-
Checkthatallwashersforthecylinderheadboltsarein
placebeforeinstalllngthebolts.Someofthewashers
maybestakedtothecylinderhead.
6.Tightencylinderheadboltsincorrectsequence.See
Fig.41.
Fig.41.CylinderheadbolttighteningsequenceforM50engine.
Fig.42.Protractorandpointerbeingusedtotightenboltstospecified
torqueangle.
WARNING-
Theboltsshouldbetightenedinthreestagesaslist-
edbelow.Thefinalstagesrequiretheuseofaspe-
cialtool(BMWtoolNo.112110)orasuitable
protractortotightentheboltstoaspecifiedtorque
angle.SeeFig.42.
CYLINDERHEAD,6-CYLINDER
7.Installandtightencylinderhead-to-lowertimingchain
coverbolts.
TighteningTorques
"Cylinderheadtoengineblock(TorxEl2Ml0bolts)
Stage1.......................30Nm(22ft-Ib)
Stage2...............................

+90°
Stage3................................+90°
"Cylinderheadlolowertiming
chaincover.....................10Nm(89in-lb)
8.Carefullyrotatecrankshaftindirectionofenginerota-
tionandlockitatTDCbyinsertingBMWspecialtool
no.112300throughtransmissionbellhousing.Guide
primarytimingchaintokeepitfromjammingoncrank
gear.
9.Mountprimarychainsprockettoprimarychainsothat
arrowonsprocketfacesup.Mountsprockettoexhaust
camshaftsotappedholesincamshaftareonleftmost
sideofelongatedholesinsprocket.SeeFig.43.
Fig.43.Primarychainsprocketcorrectlyafgnedtoexhaustcam-
shaft.Camshaftholesshouldbeonleftmostsideofsprocket
holes.
10.Installtimingchainguideandsecondarychaintension-
er.Tightenmountingbolts.
11.Installasanassembly,secondarychainsprocketsand
chainsothatarrow(s)onsprockt(s)arepointingup.
Centermountingholesinsprocketstoboltholesin
camshafts.SeeFig.44.
12.Installthrustwashersandspringplate(ifapplicable)to
sprockets.SeeFig.45.

Fig.44.Secondarychainsprocketsandchainbeinginstalled.Attach
sprocketswitharrowspointingupandelongatedholescen-
tered.
CYLINDERHEADREMOVALANDINSTALLATION

113-17
Spring
17
plate
0012543
Fig.45.VANOSspringplateandthrustwashersonlaterengines.
14.Insta¡¡BMWspecialtoolno.113390intoprimarytim-
ingchaintensionersleeve.Threadtoolinfingertight
untilsiackisremovedfromchain.
NOTE-
BMWspecialtoolno.113390isadummyprimary
chaintensionerandsimulatesthefunctionoftheten-
sioner.
15.Insta¡¡VANOSunitasdescribedin117CamshaftTim-
ingChain.
CAUTION-
Specialínstallationinstructionsapplywhen
mountingtheVANOSunittothecylinderhead.Be
suretofollowtheprocedurefoundin117Cam-
shaftTimingChain.
16.Slowlyuniockandreleasesecondarychaintensioner.
17.PreloadprimarychainbytighteningBMWspecialtool
no.113390(dummychaintensioner)to1.3Nm(11in-
lb).Thentightenexhaustsecondarycamshaftsprocket
mountingboltsintwostages.
TighteningTorque
"Secondarytimingchainsprockettoexhaustcamshaft
(Torxbolts)
Stage1......................

5Nm(44in-lb)
Stage2...................

, ...22Nm(17ft-1b)
18.Removeflywheellockingtoolfromtransmissionbell-
housing.Removecamshaftlockingtoolfromrearof
cylinderhead.
19.Turnengineoverbyhandatleasttwofui¡crankshaftro-
tations.Reinstallcamshaftlockingtoolandflywheel
lockingtooltomakesureal¡adjustmentsarestillcor-
rect.lfsettingsarecorrect,removelockingtools.
20.RemoveBMWspecialtool113390(dummychainten-
sioner)fromsideofcylinderhead.
CAUTION-
Mountintakecamshaftsprocketsothatcollarside

21.Insta¡¡primarychaintensionersothatcutoutintension-
ofthesprocketfacescamshaft.

erpistonengageschainrail.SeeFig.46.Using'new
seals,installandtightenaccessplugsinVANOScon
13.Installandtightenexhaustcamshaftsprocketmounting

trolunit.
boitsfingertightonly.Tightenintakecamshaftsprocket
mountingnutstospecifiedtorque.
TighteningTorques
"Accessplugs
TighteningTorque

toVANOScontrolunit.............50Nm(37ft-Ib)
"Intakecamshaftsprocket

"Primarycamshafttimingchaintensioner
mountingnuts(M6)..............10Nm(89in-lb)

totensionersleeve...............50Nm(37ft-Ib)
CYLINDERHEAD,6-CYLINDER

113-18

CYLINDERHEADREMOVALANDINSTALLATION
CYLINDERHEAD,6-CYLINDER
Fig.46.Primarychaintensionerbeinginstalled.Pistoncutoutmust
engagechainrail.
22.Installintakecamcoverandtheninstallcylinderhead
cover.Checkforcorrectseatingofhalf-moonsinback
ofcylinderheadcover.Useasmallamountof3-BondO
1209orequivalentseaiantatcornersofhalf-mooncut-
outs.
23.Installfrontexhaustpipestomanifoldsusingnewgas-
ketsandnuts.Coatmanifoldstudswithcopperpaste
priortoinstallingnuts.
24.Installationofremainingpartsisreverseofremoval.
Refillcoolingsystemasdescribedin170Radiatorand
CoolingSystem.Changeengineoilandfilterasde
scribedin020MaintenanceProgram.Checkadjust-
mentofacceleratorcable.Additionaltighteningtorques
aregivenbelow.Reconnectbatterylast.
25.Installationofremainingpartsisreverseofremoval,
notingthefollowing:
"Makesureallsealingsurfacesarecleanandfreeofold
gasketmaterial.Insta¡¡newintakemanifoldgasket.
"Reinstallharnessconnectorsforoilpressureswitch
andcoolanttemperaturesensorbeforeinstallingin-
takemanifold.
"Refillcoolingsystemasdescribedin170Radiator
andCoolingSystem.
"Changeengineoilandfilterasdescribedin020Main-
tenanceProgram.
"Ifnecessary,adjustacceleratorcable.
"Reconnectbatterylast.
CAUTION-
Topreventdamagingengineelectronicsystems,
besuretoinstallallgroundwirespreviouslyre-
moved,includingthegroundwiresatthecylinder
headfortheignitioncoils.
TighteningTorque

TighteningTorques
"Cylinderheadcover

"Coglantdrainplugtocylinderblock..25Nm(18ft-Ib)
tocylinderhead(M6screws).......10Nm(89in-lb)

"Intakemanifoldtocylinderhead.....15Nm(11ft-Ib)
"Radiatorcoolingfantocoolantpump.40Nm(30ft-Ib)
"Radiatordrainscrewtoradiator

...2.5Nm(22in-lb)

GENERAL
CYLINDERHEAD,
DISASSEMBLYANDASSEMBLY
CYLINDER HEADANDVALVETRAIN

116-1
116CylinderHeadandValvetrain
GENERAL............................116-1

Hydrauliccamfollowers,checkingandreplacing
(M42andal¡6-cylinderengines)............116-9
CYLINDERHEAD,

Valveguides.........................116-10
DISASSEMBLYANDASSEMBLY.......116-1

Valves..............................116-11
Camshafts,removingandinstalling
(M42engine).........................116-1

Valves,leaktest.......................116-11
Camshafts,removingandinstalling

Valvestemoilseals....................116-11
(M44engine).........................

116-3

Valveseats

..........................116-12
Camshafts,removingandinstalling

Valvesprings.........................116-12
(6-cylinderengine).....................116-4
Valves,removingandinstalling.............116-6

TABLES
CYLINDERHEADANDVALVETRAIN,

a.CylinderHeadHeight.........................116-7
RECONDITIONING....................116-7

b.CamshaftSpecifications.....................116-7
Cylinderhead.........................116-7

c.ValveGuideSpecifications..................116-10
d.ValveSpecifications........................116-11
Camshaft.............................116-7

e.ValveSeatDimensions.....................116-12
Hydraulicvalveadjusters,
checkingandreplacing(M44engine).....116-8
Camshafts,removingandinstalling
(M42engine)
Thisrepairgroupcoverscylinderheadandvalvetrainser-
viceandrepair.Mostoftherepairsdescribedhererequirethat

Thecamshaftscanberemovedwiththecylinderhead
thecylinderheadfirstberemovedasdescribedin113Cylin-

mountedontheengine.Thefirststepistoremovethecylinder
derHeadRemovalandInstallation.

headcover.See113CylinderHeadRemovalandInstalla-
tion.
NOTE-

SpecialBMWservicetoolsshouldalwaysbeusedtoremove
"FortimingchainandVANOSrepairinformation,see

andinstallthecamshafts.Removalandinstallationofthecam-
117CamshaftTimingChain.

shaftswithoutthespecialtoolscanresultincamshaftandvalve
"Ifitisdeterminedthatthecylinderheadwillrequire

traindamage.
significantreconditioningwork,aremanufacturedcyl-
inderheadmaybeagoodalternative.Remanufac-

WARNING-
turedcylinderheadsareavailablefromanauthorized

Theprocessofevenlylooseningthecamshaftbear
BMWdealer.

ingcapnutsisNOTanacceptablemethodofre-
movingthecamshafts.Besuretoreadthe
Theinformationgiveninthisrepairgroupisorganizedac-

procedurethroughbeforestartingthe¡ob.
cordingtoenginecode.Forengineapplicationinformation,
see100Engine-General.

1.Disconnectnegative(-)batterycable.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
BMWspecialtoolsarerequiredformostcylinderheadser-

2.Removeradiatorcoolingfanshroudandcoolingfan.
vicedescribedinthisrepairgroup.Manyofthesetoolsareex-

See170RadiatorandCoolingSystem.
pensiveandonlyavailablethroughanauthorizedBMWdealer.If
thespecialtoolsarenotavailable,onealtematveistoremove
thecylinderheadandhaveitdisassembledbyanauthorized

CAUTION-
BMWdealer.Besuretoreadeachprocedurethoroughlybefore

Radiatorfanhaslefthandthreads.
startingajobtodeterminewhichspecialtoolsandequipmentwill
benecessary.
CYLINDERHEAD,DISASSEMBLYAND ASSEMBLY

116-2

CYLINDERHEADANDVALVETRAIN
3.Removetimingchainsprocketsandtimingchainsfrom

7.Slowlyreleasepressureoncamshaftbearingcapsby
camshafts.Removeuppertimingchainguidefromcyl-

turningeccentricshaft.Removebearingcapsand
inderhead.See117CamshaftTimingChain.

camshaft.Repeatprocedureonremainingcamshaft.
NOTE-
Itisnotnecessaryloremovethelowertimingchain
cover.
4.RemovesparkplugsandinstafBMWspecialtool113
260tocylinderhead.Tightentoolretainingboltsin
sparkplugholes.Donotover-tightenbolts.SeeFig.1.
6.Removebearingcapmountingnuts.
0013033
5.Turneccentricshaftonspecialtooluntilpressureisap-
pliedtocamshaftbearingcaps.SeeFig.2.
Fig.2.

Specialtool(eccentricshaft)beingturnedtoapplypressure
tocamshaftbearingcaps.
CYLINDERHEAD,DISASSEMBLYAND ASSEMBLY
CAUTION-
Camshaftbearingcapsmustbereinstalledintheir
originallocations.
NOTE-
"Thecamshaftbearingcapsarecodedwíthaletter
andanumber.Forexample,"Al"ístheexhaustcam-
shaftbearingcapatthefrontoftheengíne,and"El"
istheintakecamshaftbearingcapatthefrontofthe
engine.
"Camshaftsarestampedwithacodeletter-`E"forthe
intakesideand`A"fortheexhaustside.
""E"isforEinlal3,(Germanforíntake)andA"isfor
Auspuff,(Germanforexhaust).
"Thefrontoftheengineisatthefrontofthecar.
8.Camshaftinstallationisreverseofremoval,notingthe
following:
"Priortoinstallation,checkal¡componentsforwearas
describedbelowunderCylinderHeadandVa¡-
Fig.1.

SpecialBMWtoolno.113260.Toolmountingbolts(arrows)

vetrain,Reconditioning.
threadintosparkplugholes.

"Crankshaftmustbeatleast45°awayfromTDCbefore
installingcamshaftstocylinderhead.
"Lubricatecamshaftspriortoinstallation.
TighteningTorque

"Installcamshaftsintocylinderheadwithlobesforcyl-
"BMWspecialtool111260

inderno.1pointingupandtowardseachother.
tocylinderhead.................23Nm(17ft-Ib)

"Afterinstallingcamshafts),observespecifiedwaiting
timeforhydrauliccamfollowerstofullycompressbe-
forebringingcrankshaftbacktoTDC.

Camshaftinstallationwaítingtimes
"Atorabove68°F(20°C)...............10minutes
"50-68°F(10-20°C)...................30minutes
"32-50°F(0-10°C).....................75minutes
"Reinstalltimingchainsprocketsandtensionerasspe-
cificallydescribedin117CamshaftTimingChain.

i
"Waitatleast10minutesbeforecrankingengineover
withstartermotorforthe
fi+

11//~~.0time.
TighteningTorques
"Camshaftbearingcaps
tocylinderhead(M7).............15Nm(11ft-Ib)
"Cylinderheadcover
tocylinderhead(M6).............10Nm(89in-lb)
"Primarytimingchaintensionerplug
tocylinderhead.................40Nm(30ft-Ib)
(see117CamshaftTimingChain)
"Sparkplugs(M12)................23Nm(17ft-Ib
"Timingchaincover(upper)
tocylinderhead.................10Nm(89in-lb)
"Timingchainsprocketstocamshaft
M6........
.
.......

..........10Nm(7.5ft-Ib)
M7

............................15Nm(11ft.lb)
(see117CamshaftTimingChain)
Camshafts,removingandinstalling
(M44engine)
SpecialBMWservicetoolsshouldalwaysbeusedtoremove
andinstallthecamshafts.Removalandinstallationofthecam-
shaftswithoutthespecialtoolscanresultincamshaftandval-
vetraindamage.
1.Disconnectnegative(-)batterycable.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
CYLINDERHEADANDVALVETRAIN

116-3
2.Removesparkplugs.See1201gnitionSystem.
3.Rotateengineuntilapairofcamshaftlobesarepoint-
ingup.UsingBMWspecialtool115130,depresseach
valveandvalvespringenoughtoremoverockerarms.
Rotateengineforthenextpairofrockerarms.SeeFig.
3.
cover.
Fig.3.

BMWspecialtoolno.115130(arrow)beingusedtodepress
valvestemtoremoverockerarm.
WARNING-
Removedrockerarmsmustbereinstalledinthe
samelocations.
4.Removeprimarytimingchaintensionerfromrightside
ofcylinderhead.
Thecamshaftscanberemovedwiththecylinderhead

5.Removeuppertimingchaincover.
mountedontheengine.Thefirststepistoremovethecylinder
headcover.See113CylinderHeadRemovalandInstalla-

NOTE-
tion.

ltisnotnecessarytoremovethelowertimingchain
6.Removetimingchainsprocketswithtimingchainsfrom
frontofcamshafts.See117CamshaftTimingChain.
Removeuppertimingchainguidefromcylinderhead.
WARNING-

7.Removecamshaftbearingcaesandremovecam
Theprocessofevenlylooseningthecamshaftbear-

shafts.
ingcapnutsisNOTanacceptablemethodofre-
movingthecamshafts.Besuretoreadthe

CAUTION-
procedurethroughbeforestartingthejob.
Camshaftbearingcapsmustbereinstalledintheir
originallocations.
CYLINDERHEAD,DISASSEMBLYAND ASSEMBLY

116-4

CYLINDERHEADANDVALVETRAIN
NOTE-
"Thecamshaftbearingcapsarecodedwithaletter
andanumber.Forexample,'541"istheexhaustcam-
shaftbearingcapatthefrontoftheengine,and`El"
istheintakecamshaftbearingcapatthefrontofthe
engine.
"Camshaftsarestampedwithacodeletter-'E"forthe
intakesideandA"fortheexhaustside.
""E"isforEinla3,(Germanforintake)andA"isfor
Auspuff,(Germenforexhaust).
"Thefrontoftheengineisatthefrontofthecar.
8.Camshaftinstallationisreverseofremoval,notingthe
following:
"Priortoinstallation,checkallcomponentsforwearas
describedbelowunderCylinderHeadandVal-
vetrainReconditioning.
"Lubricatecamshaftspriortoinstallation.
"Reinstalltimingchainsprocketsandtensionerandset
valvetimingbeforereinstallingrockerarms,asspe-
cificallydescribedin117CamshaftTimingChain.
"Besurecorrespondingcamshaftlobeispointingup
beforeinstallingrockerarms.Notethateachrocker
armanglesawayfromcorrespondingsparkplughole.
SeeFig.4.
"Waitatleast10minutesforhydrauliccamfollowersto
fullycompressbeforecrankingengineoverwithstart-
erforthefirsttime.
TighteningTorques
"Camshaftbearingcaps
tocylinderhead(M7).............15Nm(11ft-Ib)
"Cylinderheadcover
tocylinderhead(M6).............10Nm(89in-lb)
"Primarytimingchaintensionerplug
tocylinderhead.................40Nm(30ft-lb)
(sea117CamshaftTimingChain)
"Sparkplugs(M12)................23Nm(17ft-lb
Timingchaincover(upper)tocylinderhead
M6...........................10Nm(7.5ft-Ib)
M7...........................15Nm(11ft-Ib)
"Timingchainsprocketstocamshaft
M6...........................10Nm(7.5ft-Ib)
M7............................15Nm(11ft.lb)
(sea117CamshaftTimingChain)
Camshafts,removingandinstalling
(6-cylinderengine)
Camshaftson6-cylinderenginescanberemovedwiththe
cylinderheadmountedontheengine.Thefirststepistore-
movethecylinderheadcover.See113CylinderHeadRe-
movalandInstallation.
CYLINDERHEAD,DISASSEMBLYAND ASSEMBLY
Fig.4.

Correctinstallationpositionofrockerarms(arrows)onM44
engine.
SpecialBMWservicetoolsshouldalwaysbeusedtore-
moveandinstanthecamshafts.Removalofcamshaftswith-
outthespecialtoolscanresultinpersonalinjuryand/or
cylinderheaddamage.
WARNING-
Theprocessofevenlylooseningthecamshaftbear-
ingcapnutsisNOTenacceptablemethodofre-
movingthecamshafts.Specialtoolsshouldalways
beusedloremovethecamshafts.Besuretoread
theprocedurethroughbeforestartingajob.
1.Disconnectnegative(-)batterycable.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagaviii.
516
2.SetenginetoTDCandlockintopositionbyinstalling
BMWspecialtool112300throughtransmissionbell-
housingandintoholeinflywheelordriveplateaSee
Fig.5.
NOTE-
Arrowsoncamshaftsprocketsshouldbepointingup.
Sea117CamshaftTimingChain.
3.RemoveVANOScontrolunitfromcylinderhead.Re-
movetimingchainsprocketsfromcamshafts.See117
CamshaftTimingChain.
4.Removesparkplugsandinsta¡¡BMWspecialtool113
260/113270tocylinderhead.Tightentoolretaining
boltsinsparkplugholes.Donotovar-tightenbolts.See
Fig.6.

Fig.5.

BMWspecialtool112300(arrow)insertedthroughbell-
housingholeandfintoflywheel.
A
TighteningTorque
"BMWspecialtool111260/113270
tocylinderhead.................23Nm(17ft-Ib)
5.Removeintakecamshaftbearingcapno.1.
6.Turneccentricshaftonspecialtooluntilpressureisap-
pliedtocamshaftbearingcaps.SeeFig.7.
7.Removeremainingbearingcapmountingnuts.
CYLINDER HEADANDVALVETRAIN

116-5
NOTE-
Fig.7.

Specialtool(eccentricshaft)beingturnedtoapplypressure
tocamshaftbearingcaps.
8.Slowlyreleasepressureoncamshaftbearingcapsby
turningeccentricshaft.Removebearingcapsand
camshaft.Repeatprocedureonremainingcamshaft.
CAUTION-
Camshaftbearingcapsmustbereinstalledintheir
originallocations.
"Thecamshaftbearingcapsarecodedwithaletter
andanumber.Forexample,`A1"istheexhaustcam-
shaftbearingcapatthefrontoftheengine,and"E1"
istheintakecamshaftbearingcapatthefrontofthe
engine.
"Thecamshaftsarestampedwithacodeletter-`E"for
theintakesídeand`A"fortheexhaustside.
F19.6.

SpecialBMWtoolno.113260(A)withadapterll3270(B).
Toolmountingbolts(arrows)threadintosparkplugholes.

""E"isforEinfal3,(Germanforintake)and`A"isfor
Auspuff,(Germanforexhaust).
"Thefrontoftheengineisatthefrontofthecar.
CYLINDER HEAD,DISASSEMBLYAND ASSEMBLY

116-6

CYLINDERHEADANDVALVETRAIN
9.Camshaftinstallationisreverseofremoval,notingthe
following:
"Priortoinstallation,checkal¡componentsforwearas
describedbelowunderCylinderHeadandVal-
vetrainReconditioning.
"Crankshaftmustbeatleast45°awayfromMCbefore
installingcamshaftstocylinderhead.
"Lubricatecamshaftspriortoinstallation.
"Insta¡¡camshaftsintocylinderheadwithlobesforcyl-
inderno.1pointingupandtowardseachother.See
Fig.8.
"Afterinstallingcamshaft(s),observespecifiedwaiting
timeforhydrauliccamfollowerstofullycompressbe-
forebringingcrankshaftbacktoTDC.
Fig.8.

Camshaftcorrectlypositionedforreassemblysothatcylinder
no.1lobes(arrows)faceeachother.
TighteningTorques
"Camshaftbearingcaps
tocylinderhead(M7).............15Nm(11ft-Ib)
"Cylinderheadcover
tocylinderhead(M6).............10Nm(89in-lb)
"Primarytimingchaintensionerto
cylinderhead-see117CamshaftTimingChain
"Sparkplugs(M12)...............23Nm(17ft-Ib)
"Timingchainsprockettocamshaft
flange(M6)-see117CamshaftTimingChain
CYLINDERHEAD,DISASSEMBLYAND ASSEMBLY
Valves,removingandinstalling
1.Removecylinderheadasdescribedin113Cylinder
HeadRemovalandInstallation.Removeexhaust
manifold(s).
2.Removecamshaftsusingspecialtoolsasdescríbed
earlier.
3.OnM42andal¡6-cylinderengines:Removecamshaft
carriersbypullingthemstraightupoffmountingstuds.
CAUTION-
"Donotletthehydrauliccamfollowersfa¡¡outas
thecamshaftcarrierisremoved.Specialsuction
cupsareavailablefromBMWtoholdthehydrau-
liccamfollowersinplaceduringcarrierremoval.
Camshaftinstallationwaitingtimes
"atorabove68°F(200C)...............10minutes
"50-68°F(10-20°C)...................30minutes
"32-50°F(0-10°C)....................75minutes
4.OnM44engines:Removeallhydraulicvalveadjusters.
SeeHydraulicvalveadjusters,checkingandre-
"Reinstalltimingchainsprocketsandtensionerasspe-

placing(M44engine),laterinthissection.
cificallydescribedin117CamshaftTimingChain.
"Waítatleast10minutesbeforecrankingengineover

CAUTION-
withstartermotorforthefirsttime.

Hydraulicvalveadjustersshouldbestoredinan
uprightposition.lfnecessary,useamagnetictool
toaidinremovaloftheadjusters.
"Hydrauliccamfollowersshouldbestoredinan
uprightposition.
5.Removevalvesusingavalvespringcompressor.
NOTE-
"TheM44cylinderheadhasrecessedvalvestems.
Thisrequirestheuseofaspecialvalvespringcom-
pressortool.
"Labeleachvalveassemblyasitisremovedsoitcan
beinstalledinitsoriginalposition.
6.Removeanddiscardvalvestemoilsealsfromvalve
guides.SeeValvestemoilsealslaterinthissection.
7.Valveinstallationisreverseofremoval.
"Reinstallexhaustmanifold(s)withnewgaskets.Use
MolycoteHSC'5orequivalentanti-seizethreadcom-
poundonfasteners.
TighteningTorque
"Exhaustmanifoldtocylinderhead
M7...........................20Nm(15ft-Ib)

CYLINDERHEADANDVALVETRAIN,
RECONDITIONING
Thíssectionprovidesthespecificationsandspecialrecon-
ditioninginformationnecessarytorepairthecylinderheads
coveredbythismanual.
Ifmachineshopservicesarenotreadilyavailable,oneal-
ternativeistoinstallaremanufacturedcylinderheadfroman
authorizedBMWdealer.
Cylinderhead
NOTE-
Whenreplacingthecylinderheadonengineswithre-
movablecamshaftcarriers,besuretocheckthecam-
shaftcarrierbearingsurfacesforwarpage.
4-cylinder

1140.0mm(5.512in)

1139.55mm(5.494in)
6-cylinder

1

140.0mm(5.512in)

1

139.7mm(5.500in)
CYLINDER HEADANDVALVETRAIN

116-7
A
Thedisassembledcylinderheadshouldbeinspectedfor

Fig.9.

Frontvíewofcylinderheadshowingminimumresurfacingdi-
warpageandcracks.Checkthevalveguidesandvalveseats

mension(A).
forwearbeforemachiningawarpedhead.Alwaysdecarbon-
izeandcleantheheadbeforeinspectiogit.Ahigh-quality

Camshaft
straíghtedgecanbeusedtocheckforwarpage.
Camshaftwearisusuallycausedbyinsufficientlubrication.
Visuallyinspectthecylinderheadforcracks.Ifacracked

Visuallyinspectthecamshaftlobesandjournalsforwear.
cylinderheadissuspectedandnocracksaredetected

CamshaftwearspecificationsaregiveninTableb.
throughthevisualinspection,havetheheadfurthertestedfor
cracksbyanauthorizedBMWdealer.Acrackedcylinderhead

Tableb.CamshaftSpecifications
mustbereplaced.

4-cylinderengines
Axialplay
M42engine

0.065-0.150mm(0.0025-0.0059in)
M44engine

0.065-0.150mm(0.0025-0.0059in)
Radialplay(Plastigage)

0
.020-0.061mm(0.0008-0.0024in)
M42engine
M44engine

0.040-0.082mm(0.0016-0.0032in)
6-cylinderengines
Awarpedcylinderheadcanbemachinedprovidedno

Axialplay
morethan0.3mm(0.012in)ofmaterialisremoved.Iffurther

All

0.020-0.054mm
(0
.0008-0.0021in)
machiningisrequired,theheadshouldbereplaced.Remov-

Radialplay(Plastigage)
0
.150-0.330mm(0.006-0.013in)
ingmorethanthisamountwillreducethesizeofthecombus-

All
tionchamberandadverselyaffectengineperformance.A0.3
mmthickergasketisavailablefromanauthorizedBMWparts
departmentformachinedheads.

NOTE-
-OnM44engines,checktheoilsprayertubeinthetop
Beforemachiningtheheadtocorrectforwarpage,measure

ofthecylinderheadcoverandthetubesea¡inthecyl-
thetotalheight(thicknessofthecylinderhead).SeeFig.9.

inderhead.Acloggedsprayertubeoradefectiveseal
MinimumheightspecificationsaregiveninTablea.

willreduceoilflowtothecamshaft.SeeFig.10.
-Ifthecamshaftisbeingreplacedduetocamlobe
Tablea.CylinderHeadHeight

wear,thecorrespondingrockerarmsorcamfollowers
Engine

New

Minimumheight

shouIdalsobereplacedtoavofddamaglngthenew
(dimensionA)

camshaft.
CYLINDER HEADANDVALVETRAIN, RECONDITIONING

116-8

CYLINDERHEADANDVALVETRAIN
0012502
Fig.10.Locationofcamshaftoilsprayertubesea¡inM44cylinder
head(arrow).
Hydraulicvalveadjusters,
checkingandreplacing(M44engine)
TheM44engineuseshydraulicvalveadjusters(HVA)to
keepvalveclearanceswithinalimitedworkingrange.SeeFig.
11.HVAsaresealedunitsandrequirenomaintenance.
1.Camshafts
2.Rockerarms
3.Hydraulicvalveadjusters(HVA)
4.Valveandconicalvalvespring
Fig.11.CutawayviewofM44cylinderhead.
Undersomecircumstances,suchasacoldstart,thehy-
draulicunitsmaybecomenoisy.Hydraulicvalveadjuster
noiseisusuallyahigh-pitchedtappingorchatteringnoise.In
mostinstances,thisisconsíderednormalaslongasthenoise
goesawayinafewminutes(maximum20minutes).Ifthe
noisedoesnotgoaway,eitherthehydraulicunitisfaultyor
theoilpressuretotheadjuster(s)islow.
CYLINDER HEADANDVALVETRAIN, RECONDITIONING
NOTE-
8eforecheckingvalveadjusters,makesureengineoil
isfreshandatproperlevel.
1.Runengineuntilitreachesnormaloperatingtempera-
ture.
2.Turnengineoffandremovetopenginecover,spark
plugs,andcylinderheadcover.See113Cylinder
HeadRemovalandInstallation.
3.Useaplasticorwoodensticktopressdownontopof
rockerarmend(sideawayfromcamshaft).Ifanyplay
canbedetected,theHVAisfaultyandshouldbere-
placed.
NOTE-
WhencheckingtheHVA,makesurethecamshaftlobe
isfacingupsothatthereisnovalvespringpressureon
theadjuster.
4.ToremoveanHVA,turnengineoveruntilcamshaftlobe
pointsstraightup.UsingBMWspecialtoolno.115
130,depressvalvespringandremoverockerarmfrom
undercamshaft.SeeFig.12.
Fig.12.BMWspecialtoolno.115130(arrow)beingusedtodepress
valvestemtoremoverockerarm.
WARNING-
Removedrockerarmsmustbereinstalledinthe
samelocations.

5.Pullhydraulicvalveadjusterstraightoutofcylinder
head.SeeFig.13.
Fig.13.Removehydraulicvalveadjusterbypullingstraightoutofcyl-
inderhead(arrow).
6.Installationisreverseofremoval.Besuretoinspect
HVAboreinthecylinderheadforwearorscoring.
TighteningTorque
"Cylinderheadcovertocylinderhead/timingchaincover
M6bolt........................10Nm(89in-lb)
M7bolt........................15Nm(11ft-Ib)
Hydrauliccamfollowers,
checkingandreplacing
(M42andal¡6-cylinderengines)
TheM42engineandal¡6-cylinderenginesuseself-adjust-
inghydrauliccamfollowerstokeepthevalveclearanceswith-
inalimitedworkingrange.Thecamfollowersaresealedunits
andrequirenomaintenance.SeeFig.14..
Undersomecircumstances,suchasacoldstart,thecam
followersmaybecomenoisy.Hydrauliccamfollowernoiseis
usuallyahigh-pitchedtappingorchatteringnoise.Inmostin-
stances,thisisconsiderednormalaslongasthenoisegoes
awayinafewminutes(maximum20minutes).lfthenoise
doesnotgoaway,eitherthefollowerisfaultyortheoilpres-
suretothefollowerislow.Hydrauliccamfollowerreplace-
mentrequiresthatthecamshaftfirstberemoved.
NOTE-
Beforecheckingvalveadjusters,makesureengineoil
ísfreshandatproperlevel.
CYLINDER HEADANDVALVETRAIN

116-9
Fig.14.Sectionviewofcamshaft(A),hydrauliccamfollower(B),and
valvewithconicalvalvespring(C)usedonM52engine.
1.Runengineuntilitreachesnormaloperatingtempera-
ture.
2.Turnengineoffandremovetopenginecovers,ignition
coils,andcylinderheadcovers.See113Cylinder
HeadRemovalandInstallation.
3.Useaplasticorwoodensticktopressdownontopof
camfollower.SeeFig.15.Ifthereisanynoticeable
clearance,thefollowerisfaultyandshouldbereplaced.
811107
Fig.15.HydrauliccamfollowerinM52enginebeingchecked.Note
thatcamshaftlobeispointingup.
CYLINDERHEADANDVALVETRAIN,RECONDITIONING

116-10

CYLINDER HEADANDVALVETRAIN
NOTE-
Whencheckingacamfollower,makesurethecorre-
spondingcamshaftlobeísfacingupsothatthereisno
valvespringpressureonthefollower.
4.Toreplaceacamfollower,removeappropriatecam-
shaft.Refertocamshaftremovalproceduresgivenear-
lier.
5.Oncecamshaftisoutofway,withdrawfaultycamfol-
lowerandreplacewithnewone.Inspectcamfollower
boresforwearandscoring.
6.Camshaft,timingchainandcylinderheadcoverreas-
semblyisreverseofdisassembly.
TighteningTorques
"Camshaftbearingcapstocylinderhead
M7...........................15Nm(11ft-Ib)
"Cylinderheadcovertocylinderheadltimingchaincover
M6...........................10Nm(89in-lb)
"Timingchainhydraulictensionerto
cylinderhead-see117CamshaftTimingChain
"Timingchainsprockettocamshaft
flange(M6)-see117CamshaftTimingChain
CYLINDERHEADANDVALVETRAIN, RECONDITIONING
Tablec.ValveGuideSpecifications
Fig.16.Valveguidewearbeingcheckedwithdialindicator.Insertnew
valveuntilstemendisflushwithendofguide(whitearrow).
SeeTablecforwearlimits.
NOTE-
Valveguides

"IntemationalOrganizationforStandardization(ASO)
toleranceclassesareGstedinTablec.ISOallowanc
BMWdoesnotsupplyvalveguidesasreplacementparts.If

esarebasedonnominalsizesandshouldbeusedto
avalveguideisexcessivelyworn,itshouldbereamedtoac-

determineproperfit.Mostmachineshopsshould
ceptoversizedvalvestems.Valveguidespecificationsare

havethísinformationavailable
listedinTablec.

"Replacementvalveguidesmaybeavailablethrough
aftermarketsuppliers.Valveguidereplacementre-
Valveguidesshouldbecheckedforwearusinganew

quiresspecíaltoolsandapress.Itisalsonecessary
valve.SeeFig.16.Besuretothoroughlyinspectthecylinder

toheatthecylinderheadandchilethevalveguides
headtoensurethatitcanbereusedbeforereworkingthe

whenreplacingtheguides.
guides.
"BMWsuppllesoversizevalves.SeaValvesforaddi-
tionalinformation.
Specifications

M42engine

M421M44engines

M50engine

M50,M52,S50US,S52
~
(1992)

~
(1993-1998)

~
(1992)

~USengines(1993-1998)
Valveguidewear,maximum(valvetílt
clearancemeasuredwithnewvalve)

0.5mm(0.020in)

0.5mm(0.020in)

0.5mm(0.020in)

0.5mm(0.020in)
Valveguideinsidediameter,installed
(toleranceperISOallowanceH7)
Standard

7.0mm(0.276in)

6.0mm(0.236in)

7.0mm(0.276in)

6.0mm(0.236in)
Oversize1

7.1mm(0.279in)

6.1mm(0.240in)

7.1mm(0.279in)

6.1mm(0.240in)
Oversize2

7.2mm(0.283in)

6.2mm(0.244in)

7.2mm(0.283in)

6.2mm(0.244in)

Valves
ValvespecificationsarelistedinTabled.Removecarbon
depositsfromthevalvesusingawirebrushorwirewheel.
Specification

M42engine

M42IM44engines

M50engine

M50,M52engines

S50USIS52US
(1992)

(1993-1998)

(1992)

(1993-1998)

Iengine(1995-1998)
Valveheaddia.
Intake

133.0mm(1.299in)

133.0mm(1.299in)

33.0mm(1.299in)

33.0mm(1.299in)

130.0mm(1.181in)
Exhaust

30.5mm(1.201in)

30.5mm(1.201in)

30.5mm(1.201in)

~30.5mm(1.201in)

27.0mm(1.063in)
Valvestemdia.
Standard
Intake

6.975-0.015mm

5.975-0.015mm

6.975-0.015mm

5.975-0.015mm

5.975-0015mm
(0.2746-00006in)

(0.2352-00006in)

(0.2746-00006in)

(0.2352-00006in)

(0.2352-00006in)
Exhaust

6.960-0015mm

5.960-0.015mm

6.960--0.015mm

5.960-0.015mm

5.960-0.015mm
(0.2740-00006in)

(0.2345-0.0006in)

(0.2740--0.0006in)

(0.2345-0.0006in)

(0.2345-0.0006in)
Intake

7.075-0.015mm

6.075-0.015mm

7.075-0.015mm

6.075-0.015mm

6.075-0.015mm
(0.2785-00006in)

(0.2392-0.0006in)

(0.2785-00006in)

(0.2392-00006in)

(0.2392-00006in)
Exhaust

7.060-0015mm

6.060-0015mm

7.060-0.015mm

6.060-0015mm

6.060-0015mm
(0.2779-0.0006in)

(0.2386-00006in)

(0.2779-00006in)

(0.2386-00006in)

(0.2386-00006in)
Oversize2
Intake

7.175-0.015mm

6.175-0.015mm

7.175-0.015mm

6.175-0.015mm

6.175-0.015mm
(0.2825-00006in)

(0.2431-00006in)

(0.2825-00006in)

(0.2431--0.0006in)

(0.2431-00006in)
Exhaust

7.160-0015mm

6.160-0015mm

7.160-0.015mm

6.160-0015mm

6.160-0-015mm
(0.2819-00006in)

(0.2425-00006in)

(0.2819-00006in)

(0.2425-00006in)

(0.2425-00006in)
Valves,leaktest NOTE-
BMWspeclaltoolsareavailabletoremovethevalve
Totestthevalvesforleakage,thecamshaftsandcamshaft

stemoilseals.Asanalternative,standardvalvesea¡
carriers(whereapplicable)shouldfirstberemoved.Instalithe

removaltoolsareavailablefrommostautomotiveparts
valveassembliesandthesparkplugsineachcylinder.Place

stores.SeeFlg.17.
thecylinderheadonaworkbenchwiththecombustioncham-
berfacingupward.Filleachcombustionchamberwithathin
non-flammableliquid,suchasapartscleaningfluid.Afterfif-
teenminutes,checktheleve¡ofthefluid.Ifthefluidlevelinany
cylinderdrops,thatcylinderisnotsealingproperly.
ValveStemOilSeals
Thepurposeofthevalvestemoilsea¡istopreventexcess
oilfromenteringthecombustionchamber.Thesignoffautty
valvestemoilsealsisexcessiveoilconsumptionandsmoke
fromtheexhaustimmediatelyafterstartingandduringdecel-
erat¡on
NOTE-
Valvestemoilsealsshouldnotbereused.ffvalvesare
removed,newvalvestemoilsealsshouldbeinstalled.
Valvestemoilsea¡replacementrequiresthatthecylinder
headbedisassembledandthevalvesremovedasdescribed
aboveunderValves,removingandinstalling.
CYLINDERHEADANDVALVETRAIN

116-11
Tabled.ValveSpecifications
Fig.17.Valvestemoilsea¡beingremovedfromvalveguide.
Lubricatethenewsealsandinsta¡]themusinghandpres-
sureonly.Besuretoinstallthevalvespringseat(s)beforein-
stallingthesea¡.
CYLINDERHEADANDVALVETRAIN,RECONDITIONING

116-12

CYLINDER HEAD AND VALVETRAIN
ValveSeats

ValveSprings
Thevalveseatsshouldberesurfacedwhenevernewvalves

Thevalvespringsshouldbecheckedforfatigue.Toquickly
orvalveguidesareinstalled.Cuttersarerequiredtoresurface

checkthesprings,linethemupinarow.Placeastraightedge
theseats.Alwayscheckthevalvesforleaksafterrecondition-

acrossthetopofthesprings.Anyspringthatissignificantly
ingavalveseatasdescribedabove.Tableelistsvalveseat

shorterthantheothersiswornandshouldbereplaced.
dimensions.
NOTE-
NOTE-

Valvespringspecificationsandwearlímitsarenot
Standardsizereplacementvalveseatsarenotavail-

availablefromBMW.
ablefromBMW.Replacementvalveseatsareonly
availablefromBMWin0.4mmoversize(oversizedin
bothheightanddiameter).Themanufacturerdoesnot
providespecíficationsforvalveseatreplacementfor
theenginescoveredbythismanual.
Tablee.ValveSeatDimensions
"Y
Valveseatoutsidedia.(B)
CYLINDERHEADANDVALVETRAIN,RECONDITIONING
60°
yl
1B11110c
Specification

M42engine

M42engine

M44engine

M50engine

M501M52engines

S50USIS52US
(1992)

((1993-1995)

I(1996-1998)

(1992)

I(1993-1998)

Iengines(1995-
1998)
Valveseat

45°

451

145°

145°

(45°

145°
angle
Correction

115°

15°

115°

(15°

15°

15
angle,outside
Correction 60°

60°

I60°

60°

I60°

I60°
angle,inside
Valveseatwidth(A)
intake

11.65±0.25mm

11.65±0.25mm

11.65t0.25mm

11.4-1.9mm

11.65±0.25mm

11.65±0.25mm
(0.065+0.014in)

I
(0.065t0.014in)

(0.065:E0.014in)

(0.055-0.075in)

(0.065t0.014in)

l
(0.065t0.014in)
_______
exhaust

12.0±0.25mm

12.0t0.25mm

11.65t0.25mm

11.4-1.9mm

11.65±0.25mm

11.65:t0.25mm
(0.079±0.014in)

1
(0.079t0.014in)

1(0.065±0.014in)

1(0.055-0.075in)

1(0.065t0.014in)

1(0.065t0.014in)
intake

32.4mm(1.276in)

32.4mm(1.276m)

32.4mm(1.276in)

32.4mm(1.276in)

32.4mm(1.276in)

29.4mm(1.157in)
exhaust

30.1mm(1.185in)

30.1mm(1.185in)

30.1mm(1.185in)

30.1mm(1.185in)

29.4mm(1.157in)

26.4mm(1.039in)

GENERAL............................117-1

Camshafttimingchains,removing
(6-cylinderengines).....................117-7
CAMSHAFTTIMINGCHAIN,

Camshafttimingchains,installing
4-CYLINDER..........................117-2

6-clinderennes

117-11
Camshafttimingchain,removing

(

y

gi
(4-cylinderengines).....................117-2

VANOS(VARIABLEVALVETIMING)...117-14
Camshafttimingchain,installing

VANOSsystemoperation,testing..........117-14
(4-cylinderengines)

....................117-4

VANOScontrolunit,removing.............117-16
CAMSHAFTTIMINGCHAINS,

VANOScontrolunit,installing..............117-17
6-CYLINDER..........................117-6
GENERAL
117CamshaftTimingChain
Thisrepairgroupcoverstimingchainrepairinformationfor
the4-and6-cylinderengines.
4-cylinderenginesuseonedouble-rowchaintodrivethe
dualoverheadcamshafts.SeeFig.1.
Fig.1.

M44enginevalvetrainchaindrive.M42engineissimilar.
CAMSHAFTTIMINGCHAIN

117-1
6-cylinderenginesusetwochainstodrivethecamshafts.A
primarychainisdrivenoffthecrankshaftanddrivestheprima-
rysprocketontheexhaustcamshaft.Thesecondarychain
drivestheintakecamshaft.Eachchainistensionedbyahy-
draulictensioner.SeeFig.2.
Thetimingchainsarelubricatedbyengineoilanddonotre-`
quiremaintenance.Aworntimingchainandsprocketscan
leadtonoisyoperationanderraticvalvetiming.Afaultyten-
sionercanalsocausetimingchaínnoises.
Primarychain
NOTE-
See100Engine-Generalforenginecodeandapplica-
tioninformation.
Secondary
chaintensioner
Secondary
chain
B11115
Fig.2.

Cutawayviewofcamshafttimingchainson1963andlater6-
cylinderenginewithVANOS.
GENERAL

117-2

CAMSHAFTTIMINGCHAIN
CAMSHAFTTIMINGCHAIN,
4-CYLINDER
SpecialBMWservicetoolsareneededfortimingchainre-
movalandinstallationprocedures.Thespecialtoolsassure
propertimingofthevalvetrain.Precísemarkstosetthetiming
onthecamshaftsarenotprovidedforreassembly.Readthe
proceduresthroughbeforebeginningthejob.
CAUTION-
lfthecamshaftsarenotproperlytimed,thepis-
tonscancontactthevalves.
Camshafttimingchain,removing
(4-cylinderengines)
U0119-
Fig.3.

Uppertimingchaincovermountingbolts(arrows).Thermo-
1.Disconnectnegative(-)cablefrombattery.

stathousingshownremoved.Cylinderídentificationsensor
(A)alsoshown.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Drainenginecoolant.Drainengineblockbyremoving
blockdrain.Removeradiatorcoolingfanshroudand
coolingfan.See170RadiatorandCoolingSystem..
WARNING-
Allowtheenginetocoolbeforeopeningordraining
thecoolingsystem.
CAUTION-
Oncarswithviscous-typefanclutch,fanhasleft
handthreads.
NOTE-
Theblockdrainplugislocatedontheexhaustsideof
theengine,belowcylinderno.4.
3.Removecylinderheadcover.See113CylinderHead
RemovalandInstallation.
NOTE-
Makenoteofthearrangementoftherubberinsulators
whenremovingthecylinderheadcovermountingbelts.
4.Loosensparkplugs.See120IgnitionSystem.
5.Disconnectcoolanthosesfromthermostathousingon
frontofcylinderhead.Unboltthermostathousingfrom
cylinderhead.
6.Removecylinderidentificationsensorfromuppertim-
ingchaincover.Removeuppertimingchaincover.See
Fig.3.
CAMSHAFTTIMINGCHAIN,4-CYLINDER
7.SetenginetoapproximateTDCbyrotatinginnormal
operatingdirectionuntilcamshaftlobesatcylinderno.
1arefacingupandtowardeachother.SeeFig.4.
0011998
Fig.4.

EnginesettoapproximateTDC.Cylinderno.1camshaft
lobesfaceinandsprocketarrowspointup(arrows).
8.Removeairconditioningdrivebelt.Loosenandpush
asideairconditioningcompressor.Removeaircondi-
tioningcompressormountingbracket.See640Heat-
ingandAirConditioning.
9.Removeenginedrivebeltsandcoolantpumppulley.
See020MaintenanceProgram.
10.Securecrankshaftvibrationdampertopreventcrank-
shaftfromturning.Usingasocket,loosenvibration
damperhubcenterbolt.

NOTE-
Thevibrationdampercenterboltisverytight.Aheavy
dutyholdingdevice,suchasBMWspecialtoolno.112
150,shouldbeusedtoholdthevibrationdamperhub

V
stationarywhiletheboltisloosened.
v
11.Usingloosenedboltatvibrationdamper,turncrank-
shafttoTDCandlockinpositionbyinsertingBMW
specialtoolno.112300throughtransmissionbell-

-

p
housing.SeeFig.5.

v
O
NOTE-

I\

0011966a
"Ifnecessary,removeplugfromlocatingboyeinlower
edgeofbellhousing.
"Confirmthatlocatngtoolhasbeencorrectlyinstalled
bytryingtorotatethecrankshaft.
Fig.7.

Lowertimingchaincovermountingbolts(arrows).BoltsA
Fig.5.

BMWspecialtoolno.112300installedthroughbellhousing

areinstalledthroughhollowlocatingdowels.
andfintoflywheeltolockcrankshaftatTDC(arrow).
CAUTION-
ThecamshaftsmustbelockedintheMCposition
usingthespecialservicetoolbeforeremovingthe
timingchain.Thetoolholdsthecamshaftsparallel
toeachotherandperpendiculartothevalvecover
gasketsurface.
12.LockcamshaftsatTDCbymountingBMWspecialtool
no.113240oversquareendsofcamshafts.SeeFig.6.
"Checkthattoolissquarelyseatedoncylinderhead
gasketsurface.Ifnecessary,rotatecamshaftsslightly
usinganopen-endwrenchathexoncamshafts.
13.Removelowertimingchaincovermountingboltsand
carefullyliftcoveroff.Cleansealingsurfacesandgas-
ketgrooves.SeeFig.7.
14.Removehydraulicchaintensionerfromrightsideofcyl-
inderhead.SeeFig.8.
CAMSHAFTTIMINGCHAIN

117-3
Fig.6.

BMWspecialtoolno.113240installedonrearofcamshafts
topositioncamshaftsatTDC.(M44camshaftsshown.Other
enginesaresimilar.
Fig.8.

Hydraulicchaintensionerplug(arrow).
CAMSHAFT TIMINGCHAIN,4-CYLINDER

117-4

CAMSHAFTTIMINGCHAIN
15.Removemountingboltsfromleftandrightcamshaft

4.Insta¡¡andhand-tightensprocketmountingbolts.
sprockets.
16.OnM42engines,removeupperboltonrightsidechain
guideandunboltlowertimingchainguidebelowcrank-
shaft.
17.Removecamshaftsprocketsfromcamshaftstogether
withchainandcrankshaftsprocket.NoteWoodruffkey
whenremovingcrankshaftsprocket.
CAUTION-
Thecrankshaftmustnotbeallowedtorotate
whenthetimingchaínisremoved.Thepistons
cancontactthevalves.
Camshafttimingchain,installing
(4-cylinderengines)
Inspectal¡sprocketsforwearordamage.Inspectthechain
guideandtensionerrailsforgroovescausedbychaincontact.
Replaceanypartthatisworn.Ifanyofthesprocketsareworn,
thechainandsprocketsarereplacedasanassembly.
Theprocedureoutlinedbelowassumesthatthecamshafts
andthecrankshaftarelockedintheTDCinstallationposition
withspecialtools(shownearlierinFig.5andFig.6).
1.Installtimingchaintocrankshaftsprocket,thenslide
sprocketoncrankshaftwhílealigníngwoodruffkey.
2.Placecamshaftsprocketsonchain,thenplacesprock-
etsoncamshaftssothatarrowsonsprocketspointup
andelongatedholesinsprocketsarecenteredlo
tappedholesincamshafts.SeeFig.9.
.
I
P a-s

~_

a
Ge
..
.
0012509
5.OnM42engine:Installlowerchainguide.
6.OnM44engine:Removeallen-headretainingscrewat
leftchain-guide.Turnslotted-headofadjustingsleeve
sothatsleevecontactscylinderhead.Theninstalland
tighten'allen-headscrewfully.SeeFig.10.
Fig.10.Leftupperchainguideadjustingsleeve(arrow).Notecam-
shaftposition
CAUTION-
Differenthydraulicchaintensionerswereused
duringmanufacture,dependingonengínetype.
SeeFig.11.Notethatthelatestyletensionercan
beretrofittedtotheearlierengíne,sobesureto
identifytheversíonoftensionerínstalledasínstal-
lationinstructionsvarybetweenthetwo.
7.OnM42engine:Disassemblechaintensionerbystrik-
ingoutersleeveagainstasolidobject.Thiswillrelease
snapringandtensionerwillseparate.SeeFig.12.
8.OnM42engine:Clampchaintensionerpistoninvice
(softjaws).Slowlycompresspiston,makingsurede-
tentringfitsintotaperofoutersleeve.Ifnecessary,
pressendsofdetentringtogether.Slowlycontinue
Fig.9.

Camshaftsprocketscorrectlyinstalledwitharrowspointing

pressingtensionertogetheruntilsnapringaudibly
upandborescenteredtotappedholes(M44engine).

clicksintooutersleeve.Measureoveralllengthoften-
sionertoconfirmcorrectassembly:68.5mm(2.7in.).
3.OnM44engine:Placecylinderpositionsensorplateon
intakecamshaftsprocketsothatarrowonsensorplate

NOTE-
pointsup.

The¡ate-styletensionerontheM44enginecanberet-
rofittedtotheM42engíne.
CAMSHAFT TIMINGCHAIN,4-CYLINDER

M42Engine
CL(EM
Fig.11.Twoversionsofhydraulicchaintensioners.Originalchainten-
sioneronM42engine(top)canbedisassembled.Chainten-
sioneronM44engine(bottom)cannotbedisassembled.
Notedifferencesinoutersleeve.Also,theM42tensionerde-
tentringgrooveisvisiblewhentensionerisextended(arrow).
Outersleeve
Spring
0013024a
Detent
ring
9.OnM44engines:Clamptensionerpistoninvice(soft
jaws)andsqueezeoilfromit.Slowlycompresspiston
onlyuptoendcírclip.Repeatproceduretwicetoensure
al¡oilisexpelled.SeeFig.13.
10.Insta¡¡hydraulicchaintensionerlocylinderhead.Usea
newsealingwasherontensionerplugwheninstalling.
TighteningTorque
"Chaintensionertocylinderhead....40Nm(30ft-Ib)
11.OnM42engines:Releaseearly-stylechaintensioner
bypressingchainguideagainsttensioneruntilitun-
locksandexpandsout.
CAMSHAFTTIMINGCHAIN

117-5
0012507
Fig.13.Whenreinstallingchaintensiones,oilintensionerpistonmust
firstbeexpelledbycompressingpistoninvise.Whencom-
pressingpiston,onlycompressuptoandcirclip(arrow).
TighteningTorque
"Chainsprocketlocamshaft
flange(M6).....................10Nm(89in-lb)
13.Removecrankshaftlockingtoolfrombellhousingand
camshaftlockingtoolfromrearofcylinderhead.
14.Installlowertimingchaincover:
"Insta¡¡newcrankshaftoilsealincover.
"Usenewgasketswheninstallingcover.
"Thoroughlycleanprofilegasketgrooveandallgasket
sealingsurfacesonlowerchaincover.
"Applyasmallbeadofsiliconsealer(3-Bond1209or
Snap

equivalent)lojointcornerswherechaincovermeets
ring

0013024

headandblock.SeeFig.14.
"Tapcoverintopositiontoengagelocatingdowels.
Fig.12.Disassembledearly-stylechaintensionerusadonM42en-

"Tightencovermountingboltsalternatelyandinstages.
gine.
12.Checkthatchainisnowfreeofsiack.Tightendown
sprocketmountingbolts.

wherechaincovermeetsheadandblock(arrows).
Fig.14.Applysealer(3-Bond12090orequivalent)tojointcorners
CAMSHAFT TIMINGCHAIN,4-CYLINDER

117-6

CAMSHAFTTIMINGCHAIN
15.Insta¡¡uppertimingchaincover:

17.Removecrankshaftlockingtoolfromtransmissionbell-
"Thoroughlycleanprofilegasketgrooveandallsealing

housingandcamshaftlockingtoolfromrearofcylinder
surfaces.

head.
"Applyasmallbeadofsiliconsealer(3-Bond1209®or
equivalent)toupperandlowerjointcomerswhere

18.Turnengineoverbyhandindirectionofrotationatleast
chaincovermeetscylinderhead.

twofullrotations.Reinstallcamshaftandcrankshaft
"Insta¡¡newprofilegaskettogrooveinlowerchaincover.

lockingtoolstocheckenginetiming.Repeatcamtiming
"Protecttopofprofilegasketusingthinsheetmetal

procedureiftoolsdonotfiteasilyintoposition.Remove
(BMWspecialtoolno.112330orequivalent).See

lockingtools.
Fig.15.
"Attachnewgasketstocoverwithlightdabsofgasket

19.Installcylinderheadcoverasdescribedin113Cylin-
sealant,holdgasketsinplaceusingcovermounting

derHeadRemovalandInstallation.
screws.
"Placeuppertimingcoverintoposition.Snugdownal¡

NOTE-
screws,withouttightening.Carefullyslideoutsheet

OnM44engines,noteoilsupplyO-ringandreplaceff
metal.

necessary.
"Temporarilyinstallcylinderheadcoverwithoutgasket.
Insta¡¡andtightenatleasttwocylinderheadcover
mountingboltstoseatuppertimingchaincover.
"Tightenalluppertimingcoverscrews.

TighteningTorque
"Removevalvecover.

"Cylinderheadcover
tocylinderhead(M6screws).......10Nm(89ín-Ib)
-

CAMSHAFTTIMINGCHAINS,
Fig.15.Wheninstallinguppertimingchaincover,usethinsheetmetal

6-CYLINDER
(arrow)toprotectprofilegasketwheninstallinguppercover.
TighteningTorque
"Uppertimingchaincovertoengineblock
orcylinderhead(M6screws).......10Nm(89in-lb)
16.Installvibrationdamperwhilealigningwoodruffkey.
Holdcrankshaftstationaryandtightenmountingbolt.
TighteningTorques

ICAUTION-
"Pulleytovibrationdamper.........22Nm(17ft-Ib)

lfthecamshaftsarenotproperlytimed,the
1
pis-
tonscancontactthevalves.
"Vibrationdampertocrankshaft
M16stretchbolt(alwaysreplace).330Nm(244ft-Ib)
CAMSHAFT TIMINGCHAINS,6-CYLINDER
20.Installationofremainingpartsisreverseofremoval.
Wheninstallingthermostat,makesurearroworvent
holefacesup.Refillcoolingsystemasdescribedin170
RadiatorandCoolingSystem.
TighteníngTorques
"Coolantdrainplug
tocylinderblock.................25Nm(18ft-Ib)
"Radiatorcoolingfan
tocoolantpump.................40Nm(30ft-Ib)
"Radiatordrainscrewtoradiator....2.5Nm(22in-lb)
Camshafttimingchainremovalon6-cylinderenginesre-
quiresthatyouRmovetheengineoilpanbyraisingtheen-
gineand/orloweringthefrontsuspensioncrossmember.
SpecialBMWservicetoolsareneededfortimingchainre-
movalandinstallationprocedures.Thespecialtoolsassure
propertimingofthevalvetrain.Precisemarkstosetthetiming
onthecamshaftsarenotprovidedforreassembly.Readthe
proceduresthroughbeforebeginningthejob.

Camshafttimingchains,removing
(6-cylinderengines)
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Disconnectingthebatterymayerasefaultcodes)
storedincontrolmodulememory.Checkforfault
codesusingspecialBMWdiagnosticequipment.
2.Drainenginecoolant.Drainengineblockbyremoving
blockdrain.Removeradiatorcoolingfanshroudand
coolingfan.See170RadiatorandCoolingSystem..
WARNING-
Allowtheenginetocoolbeforeopeningordraining
thesystem.
CAUTION-
Radiatorfanhaslefthandthreads.
NOTE-
Theblockdrainplugislocatedontheexhaustsideof
theengine,belowcylinderno.4.
3.Drainengineoílandremoveoilpan.See119Lubrica-
tionSystem.
4.Removealternatorcoolingduct.
5.Removetwolargecoolanthosesfromthermostat
housing.Removeengineliftingbracketandthermostat
housingfromfrontofcylinderhead.
6.Loosenboltsforcoolantpumppulley.Thenremove
drivebeltsforalternatorandA/Ccompressor.See020
MaintenanceProgram.Removecoolantpumppulley.
Fig.16.
NOTE-
OnM50engineswithatwo-rollerdrivebelttensioner,
removetheupperrollertoaccessthetensionermount-
ingbolts.
NOTE-
Makenoteofthearrangementoftherubberinsulators
whenremovingthecylinderheadcovermountingbolts.
CAMSHAFTTIMINGCHAIN

117-7
Fig.16.Drivebelttensionermountingbolts(arrows).
B11055
7.Removedrivebelttensionerfromfrontofengine.See

Fig.17.1992-1995M50enginespeedsensorontimingcover(ar-
row).
10.Unclipandremovebafflecoverfromaboveintakecam-
shaft.SeeFig.18.
11.On1992engines:Removeuppertimingchaincover
fromfrontofcylinderhead.SeeFig.19.
8.Removeenginespeedsensorfromlowertimingchain

12.Loosensparkplugs.See120IgnitionSystem.
cover,ifapplicable.SeeFig.17.
13.SetenginetoapproximateTDCbyrotatinginnormal
9.Removecylinderheadcover.See113CylinderHead

operatingdirectionuntilcamshaftlobesatcylinderno.
RemovalandInstallatíon.

1arefacingeachother.SeeFig.20.
14.SetenginetoTDCbyaligning"0/T'mark(0°TDC)on
frontvibrationdamperwithcastbossonlowertiming
chaincover.SeeFig.21.
15.Removevibrationdampermountingboltsandremove
vibrationdamperandpulley.SeeFig.22.
CAMSHAFTTIMINGCHAINS,6-CYLINDER

117-8

CAMSHAFTTIMINGCHAIN
Fig.18.Oilbaffle'coverbeingremoved.
Fig.19.Uppertimingchaincovermountingnuts(arrows)onpre-
VANOSengines.
16.Securecrankshafthubtopreventcrankshaftfromturn-
ing.Usingasocket,loosenbutdonotremovecrank-
shafthubcenterbolt.
CAMSHAFT TIMINGCHAINS,6-CYLINDER
Fig.20.EnginesettoapproximateTDC.Camshaftlobesfaceinand
arrowsonsprocketspointup(arrows).
B11123a
Fig.21.O/T(0°TDC)markonvibrationdamperalignedwithbosson
timingchaincover(arrow).
17.LockcrankshaftinTDCpositionbyinsertingBMWspe-
cialtoolno.112300throughtransmissionbellhousing
andintoholeinflywheelordriveplate.SeeFig.23.
NOTE-
Confirmthatthelockingtoolhasbeencorrectlyin-
stalledbytryingtorotatethecrankshaft.
NOTE-
Thecrankshafthubcenterboltistightenedtoatorque

18.Removecrankshafthubboltandwasher.Removehub
of410Nm(300ft-ib).Aheavydutyholdingdevice,

fromcrankshaft.
suchasBMWspecialtoolno.112150,shouldbeused
toholdthecrankshafthubstationarywhiletheboltis

19.Removecylinderheadcovermountingstudsatrearof
loosened.Useaheavyduty314-inchdrivesocketand

head.LockcamshaftsatTDCusingBMWspecialtool
breakerbartobreaktheboltfree.

no.113240atendsofcamshafts.SeeFig.24..

Fig.22.Vibrationdamperwithdrivebeltpulleybeingremoved.Note
hublocatingdowel(arrow).
Fig.23.BMWspecialtoolno.112300installedthroughbellhousing
andintoflywheel.
20.Removeprimarychaintensionerplugandprimary
chaintensioner.SeeFig.25.
CAMSHAFTTIMINGCHAIN

117-9
Fig.24.BMWspecialtoolno.113240installedonrearofcamshafts
topositioncamshaftsatTDC.(M44camshaftsshown.Other
enginesaresimilar.)
Fig.25.Primarychaintensionerplug(arrow).
CAUTION-
"Checkthattoolissquarelyseatedoncytinder
headgasketsurface.Ifnecessary,rotatecam-
shaftsslightlyusinga24mmwrench
"Onpre-VANOSengines(enginesbuiltupto8-
92),thecamshaftlockingtoolmaynotfitcorrect-
lywhenthecrankshaftissettoTDC.Donotas-
sumethevalvetrainisoutoftime.Onsome
engines,valveoverlapmayhavebeenreduced
asadealerservicecampaigntocorrectforan
unevenidle.Checkthetimingbyplacinga3mm
drillbitundertheleftandrightoutsideedges
whilepressíngdownonthecenterofthetool
(toolcenterboltsloosened).Ifthetoolnowfits,
thecampaignhasbeendoneontheengine.
CAMSHAFT TIMINGCHAINS,6-CYLINDER

117-10

CAMSHAFTTIMINGCHAIN
21.On1993andlatesengines:Removeaccessplugsfrom

24.On1993andlaterengines:
VANOScontrolunitinfrontofexhaustcamshaft

"RemoveVANOScontrolunitasdescribedlaterinthis
sprocket.Remove4boltsfromexhaustcamshaft

repairgroup.
sprocket(useTonoEl0socket).SeeFig.26.

"Removeintakecamshaftsprocketmountingnuts.
"Removeintakeandexhaustsprocketstogetherwith
secondarychain.Notelocationofthrustwashersand
springplate(whereapplicable)onintakesprocket.
Fig.26.Exhaustcamshaftmountingbolts(arrows).
CAMSHAFTTIMINGCHAINS,6-CYLINDER
0013056
22.Depresssecondarytimingchaintensionesandlock
downbyinsertingstiffwireintotheopeningsinrearof
tensioner.SeeFig.27.
Fig.27.SecondarytimingchaintensionerbeinglockeddownonM50
engine.Presstensionerdownandinsertlockingwirethrough
holes(arrows).TensioneronM52/S52USenginesvaryslight-
23.Removesecondarychaintensionerandliftoutprimary
chainguide.
NOTE-
Holdthecamshaftstationary(athexoncamshaft)
whenlooseningortighteningsprocketmountingboits.
CAUTION-
Thecrankshaftmustnotbeallowedtorotateonce
thetimingchainisremoved.Thepistonscancon-
tactthevalves.
25.On1992engines:
"Removefromintakeandexhaustsprocketmounting
bolts.
"Removesprocketstogetherwithsecondarychain.
26.Removeboltsholdinglowertimingchaincovertocylin-
derhead(useTorxE8socket).SeeFig.28.
MR111:R
Fig.28.Cylinderhead-to-timingchaincovermountingbolts(arrows).
27.Usingadrift,drivetwolocatiogdowelsinleftandright
sidesoflowertimingchaincovertowardrearofcar.Re-
movecovermountingboitsandcarefullyliftcoveroff.
SeeFig.29.
CAUTION-
Usecarewhenremovingthecoverfromthecylin-
derheadgasket.Ifthecoverisstuck,useasharp
knifetoseparateitfromtheheadgasket.

9)
B11126
Fig.29.Lowertimingchaincovermountingbolts(arrows)anddowel
locations(A).CoolanthosefittingBisreplacedbycoolant
pipepressurefittinginlatermodels.
28.RemoveremainingTorxboltfromtimingchainguide.
SeeFig.30.
Fig.30.Timingchainguidemountingbolt(A).
CAMSHAFTTIMINGCHAIN

117-11
29.Liftprimarychainsprocketoffexhaustcamshaftand
removechain.
NOTE-
"Ifanyofthesprocketsarebeingreplacedduetowear,
thechainshouldalsobereplaced.
"Ifthecrankshaftsprocketrequiresreplacement,the
oilpumpdrivesprocketandchainmustberemoved
asdescribedunder119LubricationSystem.
Camshafttimingchains,installing
(6-cylinderengines)
Inspecttimingchainsprockets.Sprocketsthathavewornor
missingteethshouldbereplaced.Inspectguiderailandten-
sionerrailfordeepgroovescausedbychaincontact.Replace
anyparíthatisworn.
Theprocedureoutlinedbelowassumesthatthecamshafts
andthecrankshaftarelockedintheTDCinstallationposition
withspecialtools(shownearlierinFig.23andFig.24).
NOTE-
NOTE-

Onpre-VANOSengines(enginesbuiltupto8-92),the
"Thetimingchaincovercanberemovedwiththecool-

camshaftlockingtool(Fig.24)shouldberaisedupon
antpumpinstalled.

eithersideby3mm(usefeelergaugeordril¡bits).Be
suretheclampingboltsontoolarelooseandthecenter
"Usecarewhenremovingthechaincoverfromthe

ofthetooliscontactingthecylinderheadsurface.This
coolantpipeorhoseattherearofthecover.

servicecampaignhelpsimproveidlecharacteristicsby
reducingvalveoverlap.
1.Installprimarytimingchaintocrankshaftsprocketand
tieitupthroughcylinderheadopening.
2.UsingnewgasketsandcoolantpipeO-ring;insta¡¡low-
ertimingchaincover:
"Drivetimingcoverdoweisinuntiltheyjustprotrude
slightlyfromsealingsurface.
"Applyasmallbeadofsiliconsealer(3-Bond1209©or
equivalent)tocornersofcylinderheadwheretiming
covermeetscylinderheadandengineblock.
"Tapcoverintopositiontoengagedoweis.
"Installmountingboltshandtight,includingtwoouter
Torxboltsfromabove.
"Drivedoweisinflushtofrontofcover.
"Tightencovermountingboltsalternatelyandinstages.
TighteningTorque
"Lowertimingcovertocylinderblock
M7...........................15Nm(11ft-Ib)
M8...........................20Nm(15ft-Ib)
3.Insta¡¡oilpanusinganewgasket.See119Lubrication
Systern.
CAMSHAFT TIMINGCHAINS,6-CYLINDER

117-12

CAMSHAFTTIMINGCHAIN
4.Mountprimarytimingchainsprockettoprimarychain
sothatarrowonsprocketfacesup.Mountsprocketto
camshaftsothattappedholesincamshaftareonleft
sideofelongatedholesinsprocket.SeeFig.31.
NOTE-
OnenginesbuiltbeginningfromMarch1995,the
VANOSintakecamsprocketassemblywasupdatedto
íncludeaspringplateandtwothrustwashers.SeeFig.
Fig.31.Primarytimingchainsprocketcorrectlyalignedtoexhaust

33.
camshaft.Elongatedsprocketholesshouldbealignedtoleft
sideofthreadedcamshaftholes.
5.On1993andlaterengines:InstallBMWspecialtoolno.
11-3390intoprimarytimíngchaintensionersleeve.
Threadtoolinfingertightuntilslackisremovedfrom
chain.
"Checkthatelongatedholesinprimarysprocketare
centeredtoboltholesincamshaftandchainisfreeof
slack.
NOTE-
BMWspecialtoolno.113390ísadummyprimary
chaíntensionerandsimulatesthefunctionofthehy-
draulictensíoner.
7.Installcylinderidentificationtriggerpíatetofrontofin-
takecamshaft.On1993andlaterengines,instanthrust
washertofrontofintakecamshaft.
CAMSHAFTTIMINGCHAINS,6-CYLINDER
B11136
Fig.32.Secondarychainsprocketsbeinginstalled.Attachsprockets
witharrowspointingupandelongatedholescenteredto
threadedholesinshaftflange.
6.Installprimarytimingchainguideandsecondarychain
tensioner.Tightenmountingbolts.(Tensionerremains

Fig.33.VANOSspringplateandthrustwashersonenginesbuilt3/95
lockeddownfornow.)

andlater.
10.On1993andlatercars,tightennutsatintakecamshaft
sprocket.
8.Insta¡¡secondarychainsprocketsandchainasanas-
semblysothatarrowsonsprocketsarepointingup.

TighteningTorque(1996andlater)
Centermountingholesinsprocketstoboltholesin

"Intakecamshaftsprocketnut
camshafts.SeeFig.32.

tostud(M6)..............10t1Nm(89±9in-lb)
9.On1993andlaterengines:Insta¡¡thrustwashersand
springplate(whereapplicable)tointakecamsprocket.

11.On1992engines:Insta¡¡primarychaintensionerso
thatcutoutintensionerpistonengageschainrail.See
Fig.34.Checkthatchainisfreeofslack.

Fig.34.Primarytimíngchaintensionerbeinginstafed.Pistoncutout
mustbeinpositionshowntoengagechainrail.
12.On1993andlaterengines:InstallVANOScontrolunit
asdescribedlaterinthisrepairgroup.
13.Unlockandreleasesecondarychaintensioner.

NOTE-
Onpre-VANOSengines,besuretoinstallthe3mmdrill
bitsonleftandrightsidesoftool.
14.On1992engines:Tightenintakeandexhausttiming
chainsprocketboltsalternatelyintwostages,working
atintakesidefirst.
TighteningTorques
"Secondarytimingchairasprocketstocamshafts
(M7Torxbolts)
Stage1.........................5Nm(44in-lb)
Stage2........................22Nm(17ft-Ib)
15.On1992engines:Installuppertimingchaincoverto
cylinderheadusinganewgasket.Applyasmall
amountofliquidgasketsealer(3-Bond1209®orequiv-
alent)aroundcoveralignmentdowels.
16.On1993andlaterengines:Preloadprimarychainby
tighteningBMWspecialtoolno.113390(dummy

21.Installcylinderheadcovermountingstuds.Insta¡¡oil
chaintensioner)to1.3Nm(11in-lb).Thentightenex-

bafflecover.Installcylinderheadcover.
haustcamshaftsprocketboltsalternatelyintwostages.
TighteningTorques(1993andlaterengines)
"Exhaustcamshaftsprocketstocamshafts
(M7Torxbolts)
Stage1.........................5Nm(44in-lb)
Stage2........................22Nm(17ft-Ib)
17.Removeflywheellockingtoolfromtransmissionbell-
housing.Removecamshaftlockingtoolfromrearof
cylinderhead.
CAMSHAFT'TIMINGCHAIN

117-13
18.Insta¡¡crankshafthubandwasherwhilealigningwoo-
druffkey.Holdhubstationaryandtightenmountingbolt.
Installvibrationdamperandpulley,makingsurethatlo-
catingpininhubengagesholeinvibrationdamper.
NOTE-
Wheninstallingcrankshafthubmountingbolt,the
stepped(shouldered)sideofthewashershouldfase
thehub.
TighteningTorques
Crankshafthubtocrankshaft(stretchbolt-
alwaysreplace)........410±20Nm(300±15ft-1b)
"Vibrationdamperandpulley
tocrankshafthub(M8)............22Nm(17ft-Ib)
19.Turnengineoverbyhandindirectionofrotationatleast
twofullrotations.Reinstallcamshaftandcrankshaft
lockingtoolstocheckenginetiming.Removelocking
toolsifnofaultsarefound.
20.On1993andlaterengines:RemoveBMWspecialtool
113390(dummytensioner).Installprimarychainten-
sionersothatcutoutintensionerpistonengagesthe
chainrail.SeeFig.34.Installandtightenaccessplugs
inVANOScontrolunit.
TighteningTorques
"Accessplugs
toVANOScontrolunit.............50Nm(37ft-Ib)
"Primarytimingchaintensionertotensionersleeve
M50/S50USengine..............50Nm(37ft-Ib)
M52/S52USengine..............40Nm(30ft-Ib)
TighteningTorque
"Cylinderheadcover
tocylinderhead.................10Nm(89in-lb)
CAMSHAFT TIMINGCHAINS,6-CYLINDER

117-14

CAMSHAFTTIMINGCHAIN
22.Installationofremainingpartsisreverseofremoval,

Whentheengineisrunning,thepistonhousingissupplied
notingthefollowing:

withpressurizedengineoil.Atidie,thesolenoidisintheoff
"Wheninstallingthermostat,makesurearroworvent

position(de-energized)andvalvetimingismaintainedinthe
holefacesup,ifapplicable.

normalposition:Whenthesolenoidisenergized,thegearcup
"Refillcoolingsystemasdescribedin170Radiator

pistonmovesforwardtoadvancethecamshaftbyamaximum
andComingSystem.

of12.5.
"Installoilpanasdescribedin119LubricationSys-
tem.
"Fillenginewithoilandinstallanewoilfilterasde-
scribedin020MaintenanceProgram.
"Insta¡¡groundwiresatcylinderheadcovermounting
studsandatfrontofcylinderheadandthermostat
housing,whereapplicable.

VANOSsystemoperation,testing
TighteningTorques

Thereare3specialtoolsrequiredtocheckVANOSopera-
"Coolantdrainplugtocylinderblock..25Nm(18ft-Ib)

tion;anelectricaltestlead(BMWspecialtoolno.126410),an
"Radiatorcoolingfantocoolantpump.40Nm(30ft-Ib)

airlinefitting(BMWspecialtoolno.113450),andacrank-
"Radiatordrainscrewtoradiator....2.5Nm(22in-Ib)

shaftTDClockingtool(BMWspecialtoolno.112300).
"Uppertimingchaincovertocylinderhead

Thetestlealisusedtopowerthesolenoid,simulatingthe
M6nut........................10Nm(89in-lb)

groundsignalfromtheDMEcontrolunit.Theairlinefitting
M8bolt........................22Nm(17ft-Ib)

takestheplaceoftheoilsupplylinefittingtosimulateoilAres-
"VANOScontrolunittocylinderhead

sure.Thelockingtoolpositionsandlocksthecrankshaftat
M6nut........................10Nm(89in-lb)

TDC,cylinderno.l.
M8bolt........................22Nm(17ft-Ib)
"VANOSoilsupplypipetoVANOScontrolunit

1.Removealternatorcoolingairduct.
banjobolt......................32Nm(24ft-Ib)
VANOS(VARIABLEVALVETIMING)

3.Removetopplasticenginecovers.Disconnectignition
coilharnessconnectorsfromcofs.Removeignition
1993andlater6-cylinderenginesareequippedwithavari-

coils.
ablevalvetimingsystemcalledVANOS.Thissystemiscon-
trolledbytheenginemanagementsystemanddynamically

4.Removecylinderheadcovermountingboltsandre-
adjustsintakecamshafttimingbasedonengineload,engine

movecylinderheadcover.Unclipandremoveoilbaffle
speedandenginetemperature.

coverfromaboveintakecamshaft.See113Cylinder
HeadRemovalandinstallation.
ThemaincomponentsoftheVANOSsystemarethecontrol
unitwithpistonhousingandintegralspoolvalve,andthemod-
ifiedintakecamshaft.SeeFig.35.
VANOS(VARIABLEVALVETIMING)
Fig.35.VANOScontrolunitwithmodifiedintakecamshaft.
B11001
WARNING-
SpecialBMWservicetoolsarerequiredtocheck
andrepairtheVANOSSystem.Readtheproce-
duresthroughbeforebeginningthejob.
2.Disconnectcrankcaseventilationhosefittingfromcyl-
inderheadcover.
NOTE-
Notethearrangementofthecylinderheadcoverbolt
insulatorsandgasketsduringremoval.
5.SetenginetoapproximateTDCbyrotatinginnormal
operatingdirectionuntilcamshaftlobesatcylinderno.
1arefacingeachother.SeeFig.20.
6.SetenginetoTDCbyaligning"0/T"mark(0°TDC)on
frontvibrationdamperwithcastbossonlowertiming
chaincover.SeeFig.21.
7.LockcrankshaftinpositionbyinsertingBMWspecial
toolno.112300throughtransmissionbellhousingand
intoholeinflywheelordriveplate.SeeFig.36.
NOTE-
Confirmthatthelockingtoolhasbeencorrectlyin-
stalledbytryingtorotatethecrankshaft.

Fig.36.BMWspecialtoolno.112300installedthroughbellhousing
andfintoflywheel.
8.RemoveoillinefittingfromVANOScontrolunit.
NOTE-
WraptheVANOSoillinefittingwithashoptoabsorb
leakingoil.
9.Usinghollowboltandsealsfromoilsupplyline,instan
BMWspecialtoolno.113450(airlinefitting)andcon-
nectasupplyofcompressedair(30-115psi)toVANOS
oilfitting.
10.Measureandrecorddistancebetweentriggerplate
edgeandsideofsecondarytimingchaintensioner.
SeeFig.37.
Fig.37.VANOSreferencemeasurement(dimensionA)betweentrig-
gerpíate(sendergear)andsideofsecondarychaintensioner.
CAMSHAFTTIMINGCHAIN

117-15
11.DisconnectharnessconnectorfromVANOSsolenoid.
ConnectBMWspecialtoolno.126410(electricaltest
lead)toVANOSsolenoidconnector.
"Connectpositive(+)testleadtopositive(+)terminalof
batteryConnectnegative(-)testleadtochassis
ground.solenoidshouldaudiblyclickandintakecam-
shaftshouldadvance.
CAUTION-
"Besuretoconnectthetesthamesspolaritycor-
rectly.lfthepolarityisreversed,theintemaldiode
intheVANOSsolenoidwillbedestroyed.Although
thesolenoidwillstillfunctionwithafaultydiode,a
faultcodemaybesetintheECMmemory.
"Toconfirmvoltagepolarity,turntheignitionon
andcheckforpositive(+)batteryvoltageatthe
terminalcorrespondingtotheredlwhitewirein
themainharnessconnector.Checkthatthepos-
itiveterminal(+)inthemainconnectorcorre-
spondstothesameterminalinthesolenoid
connectorthatisbeingconnectedtothebattery.
12.Withsolenoidactuated,measureandrecordnewdis-
tancebetweentriggerplateedgeandside'ofsecond-
arytimingchaintensioner,asshowninFig.37.
13.Differencebetweenfirstmeasurement(step10)and
secondmeasurement(step12)shouldbeatleast8.5
mm(0.3346in.).lfanyfaultsarefound,solenoidmay
befaulty,orhydrauliccontrolunitmaybefaultyorincor-
rectlyinstalled.
14.CheckVANOSsolenoidbyremovingitfromcontrol
unit.Checkthatsolenoidplungerandcontrolunit
plungermovefreely.Installsolenoidusingtighteníng
torquegivenbelow.
NOTE-
"Thesolenoidisavailableasareplacementpart.lfthe
controlunitplungerissticking,thecompletecontrol
unitwillhavetobereplaced.
"lftheVANOSsystemdoesnotadvancecorrectlyand
nootherfaultscanbefound,itispossiblethatthe
VANOScontrolunitmayNavebeenfnstalledincor-
rectly-especiallyifthecamshaftsprocketshavepre-
víouslybeenremovedforotherrepairs.Checkthe
installationbyremovingandreinstallingthecontrol
unitasdescribedlater.
VANOS(VARIABLEVALVETIMING)

117-16

CAMSHAFTTIMINGCHAIN
15.Removecrankshaftlockingtool.Removespecialtest
equipment.Insta¡¡oilsupplylineusingnewsealsand
reconnectsolenoidconnector.Remainderofinstalla-
tionisreverseofremoval.
TighteningTorque
"Cylinderheadcovertocylinderhead.10Nm(89in-lb)
"VANOSoilsupplylinetoVANOS
controlunit(banjobolt)

...........32Nm(24ft-Ib)
"VANOSsolenoidloVANOS
controlunit.....................30Nm(22ft-Ib)
VANOScontrolunit,removing
SpecialBMWservicetoolsarerequiredloremoveandin-
stalltheVANOScontrolunit.Readtheprocedurethroughbe-
forestartingthejob.
1.Removeradiatorcoolingfanshroudandcoolingfan.
See170RadiatorandCoolingSystem.
CAUTION-
Radiatorfanhaslefthandthreads.
2.Removetopplasticenginecovers.Disconnectignition
coilharnessconnectorsfromcoils.Removeignition
coils.Removecylinderheadcover.Unclipandremove
oilbafflecoverfromaboveintakecamshaft.See113
CylinderHeadRemovalandInstallation.
NOTE-
Makenoteofthemountingboltinsulatorarrangement
duringremovalofthecylinderheadcover.
3.SetengineloTDCbyrotatingengineinnormaloperat-
ingdirectionuntilcamshaftlobesatcylinderno.1are
facingeachotherand"0/T"mark(0°TDC)onvibration
damperlinesupwithcastbossonlowertimingchain
cover.SeeFig.38.
4.LockcrankshaftatTDCbyinsertingBMWspecialtool
no.112300throughtransmissionbellhousingandfinto
flywheelordriveplate.RefertoFig.36givenearlier.
NOTE-
Confirmthatthelockingtoolhasbeencorrectlyin-
stalledbytryingtorotatethecrankshaft.
5.Removethreecylinderheadcovermountingstudsfrom
rearofhead.LockcamshaftsatTDCbymounting
BMWspecialtoolno.113240atendsofcamshafts.
Checkthattoolissquarelyseatedoncylinderhead
gasketsurface.Ifnecessary,rotatecamshaftsslightly
usinga24mmwrench.RefertoFig.24givenearlier.
VANOS(VARIABLEVALVETIMING)
Fig.38.CamshaftspositionedatTDC-Cyl.No.1camlobesfacein
Note0/Tmark(0°TDC)onvibrationdamperalígnedwithboss
onfrontcover.
CAUTION-
ThecamshaftsmustbelockedintheTDCposition
usingthespecialservicetooloranequivalentbe-
foreremovingthetimingchain.Thearrowsonthe
sprocketsshouldnotbeusedtoaccuratelysetthe
enginetoTDCThespecialtoolholdsthecam-
shaftsparalleltoeachotherandperpendicularto
thevalvecovergasketsurface.
6.Disconnectharnessconnectorandoillinefittingfrom
bottomofVANOScontrolunit.
NOTE-
WraptheVANOSoilfinefittingwithashopragtoab-
sorbleakingoil.
7.RemovetwoaccessplugsfromVANOScontrolunitin
frontofexhaustcamshaftsprocket.Loosen4exhaust
camshaftsprocketmountingboltsbutdonotremove
(TorxEl0socket).
NOTE-
Removaloftheaccessplugsallowsthelowerexhaust
camshaftsprocketmountingboltstobeaccessed.
8.Depresssecondarytimingchaintensionerandlockitin
downpositionbyinsertingastiffwireintorearoften-
sioner.SeeFig.27.
9.RemoveVANOScontrolunítmountingnutsandboltat
frontofcylinderhead.

10.Oncarsbuiltupto3/95:Slidecontrolunitofffrontof
cylinderhead,handturningtheexhaustsprocketclock-
wise(asviewedfromfront)astheunitisremoved.
11.Oncarsbuilt3/95andlatee:Useaspannertooltoro-
tateexhaustsprocketuntilstopon'intakesprocketis
contacted.SeeFig.39.Thenslidecontrolunitofffront
ofcylinderhead.
EMAÑ
0012514
Fig.39.OnVANOScontrolunitwithspringplate(carsbuilt3/95and
later),rotateexhaustcamshaftsprocketclockwiseuntilintake

NOTE-
camshaftcontactsstop.BMWspecialtool115490shown.

BMWspecialtoolno.113'390isadummychainten-
sionerandsimulatesthefunctionofthetensioner.
VANOScontrolunit,installing
CAUTION-
IncorrectinstallationoftheVANOScontrolmay
resultindamagetotheenginevalvetráin.
1.LockcamshaftsandcrankshaftinTDCpositionwith
BMWspecialtoolsasdescribedaboveinremovalpro-
cedure.
CAUTION-
Thecamshaftsandcrankshaftmustbelockedin
theTDCpositionusingBMWspecialtoolsno.11
2300and113240.Ifthecamshaftsandcrank-
shaftarenotatTDC,thevalvescancontactthe
pistonswhentheengineisturnedover.
NOTE-
Besurethesecondarytimingchaintensionerislocked
downandtheexhaustcamshaftmountingboltsare
loosebeforeproceeding.
2.Removeprimarytimingchaintensionerfromsideof
cylinderhead.SeeFig.40.
CAMSHAFTTIMINGCHAIN

117-17
Fig.40.Primarytimingchaintensioner(arrow).Removetensioner
slowlytorelievespringtensionbeneathendplug.
3.InstallBMWspecialtoolno.113390intoprimarytim-
ingchaintensionersleeve.Threadtoolinfingertightto
removechainslack.
4.Handturnsecondarysprocketsclockwise(asviewed
fromfrontofengine)untilsprocketscontactstops.
5.Applyasmallamountof¡¡quidgasketsealer(3-Bond
1209®orequivalent)toVANOShousingalignment
doweisonfrontofcylinderhead.lnstallanewgasket.
6.PushVANOSpistongearcupfintoVANOShousinguntil
itbottomsoutinhousing.PositionVANOScontrolunit
intoplace,butdonotengagesplinesongearcup.
7.Oncarsbuiltupto3/95:
"Handturnexhaustsprocketcounterclockwise(as
viewedfromfrontofengine)onlyenoughtomesh
gearcupsplineswithcamshaftgear:
"SlowlypushVANOScontrolunitinuntilfullyseated,
guidingchainsincounterclockwisedirection.
VANOS(VARIABLEVALVETIMING)

117-18

CAMSHAFTTIMINGCHAIN
CAUTION-
Itiscríticalthattheexhaustcamshaftsprocketbe
turnedonlythemínimumamountnecessaryto
engagethegearcup.Ifthisprocedureisdoneín-
correctly,theVANOSsystemmaynotfunction
throughoutítsfullrange.
NOTE-
Asthecontrolunitisinstalled,thesecondarysprockets
willrotateinthecounterclockwisedirection.Itmaybe
necessarytoguidesprocketscounterclockwiseasthe
controlunitisinstalled.
8.Oncarsbuiltfrom3/95:Useaspannertool(SeeFig.
39.),turnexhaustsprocketcounterclockwise(as
víewedfromfrontofengine)onlyenoughtomesh
gearcupsplineswithcamshaftgear.Slowlypush
VANOScontrolunittowardscamshaftuntilitisfully
seated,guidingchainsincounterclockwisedirection.
CAUTION-
Ensurethatthefirstavailabletoothengages.
9.Installandtightencontrolunitnutsandbolt.
10.ConnectharnessconnectortoVANOSsolenoid.Using
newseals,insta¡¡oillinefitting.
TighteningTorques
"VANOScontrolunittocylinderhead
M6nut........................10Nm(89in-lb)
M8bolt........................22Nm(17ft-Ib)
"VANOSoilsupplylinetocontrolunit.32Nm(24ft-Ib)
11.Slowlyunlockandreleasesecondarychaintensioner.
12.PreloadprimarychainbytighteningBMWspecialtool
no.112240(dummychaintensioner)to1.3Nm(11in-
lb).Thentightenexhaustcamshaftsprocketmounting
boltsalternatelyintwostages.
TighteningTorque
"Secondarytimingchainsprocketstocamshafts
(Toraboits)
Stage1.........................5Nm(44in-lb)
Stage2........................22Nm(17ft-Ib)
VANOS(VARIABLEVALVETIMING)
13.Removeflywheellockingtoolfromtransmissionbell-
housing.Removecamshaftlockingtoolfromrearof
cylinderhead.
14.Turnengineoverbyhandatleasttwofui¡crankshaftro-
tations.Reinstallcamshaftlockingtoolandflywheel
lockingtooltomakesurealladjustmentsarecorrect.If
settingsarecorrect,removelockingtools.
15.RemoveBMWspecialtool112420(dummychainten-
sioner)fromsideofcylinderhead.Installprimarychain
tensionersothatcutoutintensionerpistonengages
chainrail.SeeFig.34.Usingnewseals,installand
tightenaccessplugsinVANOScontrolunit.
TighteningTorque
"Accessplugsto
VANOScontrolunit...............50Nm(37ft-lb)
"Primarytimingchaintensionerplugtotensionersleeve
M50/S50USengine...............50Nm(37ft-Ib)
M52/S52USengine..............40Nm(30ft-Ib)
16.Installoilbafflecoveraboveintakecamshaft.Install
threecylinderheadcovermountingstudstorearof
head.Instalicylinderheadcover.
TighteningTorque
"Cylinderheadcover
tocylinderhead(M6screws)......

10Nm(89in-Ib)
17.Installationofremainingpartsisreverseofremoval.
NOTE-
Besuretoinstallthegroundwíresatthecylinderhead
covermountingstudsandatthefrontofthecylinder
head,ifapplicable.

119LubricationSystem
LUBRICATIONSYSTEM

119-1
GENERAL...................,,.......119-1

OHpan,removingandinstalling
(6-cylinderengine,1992models).........119-4
TROUBLESHOOTING..................119-1

Oilpan,removingandinstalling
Oilpressure,checking..................119-1

(6-cylinderengine,1993andlatermodels).119-6
Oilpressurewarningsystem,testing.......119-2

OILPUMP......................

.119-8
OILPAN..............................119-2

Oilpump,removingandinstalling
Oilpan,removingandinstalling

(4-cylinderengine)....................119-8
(4-cylinderengines)...................119-2

Oilpump,removingandinstalling
(6-cylinderengine)...................119-10
GENERAL

Oilpressure,checking
Theoilpanandtheoilpumpcanberemovedwiththeen-
gineinstalled,althoughengineliftinglsupportequipmentis
necessary.
NOTE-
Oilchangeprocedureandoilfilterreplacementare
coveredin020MaintenanceProgram.
Al¡enginesareequippedwithanoilpressurewarningsys-
temtohelppreventenginedamage.Othersafetyfeaturesin-
clude:
"Afilterbypasstoprovidelubricationshouldtheoilfilter
becomeclogged.
"Anoilpumppressurereliefvalvetopreventexcessive
systempressure.
TROUBLESHOOTING
Thelubricationwarningsystemconsistsofanoilpressure
switchmountedintheoilcircuitandaninstrumentpanelwarn-
inglight.
CAUTION-
Iftheredoilpressurewarninglightcomesonor
flashesonwhiledriving,alwaysassumethatthe
oilpressureislow.
Toperformanoílpressuretest,BMWspecifiesspecialtools
thatattachtothetopoftheoílfilterhousing.Thefollowingpro-
cedureworkswellusingstandardautomotiveoilpressure
testingequipmentattachedtotheoilpressureswitchportin
theengine.Insomeengines,however,accesstothisport
maybeextremelyrestricted.
1.Disconnectharnessconnectorfromoilpressureswitch
andremoveswitch.SeeFig.1.
NOTE-
Thoroughlycleanaroundtheoilpressureswitchbefore
removingit.
Fig.1.

OilpressureswitchlocationonM50engine(arrow).
TROUBLESHOOTING

119-2

LUBRICATION SYSTEM
NOTE-
ComponentLocation

Ifthelightdoesnotgoout,thewiringtotheswitchis
"Oilpressureswitch

mostlikelygroundedsomewherebetweentheswitch
allengines...................oraoilfilterhousing

terminalandthewarninglight.SeaElectricalWiring
Diagramsatrearofmanualforelectricalschematics.
CAUTION-
Someoilmaydrainoutastheoilpressureswitch
isremoved.Usearagtosoakupanyspills.
2.Installpressuregaugeinplaceofswitch.
3.Withgaugeinstalied,startengineandallowtoreach
operatingtemperature.Checkoilpressurebothcold
andhot.
NOTE-
Forthemostaccuratetestresults,theengineoil(and
filter)shouldbenewandofthecorrectgrade.
OilPressure
"¡dle(mínimum)....................0.5bar(7psi)
"Regulatedpressure(elevatedenginespeed)
4-cylinderengines........4.3±0.2bar(63t3psi)
6-cylinderengines................4.0bar(59psi)
4.Removepressuregaugeandreinstallpressureswitch.
Iftestingshowslowoilpressure,oneormoreofthefollow-
ingconditionsmaybeindicated:
OILPAN
"Wornorfaultyoiipump.
"Wornorfaultyenginebearings

Theoilpancanberemovedwiththeengineinstalied,al-
Severeenginewear.

thoughspecíalenginesupportequipmentwillbeneeded.
Al¡oftheseconditionsindicatetheneedformajorrepairs.
Oilpressurewarningsystem,testing
Whentheignitionistumedora,theoilpressurewarninglight
comesora.Whentheengineísstartedandtheoilpressureris-
esslightly,theoilpressureswitchopensandthewarninglight
goesout.Makesuretheoilleve¡iscorrectbeforemaking
tests.
1.Turraignitionswitchora.
"Warninglightorainstrumentpanelmustlightup.
2.Removeconnectorfromoilpressureswitch.
"Warninglightorainstrumentpanelmustgoout.
OILPAN
3.Ifwarninglightdoesnotlightwhenignitionisora,re-
moveconnectorfromoilpressureswitchandusea
jumperwiretogroundconnectorterminaltoaclean
metalsurface.
NOTE-
Ifthewarninglightcomesora,checktheswitchasde-
scríbedinthenextstep.Ifthewarninglightdoesnot
comeora,thewiringtotheinstrumentclusterortothe
lightitselfisfaulty.
4.Totestswitch,connectaraohmmeterbetweenterminal
inswitchbodyandground.Withengineoff,these
shouldbecontinuity.Withenginerunning,oilpressure
shouldoperaswitchandthereshouldbenocontinuity
Replaceafaultyswitch.
WARNING -
Keepinmindthatlowoilpressuremaybeprevent-
ingtheswitchfromtumingthelightout.Ifthelight
remainsorawhiletheengineisrunning,checkthe
oilpressureasdescribedearlier.Donotdrivethe
caruntiltheproblemiscorrected.Theenginemay
beseverelydamaged.
Oilpan,removingandinstalling
(4-cylinderengines)
1.Raisecararadplacesecurelyorajackstands.
2.Removesplashshíeld(s)fromunderengine,whereap-
plicable.
3.Drainengineoilasdescribedin020MaintenancePro-
gram.
4.Disconnectvacuumhoseadapterfromvacuumbrake
boosteratrearofenginecompartment.
5.Removeoildipstickguidetubemountingnutandpull
guidetubefromoilpan.SeeFig.2.

NOTE-
TheguidetubeissealedinthepanwithanO-ring.
CheckthattheO-ringcomesoutwiththetube.Usea
newO-ringwheninstallingthetube.
Fig.2.

Oildipstickguidetubemountingnut(arrow)onM44engine.
UsenewO-ringatbaseoftubeduringinstallatidn.
6.Installengineliftingequipmentatfrontenginelifting
pointandraiseengineapproximately5mm(1/4inch)
untilengineweightissupported.
7.Workingbeneathcar,separatesteeringcolumnshaft
fromsteeringrackatuniversaljoint.
"Pointwheelsstraightaheadbeforedisconnectingshaft
fromrack.Marksteeringcolumnshaftjointtosteering
rackspíndle.See320SteeringandWheelAlign-
ment.
CAUTION-
Inordertoavoídtheneedforfront-endrealign-
ment,donotunboltpowersteeringrackfromsus-
pensioncrossmember.
8.Supportsuspensioncrossmember(subframe)frombe-
lowusingappropriatejackingequipment.
9.Atleftandrightsides,unboltcontrolarmbushingcarri-
ersfrombody.Disconnectstabilizerbarlinksfromcon-
trolarms.SeeFig.3.
LUBRICATIONSYSTEM

119-3
0011960
Fig.3.

Stabilizerbarlinknut(A)andcontrolarmbushingcarrierbolts
(B).Rightsideshows.
10.Removeboltsfromleftandrightsidesofsuspension
crossmember.RemoveM10nutsfrombottomofleft
andrightenginemounts.Lowercrossmemberasfaras
possible.SeeFig.4.
uu1ibb4
Fig.4.

Suspensioncrossmemberbolts(A)andlowerenginemount-
ingnut(B).Rightsideshows.
11.Removeclampingbracketsholdingfuellinestooilpan.
12.Oncarswithautomatictransmission,removeATFcool-
erlinebracketsfromoilpan.
13.Removeenginedrivebeltfrompowersteeringpump.
See020MaintenanceProgram.
14.Unboltpowersteeringpumpbracketandremove
bracketwithpump.Hangpumpfromchassisusing
wire.
OILPAN

119-4

LUBRICATIONSYSTEM
15.Removeoilpanscrews.Lowerandremoveoilpanto-
wardrear.

TighteningTorques
"Controlarmbushingcarrier
CAUTION-

tobody(M10bolt)...............42Nm(31ft-Ib)
'

lftheoilpandoesnotseparateeasilyfromtheen-

"Enginemountto
ginecylinderblock,makesureallmountingbolis

suspensioncrossmember(M10nut).42Nm(31ft-Ib)
havebeenremoved.Ifnecessary,afewtapswith

"Frontsuspensioncrossmember
arubbermalletshouldbreakitfree.Neverprythe

tobody..............See310FrontSusPension
oilpanloose.
"Oilpantoengineblock(M6bolt)
8.8grade......................10Nm(89in-lb)
16.Installationisreverseofremoval.

10.9grade......................12Nm(9ft-Ib)
"Thoroughlycleanalloldgasketmaterialfrommating

"Powersteeringpumptobracket
surfacesanduseanewgasket.

(self-lockingnuts)................22Nm(16ft-Ib)
"Applyasmallamountofnon-hardeningsealer(3-

"Powersteeringpumpbrackettoengine
BondOl209orequivalent)tooilpangasketdirectly

blockoroilpan(self-lockingnuts)...22Nm(16ft-Ib)
belowjointsforendcoverandfronttimingcasecover.

"Stabilizerbarlinktocontrolarm
SeeFig.5.

M8nut........................22Nm(17ft-Ib)
"Wheninstallingoilpantoengine,tightenforward

M10nut.......................42Nm(31Ib-ft)
screwsfirst,thentightenrear.

"Steeringcolumnuniversaljoint
"Fillenginewithoilasdescribedin020Maintenance

tosteeringrackspindle(M8bolt)....19Nm(14ft-ib)
Program.
0011950
Fig.5.

Joint-matingareasatoilpangasketwheresealershouldbe
applied(arrows).Applyabead3mmwideby2mmhigh.
OILPAN
WARNING-
Alwaysusenewboliswhenmountingthesubframe
tothebody.Theone-timeonlybolisshouldbere-
placedanytimetheyareremoved.
NOTE-
Theoilpickupisattachedtotheoilpanusingself-tap-
pingscrews.Forthisreasonnothreadingforthepickup
ispresentonnewoilpans.Replacethesealforthe
pickupandusetheoídscrewstoreattachthepickupto
thepan.
Oilpan,removingandinstalling
(6-cylinderengine,1992models)
NOTE-
Carsbuiltupto9/92(1992models)useadifferentsus-
pensioncrossmemberthanlaterproductioncars.Oil
panremovalprocedureontheearliercarsrequiresthat
theengineberaisedandsupportedfromabove.
1.Raisecarandplacesecurelyonjackstands.
2.Removesplashshield(s)fromunderengine,whereap-
plicable.
3.Drainengineoilasdescribedin020MaintenancePro-
gram.
4.Removecompleteexhaustsystem.See180Exhaust
System.
5.Removeairfilterhousingcompletewithmassairflow
sensor.See113CylinderHeadRemovalandInstal-
lation.
6.Removealternatorcoolingductfromalternatorandra-
diatorsupport.
7.Removeradiatorcoolingfanandfanshroud.Remove
radiatorsecuringclipsattopofradiator.See170Radi-
atorandCoolingSystem.
Centerthesteeringspindletothesteeringrackbeforein-

NOTE-
stallingthesteeringcolumnshaft.See320Steeringand

Theradiatorcoolingfannut(32mmwrench)hasleft
WheelAlignmentforspecificinstallationmarkingsandpro-

handthreads.
cedures.

8.Removeairplenumfromrearofenginecompartment.
See640HeatingandAirConditioning.
9.Releasedrivebelttensionandremovealternatordrive
belt.RemoveA/Ccompressordrivebelt.SeeFig.6.
B11143
Fig.6.

Toremovepoly-ribbeddrivebelt,prycoverfromfrontoften-
sioner.Thenusing8mmhexkey,turntensionerclockwise
(arrow)toreleasetensionandslipbeltoffpulleys.
10.Unboltpowersteeringreservoirandpullreservoiroff
enginemountbracket.
11.Withoutdisconnectingfluidlines,removepowersteer-
ingbracket(withpump)fromoilpanandengineblock.
SeeFig.7.Disconnectfluidlinesfrombracketonen-
ginemount.Hangpumpfromchassisusingwire.
12.Withoutdisconnectingrefrigerantlines,removeA/C
compressorfromengineblock.Hangcompressorfrom
chassisusingwire.See640HeatingandAirCondi-
tioning.
13.Removeoildipstickguidetubemountingboltandre-
movetube.SeeFig.8.
NOTE-
TheguidetubeissealedintheoilpanwithanO-ring.
CheckthattheO-ringcomesoutwiththetube.Usea
newO-ringwheninstallingthetube.
14.Oncarswithautomatictransmission,removebrackets
holdingATFcoolerlinestooilpanandcylinderblock.
LUBRICATIONSYSTEM

119-5
Fig.7.

Powersteeringpumpmountingbolts(arrows).
Fig.8.

Oildipstickguidetubebeingremoved.UseanewO-ring
(arrow)duringinstallation.
15.Insta¡¡engineliftingequipmentatfrontenginelifting
pointandraiseenginejustuntilitsweightissupported.
16.Removenutsatbottomofleftandrightenginemounts.
Removegroundwirefromrightenginemount.1-oosen
nutsattopofleftandrightenginemounts(donotre-
move).
OILPAN

119-6

LUBRICATIONSYSTEM
17.Raiseengineasmuchaspossible.Checkcarefullyfor

22.Installationisreverseofremoval.
obstructions,wiringharnessclearanceandpinched
hosesorlinesasengineisraised.

"Wheninstallingoilpan,applyab

dofnon-hardening
sealingcompound(3-Bond12090orequivalent)to
18.Removeoilpanmountingboltsandloweroilpanto

frontandrearendcoverseamareasonblock.
subframecrossmember.

"Positionoilpumppickuptubeandoilpanontoblock
andinstallpickuptubeusinganewgasket.
"Besuretabongasketfacesdowntowardsintakeof
NOTE-

pickuptube.
Iftheoilpandoesnotseparateeasilyfromtheengine

"Tightenforwardoilpanscrewsfirst,thentightenrear.
cylinderblock,afewtapswitharubbermalletshould

"Fillenginewithoilasdescribedin020Maintenance
breakitfree.Donotprytheoilpanloose.

Program.
"Afteraddingengineoil,startandrunengine.Raiseen-
19.Removeoilpumpsprocketmountingnut.SeeFig.9.

ginespeedto2,500rpmuntiloilpressurewarning
Liftsprocketofftogetherwithdrivechain.

lampgoesout(about5seconds).
Fig.9.Oilpumpsprocketmountingnut(left-handthread)on6-cylin-

OIIpan,removingandinstalling
derengine(arrow).

(6-cylinderengine,1993andlatermodeis)
NOTE-
Theoílpumpsprocketnuthaslefthandthreads.
20.Unboltoilpumppickuptubefromoilpump.Unboltoil
pumpfromengineblock.SeeOilpump,removing
andinstalling(6-cylinderengine).
21.Removeoilpanfromrear.
TighteningTorques
"Enginemountto
suspensioncrossmember(M10nut)..42Nm(31ft-Ib)
"Oilpantoengineblock(M6bolt)
8.8grade......................10Nm(89in-lb)
10.9grade....................12Nm(106in-lb)
"Oilpumptoengineblock..........22Nm(16ft-Ib)
"Oilpumpsprockettooilpumpshaft
(M10x1left-handthread)..........25Nm(18ft-Ib)
"Powersteeringpumptobracket
(self-lockingnuts)................22Nm(16ft-lb)
"Powersteeringpumpbrackettoengine
blockoroilpan(self-lockingnuts)...22Nm(16ft-Ib)
NOTE-
Carsbuiltafter9/92useadifferentsuspensioncross-
member¡hanearfierproductíoncars.Oilpanremoval
procedureonthelatercarsrequíresthattheenginebe
supportedfromaboyeandthefrontsuspensioncross-
memberbeunboltedandloweredfromthechassis.
1.Raisecarandplacesecurelyonjackstands.
2.Removesplashshieldfromunderengine,ifapplicable.
3.Drainengineoilasdescríbedin020MaintenancePro-
gram.
4.Removealternatorcoolingductfromalternatorandra-
diatorsupport.

5.Removeairfilterhousingcompletewithmassairflow
sensor.See113CylinderHeadRemovalandInstal-
lation.
6.Removeoildipstickguidetubemountingbolt.Discon-
nectoilseparatorhosefrombaseofguidetubeandre-
movetubefromoilpan(whereapplicable).SeeFig.10.
NOTE-
TheguidetubeissealedintheblockusinganO-ring.
CheckthattheO-ringcomesoutwiththetube.Usea
newO-ringwheninstallingthetube.
Fig.10.Oildipstickguidetubebeingremoved.UsenewO-ring(ar-
row)duringinstallation.
7.M50/S50USengine:Usingacleansyringe,remove
powersteeringfluidfromfluidreservoir.Disconnect
powersteeringfluidlinesfromsteeringrack.See320
SteeringandWheelAlignment.
8.M52/S52USengine:Unboltpowersteeringreservoir
fromengíne,thentietochassiswithwire.
9.Insta¡¡engineliftingequipmentatfrontenginelifting
pointandraiseengineapproximately5mm('/ainch)
untilengineweightissupported.SeeFig.11.
10.Workingbeneathcar,separatesteeringcolumnshaft
fromsteeringrackatuniversaljoint.
"Marksteeringcolumnshaftjointtosteeringrackspin-
dle.Pointwheelsstraightaheadbeforedisconnecting
shaftfromrack.See320SteeringandWheelAlign-
ment.
LUBRICATIONSYSTEM

119
Fig.11.Engineliftingequipmentshowninstalledacrossengíne.
CAUTION-
Inordertoavoidtheneedforfront-endrealign-
ment,donotunboltpowersteeringrackfromsus-
pensioncrossmember.
11.Supportsuspensioncrossmemberfrombelowusing
appropriatejackingequipment.
12.Loosennutsattopofleftandrightsideenginemounts.
Removenutsfrombottomofleftandrightsideengine
mounts.
13.Atleftandrightsides,unboltcontrolarmbushíngcarri-
ersfrombody.Disconnectstabilizerbarlinksfromcon-
trolarms.RefertoFig.3.
14.Removeboltsfromleftandrightsidesofsuspension
crossmemberandlowerfrontaxleasfaraspossible.
15.Removefuellineclampingbracketsfromoilpan.On
carswithautomatictransmission,removeATFcooler
linebracketsfromoilpan.
16.Removeoilpanscrews.Lowerandremoveoilpanfor-
wardtoremove.
CAUTION-
Iftheoilpandoesnotseparateeasilyfromtheen-
ginecylinderblock,afewtapswitharubbermallet
shouldbreakitfree.Donotprytheoilpanloose.
OILPAN

119-8

LUBRICATION SYSTEM
17.Installationisreverseofremoval.
"Thoroughlycleanalloldgasketmaterialfrommating
surtacesanduseanewgasket.
"Applyasmallamountofnon-hardeningsealer(3-Bond
12090orequivalent)tooilpangasketdirectlybelow
jointsforandcoverandfronttimingcasecover.See
Fig.12.
"Tightenoilpanboltsstartingatfrontfirst,workingto-
wardback(transmission)end.
"Fillenginewithoilasdescribedin020Maintenance
Program.
"Afteraddingengineoil,startandrunengine.Raiseen-
ginespeedto2,500rpmuntiloílpressurewarning
lampgoesout(about5seconds).
OILPUMP
applied(arrows).Applyabead3mmwideby2mmhigh.
WARNING -
"Alwaysusenewboltswhenmountingthesub-
frametothebody.Theone-timeonlyboltsshould
bereplacedanytimetheyareremoved.
"Specialinstallationinstructionsapplywhenin-
stallingthefrontsuspensioncrossmembertothe
body.See310FrontSuspensionforfastener
specificationsandtighteningtorques.
Fig.12.Joint-matingareasatoilpangasketwheresealershouldbe
Centerthesteeringspindletothesteeringrackbeforein-
stallingthesteeringcolumnshaft.See320Steeringand
WheelAlignmentformorespecificprocedures.
TighteningTorques
"Controlarmbushingcarrier
tobody(M10bolt)...............47Nm(35ft-Ib)
"Enginemountto
suspensioncrossmember(M10nut)..42Nm(31ft-Ib)
"Oilpantoengineblock(M6bolt)
8.8grade......................10Nm(89in-lb)
10.9grade....................12Nm(106in-lb)
"Stabilizerbarlink
tocontrolarm(M10nut)...........42Nm(31Ib-ft)
"Steeringcolumnuniversaljoint
tosteeringrackspindle(M8bolt)....19Nm(14ft-Ib)
"Suspensíoncrossmember
tobody..............See310FrontSuspension
OILPUMP
Oilpump,removingandinstalling
(4-cylinderengine)
OilpressureonM42andM44enginesisgeneratedbya
gear-typepumpmountedtotherearofthefrontenginecover
(timingchaincase).Thepumpisgear-drivenoffthefrontof
thecrankshaft.
NOTE-
Oilpumpremovalrequiresloweringofthefrontsus-
pensionandremovaloftheoilpan,aswellasremoval
ofthetimingchainassembly.
1.Disconnectnegative(-)batterycablefrombattery.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagavÍii.
2.Drainengineoilasdescribedin020MaintenancePro-
gram.
3.Withenginecold,draincoolant.See170Radiatorand
CoolingSystem.
4.Removetopcoverfromoilfilterhousingtoallowengine
oiltodrainintooilpan.Removeoilpanasdescribed
earlier.Reinstalloilfiltercover.
5.Removealternator.Unboltpowersteeringpumpfrom
bracket,thenremovealternatormountíngbracket.See
121Battery,Starter,Alternator.
6.Removecrankshaftvibrationdamperandhub.Thenre-
moveupperandlowertimingchaincovers,complete
timingchain,chainsprocketsandchainguides.See
117CamshaftTímingChain.

7.Unbolttimingchaincasefromfrontofengine.SeeFig.13.

9.Installationisreverseofremoval.
Fig.13.Timingchaincasemountingbolts(arrows)onM44engine.
8.Removecoverfromoilpumponrearoftimingchain
case.SeeFig.14.Inspectoilpumpgearsandoilpump
cavityintimingchaincaseforwearandlorscoring.
Fig.14.Oilpumpcovermountingbolts(arrows)onM44engine.
LUBRICATIONSYSTEM

119-9
"Replaceal¡gasketsandO-rings.
"Installanewrubbersea¡(profilegasket)betweentop
oftimingchaincaseandcylinderhead.
"Besuretothoroughlycleansealingsurfaces.
-Use3-Bond1209orequivalentsealantonbothsides
ofsea¡beforeinstalling.
10.Protectprofilegasketusingthinsheetmetal(BMW
specialtoolno.112330)wheninstallingtimingchain
case.SeeFig.15.
"Applyathincoatingofgreasetobothsidesofsheet
metaltoolandtotopsurfaceofprofilegasket.
"Placesheetmetalbetweengasketandcylinderhead
andcarefullyslídeupperchaincoverintoposition.
"Tightenal¡mountingboltsandthencarefullywithdraw
sheetmetal.Installtimingchainasdescribedin117
CamshaftTimingChain.
Fig.15.Usethinsheetmetal(arrow)toprotectprofilegasketduring
installationoftimingchaincase.Carefullywithdrawsheet
metalaftertighteningfasteners.
TighteningTorques
"Timingchaincasetoengineblock
M6...........................10Nm(7.5ft-Ib)
M8...........................22Nm(16ft-Ib)
"Thermostathousingtoupper
timingchaincover(M6)............10Nm(89in-lb)
"OHfiltercover
tooilfilterhousing(M8)...........25Nm(18ft-lb)
"Oilpumpcoverto
timingchaincase(M6)............10Nm(89in-lb)
"Oilpantoengineblock(M6bolt)
8.8grade......................10Nm(89in-lb)
10.9grade....................12Nm(106in-lb)
"Alternatortoalternatorbracket.....43Nm(32ft-Ib)
OILPUMP

119-10

LUBRICATIONSYSTEM
Oilpump,removingandinstalling
(6-cylinderengine)
Oilpressureonthe6-cylinderenginesisgeneratedbya
gear-typepumpboltedtothebottomoftheengineblock.The
oilpumpischaindrivenoffthefrontofthecrankshaft.
NOTE-
Oilpumpremovalrequiresraisingtheengine(carsbuilt
upto9-92)orloweringthefrontsuspensioncrossmem-
ber(carsbuiltfrom9-92)toremovetheoilpan.
1.Drainoilasdescribedin020MaintenanceProgram.
2.Removeoilpanasdescribedearlier.
3.Removeoilpumpsprocketmountingnut(left-hand
thread).SeeFig.16.Liftsprocketofftogetherwithdrive
chain.
Fig.16.Oilpumpsprocketmountingnut(left-handthread)on6-cylin-
derengine(arrow).
4.Removemountingboltsfromoilpumpandoilpump
pickuptube.Withdrawpump.
NOTE-
Noteanyspacersbetweenpumpandengineblock.
SeeFig.17.
"Notepositionoflocatingdowels.
OILPUMP
811186
0011952
Fig.17.Oilpumpmountingpoints(1)andpickuptubemountíng
points(2).
5.Removecoverfromoilpumpandcheckforwearor
scoring.Spinoilpumpshaftandcheckthatgearsturn
smoothly.Replacepumpifgearsspinwithdifficultyor
anywearispresent.
6.Installationisreverseofremoval,notingthefollowing:
"Alignsprocketsplinestooilpumpshaftsplinesbefore
tighteningsprocketnut.
TighteningTorques
"Oilpumptoengineblock(M8)......22Nm(16ft-Ib)
"Oilpantoengineblock(M6bolt)
8.8grade......................10Nm(89in-lb)
10.9grade....................12Nm(106in-lb)
"Oilpumpsprockettooilpumpshaft
(M10x1left-handthread)..........25Nm(18ft-Ib)

GENERAL............................120-1

CamshaftPosition(CMP)Sensor..........120-6
DisablingIgnitionSystem................120-2

Camshaftposition(CMP)sensor,replacing
WarningsandCautions..................120-2

(4-cylinderengine)....................120-6
Camshaftposition(CMP)sensor,replacing
IGNITIONSYSTEMDIAGNOSTICS......120-3

(6-cylinderengine)....................120-7
BasicTroubleshootingPrinciples..........120-3

Knocksensors,replacing.................120-7
IgnitionFiringOrder.....................120-7
IGNITIONSYSTEMSERVICE...........120-3
CheckingforSpark.....................120-3
Ignitioncoil,testingandreplacing
(4-cylinderengine)....................120-3
Ignitioncoil,testingandreplacing
(6-cylinderengine)....................120-4
CrankshaftPositionlrpmSensor...........120-5
Crankshaftposition/rpmsensor,testingand
replacing(frontmounted)...............120-6
Crankshaftposition/rpmsensor,replacing
(rearmounted).......................120-6
GENERAL

Troubleshootingandtestingoftheenginemanagement
systemshouldbecarriedoutusingtheBMWspecializedser
Thisrepairgroupcoversrepairandcomponentreplace-

vicetester(scantool).
mentinformationfortheignitionsystem.
Allenginesuseadistributorlessignitionsystemwithindívid-
ualignitioncoilsforeachcylinder.Thereisnodistributorcap
NOTE-

orignitionrotor.Eachcoilcanbeselectivelycontrolledbythe
"Sparkplugreplacementiscoveredin020Mainte-

enginecontrolmoduleonacylinder-by-cylinderbasis.Onlater
nanceProgram.

systems,knocksensorsareusedtomonitorandcontroligni-
"Forfuelrelatedtroubleshootingandtesting,see130

tionknock(ping)andadjusttimingaccordingly.
Fuellnjection.
Ignitiontimingiselectronicallycontrolledandnotadjust-
Allenginescoveredbythismanualuseanadvanceden-

able.Theenginecontrolmodule(ECM)usesengineload,en-
ginemanagementsystem.Theenginemanagementsystem

ginespeed,coolanttemperature,andintakeairtemperature
incorporateson-boarddiagnostics,fuelinjection,ignitionand

asthebasicinputsfortimingcontrol.Knockdetectionisalso
otheradvancedenginecontrolfunctions.

aninputtothecontrolmodule,whereapplicable.
Tablea.EngineManagementSystemVariants
Enginecode

1System
4-cylinder
M42(1.8I)

BoschDMEMl.7
M44(1.9I)

BoschDMEM5.2(OBDII)
6-cylinder
M50
1992(2.5I)

BoschDMEM8.1
1993-1995(2.5I)

BoschDMEM33.1
M52
1996-1998(2.8I)

SiemensMS41.1(OBDII)
1998(2.5I)

SiemensMS41.1(013D11)
S50US(3.0I)

BoschDMEM3.3.1
S52US(3.2I)

SiemensMS41.1(OBDII)
120IgnitionSystem
IGNITIONSYSTEM

120-1
IGNITION SYSTEM SCHEMATICS .......120-7
TABLES
a.EngineManagementSystemVariants......120-1
b.IgnitionCoilResistance(M42engine)......120-4
c.IgnitionCoilResistance(M44engine)......120-4
d.IgnitionCoilResistance
(6-cylinderengine).....................120-5
NOTE-
Allenginescoveredbythismanual,withtheexception
ofthe1992M50,incorporateknocksensorsaspartof
theenginemanagementsystem.
Theinitialignitionpointisdeterminedbythecrankshaftpo-
sition/rpmsensorduringcranking.Oncetheengineisrun-
ning,timingiscontinuallyadjustedbasedonoperating
conditions.AcharacteristicignitionmapisshowninFig.1.A
mapsimilartotheoneshownisdigitallystoredintheengine
controlmodule.
GENERAL

120-2

IGNITIONSYSTEM
Fig.1.

Ignitioncharacteristicmap.
DisablingIgnitionSystem
WARNING -
Theignitionsystemisahigh-energysystemoperat-
inginadangerousvoltagerangethatcouldproveto
befatalifexposedterminalsorlivepartsarecon-
tacted.Useextremecautionwhenworkingonacar
withtheignitiononortheenginerunning.
Theignitionsystemoperatesinalethalvoltagerangeand
shouldthereforebedisabiedanytimesenriceorrepairworkis
beingdoneontheenginethatrequirestheignitiontobe
switchedon.
Theenginemanagementsystemcanbedisabledbyremov-
ingthemainrelay.Therelayislocatedinthepowerdistribution
boxintheleftrearoftheenginecompartment.SeeFig.2.
0013134
Fig.2.

Maínsystemrelay(arrow)inpowerdistributionbox(leftrear
ofenginecompartment).
GENERAL
WARNING -
"Donottouchordisconnectanyofthehighten-
sioncablesatthecotlsorsparkplugswhilethe
enginetsrunningorbeingcrankedbythestarter.
Fatalvoltagesarepresent.
"Beforeoperatingthestarterwithoutstartingthe
engine(forexamplewhenmakingacompression
test)alwaysdisabletheignition.
CAUTION-
"Priortodisconnectingthebattery,readthebat-
terydisconnectioncautionsgtvenatthefrontof
thtsmanualonpageviti.
"Donotattempttodisabletheignitionbyeitherre-
movingthecotlfromthesparkplugs(6-cylinder
engines)ordisconnectingthecollwiresfromthe
plugs(4-cylinderengines).
"Connectordisconnectignitionsystemwires,
multipleconnectors,andignitiontestequipment
leadsonlywhiletheignitionisoff.Switchmulttm-
eterfunctionsormeasurementrangesontywith
thetestprobesdisconnected.
"Donotdisconnectthebatterywhiletheenginets
running.
"Manyofthetestsofignitionsystemcomponents
requiretheuseofhigh-impedancetestequip-
menttopreventdamagetotheelectricalcompo-
nents.Ahighimpedancedigitalmultimeter
shouldbeusedforallvoltageandresistance
tests.AnLEDtestlightshouldbeusedinplaceof
anincandescent-typetestlamp.
"Ingeneral,maketestconnectionsonlyasspeci-
fiedbyBMW,asdescribedinthismanual,oras
describedbytheinstrumentamanufacturer.

IGNITIONSYSTEMDIAGNOSTICS

IGNITIONSYSTEMSERVICE
Poordriveabilitymayhaveavarietyofcauses.Thefault

On4-cylinderengines,anignitioncoilpackismountedto
mayliewiththeignitionsystem,thefuelsystem,partsofthe

thepassengersidestruttowerintheenginecompartment.
emissioncontrolsystem,oracombinationofthethree.Be-

Thecoilpackintegrates4individualcoils.
causeoftheseinterrelatedfunctionsandtheireffectsoneach
other,itisoftendifficulttoknowwheretobeginlookingfor

On6-cylinderengines,anignitioncoilislocateddirectly
problems.

aboveeachsparkplug.
Forthisreason,effectivetroubleshootingshouldalwaysbe-
ginwithaninterrogationoftheOn-BoardDiagnostic(OBD)
system.TheOBDsystemdetectscertainemissions-related
enginemanagementmalfunctions.Whenfaultsaredetected,
theOBDsystemstoresaDiagnosticTroubleCode(DTC)in
thesystemECM.Inaddition,theCheckEnginewarninglight
willcomeonifanemissions-relatedfaultisdetected.
TwogenerationsofOBDareusedonthecarscoveredby
thismanual.See100Engine-GeneralforOBDinformation.
On-BoardDiagnostics
"1992-1995models.....................

OBDI
"1996andlatermodels..................OBDII
NOTE-
"OncarswithOBDti,specializedOBD11scantool
equipmentmustbeusedtoaccessDTCs,eitherusing
theBMWspecialtoolora`generic"OBD11scantool.
"TheOBD11faultmemory(includinganilluminated
CheckEnginelight)canonlyberesetusingthespe-
cialscantool.RemovingtheconnectorfromtheECM
ordísconnectingthebatterywillnoterasethefault
memory.
BasicTroubleshootingPrincipies
Anenginethatstartsandrunsindicatestheignitionsystem
isfundamentallyworking-deliveringvoltagetoatleastsome
ofthesparkplugs.Ahard-startingorpoor-runningengine,
however,mayindicateignitioncoilproblems,crackedordete-
rioratedsparkplugwires(4-cylinderenginesonly),andworn
orfouledsparkplugs.
WARNING -
Inefficientcombustion(richair/fuelmixture)can
causethecatalyticconvertertooverheatandplug.
Anoverheatedcatalyticconvertercanalsobeatire
hazard.
CheckingforSpark
IGNITIONSYSTEM

120-3
WARNING -
Ifasparktestisdoneincorrectly,damagetotheen-
ginecontrolmodule(ECM)ortheignitioncoil(s)
mayresult.
Checkingforsparkisdifficultonengineswithdistributorless
ignitionsystems.
TryRmovngtheplugsandinspectingfordifferencesbe-
tweenthem.Apoor-firingplugmaybewetwithfueland/or
blackandsooty,butnotalways.Ifacoilisnotoperating,the
enginemanagementsystemwillelectricallydisablethefuel
injectortothatcylinder.Thekeyistolookfordifferencesbe-
tweencylinders.
Ignitioncoil,testingandreplacing
(4-cylinderengine)
1.Disconnectmainharnessconnectorfromcoils:
"OnM42engine,removeplasticcoveringfromcoilsand
disconnectindividualharnessconnectors.
"OnM44engine,disconnectmainharnessconnectorat
endofcoilpack.SeeFig.3.
Fig.3.

IgnitioncoilpackforM44engine(arrow).Coilharnesscon-
nectorshownat1.
IGNITIONSYSTEMSERVICE

120-4

IGNITIONSYSTEM
2.Checkforbatteryvoltageocofs.Ifvoltageisnot

Tableb.IgnitionCoilResistance
present,checkwirebetweenterminal15andignition

(M42Engine)
switch.SeeElectricalWiringDiagrams.
"OnM42engine,connectdigitalmultimeterbetweenter-
minal15(+)ineachharnessconnectorandground.See
Fig.4.
"OnM44engine,connectvoltmeterbetweenterminal2
(15+)inconnectorandground.Turnignitiononand
checkforvoltage.SeeFig.5.
3.Turnignitionoff.
04a15
Fig.4.

IgnitioncoilharnessconnectorterminalidentificationforM42
engine.
Fig.5.

IgnitioncoilharnessconnectorterminalidentificationforM44
engine.
CAUTION-
Thewiringtothecoil(viatheignitionswitch15+)
isnotfuseprotected.Usecarewhentestingthis
circuit.
4.Useadigitalmultimetertotestcoilprimaryresistance.
"OnM42engine,useTablebasaguidetocheckcoil
resistance.Makechecksateachharnessconnector.
"OnM44engine,useTable,casaguidetocheckcoil
primaryresistance.
5.Inspectcoilhousingforhairlinecracksorleakingcast-
ingmaterial.SeeFig.7.Aleakyignitioncoilmayindi-

11502
cateafaultyECM(enginecontrolmodule).Checkthe
ECMbeforeinstallinganewcoil.

Fig.6.

Ignitioncoilharnessconnectorterminalidentificationfor6-
cylinderengine.
IGNITIONSYSTEMSERVICE
11502
Terminals Resistance
(refertoFig.4.)
Coilprimary

1(-)and15(+)

10.4-0.8ohms
Coilsecondary

N.A.

N.A.
Tablec.IgnitionCoilResistance
(M44Engine)
Terminais Resistance
(refertoFig.5.)
Coil#1primary

1(-)and2(+)

0.4-0.8ohms
Coil#2primary

6(-)and2(+)

0.4-0.8ohms
Coil#3primary

7(-)and2(+)

0.4-0.8ohms
Coil#4primary

5(-)and2(+)

0.4-0.8ohms
Coilsecondary

N.A.

N.A.
NOTE-
IfasinglecoilísfaultyonM44engines,thecomplete
coilpackwillhavetobereplaced.
Ignitioncoil,testingandreplacing
(6-cylinderengine)
CAUTION-
Useadigitalmultimeterforthefollowingtests.
1.Removeplasticenginecoversfromtopofengineby
pryingoffnutcoversandremovingcovermounting
nuts.See113CylinderHeadRemovalandInstalla-
tion.
2.Disconnectharnessconnectorfromcof.Connectmul-
timeterbetweenterminal15(+)inconnectorand
ground.SeeFig.6.
3.Turnignitiononandcheckforbatteryvoltage.
"Ifbatteryvoltageisnotpresent,checkwirebetween
terminal15andignitionswitch.SeeElectricalWiring
Diagrams.
"mozo

CAUTION-
Thewiringtotermina¡15(+)ofthecoil(víatheig-
nitionswitch)isnotfuseprotected.Usecarewhen
testíngthiscircuit.
4.Turnignitionoff.
5.Useamultimetertotestcoilprimaryresistanceatcoil
terminals.SeeTabled.
Tabled.IgnitionCoilResistance
(6-cylinderEngine)
Terminals Resistance
(refertoFig.4.)
Coilprimary

11(-)and15(+)

X0.4-0.8ohms
Coilsecondary

lN.A.

N.A.
6.Removecoilandinspectcoilhousingforhairlinecracks
orleakingcastingmaterial.SeeFig.7.Aleakyignition
coilmayindícateafaultyenginecontrolmodule(ECM).
CheckECMbeforeinstallinganewcoil.
811004
Fig.7.

Ignitioncoilbeingremovedon6-cylinderengine(M52engine
shown).
CAUTION-
"Notelocationofcoilgroundstrapsbeforecoilre-
moval;reinstallinthesamelocation.
"Whenreplacingignitioncoils,ensurethatthere-
placementcoil(s)arefromthesamemanufactur-
ercontainingthesamepartlcodenumbers.If
individualcoilswiththecorrectspecificationsare
notavailable,allcoilsshouldbereplaced.
IGNITIONSYSTEM

120-5
CrankshaftPosition/rpmSensor
Iftheenginecontrolmodule(ECM)doesnotreceivea
crankshaftpositionsignalduringcranking,theenginewillnot
start.
On1992-1995(pre-OBDII)cars,thecrankshaftposi-
tion/rpmsensorismountedonthefrontenginecoverand
readsthetoothedvibrationdampenerwheel.SeeFig.8.
Fig.8.

Crankshaftposition/rpmsensormountedatfrontofengine
on1992-1995cars.(arrow).
On1996andlateecars(OBDIIcompliant),thecrankshaft
position/rpmsensorismountedintheleftrearsideofthecyl-
inderblock.Thesensorreadsatoothedwheelmountedtothe
endofthecrankshaft.SeeFig.9.
Fig.9.

Crankshaftposition/rpmsensortoothedwheelmountedto
rearofcrankshaftOBDIIcompliantcars.Thesensoris
mountedintheleftrearsideofthecylinderblock.
IGNITIONSYSTEMSERVICE

120-6

IGNITIONSYSTEM
Crankshaftposition/rpmsensor,
testingandreplacing(frontmounted)
1.Disconnectsensorharnessconnector.
2.Usingadigitalmultimeter,checkresistancebetween
terminals1and2inconnector.SeeFig.10.
n1n2n3
Fig.10.Crankshaftposition/rpmsensorconnector.
Crankshaftpositionlrpmsensorspecifications
"Coilresistance(approx.)
terminais1and2..............1280±10%ohms
"Airgap(sensordistancefromtoothed
wheel).............1.0±0.3mm(0.04±0.01in.)
3.Iftheresistanceisnotcorrect,thesensorisfaultyand
shouldbereplaced.
NOTE-
Wheninstallingthenewsensor,besurethewiringIs
reroutedinthesameorientation.Securethesensorus-
ingnewwireties.
TighteningTorque
"Crankshaftposition/rpmsensorto
mountingbracket...........5t1Nm(62t9in-lb)
Crankshaftposition/rpmsensor,

4.Installationisreverseofremoval.UseanewO-ring
replacing(rearmounted)

wheninstallingsensor.Besurewiringisreroutedin
sameorientation.
1.Disconnectsensorharnessconnector.
6502AGN56
2.Locatesensoronrearleftsideofcylinderblock.Re-
movesensormountingboltandremovesensorfrom
cylinderblock.
IGNITIONSYSTEM SERVICE
3.Installationisreverseofremoval.UseanewO-ring
wheninstallingsensor.Besurewiringisreroutedin
sameorientation.Securesensorusingnewwireties.
NOTE-
Itmaybeeasiertoremovethesensorworkingfromthe
undersideofthevehicle.
CamshaftPosition(CMP)Sensor
Thecamshaftposition(CMP)sensorisusedbytheengine
managementsystemforsequentialfuelinjectionandknock
control.
Camshaftposition(CMP)sensor,
replacing(4-cylinderengine)
1.RemoveCMPsensorfromtoptimingcover,justabove
coolantthermostathousing.SeeFig.11.
Fig.11.Camshaftpositionsensormountingbolt(arrow).M42engine
shown.
2.OnM42enginesto9/93:DisconnectCMPharnessplug
justaboveoilfilterhousing.
3.OnM42from9/93andallM44engines:Removeupper
intakemanifoldasdescribedin113CylinderHeadRe-
movalandInstallation.ThenunplugCMPsensorhar-
nessconnectorbelowmanifold.

Camshaftposition(CMP)sensor,
replacing(6-cylinderengine)
1.Removeplasticcoverfromabovefuelinjectors.
2.DisconnectharnessconnectorfromVANOSsolenoid
andunscrewsolenoidfromVANOScontrolunit.Re-

"Cleancontactsurfaceonengineblockbeforefnstall
moveoilsupplylinefromVANOScontrolunit.See117

ingknocksensors.
CamshaftTimingChain.
3.Removecamshaftposition(CMP)sensorfromleftfrontof
cylinderhead,nexttotopofoilfilterhousing.

"Knocksensortocylinderblock....20Nm(15ft.lbs.)
4.DisconnectCMPsensorharnessfromunderintake
manifold.
5.Installationisreverseofremoval.UseanewO-ring
wheninstallingsensor.Besurewiringisreroutedin
sameorientation.
TighteningTorques
"CMPsensortocylinderhead........5Nm(3.5ft-Ib)
"VANOSoilsupplypipeto
VANOScontrolunit..............32Nm(24ft-Ib)
"VANOSsolenoidtoVANOS
controlunit.....................30Nm(22ft-Ib)
Knocksensors,replacing
KnocksensorsareusedonengineswithBoschDMEM1.7,
BoschDMEM3.3.1,BoschDMEM5.2,andSiemensMS41.1
enginemanagementsystems.Theknocksensorsarebolted
totheleftsideofthecylinderblockandmonitorthecombus-
tionchamberforengine-damagingknock.Ifengineknockis
detected,theignitionpointisretardedaccordinglyviatheen-
ginecontrolmodule.
CAUTION-
"Labelknocksensorharnessconnectorsbefore
disconnectingthem.Theconnectorsmustnotbe
interchanged.Enginedamagemayresultifthe
sensorsaremonitoringthewrongcytinders.
"Notetheinstalledangleoftheknocksensoronthe
blockbeforeremovingit.Reinstallthesensorin
thesameposition.Besuretouseatorquewrench
whentighteningthesensormountingbola
NOTE-
"OnM52engines,asingleharnessconnectsthetwo
sensorstothemainharnessconnector.Theshorter
cableleadfsfortheknocksensorforcytinders4,5,
and6.
TighteningTorque
IGNITIONSYSTEM

120-7
0012730
Fig.12.Knocksensormountingboltonfrontleftsideofcylinder
block.
NOTE-
KnocksensorfunctionIsmonitoredbytheOn-Board
Diagnosticsystem.Ifaknocksensorisdetectedtobe
faulty,anappropriatediagnostictroublecode(DTC)
maybestoredinmemory.See100Engine-General
forinformationonretrievingDTCs.
On6-cylinderengines,theknocksensorsareaccessibleaf-
terremovingtheintakemanifold.On4-cylinderengines,the
uppersectionoftheintakemanifoldshouldberemovedtoac-
cessthesensors.SeeFig.12.
NOTE-
Intakemanifoldremovalandinstallationproceduresare

"Cylinderno.1isatthefrontoftheengine.
coveredin113CylinderHeadRemovalandInstallation.
IgnitionFiringOrder
IgnitionFiringOrder
"4-cylinderengines......................1-3-4-2
"6-cylinderengines...................1-5-3-6-2-4
IGNITIONSYSTEMSCHEMATICS
Fig.13throughFig.17showignitionsystemschematics
usedontheenginescoveredbythismanual.
IGNITIONSYSTEMSCHEMATICS

120-8

IGNITIONSYSTEM
1

1.0GN

1.0
Gl
.0GNI

Igncoil

1.0GN
.
Tti

%ti

r,

_%ti_

_ice_
I

25

52 55 24

51

54

56
I

Powerinput

powerinput
t

U

EngineControlModule(BoschDMEMl.7)

I
I

PowerinputMainrelaycontrolI
15 42

43

16 44 28 68 67

34 6 26

27
1-----

__
V

_

--

_
~8K

.35BK
.3513,11

.35YE

1

.35
BK35 VE
.35
3

cyl.1
1
11
E
S
2
1.0BR
2.5BR
Ign.coil
cyl.3

II
Ign.coil

Ign.coil
3

cyI.2

1Y_Y2

k
3

cyl.4
IGNITIONSYSTEMSCHEMATICS
Batteryvoltage
inrunorstart
(víaignitionswitch
terminal15)

WIRING
COLORCODE
4.0GN
1.0BR'V.
Camshaft
KnockSensorKnockSensor

Position
(cyl.1-2) (cyl.3-4)

Sensor
Fig.13.BoschDMEM1.7ignitionsystemcircuitforM42engine.
Ground
(RHrearofengine
compartment,rear
ofshocktower)
N[INS
Crankshaftlrpm
PositionSensor
Batteryvoltage
inrunorstart
(víamainrelay
terminal87)
Ground
(RHrearofengine
compartment,rear
ofshocktower)
5GN
BK-BLACK
BR"BROWN
RD -RED
YL-YELLOW
GN-GREEN
BL -BLUE
VI-VIOLET
GY-GREY
WT-WHITE
PK-PINK
Warning:
Lethalvoltage
present
Batteryvoltage
at
alltimes
toMainrelay
(terminal85)
'Y Y
---------------------
0013087

^1.5WT ^1.5RD ^1.5YL ^1.5BL
r

--__

____-

__-_

___-_

-___-_____--__--

-____-___

____- i
26
g 50
22
23

54

5
I

Powerinput

powerinput
I

EngineControlModule(BoschDMEM5.2)

I
I

grounds

I
Powerinput

Mainrelaycontrol

I
70 40

71

21

20 78

34 55 6
26

27
------
-
-------------------------
--
-
-----
--------------------
.,

v 11.1

v
`135BK

35BK
2(

1Y

¡3

194
KnockSensorKnockSensor
(cyl.1-2) (cyl.3-4)
Frommainrelay
terminal87
(batteryvoltage
inrunorstart
Batteryvoltage
inrunorstart
(viaignitionswitch

Warnin
terminal15)

Lethalóltage

WIRING
present

COLORCODE
2.5GN

'
1.0YL

/1.0BL

/1.0RDNJT
.35BK/

/.35BK
Camshaft
Position
Sensor -_
Fig.14.BoschDMEM5.2ignitionsystemcircuitforM44engine.
Ground
(RHrearofengine
compartment,rear
ofshocktower)
Crankshaftirpm
PositionSensor
IGNITIONSYSTEM

120-9
Batteryvoltage

Batteryvoltage
inrunorstart

inrunorstart
(viamainrelay

(viaignitionswitch
terminal87)

terminal15)
BK -BLACX
BR -BROWN
RD -RED
YL-YELLOW
GN -GREEN
BL -BLUE
VI-VIOLET
GY -GREY
WT-WHITE
PK -PINK
Batteryvoltage
at
alltimes
toMainrelay
(terminal85)
Ground
(RHrearofengine
compartment,rear
ofshocktower)

0012721
lGNITIONSYSTEMSCHEMATlCS

120-10

IGNITIONSYSTEM
Ground(rearof
enginecompartment,
rearofpassengerside
shocktower)
.!BK
Camshaft
PositionSensor
IGNITIONSYSTEMSCHEMATICS
Batteryvoltage
inrunorstart
(viaignitionswitch
terminal15)
---------------------------------------------------------
55

S5154
i
powerinput

Powerinput

1
DMEControlModule(BoschDMEM3.1)
Ground-
(RHrearofengine
compartment,rearof
passengersideshocktower)
Fig.15.BoschDMEM3.1usedon1992M50engines(withoutVANOS).
.EBK
Crankshaftlrpm
PositionSensor
5GN
1.0RD
Ground
(RHrearofengine
compartment,rearof
passengersideshocktower)
WIRING
COLORCODE
BK-BLACK
BR-BROWN
RD-RED
YL-YELLOW
GN-GREEN
BL -BLUE
VI-VIOLET
GY"GREY
WT"WHITE
PK-PINK
Batteryvoltage
inrunorstart
(viamainrelay
Batteryvoltage

terminal87)
inrunorstart
(viaignitionswitch
terminal15)
11508
1
grounds

MainrelacontrolPowerInput

Y

I
-34---"-- 6 26 27
1
Batteryvoltage
at
alltimes
toMainrelay
(terminal85)

RER
KnockSensorKnockSensor
(cyl.1-3) (cyl.4-6)
Batteryvoltage

IMIRING
inrunorstart

COLOR CODE
(viaignitionswitch
termina¡15)

BK

BLAOK
BR BROWN
RD-RED
YL-YELLOW
GN"GREEN
EL-BLUF
VI-VIOLET
GY-GREY
WT-WHITE
PK-PINK
4.0GN
l1 /1 j\ I'1 /~ /1 r1

l\ r1
1
55

so

si

52

23

25

24

56

54 1
Powerinput

Powerinput

I
I
I

O
EngineControlModule(BoschDMEM13.1)

I
I

grounds

Powerinput

MainrelaYcontrolI
70
___
71

69

17

28

43

16

-34---"-6

26

27
____________________________________________
Frommainrela
terminal87
(batteryvoltage
inrunorstart
.5YL
Camshaft
Position
Sensor
Ground
(RHrearofengine
compartment,rear
ofshocktower)
.5BK
Crankshaft/rpm
PositionSensor
Fig.16.BoschDMEM33.1ignitionsystemcírcuitfor1993-1995M50engineswithVANOS.
IGNITIONSYSTEM

120-11
Ground=
(RHrearofengine
compartment,backside
ofshocktower)
Batteryvoltage

Batteryvoltage
inrunorstart

inrunorstart
(viaignitionswitch

(viamainrelay
terminal15)

terminal87)
1.0RD
11506a
.5BR
Batteryvoltage
at
alltimes
toMainrelay
(terminal85)
IGNITIONSYSTEMSCHEMATICS

120-12

IGNITIONSYSTEM
Warning.
Lethalvoltage
present
Batteryvoltage
inrunorstart
(viaignitíonswitch
terminal15)
I
t
IGNITIONSYSTEM SCHEMATICS
Batteryvoltage
inrunorstart
(viaignitionswitch
terminal15)

WIRING
COLORCODE
KnockSensorKnockSensor

Crankshaftlrpm

Camshaft
(cyl.1-3)

(cyl.4-6)

PositionSensor

Position
-
-
Sensor -
Fig.17.SiemensMS41.1ignitionsystemusedon1996andlater6-cylinderengines.
1.0BR
PQ
1.08~1 .0BKIRD

/1.0BK/YL

'10BK/BL

'1.03KIGN

10BKNI4
1D
BK-BLACK
BR-BROWN
RD-RED
YL-YELLOW
GN-GREEN
BL-BLUE
VI-VIOLET
GY-GREY
WT-WHITE
PK-PINK
Batteryvoltage
inrunorstart
(viamainrelay
terminal87)
!1

rl1.0B~

^1.0BK/RD

^1.0BKIYL

^1.0BK/BL

n1.0BK/GN

n1.0BKIVI

%~
r------- --------------_____________----_______-_-____
49

29

1

30

2

31

3

87 54
1powerinput

Powerinput

I
1

EngineControlModule(SiemensMS41.1)

1
1

grounds

1
n
1

PowerinputMainrelaycontrol1
1-
57___
58

_59___63_

38

83

48

40

64

43

65

41

28

32

34

4

26

73

1
-

------------_------------_-----------------

-
.5Y1-

.5BKY.5GNY
.5BRYY

.35BKY
1Y

Y

.35BKY/Y35YY
75.18R/
.5YL-1 1
'.
Batteryvoltage
at
alltimes
toMainrelay
(terminal85)
Ground

v
(RHrearofengine

Z
compartment,rear

=
ofshocktower)

Ground
(RHrearofengine
compartment,rear
ofshocktower)

0012731

CHARGING SYSTEM
TROUBLESHOOTING ..................121-2
ChargingSystemQuick-Check...........121-2
Staticcurrentdraw,checking.............121-2
BATTERYSERVICE....................121-3
BatteryTesting........................121-3
HydrometerTesting....................121-3
BatteryOpen-CircuitVoltageTest.........121-4
BatteryLoadVoltageTest...............121-4
BatteryCharging.......................121-4
ALTERNATOR SERVICE...............121-4
Chargingsystem,checking..............121-4
Alternator,removingandinstalling
(4-cylinderengine)....................121-5
Alternator,removingandinstalling
(6-cylinderengine)....................121-6
GENERAL
Thechargingsystemconsistsofabelt-drivenalternator
withintegralvoltageregulatorandabatterymountedinthe
luggagecompartment.
Variousversionsofalternators,voltageregulators,starters,
andbatteriesareusedintheE36cars.Itisimportanttore-
placecomponentsaccordingtotheoriginalequipmentspeci-
fication.CheckwithanauthorizedBMWdealerforspecific
applicationandpartsinformation.
WARNING -
"Weargoggles,rubbergloves,andarubberapron
whenworkingaroundbatteriesandbatteryacid
(electrolyte).
"Batteryacidcontainssulfuricacidandcancause
skinirritationandburning.ffacidisspilledonyour
skinorclothing,flushtheareaatoncewithlarge
quantitiesofwater.lfelectrolytegetsintoyour
eyes,flushthemwithlargequantitiesofcleanwa-
terforseveralminutesandcallaphysician.
"Batteriesthatarebeingchargedorarefully
chargedgiveoffexplosivehydrogengas.Keep
sparksandopenflamesaway.Donotsmoke.
BATTERY,STARTER,ALTERNATOR

121-1
121Battery,Starter,Alternator
GENERAL ............................121-1

Voltageregulator,removingandínstalling...121-6
Alternatorbrushes,inspectingandreplacing.121-7
STARTERSERVICE....................121-7
StarterTroubleshootíng

121-7

15..................
Starter,removingandinstalling
(4-cylinderengine)....................121-8
Starter,removingandinstalling
(6-cylinderenginewith
manualtransmission)..................121-8
Starter,removingandinstalling
(6-cylinderenginewith
automatictransmission)................121-9
Solenoidswitch,removingandinstalling....121-10
TABLES
a.Battery,StarterandChargingSystem
Troubleshooting................:...........121-2
b.SpecificGravityofBatteryElectrolyte
at80°F(27°C).............................121-3
c.Open-CircuitVoltageandBatteryCharge........121-4
d.BatteryLoadTest-MinimumVoltage...........121-4
CAUTION-
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
"Disconnectingthebatterycablesmayerasefault
codesstoredincontrolunitmemory.
"Alwaysdisconnectthenegative()batterycable
firstandreconnectitlast.Coverthebatterypost
withaninsulatingmaterialwheneverthecableis
removed.
"Afterreconnectingthebattery,thepowerwindow
motorsmustbereinitialized.See511DoorWin-
dows.
"Neverreversethebatterycables.Evenamomen-
tarywrongconnectioncandamagethealternator
orotherelectricalcomponents.
"Batterycablesmaybethesamecolor.Labelca-
blebeforeremoving.
GENERAL

121-2

BATTERY,STARTER,ALTERNATOR
CHARGINGSYSTEMTROUBLESHOOTING

Staticcurrentdraw,checking
Chargingsystemdiagnosticsrequiresspecialtestequip-
ment.Ifthetestequipmentisnotavailable,chargingsystem
faultdiagnosiscanbeperformedbyanauthorizedBMWdeal-
erorotherqualifiedrepairshop.Ageneraltroubleshooting
guideisgiveninTablea.
ChargingSystemQuick-Check
Asaquick-check,useadigitalmultimeterlomeasurevolt-

2.Disconnectbatterynegative(-)cable.
ageacrossthebatteryterminalswiththekeyoffandthen
againwiththeenginerunning.Thebatteryvoltageshouldbe

CAUTION-
about12.6voltswithkeyoffandapproximately14.0voltswith

Priortodisconnectingthebattery,readthebattery
theenginerunning.Ifthevoltagedoesnotincreasewhenthe

disconnectioncautionsgivenatthefrontofthis
engineisrunning,thereisafaultinthechargingsystem.

manualonpagaviii.
NOTE-
Theregulatedvoltage(enginerunning)shouldbebe-
tween13.5and14.5,dependingontemperaturaand
operatingconditions.Ifthevoltageishigherthan14.8,
thevoltageregulatorismostMelyfaulty.
Checkforcleanandtightbatterycables.Checktheground
cablerunningfromthenegative(-)batteryterminallothe
chassisandthegroundcablerunningfromtheenginelothe
chassis.Checkthealternatordrivebeltconditionandtension.
Ifthebatterydischargesovertime,theremaybeaconstant
drainorcurrentdrawonthebattery.Asmallstaticdrainonthe
batteryisnormal,butalargedrainwillcausethebatterylo
quicklydischarge.Makeastaticcurrentdrawtestasthefirst
stepwhenexperiencingbatterydischarge.
1.Makesureignitionandal¡electricalaccessoriesare
switchedoff.
3.Connectadigitalammeterbetweennegativebattery
postandnegativebatterycablelomeasurecurrent.
SeeFig.1.Waitatleastoneminutalogetanaccurate
reading.
Arangeofabout0lo100milliampsisnormal,dependingon
thenumberofaccessoriesthatneedconstantpower.Acurrent
of400milliamps(0.4amp)ormoremayindicateaproblem.
Tablea.Battery,StarterandChargingSystemTroubleshooting
Symptom

1

ProbableCause

1

CorrectivaAction
1.Enginecranksslowlyornot

a.Batterycablesloose,dirtyorcor-

a.Cleanorreplacecables.See020MaintenanceProgram.
atall,solenoídclickswhen

roded.
starterisoperated.

b.Batterydischarged.

b.Chargebattery,testandreplaceifnecessary.
c.Bodygroundstraploose,dirtyor

c.Inspectgroundstrap,clean,tightenorreplaceifnecessary.
corroded.
d.Poorconnectionatstartermotor

d.Checkconnections,testforvoltageatstarter.Testforvoltageat
terminal30.

neutralsafetyorclutchinterlockswitch.
e.Startermotororsolenoidfaulty.

e.Teststarter.
2.Batterywillnotstay

a.Shortcircuitdrainingthebattery.

a.Testforexcessivecurrentdrainwitheverythingelectricalinthe
chargedmorethanafew

vehicleoff.
days.

b.Shortdrivingtripsandhighelec-

b.Evaluatedrivingstyle.Wherepossible,reduceelectricalcon
tricaldrainonchargingsystem

sumptionwhenmakingshorttrips.
doesnotallowbatterytore-
charge.
c.Drivebelt(s)wornordamaged.

c.Inspectorreplacemulti-ribbedbelt(s).See020Maintenance
Program.
d.Batteryfaulty.

d.Testbatteryandreplaceífnecessary.
e.Batterycablesloose,dirtyorcor-

e.Cleanorreplacecables.See020MaintenanceProgram.
rodad.
f.Alternatororvoltageregulator

f.Testalternatorandvoltageregulator.
faulty.
3.Batterylosingwater.

1a.Batteryovercharging.

1a.Testvoltageregulatorforproperoperation.
4.Lightsdim,lightintensity

a.Drivebelt(s)wornordamaged.

a.Inspectorreplacemulti-ribbedbelt(s).See020Maintenance
varieswithenginespeed.

Program.
b.Alternatororvoltageregulator

b.Testalternatorandvoltageregulator.
faulty.
c.Bodygroundstrapsloose,dirtyor

c.Inspectgroundstraps,clean,tightenorreplaceasnecessary.
corroded.
CHARGINGSYSTEMTROUBLESHOOTING

Fig.1.

Electricalsystemstaticcurrentdrawbeingmeasured.
Todeterminethecircuitorcomponentcausingtheproblem,
removeonePuseatatimeuntilthecurrentdropstoanormal
range.
BATTERYSERVICE
TheE36usesasix-cell,12-voltleadacidbatterymounted
intheluggagecompartment.SeeFig.2.
NOTE-
E36convertiblemodelsrequireaspecialbatterywhich
isdesignedforconstantvibratfon.Abatterynotde-
signedforthiswillfailmuchearlier.
Batterycapacityisdeterminedbytheamountofcurrent
neededtostartthevehicle,andbytheamountofcurrentcon-
sumedbytheelectricalsystem.
BMWbatteriesareratedbyampere/hours(Ah)andcold
crankingamps(CCA)rating.TheAhratingisdeterminedby
theaverageamountofcurrentthebatterycandeliverover
timewithoutdroppingbelowaspecifiedvoltage.TheCCAis
determinedbythebattery'sabilitytodeliverstartingcurrentat
0°F(-18°C)withoutdroppingbelowaspecifiedvoltage.
BatteryTesting
noN~A
B9517
Batterytestingdeterminesthestateofbatterycharge.On
conventionalorlow-maintenancebatteriesthemostcommon
methodoftestingthebatteryisthatofcheckingthespecific
gravityoftheelectrolyteusingahydrometer.Beforetesting
thebattery,checkthatthecablesaretightandfreeofcorro-
sion.SeeFig.2.
HydrometerTesting
Thehydrometerconsistsofaglasscylinderwithafreely
movingfloatinside.Whenelectrolyteisdrawnintothecylin-
der,theleveltowhichthefloatsinksindicatesthespecific
BATTERY,STARTER,ALTERNATOR

121-3
Fig.2.

Batteryinrightsideofluggagecompartment.
gravityoftheelectrolyte.Themoredensetheconcentrationof
sulfuricacidintheelectrolyte,thelessthefloatwillsink,result-
inginahigherreadingandindicatingahigherstateofcharge).
NOTE-
Electrolytetemperatureaffectshydrometerreading.
Checktheelectrolytetemperaturewithathermometer.
Add0.004tothehydrometerreadingforevery10°F
(6°C)thattheelectrolyteisabove80°F(27°C).Sub-
tract0.004fromthereadingforevery10°F(6°C)that
theelectrolyteisbelow80°F(27°C).
Beforecheckingthespecificgravityofabattery,loadthe
batterywith15amperesforoneminute.lfthebatteryisin-
stalledinthevehicle,thiscanbedonebyturningonthehead-
lightswithouttheenginerunning.Tablebliststhepercentage
ofchargebasedonspecificgravityvalues.
Tableb.SpecificGravityofBatteryElectrolyteat
80°F(27°C)
Specificgravity

1

Stateofcharge
1.265

Fullycharged
1.225

75%charged
1.190

50%charged
1.155

25%charged
1.120

Fullydischarged
Thebatteryisinsatisfactoryconditioniftheaveragespecif-
icgravityofthesixcellsisatleast1.225.Ifthespecificgravity
isabovethisleve¡,butthebatterylackspowerforstarting,de-
terminethebattery'ssenriceconditionwithaloadvoltagetest,
asdescribedbelow.Iftheaveragespecificgravityofthesix
cellsisbelow1.225,removethebatteryfromtheluggage
compartmentandrecharge.If,afterrecharging,thespecific
gravityvariesbymorethan0.005betweenanytwocelis,re-
placethebattery.
CHARGING SYSTEM TROUBLESHOOTING

121-4

BATTERY,STARTER,ALTERNATOR
BatteryOpen-CircuitVoltageTest

BatteryCharging
Beforemakingthetest,loadthebatterywith15amperesfor

Dischargedbatteriescanberechargedusingabattery
oneminutewithabatteryload-testerorturnontheheadlights

charger.Thebatteryshouldberemovedfromtheluggage
foraboutoneminutewithouttheenginerunning.Thendiscon-

compartmentduringcharging.
nectthebatterynegative(-)cableandconnectadigitalvolt-
meteracrossthebatteryterminals.Open-circuitvoltage

Prolongedchargingcauseselectrolyteevaporationtoalev
levelsaregiveninTablec.

elthatcandamagethebattery.Itisbesttousealow-current
charger(6amperesorless)topreventbatterydamage
Iftheopen-circuitvoltageísOKbutthebatterystilllacks

causedbyoverheating.
powerforstarting,makealoadvoltagetest.Iftheopen-circuit
voltageisbelow12.4volts,rechargethebatteryandretest.

WARNING-
Hydrogengasgivenoffbythebatteryduringcharg-
Tablec.Open-CircuitVoltageandBatteryCharge

ingisexplosive.Donotsmoke.Keepopenllames
awayfromthetopofthebattery,andpreventelec
Open-circuitvoltage

Stateofcharge

tricalsparksbyturningoffthebatterychargerbe-
12.6Vormore

Fullycharged

foreconnectingordisconnectingit.
12.4V

1

75%charged
12.2V

50%charged

CAUTION-
12.0V

25%charged

"Batteryelectrolyte(sulfuricacid)candamage
thecar.Ifelectrolyteisspilled,cleanthearea
11.7Vorless

Fullydischarged

withasolutionofbakingsodaandwater.
BatteryLoadVoltageTest
Abatteryloadtesterisrequiredforaloadvoltagetest.The

-Alwaysdisconnectbothbatterycablesandre-
testismadebyapplyingahighresistiveloadtothebatteryter-

movebatteryfromvehicleduringbatterycharg-
ing.Donotexceed16.5voltsatthebattery.
minalsandthenmeasuringbatteryvoltage.Thebatteryshould
befullychargedforthemostaccurateresults.Thebatteryca-
blesmustbedisconnectedbeforemakingthetest.Ifthevolt-

ALTERNATOR$ERVICE
ageisbelowthatlistedinTabled,thebatteryshouldbe
replaced.
WARNING-
Alwayswearprotectivegogglesandclothingwhen
performingaloadtest.
Tabled.BatteryLoadTest-MinimumVoltage
(apply200amploadfor15seconds)
Ambienttemperature

Voltage
80°F(27°C)

9.6V
60°F(16°C)

9.5V
40°F(4°C)

9.3V
20°F(-7°C)

8.9V
0°F(-18°C)

8.5V
ALTERNATOR SERVICE
"Alwaysallowafrozenbatterytothawbeforeat-
temptingtorechargeit.
Beforecheckingthealternatorandregulator,makesurethe
batteryisfullychargedandcapableofholdingacharge.
Checkthatthebatteryterminalsarecleanandtightandtheal-
ternatordrivebeltisproperlytensionedandnotseverely
worn.
Chargingsystem,checking
CAUTION-
Donotdisconnectthebatterywhiletheengineis
running,.Damagetothealternatorandlorengine
electronicsystemsmayresult.
1.Turnignitionkeyon.Checkthatthechargewarning
lampcomeson.
NOTE-
Ifthewarninglightdoesnotcomeon,repairanywiring
orbulbfaultsbeforecontinuingtocheckthecharging
system.

2.Removecoolingductorterminalcoverfromrearofal-

2.Removeaircleaneruppersectionwithmassairflow
ternator.

sensor.
3.Checkforbatteryvoltagebetweengroundandterminal

3.Removeterminalcoverfromrearofalternator.Discon
B+atbackofalternator.Thenturnignitiononand

nectwiring.
checkforbatteryvoltagebetweenterminalD+and
ground.SeeFig.3.lfvoltageisnotpresentateither

4.Removedrivebeltfromalternatorpulley.See020
point,checkwiringforfaults.

Maintenanceprogram.
001¡987
Fig.3.

TerminalB+issuppliedbatteryvoltagedirectlyfromthebat-
tery.TerminalD+issuppliedbatteryvoltageviathecharge
warningbulbwhenthekeyisonortheengineisrunning.
4.lfnofaultsarefounduptothispoint,testalternatorout-
putusingaloadtester.
5.Ifaloadtesterisnotavailable,acrudeoutputtestcan
bedonebyrunningengineatabout2000rpmandturn-
ingonelectricalloads(fans,lightsandrearwindowde-
froster,wipers).Withal¡accessorieson,batteryvoltage
shouldbeabove12.0VDC.
Areplacementalternatorshouldhavethesameratingas
theoriginal.Alternatormanufacturerandampereratingare
normallymarkedonthealternatorhousing.
1.Disconnectnegative(-)batterycable.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
BATTERY,STARTER,ALTERNATOR

121-5
6.Removeupperandlowermountingboltsandliftoutal-
ternator.SeeFig.4.
NOTE-
Ifreusingdrivebelt,markdirectionofrotationonbelt
beforeremoving.
5.OnM44enginewithhydraulicbelttensioner:Remove
tensioneridlerpulley(upperroller)fromalternator
bracket.
Fig.4.

Alternatormountingbolts(arrows).
O

u JSv~~
U
I

1in
-12.22
Alternator,removingandinstalling

7.Installationisreverseofremoval.Installdrivebeltas
(4-cylinderengine)

describedin020MaintenanceProgram.
TighteningTorques
"D+viretoalternator(M6nut).......7Nm(53in-lb)
"B+wiretoalternator(M8nut).......13Nm(10ft-Ib)
"Pulleytoalternator(M16nut).......60Nm(44ft-Ib)
ALTERNATOR SERVICE

121-6

BATTERYSTARTER,ALTERNATOR
Alternator,removingandinstalling
(6-cylinderengine)
Areplacementalternatorshouldhavethesameratingas
theoriginal.Alternatormanufacturerandampereratingare
normallymarkedonthealternatorhousing.
1.Disconnectnegative(-)batterycable.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removealternatorcoolingductandairfilterhousing
assemblyfromcar.Disconnectwiringfromrearofalter-
nator.
3.Removeradiatorcoolingfanandfanshroud.See170
RadiatorandCoolingSystem.
4.Removealternatordrivebeltfromalternatorpulley.On
engineswithhydraulicbelttensioner,removetensioner
idlerpulley(upperroller)fromalternatorbracket.See
Fig.5.
ALTERNATORSERVICE
Fig.5.

Pryoffcoverfromtensionerandthenlevertensionerclock-
wisetoreleasebelttension.Removeupperroller(A)oncebelt
ísremoved.
NOTE-
Ifreusingdrivebelt,markdirectionofrotationonbelt
beforeremoving.
5.Removeupperandlowermountingboltsandliftoutal-
ternator.
6.Installationisreverseofremoval.Notelocatingnotches
ontensioneridlerpulley(upperroller)alternatorbrack-
etwheninstallingpulley.
TighteningTorques
"D+wiretoalternator(M6nut).......7Nm(53in-lb)
"B+wiretoalternator(M8nut).......13Nm(10ft-Ib)
"Pulleytoalternator(M16nut).......60Nm(44ft-Ib)
Voltageregulator,removingandinstalling
1.Disconnectnegative(-)cablefrombattery.
NOTE-

2.Removealternatorasdescribedearlier.
Theradiatorcoolingfannut(32mmwrench)hasleft-
handthreads.

3.Removecoolingductfromrearofalternator.SeeFig.6.
Alternator
..g-

p~J
-...
Fig.6.

Alternatorassemblyandrelatedparts.
Cooling
duct
0012524
4.Removevoltageregulatormountingscrewsandre-
moveregulatorfromalternator.
5.Installationisreverseofremoval.Cleanbrushcontact
surfacesinalternatorandcheckbrushlengthasde-
scribedlater.

Alternatorbrushes,

STARTERSERVICE
inspectingandreplacing
Regulatorbrushesarenotavailableasreplacementparts
fromBMW.Replacementbrushesmaybeavailablefromaf-
termarketsources,however.
1.Removevoltageregulatorasdescribedabove.
2.Cleanbrushcontactsürfacesandmeasurebrushpro-
trusion.SeeFig.7.
Checkforbatteryvoltageatterminal50ofthestartermotor
Fig.7.

Regulatorbrushprotrusion(A).

withthekeyinthestartposition.SeeFig.8.Ifvoltageisnot
present,checkthewiringbetweentheignitionswitchandthe
starterterminal.Ifvoltageispresentandnoothervisiblewir
VoltageRegulator

ingfaultscanbefound,theproblemismostlikelyinterna¡in
"Brushprotrusion(minimum)..........5mm(1/4in.)

thestartermotor.
3.Toreplacebrushes,carefullyandasquicklyaspossi-
ble,unsolderbrushleadfrombrushholdertermina¡,
withdrawingbrushfromholderatsametime.
4.Removeanytracesofsolderfrombrushholdertermi-
nalusingsolderwick.
5.Fitspringintobrushholderandinserínewbrush.
6.Guidebrushleadintoterminalandsolderintoplace.
Checkforfreemovementofbrusheswhensolder
cools.
7.Checkbrushslipringsinalternatorforwear.Lightly
cleanslipringsusingfineabrasivecloth.
BATTERY,STARTER,ALTERNATOR

121-7
StarterTroubleshooting
Ifthestartertucostheengineslowlyorfailstooperatewhen
theignitionisinthestartposition,checkthebatteryfirst.In-
spectthestarterwires,terminals,andgroundconnectionsfor
goodcontact.Inparticular,makesurethegroundconnections
betweenthebattery,thebodyandtheenginearecompletely
cleanandtight.Ifnofaultscanbefound,thestartermaybe
faultyandshouldbereplaced.
NOTE-
"Startingin1194,afactory-installeddrive-awayprotec-
tionsystem,alsoreferredtoasEWSorEWS11,was
usedonallE36cars.Thissystemprevenísoperation
ofthestarterwhenthesystemisengaged.See515
CentralLockingandAnti-theft.
"Oncarswithautomatictransmission,astarterrelay
andaneutralsafetyswitchareusedtopresenttheen-
ginefromstartingingearpositionsotherthanparkor
neutral.ffvoltageisnotpresentatterminal50withthe
keyinthestartposition,checkthesecomponents
Tomakethemostaccuratecheckofthebatterycablesand
starterwiring,makeavoltagedroptestonthecablesandwir-
ingasdescribedin600ElectricalSystem-General.
Terminal30
'\

/
Terminal30h
0012518
8.Reinstallregulatorandalternator.

Fig.8.

Typicalstarterwiringterminalidentification.Largewireatter-
minal30isdirectbatteryvoltage.Smallerwireatterminal50
operatesstartersolenoidviaignitionswitch.
STARTERSERVICE

121-8

BATTERY,STARTER,ALTERNATOR
1fthesolenoidaudiblycliicksbutthemotordoesnotturn,

Starter,removingandinstalling
switchonthelightsandtumthekeytothestartposition.lfthe

(6-cylinderenginewith
lightsgooutwhileattemptingtostart,thebatterycablemaybe

manualtransmission)
looseorthestartermayhaveashortcircuit.Ifthelightsstay
on,thesolenoidismostlikelyatfault.
Thestarterona6-cylindercarwithmanualtransmissionis
Starter,removingandinstalling
(4-cylinderengine)

1.Disconnectnegative(-)batterycable.
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removeguidetubeforoildipstick.
3.Raisevehicle.
WARNING -
Makesurethecarísstableandweflsupportedatall
times.Useaprofessionalautomotiveliftorjack
standsdesignedforthepurpose.Afloorjackisnot
adequatesupport.
4.Disconnectwiringfromstarter.
5.Removetopandbottomstarterbolts.Bottomboltmust
beremovedfrombelowcar.Removestartersupport
bracket,ifapplicable.
removedfrombelow.
2.Raisevehicle.
3.Removereinforcingcrossbracefromundertransmís-
sion,ifapplicable.
4.Removecoverfromfuelfilterandfuellinesonleftside
underneathcar,ifapplicable.Detachfuellinesandhar-
nessconnectorsfromretainingbrackets,asnecessary
5.Disconnectwiringfromstarter.
6.Loosenandremoveboltsandnutsfasteningstarterto
transmissionbellhousingand/orengineblock.Remove
startersupportbracket.
7.Removestarterfrombelow.
8.Checkstarterpiniongearandflywheelteethfordam-
age.
9.Installationisreverseofremoval.
6.Pullstarterdownwardandturnuntilsolenoidisattop,

TighteningTorques
thenremovefromcar.

"Re¡nforcingcrossbrace
tochassis(M10).................42Nm(31ft-Ib)
7.>Checkstarterpiniongearandflywheelteethfordam-

"Startertoengineblock(M10bolt)...50Nm(37ft-Ib)
age.

"Supportbrackettostarter(M5nut)...5Nm(44in-lb)
"Supportbracket
8.Installationisreverseofremoval.

toengineblock(M10bolt).........47Nm(35ft-Ib)
"Wiretoterminal50(M6nut).........6Nm(53ín-Ib)
"Wiretoterminal30(M8nut).........12Nm(9ft-lb)
TighteningTorques
"Startertoengineblock(M10bolt)...50Nm(37ft-lb)
Wiretoterminal50(M6nut)........6Nm(53in-lb)
"Wiretoterminal30(M8nut)...,..:.12Nm(9ft-Ib)
STARTERSERVICE

Starter,removingandinstalling
(6-cylinderenginewith
automatictransmission)
Thestarterona6-cylindercarwithautomatictransmission
ísremovedfromabove.Itisnecessarytoremovetheíntake
manifoldanddisconnectanumberofelectricalharnesscon-
nectors.
1.Disconnectnegative(-)batterycable.
2.Removeairplenumfromrearofenginecompartment.
See640HeatingandAirConditioning.
3.Removetopenginecovers.SeeFig.9.
Fig.9.

Removetopenginecoverbypryingoutplugsandremoving
nuts(A).Makesurerubberinsulators(B)oneithersideof
largecoverdonotfalloffduringcoverremoval.
4.Removeignitioncoilharnessconnectors.Remove
groundconnectionatfrontofcylinderhead.
5.Removetworetainingboltsandliftofffuelinjectorhar-
nessconnectorstrip.Carefullyfoldawayallharnesses
towardrightsideofenginecompartmentandplaceat
baseofwindshield.SeeFig.10.
6.Removeintakemanifold.See113CylinderHeadRe-
movalandInstallation.
7.Disconnectwiringfromstarter.
BATTERY,STARTER,ALTERNATOR

121-9
Fig.10.Fuelinjectionharness(A)andignitioncoílharnessconnectors
(B)beingliftedoffenginetobeplacedatbaseofwindshield.
M50engineshown.Other6-cylinderenginesaresimilar.
8.Loosenandremoveboltsandnutsfasteningstarterto
transmissionbellhousingand/orengineblock.Remove
startersupportbracket.
Fig.11.Starterwiringterminalsandsupportbracket(arrow).Intake
manifoldhasbeenremoved.
STARTERSERVICE

121-1O

BATTERY,STARTER,ALTERNATOR
9.Removestarterfromabove.
10.Checkstarterpiniongearandflywheelteethfordam-
age.
11.Installationisreverseofremoval.
TighteningTorques
"tntakemanifoldtocylinderhead
M7nut........................15Nm(11ft-Ib)
M8nut/bolt....................22Nm(16ft-Ib)
"Startertoengineblock(M10bolt)...50Nm(37ft-Ib)
"Supportbrackettostarter(M5nut)...5Nm(44in-lb)
"Supportbracket
toengineblock(M10bolt).........47Nm(35ft-Ib)
"Wiretoterminal50(M6nut)........6Nm(53in-lb)
"Wiretoterminal30(M8nut)........12Nm(9ft-Ib)
Solenoidswitch,removingandinstalling
1.Removestarterasdescribedabove.
TighteningTorque
2.Removecoverfromsolenoidswitch.

"Fieldwindingstraptostarter(M8)....12Nm(9ft-Ib)
3.Disconnectfieidwindingstrapbetweenstartermotor
andsolenoidswitch.
NOTE-
Theconditionofthefieldwindingstrapiscritical.Ifitis
damaged,bumedorpartiallymeltedthrough,anewor
rebuiltstartermotorisneeded.
4.Removesolenoidswitchmountingscrews,andsepa-
,ratesolenoidfromstarter.SeeFig.12.
CAUTION-
Wheninstallingfieidwindingstraptostarter,posi-
tionitsothatitdoesnotcontactthestarterbody.
STARTERSERVICE
131~184
Fig.12.Startersolenoidmountingscrews(arrows)aretight.Useen
impactscrewdrivertoloosenthescrews.
5.Installationisreverseofremoval.Lubricatesolenoid
pistoswithlightgrease.

GENERAL ............................130-2

Intakeairtemperature(IAT)sensor,
PrinciplesofOperatinn..................130-2

testingandreplacing..................130-19
BasicEngineSettings.................:.130-3

Throttlepositionsensor(TPS),
DISA(DualResonanceIntakeSystem).....130-3

testingandreplacing..................130-19
On-BoardDiagnostics(OBD)

Idlespeedcontrolvalve,testing..........130-20
andFaultDiagnosis...................130-4

Idlespeedcontrolvalve,replacing........130-21
SecondaryAirInjection..................130-5

BOSCHDMEM5.2COMPONENT
WarningsandCautions..................130-6

REPLACEMENT ......................130-21
ELECTRICAL CHECKS AND

Massairflowsensor,replacing...........130-22
COMPONENT TESTING................130-7

Enginecoolanttemperature(ECT)
Main

sensor,replacing....................130-22
relaytesting

130-7, ........
......
.
...
....

Intakeairtemperature(IAT)sensor,
Fuelpumprelay,testing.................130-7

replacin...........g

................130-22
Oxygensensor,testing(Boschsystemsonly)130-8

Throttleposonsensor(TPS)replacing

13022,

...-
FUELDELIVERYTESTS...............130-9

Idlespeedcontrolvalve,replacing.........130-23
Operatingfuelpumpfortests.............130-9

SIEMENSMS41.1COMPONENT
Relievingfuelpressureand

REPLACEMENT ......................130-23
connectingfuelpressuregauge.........130-10
Residualfuelpressure,testing...........130-10

Massairflowsensor,replacing...........130-25
Fuelpressureregulatorresponse

Enginecoolanttemperature(ECT)
toengineload,testing................130-11

sensor,replacing....................130-25
Fuelrailandinjectors,checking..........130-11

Intakeairtemperature(IAT)sensor,
replacing...........................130-25
Fuelrailandinjectors,replacing

.........130-12

Throttlepositionsensor(TPS),replacing...130-26
FuelPressureRegulator................130-13

Idleseedcontrolvalve,relacin

130-26
Fuelpressureregulatorreplacing

p

p

g.
'''
....
',
(fuelrailmount).....................130-13

ECMPINASSIGNMENTS ...............130-26
Fuelpressureregulator,replacing

Enginecontrolmodule(ECM),accessing...130-26
(undercarmount)...................130-14
BOSCHDMEM1.7COMPONENT
TESTSANDREPAIRS................130-14
Airflowsensor,testingandreplacing......130-14
Enginecoolanttemperature(ECT)
sensor,testingandreplacing...........130-15
Throttlepositionsensor(TPS),
testingandreplacing.................130-16
Idlespeedcontrolvalve,
testingandreplacing.................130-16
BOSCHDMEM3.1ANDM33.1
COMPONENT TESTSANDREPAIRS...130-17
MassAirFlowSensor..................130-17
Massairflowsensor(hotwire),
testingandreplacing.................130-17
Massairflowsensor(hotfilm),
testíngandreplacing.................130-18
Enginecoolanttemperature(ECT)
sensor,testingandreplacing...........130-18
130Fuelinjection
FUELINJECTION

130-1
TABLES
a.EngineManagementSystemVariants..........130-2
b.MassAirFlowSensorVariants................130-2
c.FuelPressureSpecifications.................130-11
d.EngineCoolantTemperatureSensororIntakeAir
TemperatureSensorTestValues(DME1.7)....130-15
e.ThrottlePositionSensorTests(DME1.7).......130-16
f.

EngineCoolantTemperatureSensororIntakeAir
TemperatureSensorTestValues(DME3.1/3.3.1)130-19
g.ThrottlePositionSensorTests(DME3.1/3.3.1)..130-20
h.ECMPinAssignment-BoschDMEM1.7........130-28
i.

ECMPinAssignment-BoschDMEM3.1........130-30
j.

ECMPinAssignment-BoschDMEM3.3.1......130-32
k.ECMPinAssignment-BoschDMEM5.2........130-34
I.

ECMPinAssignment-SiemensDMEMS41.1...130-36

130-2

FUEL INJECTION
GENERAL
Thisrepairgroupcoversfuelinjectionsystemcomponent
testingandrepair.Specialequipmentisnecessaryforsome
oftheproceduresgiveninthisrepairgroup.Ifyoudonothave
theequipmentrequiredtodothejob,itisrecommendedthat
theserepairsbelefttoanauthorizedBMWdealer.TheBMW
dealerisequippedwithsophisticateddiagnostictestequip-
mentthatiscapableofquicklypinpointinghard-to-findfuelin-
jectionproblems.
NOTE-
"Wiringdiagramsfortheenginemanagementsystem,
canbefoundattherearofthemanualunderElectri-
calWiringDiagrams.
"Forignitionsystemrepairinformation,see120Igni-
tionSystem.
"Forfuelsupplysystemtestingandrepair,see160

Theenginecontrolmodule(ECM)useselectricalsignals
FuelTankandFuelPump.

fromthemassairflowsensor,theairandcoolanttemperature
sensors,thecrankshaftposition/rpmsensor,theknocksen
PrincipiesOfOperation

sorsandtheoxygensensorsastheprimaryinputstoelectron-
icallycontrolfueldeliveryandignitiontiming.
Therearefiveversionsofenginemanagementsystems
usedontheE36cars.Eachhasthesamebasiccomponents
andoperatingprinciples.Themostnotabledifferenceisthat
1996andlatercarsuseasophisticatedOBDII-compliantsys-
tem.SeeTablea.
Tablea.EngineManagementSystemVariants
Enginecode/year

1System
4-cy1inder
M42(1.8I)1992-1995

BoschDMEMl.7
M44(1.91)1996-1998

~BoschDMEM5.2(OBDII)
6-cylinder
M50
1992(2.5I)

BoschDMEM3.1
1993-1995(2.5I)

BoschDMEM3.3.1(VANOS)
M52
1996-1998(3281-2.8I)

SiemensMS41.1(OBDII)
1998(3231-2.5I)

SiemensMS41.1(OBDII)
M-Power
S50US(M3-3.01)1995

BoschDMEM3.3.1
S52US(M3-3.21)1997-1998

SiemensMS41.1(0131)11)
NOTE-
-Descriptionsandproceduresinthefirstpartofthisre-
pairgrouprefertoallthevariousenginemanagement
systems.
"Particularsofeachfuelinjectionsystemaretreatedin
separatesectionsinthesecondpartofthisrepair
group.
GENERAL
Fig.1.

OBDIIdiagnosticconnectorlocatíon.
Thefuelinjectionsystemiscompletelyelectronicinopera-
tion.Airflowismeasuredelectronicallyviaamassairflow
sensorandadditionalsensorssupplyinformationabouten-
gineoperatingconditions.TheECMcalculatestheamountof
fuelneededforthecorrectair-fuelratioandactuatesthefuel
injectorsaccordingly.Theamountoffuelmeteredtotheen-
gineisdeterminedbyhowlongtheinjectorsareopen.
Airintake.Airenteringtheenginepassesthroughapleat-
edpaperairfilterintheaircleaner.Intakeairvolumeormass
isthenmeasuredbyamassairflow(MAF)sensor.Inal¡ex-
ceptthevanetypesensor(DMEM1.7),areferencecurrentis
usedtoheatathinwireorfilminthesensorwhentheengine
isrunning.Thecurrentusedtoheatthewire/filmiselectroni-
callyconvertedintoavoltagemeasurementcorrespondingto
themassoftheintakeair.
Tableb.MassAirFlowSensorVariants
System

Alrflowsensortype
BoschDMEM1.7

Vane(volumesensor)
BoschDMEM3.1

Hotwire(masssensor)
BoschDMEM3.3.1

Hotfilm(masssensor)
BoschDMEM5.2

Hotfilm(masssensor)
SiemensMS41.1

Hotfilm(masssensor)
"The16-pinOBD11diagnosticconnectorislocatedon

NOTE-
thelowerleftdashpanel.SeeFig.1.

Oncarsequippedwíthtractioncontrol,anadditional
throttlevalveiscontrolledbyanelectronicthrottleactu-
ator(motor).Thisvalveisusedforenginespeedinter
vention.Repairinformationforthissystemisnot
coveredhereduetothespecialelectricaltestingequip-
mentrequiredtoserviceit.

FUELINJECTION

130-3
Fuelmetering.TheECMmetersfuelbychangingthe

Theenginemanagementsystemcompensatesautomatical-
openingtime(pulsewidth)ofthefuelinjectors.Toensurethat

lyforchangesintheengineduetoage,minorwearorsmall
injectorpulsewídthistheonlyfactorthatdeterminesfuelme-

problems,suchasadisconnectedvacuumhose.Asaresult,
tering,fuelpressureismaintainedbyafuelpressureregula-

idlespeedandmixturedonotneedlobeadjustedaspartof
tor.Theinjectorsaremountedloacommonfuelsupplycalled

routinemaintenance.
thefuelrail.
TheECMmonitorsenginespeedtodeterminetheduration

NOTE-
ofinjectoropenings.OthersignalstotheECMhelpdetermine

Poordriveabilitymaybeencounteredwhenthebatteryis
injectorpulsetimefordifferentoperatingconditions.Atem-

disconnectedandreconnected.whenthebatteryisdis-
connected,theadaptivememoryislostThesystemwill
peraturesensorsignalsenginetemperatureformixtureadap-

readaptafterabouttenminutesofdrfving.
tion.Athrottlepositionsensorsignalsthrottleposition.The
exhaustoxygensensor(s)signalinformationaboutcombus-
tionefficiencyforcontroloftheair-fuelmixture.1992to1995

DISA(DualResonanceIntakeSystem)
enginesareequippedwithasinglesensor.1996andlater
(OBDII)enginesareequippedwithanoxygensensorbefore

TheE364-cylinderengineisequippedwithadualintake
andoneaftereachcatalyticconverter.Forexample,theM52

runnersystem,termedDISA.DISAofferstheadvantagesof
engineisequippedwithfouroxygensensors.

bothshortandlongintakepipes.Longintakerunnersare
mostusefulatlowtomediumenginerpmforproducinggood
Idlespeedcontrol.ldlespeediselectronicallycontrolled

torquecharacteristics.Shortintakerunnersproducehígher
viatheidlespeedcontrolvalve,whichmaintainsidlespeedby

horsepowerathígherenginespeeds.
bypassingvaryingamountsofairaroundtheclosedthrottle
valve.Idlespeedisnotadjustable.

NOTE-
Knock(detonation)control.Knocksensorsmonitorand

ThetermDISAcomesfromtheGermanwordsDifferen-
controlignitionknockthroughtheECM.Theknocksensors

zierteSauganlage,andcanroughlybetranslatedas"dif-
feringintakemanifoldconfiguration."See100Engine-
functionlikemicrophonesandareabletoconvertmechanical

GeneralforadditionalinformationonDISAoperation.
vibration(knock)intoelectricalsignals.TheECMispro-
grammedtoreacttofrequenciesthatarecharacteristicofen-

Manifoldconstruction:Theintakemanifoldisatwo-piece
gineknockandadapttheignitiontimingpointaccordingly.

metalconstruction,withapairofrunnersinthetopsection
See120IgnitionSystemforfurtherdetails.

andfourrunnersinthelowersection.Abutterflyvalveisin-
stalledinthelowersection,enablingtheDISAsolenoidtoiso-
NOTE-

lateonepairofrunnersfromtheotherpair.SeeFig.2.
The1992M50engineisnotequippedwithknocksen-

Operation.WiththeDISAbutterflyvalveclosed,thepipes
sors.Allotherenginesareequippedwithtwoknock

inthetophalfofthemanifoldacttogetherwiththeramair
sensors.

pipesinthelowerhalftoproduceasingle,longairintakepipe
foreachcylinder.SeeFig.3.Thecolumnofaíroscíllatingin
BasicEngineSettings

thiscombinedpipesignificantlyincreasesenginetorqueinthe
mediumrpmrange.
Idlespeed,idlemixture(%CO),andignitiontimingarenot
adjustable.Theadaptiveenginemanagementsystemisde-
signedtoautomaticallycompensateforchangesinengineop-
eratingconditions,althoughtheadaptiverangeislimited.Once
theselimitsareexceeded,driveabilityproblemsusuallybe-
comenoticeable.
Aboveapproximately4,800rpm,thebutterflyvalvebetween
theintakeairpipesforthetwocylindergroupsisopened.The
shorterpipesinthelowermanifoldsectionnowbecomethe
mainsuppliersoframairtothecylinders,yieldinggreaterpow-
erattheupperendoftheenginerpmrange.SeeFig.4.
Controlcomponents.TheDISAbutterflyvalveisactuated
NOTE-

electro-pneumaticallyviatheenginecontrolmodule(ECM).
lfthesystemadaptivelimitsareexceeded,theCheck

Thevalvebeginstoopenasenginespeedrisesaboye4,840
Enginelightwillmostlikelycomeon,indicatingan

rpmandclosesbelow4,760rpm.Theactionofthevalveisde-
emissions-relatedfaultForCheckEnginelightdiag-

liberatelydelayedtopreventitfromopeningandclosingrepeat-
nostics,see100Engine-General.

edlywithinashorttime.
GENERAL

130-4

FUELINJECTION
Main
Relay
Fig.2.

DISAsystemcomponents.DISAiscontrolledviatheengine
controlmodule(ECM).
Fig.3.

DISAmanifoldrunnerswithbutterflyvalveclosedforlowrpm-
hightorqueoperation.
yjeq
GENERAL
highpoweroperation.
0012734
Fig.4.

DISAmanifoldrunnerswithbutterflyvalveopenforhighrpm-
On-BoardDiagnostics(OBD)
andFaultDiagnosis
Poordriveabilitymayhaveavarietyofcauses.Thefault
mayHewiththeignitionsystem,thefuelsystem,partsofthe
emissioncontrolsystem,oracombinationofthethree.Be-
causeoftheseinterrelatedfunctionsandtheireffectsoneach
other,itisoftendifficulttoknowwheretobeginlookingfor
problems.
Forthisreason,effectivetroubleshootingshouldalwaysbe-
ginwithaninterrogationoftheOn-BoardDiagnostic(01313)
system.
TheOBDsystemdetectscertainemissions-relatedengine
management malfunctions.Whenfaultsaredetected,the
OBDsystemstoresaDiagnosticTroubleCode(DTC)inthe
systemECM.Inaddition,theCheckEnginewarninglightwill
comeonifanemissions-relatedfaultisdetected.
TwogenerationsofOBDareusedonthecarscoveredby
thismanual.See100Engine-GeneralforOBDIinformation
andfaultcodes.
On-BoardDiagnostics
"1992-1995models.....................OBDI
"1996-1998models.....................OBDII

Thefuelinjectionsystemsusedonthe1996andlatercars
coveredbythismanualareOBDIIcompliant.Thissystemisin-
corporatedintoboththeBoschM5.2(M44engine)andtheSi-
emensMS41.1(M52/S52USengine)enginemanagement
systems.OBDIIsystemsusesophisticateddiagnosticsoft-
warecapableofrecognizingandelectronicallystoringhun-
dredsofDTCsinthesystemECM.DTCscanonlybeaccessed
usingspecialscantooltestequipment.TheBMWdealeris
equippedwiththespecializedOBDIIscantooltoquicklyand
efficientlylocateenginemanagementproblems.Alternately,a
"generic"scantoolcanbeusedtoaccessOBDIIfaultinforma-
tion.
NOTE-
"Atthetimethismanualwenttopress,genericscan
toolswerenotwidelyavailableforBMWvehicles.The
genericseantoolisaspecializedtoolthatplugsintoa
standardizedOBD11connectoron1996andlaterpas-
sengervehíclesbuiltforsaleintheUS.
"TheOBD11faultmemory(includinganilluminated
CheckEnginelight)canonlyberesetusingthespe-
cialscantool.RemovingtheconnectortromtheECM
ordisconnectingthebatterywillnoterasethefault
memory.
"The16-pinOBD11diagnosticconnectorislocatedon
thelowerleftdashpanel.RefertoFig.1.
6
1.Secondaryairpump
2.Electricsolenoidvalve
3.One-waycheckvalve
4.Intakemanifold
5.Exhaustmanifolds
6.Secondaryaircheck-valve
® G~

i
oo

0
0
G00
00
o

,-
0
0
~
1111111in
,,
0 1--
a
Fig.5.

Componentsof6-cylindersecondaryairinjectionsystem.4-
cylindersystemissimilar.
SecondaryAirInjection
FUELINJECTION

130-5
AllOBDII6-cylinderenginesareequíppedwithasecond-
aryairinjectionsystem.Inaddition,beginninginJanuary
1997,theM44enginewasclassifiedasaTLEV(Transitional
LowEmissionVehicle)engineandisalsoequippedwithsec-
ondaryairinjection.
Typicalcomponentsofthesecondaryairinjectionsystem
aredepictedinFig.5.
Secondaryairinjectionusesanelectricpumptopumpfresh
airfintotheexhaustsystemupstreamofthecatalyticconverter
duringenginewarm-up.Byprovidingextraoxygentotheun-
burnedfuelintheexhaust,hydrocarbonsoxidizeandcarbon
monoxidecombineswithoxygentoformcarbondioxideandwa-
ter.Theairinjectionpumpstopswithinaspecifiedtimedintenral.
4
0013120
GENERAL

130-6

FUELINJECTION
WarningsandCautions
Forpersonalsafety,aswellastheprotectionofsensitive
electroniccomponents,thefollowingwarningsandcautions
shouldbeadheredtowhenworkingontheenginemanage-
mentsystem.
GENERAL
WARNING -
"Theignitionsystemproduceshighvoltagesthat
canbefatal.Avoidcontactwithexposedtermi-
nals.Useextremecautionwhenworkingonacar
withtheignitionswitchedonortheenginerun-
ning.
"Donottouchordisconnectanyhighvoltageca-
blesfromthecoilsorsparkplugswhiletheengine
isrunningorbeingcrankedbythestarter.
"ConnectanddisconnecttheDMEsystemwiring
andtestequipmentleadsonlywhentheignition
isswitchedoff.
"Gasolineishighlyflammableandftsvaporsare
explosive.Donotsmokeorworkonacarnear
heatersorotherfirehazardswhendiagnosing
andrepalringfuelsystemproblems.Haveatire
extinguisheravaílableincaseofanemergency.
"Whenworkingonanopenfuelsystem,wearsuit-
ablehandprotection,asprolongedcontactwfth
fuelcancauseillnessesandskindisorders.
"Renewfuelsystemhoses,clampsandO-rings
anytimetheyareremoved.
"Beforemakinganyelectricalteststhatrequirethe
enginetobecrankedusingthestarter,disable
theignitionsystemasdescribedin120Ignition
System.
CAUTION-
"Priortodisconnectingthebattery,readthebat-
terydisconnectinncautionsgivenatthefrontof
thismanualonpagevifi.
"Donotconnectanytestequipmentthatdelivers
a12-voltpowersupplytoterminal15(+)oftheig-
nitioncoil.Thecurrentflowmaydamagethe
ECM.Ingeneral,connecttestequipmentonlyas
speclfiedbyBMW,thismanual,ortheequipment
maker.
"Onlyuseadigitalmultlmeterforelectricaltest.
"OnlyuseanLEDtestlightforquicktests.
"Disconnectingthebatterymayerasefault
code(s)storedinmemory.Checkforfaultcodes
priortodisconnectingthebatterycables.ffthe
CheckEnginelightísilluminated,see100En-
gine-GeneralforDMEfaultcodeinformation.ff
anyothersystemfaultshavebeendetected(indi-
catedbyanilluminatedwarninglight),seeanau-
thorizedBMWdealer.Additionalsystemswith
self-diagnosticcapabilitiesinclude,ABS(Anti-
lockbrakes),SRS(Airbags),EMLandASC+T
andAST(TractionControl).
"Donotruntheenginewfthanyofthesparkplug
wiresdlsconnected.Catalyticconverterdamage
mayresult.
"Alwayswaitatleast40secondsafterturningoff
theignitionbeforeremovingtheenginecontrol
module(ECM)connector.fftheconnectorisre-
movedbeforethistime,residualpowerinthesys-
temrelaymaydamagethecontrolmodule.
"Cleanlinessisessentialwhenworkingonan
openfuelsystem.Thoroughlycleanfuellinecon-
nectionsandsurroundlngareasbeforeloosen-
ing.Avoidmovingthecar.Onlyfnstallcleanparts.
"Fuelsystemcleanersandotherchemicaladdi-
tivesotherthanthosespecificallyrecommended
byBMWmaydamagethecatalyticconverter,the
oxygensensororotherfuelsupplycomponents.

ELECTRICALCHECKSAND
COMPONENT TESTING
Mainrelay,testing
Themainrelayisenergizedviatheenginecontrolmodule
andsuppliesplus(+)powertothemanyoftheengineman-
agementcomponentsandsubsystems,includingthefuel
pumprelay.Ifthisrelayisfaulty,theenginewillnotstart.
1.Withignitionoff,removemainrelay.SeeFig.6.
.
iommooommmoi

~"""
Fuel DME
sensor
CAUTION-
Relaypositionscanvary.Besuretoconfirmrelay
positionbyidentífyíngthewiringinthesocketus-
ingthewiringdiagramsfoundattherearofthis
manual.
0013034)
Fuelpumprelay,testing
FUELINJECTION

130-7
87
851 186
30~j
1.Removefuelpumprelayfromitssocket.
87661
Fig.7.

Checkforbatteryvoltageatmainrelayterminals30and86.
Voltageshouldbepresentatalltimes.
4.Withignitiononandrelayinstalled,checkforbattery
voltageatterminals87.
"Ifbatteryvoltageispresent,relayhasenergizedandis
functioningcorrectly.
"lfbatteryvoltageisnotpresentandal¡earliertestsare
OK,relayisfaultyandshouldbereplaced.
Fig.6.

Enginemanagementrelaysinthepowerdistributionbox,left
rearofenginecompartment.

Thefuelpumprelayislocatedinthepowerdistributionbox.
RefertoFig.6.
TheECMsuppliespowertothecoilsideofthefuelpumpre-
lay.Duringstarting,thefuelpumprunsaslongastheignition
switchisinthestartpositionandcontinuestorunoncetheen-
ginestarts.Iftherelayísfaultythefuelpumpwillnotrun.
2.Checkforvoltageatterminal30andterminal86ofre-
¡aysocket.SeeFig.7.

2.Withkeyoff,checkforbatteryvoltageatsocketterminal
"Ifbatteryvoltageispresentcontinuetesting

30.SeeFig.8.
"lfbatteryvoltageisnotpresentateitherpoint,check
largeredwireinrelaysocket.SeeElectricalWiring

3.Withignitionkeyinstartpositioncheckforbatteryvolt-
Diagrams.

ageatterminal86.
NOTE-

4.Withignitionkey,usedigitalmultimetertocheckfor
Thewiringtoterminals85and86inthemainrelaymay

groundatterminal85.
bereversed.Electrically,therelayfunctionseitherway.
lfvoltageísnotpresentatterminal86,checkforvolt-

NOTE-
ageatterminal85.

Thegroundatterminal85isswitchedbytheECM.The
ECMhamessmustbeconnectedtocheckthe
3.Reinstallrelayandturnignitionon.Gainaccesstoun-

switchedgroundconnection.
dersideofrelaysocketandcheckforgroundatterminal
85(brownwire).

5.Ifnofaultsarefounduptothispoint,testfuelpumpop-
"lfgroundispresentcontinuetesting.

erationasdescribedin160FuelTankandFuelPump.
"Ifgroundisnotpresent,signalfromECMismissing.
CheckwirebetweenECMandrelay.Ifnofaultscan
befound,ECMmaybefaulty.
ELECTRICALCHECKSANDCOMPONENT TESTING

130-8

FUELINJECTION
Fig.8.

Fuelpumprelayterminalidentification.
1.Peelbackrubberbootonoxygensensorelectricalhar-
nessconnector(carwiringside).Withconnectorat-
Oxygensensor,testing

tachedtosensor,connectdigitalvoltmetertopins1
(BOSchsystemsonly)

and2inrearofconnector.SeeFig.10.
CAUTION-
"TheinformationinthissectionappliestoBosch
enginemanagementsystemsonly.
"TheSiemensMS41.1systemusesresistive-type
oxygensensors.Thissensorusesa5-voltrefer-
encesignalinputandtheoutputtotheECMvar-
eesfrom1-5volts,insteppedincrementsbased
onoxygencontentintheexhaust.
NOTE-
"Onpre-08D11(1992-1995)cars,thereisoneoxygen
sensormountedupstreamofthecatalyticconvert-
er(s)intheexhaustpipe.SeeFig.9.
"OnOBD11cars(1996-1998)cars,thereisoneoxygen
sensorbeforeandoneaftereachcatalyticconverter.
"OnM52andS52USengines,thefrontpairofoxygen
sensorsareinstalledintheexhaustmanifolds.
Theoxygensensorprovidesaninputvoltagesignal(0-1VDC)
totheECMbasedontheoxygencontentintheexhaustgas.TO
generatevoltage,thesensortemperaturemustexceed575°F
(300°C).Thereforeitíselectricallyheated.
NOTE-
"Thetestgivenbelowisnotaconclusivetestofoxygen
sensorefficiencyanddoesnottesthowquicklythe
oxygensensorcanreacttochangingconditions.
"Pinnumbersandwirecolorscanvary.Alwayscheck
thewiringdiagramstoconflrmwirecolorandpinas-
signment.
ELECTRICALCHECKSANDCOMPONENT TESTING
0013135
Fig.9.

Oxygensensorlocation(arrow)aheadofcatalyticconverter.
3181modelwithM42engineshown.
1.Black(ground)
2.Grey(signal)

4.White(heatercircuit)
3.White(heatercircuit)
0013189
Fig.10.Oxygensensorconnectorterminalidentification(sensorsede).
Terminalsnumbersaremoldedintoconnector.
2.Startengine.Oxygensensorshouldstarttooutputa
fluctuatingvoltagewithinashortperiod.Ifvoltageisin-
correct,turnengineoffandcheckpreheatercircuitas
describedbelow.
WARNING -
Exhaustmanifoldsandpipescanbehotenoughto
causeseriousburns.Wearsuitableheavygloves
andotherappropriateprotection.

OxygenSensor
FUELDELIVERYTESTS
FUELINJECTION

130-9
"Voltageat¡dle...........0.2to0.8VDC,fluctuating

Checkingfueldeliveryisafundamentalpartoftrouble-
shootinganddiagnosingtheenginemanagementsystem.
Fuelpressuredirectlyinfluencesfueldelivery.Anaccurate
NOTE-

fuelpressuregaugewillbeneededtomakethetests.
Tochecksensorresponsetoleanandrichmixtures,
createenairleak,orpullvacuumhoseofffue¡pressure

Therearethreesignificantfueldeliveryvaluestobemea-
regulatortoincreasefuelpressure.

sured:
3.Separatesensorharnessconnectorfromsensor.Check
forbatteryvoltagebetweenterminals3and4(green
wireandbrownwire)inmainwiringharnesssideofcon-
nectorwithenginerunning.Ifvoltageisnotpresent,
checkoxygensensorheaterrelay.See610Electrical
ComponentLocations.
4.Checkheaterelementresistancebetweenterminals3
and4insensorsideofconnector.Ifelementiselectri-
callyopen(nocontinuity),replacesensor.
NOTE-
Theoxygensensorheaterrelayismountedinthemain
powerdistributfonboxintheleftrearoftheenginecom-
partment.RefertoFig.6.Theheaterrelayisenergized
wíthpositive(+)batteryvoltagefromthemainrelayand
aswitchedgroundfromtheECM.SeeElectricalWir-
ingDiagrams.
"Oxygensensortoexhaustpipe.....55Nm(41ft-Ib)
"Systempressure-createdbythefuelpumpandmain-
tainedbythepressureregulator.
"Fueldeliveryvolume-createdbythefuelpumpandaf-
fectedbyrestrictions,suchascloggedfuelfilter.
"Residualpressure-thepressuremaintainedinthe
closedsystemaftertheengineandfuelpumpareshut
off.
Proceduresformeasuringthefirsttwoquantitiesarede-
scribedin160FuelTankandFuelPump.Residualfuelpres-
sureischeckedusingtheproceduredetailedlaterinthis
group.
Operatingfuelpumpfortests
Tooperatethefuelpumpfortestingpurposeswithouthav-
íngtoruntheengine,thefuelpumprelaycanbebypassedto
powerthepumpdirectly.Fuelpumprelaylocationisshownin
Fig.6.
5.¡foxygensensordoesn'tproduceafluctuatingvoltage

Torunthefuelpump,removethefuelpumprelayandcon-
andpreheatercircuitisOK,replacesensor.

nectthesocketforrelayterminal30tothesocketforrelayter-
mina¡87withafusedjumperwire.Aftercompletingthetests,
NOTE-

removethejumperwire.
Ifnotalreadyapplied,coattheoxygensensorthreads
withananti-seizecompoundbeforeinstallation.Donot

CAUTION-
getthecompoundonthesensortip.
"Relaylocationsmayvary.Usecarewhenidenti-
fyingrelaysandmakingelectricalchecksatthe
fuselrelaypanel.See610ElectricalCompo
TighteningTorque

nentLocationsforadditionalrelayinformation.
"Thefuelpumprelayhasa1.5mm2redwireatter-
minal30intherelaysocket.Terminal87hasa1.5
mm2greenlvioletwire.SeeElectricalWiringDi-
agramsforadditionalwiringinformation.
NOTE-
Thejumperwireshouldbe1.5mm2(14ga.)andin-
cludeanin-linetuseholderwitha15amptuse.To
avoidfuselrelaypaneldamagefromrepeatedconnect-
inganddisconnecting,alsoincludeatoggleswitch.A
heavy-dutyjumper,BMWtoolno.613050,isalso
availablefromanauthorizedBMWdealer.
FUELDELIVERYTESTS

130-10

FUELINJECTION
Rellevingfuelpressureandconnecting
fuelpressuregauge
WARNING -
"Gasolineishighlyflammableanditsvaporsare
explosive.Donotsmokeorworkonacarnear
heatersorotherfirehazardswhendiagnosing
andrepairingfuelsystemproblems.Haveafire
extinguisheravailableincaseofanemergency.
"Whenworkingonanopenfuelsystem,wearsuit-
ablehandprotection.Prolongedcontactwithfuel
cancauseillnessesandskindisorders.
Topreventfuelfromsprayingonahotengine,systemfuel
pressureshouldberelievedbeforedisconnectingfuellines.
Onemethodistotightlywrapashoptowelaroundafuellinefit-
tingandloosenordisconnectthefitting.
Cleanlinessisessentialwhenworkingwithfuelcircuitcom-
ponents.Thoroughlycleantheunionsbeforedisconnecting
fuellines.
NOTE-
"OnM44engines,aSchrmdervalveisintegratedin
thefuelrail.Compressedairpressurecanbeapplied
atthevalvetoforcethefuelinthesystembackinto
thetank.SeeFig.11.
0012503
Fig.11.FuelrailshowinglocationofSchraedervalvefittingonM44
engine(arrow).
NOTE-
B~specifiesaspecialgaugeandspecialconnecting
adapterstomeasurefuelpressure.Ifthespecialtools
arenotavailable,alengthoffuelfineandaT-fittingcan
beinstalledtotheinletfuelfineandconnectedtoafuel
gauge.Onsomevehicles,thisisnotpossiblewithout
cuttingfintoafuellino.Intheselnstances,itIsrecom-
mendedthatfuelpressurebecheckedattheoutput
sidoofthefuelpump.See160FuelTankandFuel
Pump.
FUELDELIVERYTESTS
OnOBDII6-cylinderengines,thefuellinesuseaspecial
lockingfitting.UseBMWspecialtool161050toreleasethe
fittingsandconnectthefuelgauge.SeeFig.12.
0012699
Fig.12.FuellinosatrearofintakemanifoldonM52engine.UseBMW
specialtool161050toreleasefittings.
WARNING -
"Gasolineishighlyflammableanditsvaporsare
explosive.
"Thefuelpressuregaugemustbesecurelycon-
nectedtopreventitfromcominglooseunder
pressure.
NOTE-
"Thefuelpressuregaugeshouldhavearangoof0to
5bar(0to75psi).
"On6-cylinderengine,thetopleft-sidoenginecover
willhavetoberemovedtoaccessthefuelrail.
Residualfuelpressure,testing
Forquickrestartsandtoavoidvaporlockwhentheengine
ishot,thefuelinjectionsystemisdesignedtoretainfuelpres-
sureaftertheenginehasbeenturnedoff.Thísresidualpres-
sureisprimarilymaíntainedbyacheckvalveatthefuelpump
outietandthefuelpressureregulator.Thefuelpumpcheck
valveisnotserviceableasanindividualpart.
1.Relievefuelpressureandconnectapressuregaugeas
describedearlier.
WARNING -
Fuelwillbedischarged.Wrapashoptowelaround
thefuellinofittingwhendisconnectingthefuelfine.
Donotsmokeorworknearheatersorotherfire
hazards.Keepanapprovedfireextinguisherhandy.
2.Operatefuelpumpforapproximatelyoneminutobyby-
passingfuelpumprelayasdescribedearlier.Observe
fuelpressure.

3.Observefuelpressuregaugeafter20minutes.The
pressureshouldnotdropoffmorethan0.5barfrom
systempressurelistedinTablec.
4.Whenfinishedtesting,disconnectpressuregaugeand
reconnectfuelline.
Ifthefuelsystemdoesnotmaintainpressure,checkvisual-
¡yforleaksinfuellinesoratunions.Leakscanalsobedueto
aleakinginjectororafaultyfuelpumpcheckvalve.Checkthe
pumpcheckvalvebyrepeatingthetest,butbeforeturningthe
fuelpumpoff,pinchofftheretumlineatthefuelrail.Ifthe
pressureisnowmaintained,thefaultismostlikelythefuel
pumpcheckvalva.
Tablac.FuelPressureSpecifications
Engine

1Fuelpressure
4-cytinder

13.0t0.2bar(43.5t2.9psi)
6-cytinder
M50/S50USengine

3.0t0.2bar(43.5±2.9psi)
M52/S52USengine

3.5f0.2bar(51t2.9psi)
Fuelpressureregulatorresponse
toengineload,testing
1.Withfuelpressuregaugeconnected,reinstallfuel
pumprelay.Startengineandallowittoidle.
NOTE-
Thefuelpressureshouldbelowerby0.4-0.7barfrom
thespecificationslistedinTablec.Enginevacuumact-
ingonthefuelpressureregulatordiaphragmreduces
thefuelpressure.
2.Withengineidling,removevacuumhosefromregula-
tor.Pressureshouldincrease.
3.Reconnecthoseandcheckthatpressuredecreases.
4.Whenfinishedtesting,disconnectpressuregaugeand
reconnectfuelline.Tightenhoseclamp.

0013190
Fig.13.Forelectricaltests,4-cytinderfuelinjectorharnessductcanbe
Iffuelpressuredoesnotdropwiththevacuumhosecon-

accessedbetweenintakemanifoldandcytinderheadcover.
nectedandnofaultyarefoundwithfuelthepressureregulator
vacuumhose,thefuelpressureregulatorisfaulty.

1.CheckthatECMsignalispresentatinjectorconnector.
NOTE-
Acrackedorleaktngpressure-regulatorvacuumhose
maycauseenerratictdle.
FUELINJECTION

130-11
Fuelrailandinjectors,checking
Thefuelinjectorsareswitchedonandoff(openedand
closed)bytheECM.Theinjectorsareconnectedtoacom-
monfuelsupply,calladthefuelrail.
Thefuelinjectorsareremovedbyfirstremovingthecom-
pletefuelrailassemblyandthenunclippingtheinjectorsfrom
thefuelrail.
CAUTION-
UseonlyadigitalmultimeteroranLEDinjector
testerwhentestinginjectorsorwiring.Useofan
analogVOMorincandescenttestlightmaydam-
agetheenginecontrolmodule.
NOTE-
"On4-cytindercarspryuptheinjectorwiringductand
thenpryoffthecover.SeeFig.13.
"On6-cytindercarsitisnecessarytoremovethetop
enginecover(s)toaccessthefuelrailandinjectors.
"Backprobeinjectorharnessconnectorusingdigital
voltmeter.SeeFig.14.
"Operatestarterorrunengineandcheckforpulsad
voltagesignal.
"Repeatforeachinjector.
NOTE-
Toquick-checkifeninjectorfunctioning,placeascrew-
driverorstethoscopeontheinjectorwiththeengine
running.Iftheinjectorisoperating,thereshouldbeen
audiblebuzz.
FUELDELIVERYTESTS

130-12

FUELINJECTION
Fig.14.Voitmeterconnectedacrossfuelinjectorconnectorwithen-
ginerunning.M50engineshown.
2.Ifnosignalispresent,checkforb+powertoinjectors.
Thereshouldbebatteryvoltage(+)atred/whitewireof
eachinjectorconnectorwiththeignitionkeyon.Ifvolt-
ageisnotpresent,checkmainrelayoutput.Injectorb+
powercomesfrommainrelay(terminal87).
NOTE-
Ifthereispositive(+)batteryvoltageatinjectorsbut
therewasnopulsedresponseatvoltmeter,checkthe
wire(s)fromtheECMtotheinjectors.Ifnowiringfaults
canbefound,thepulsedgroundsignalfromthecontrol
modulemaybemissing.Checktheoutputsfromthe
ECM.
Fuelrailandinjectors,replacing
1.Disconnectnegative(-)batterycable.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthetrontofthis
manualonpageviii.
2.M42andM50/S50USengines:Workingatendoffuel
rail,disconnectsmallvacuumhosefromfuelpressure
regulator.
3.M50/S50USengines:Removetwonutsfrominjector
duct.Carefullypryinjectorwiringductoffínjectors.See
Fig.15.
4.On4-cylindercars,removeupperintakemanifoldtoac-
cessthefuel-railandinjectors.See113CylinderHead
RemovalandInstallation.
FUELDELIVERYTESTS
Fig.15.InjectorwiringharnessductbeingremovedfromM50engine.
NOTE-
Late-modelM42andallM44fuelinjectorsareafr-
shrouded.SeeFig.16.Whenremovingthefuelrailitis
necessarytoremovetheairshroudfeederhosefrom
theintakemanifoldducting.
Fig.16.CutawayviewoffuelinjectorusedonM42orM44engine.
5.Disconnectfuelsupplylineandfuelretumlinefromfuel
railends.
WARNING -
"Clampoffthefuellinesandthenwrapaclean
shoptoweiaroundthelinesbeforeremoving
them.Residualfuelpressureispresentinthe
lines.
"Fuelwillbedischarged.Donotdisconnectany
wiresthatcouldcauseelectricalsparks.Donot
smokeorworknearheatersorotherfirehazards.
Keepanapprovedfireextinguisherhandy.

6.Removefuelrailmountingbolts.SeeFig.17.
0012504
Fig.17.Locationoffuelrailmountingbolts(A)andfuelinletandreturn
lines(B)onM44engine.Uppermanifoldhasbeenremoved.
7.Pulluponfuelrailandremoveinjectorrailwithinjec-
tors.Removeindividualinjectorsbyremovinginjector
retainingclipandpullinginjectorfromrail.SeeFig.18.
Fig.18.Pryretainingclipfrominjector(1),thenpullinjectorfromrail(2).
8.Installationisreverseofremoval.
TighteningTorque
"Fuelrailtocylinderhead..........10Nm(89in-lb)
FUELINJECTION

130-13
FuelPressureRegulator
ThefuelpressureregulatorlocationonE36modelsis
mountedinoneoftwolocations:
FuelPressureRegulatorLocation
"4-cylinderengines
1992-January1997.................onfuelrail
January1997-on....................undercar
"6-cylinderengines
1992-1995.........................onfuelrail
1996-on...........................undercar
Fuelpressureregulator,replacing
(fuelrailmount)
WARNING -
Fuelwillbedischarged.Donotdisconnectany
wiresthatcouldcauseelectrícalsparks.Donot
smokeorworknearheatersorotherfirehazards.
Keepanapprovedfireextinguisherhandy.
9.On6-cylinderengines,removetopenginecovers.Re-
movefuelrailmountingboltsandliftupfuelrail.
1.Disconnectvacuumhosefromfuelpressureregulator.
SeeFig.19.
"FitnewO-ringswheninstallinginjectors.Foreaseof
installation,lightlylubricateO-ringswithSAE90or

0012732
equivalentlubricant.

Fig.19.Fuelpressureregulator(arrow)onM42engine.Vacuumhose
"Checkthatinjectorelectricalconnectionsarecorrectly

shownatA.
fittedandthatinjectorsarefullyseatedpriortoinstall-
ingfuelrailmountingbolts.

2.Removeboltfromregulatorclamp.Removeclamp.Note
"Replacewireties.

installeddirectionofregulatortofuelrail.
3.Wrapashopragaroundregulator,thenremoveregula-
torfromfuelrailbypullingstraightout.
FUELDELIVERYTESTS

130-14

FUELINJECTION
NOTE-
Besuretoretrievethrustwasherbehindfuelpressure
regulatoron6-cylinderengine.
4.Installationisreverseofremoval.ReplaceO-rings.
Fuelpressureregulator,replacing
(undercarmount)
WARNING -
Fuelwillbedischarged.Donotdisconnectany
wiresthatcouldcauseelectricalsparks.Donot
smokeorworknearheatersorotherfirehazards.
Keepanapprovedtireextinguisherhandy.
Onlate4-and6-cylindercars,thefuelpressureregulatoris
mountedbeneaththeleftsideofthecar,underaprotective
cover.SeeFig.20.
0012726
Fig.20.Fuelpressureregulatorlocationunderneathcar(arrow).Vac-
uumhosetoregulatorisshownatA.(Protectivecoverhas
beenremoved.)
5.Installationisreverseofremoval.ReplaceO-rings.
BOSCHDMEMl.7COMPONENT TESTSANDREPAIRS
BOSCHDMEMl.7COMPONENT
TESTSANDREPAIRS
CAUTION-
Useonlyadigitalmultimeterwhentestingcompo-
nentsandwiring.UseofananalogVOMmay
damagetheenginecontrolmodule.
4-cylindercarswithM42engines(1992to1995)usethe
BoschDMEM1.7fuelinjectionsystem.
Electricaltestsofthemainandfuelpumprelaysandthe
DMEenginecontrolmodule(ECM)arecoveredearlierinthis
section.Fuelpumptestsarecoveredin160FuelTankand
FuelPump.
Airflowsensor,testingandreplacing
DMEM1.7fuelinjectionusesavolumeairflowtypesensor
withintegratedintakeairtemperature(IAT)sensor.Thesen-
sorprovidesavaryingvoltagesignaltotheECMbasedonthe
positionoftheairvane.Asthevanedoorswingsopenthepo-
tentiometerincreasesthevoltagesignaltotheECM.TheIAT
sensoradaptstheoutputsignaltotheECMbasedonintake
airtemperature.
1.CheckECMreferencevoltagetosensor:
"Peelbackrubberbootfromairflowsensorharness
connector.
"Turnignitionkeyon.
"Checkfor5voltsbetweenterminal1ofharnesscon-
nectorandground.SeeFig.21.
"Turnignitionkeyoff.
"Ifvoltageisnotpresentorincorrect,checkwringfrom
ECMandcheckairflowsensorreferencevoltageout-
putatECM.SeeTableh.
1.Workingundercarbelowdriver'sseat,removeprotec-
tivecoverfrombelowfuelpressureregulator.
"Removeintakeairbootfromsensor.
2.Removevacuumhosefromfuelpressureregulator.

"Connectadigitalmultimeter(ohms)acrossterminais1
and2.Swingairflowsensorvanethroughitstravel
3.
Removelockingclipretainingfuelpressureregulator.

range.Resistanceshouldchangesteadilywithoutin-
terruption.
4.Wrapashopragaroundregulator,thenremoveregula-

"Ifanyfaultsarefound,theairflowsensorisfaultyand
torfrom213wayvalvebypullingstraightout.

shouldbereplaced.
2.Checkairflowsensorpotentiometer:
3.CheckIATsensorresistance:
"Withharnessconnectordisconnectedatairflowsen-
sor,checkresistanceacrosssensorterminais4and5
ofairflowsensor.Comparetestsresultstovaluesin
Tabledgivenlater.Ifanyfaultsarefound,theairflow
sensorshouldbereplaced.

u0I.[Ia
Fig.21.Airflowsensorharnessconnectorterminalidentification.
4.Replacingairflowsensor:
"Removelargebandclampattachingairboottosensor.
"Removeairfiltertopcover,thenremoveairflowsensor
mountingnutsinsidecover.
"Reconnectairbootandharnessconnector.
Enginecoolanttemperature(ECT)sensor,
testingandreplacing
Theenginecoolanttemperature(ECT)sensorsendscon-
tinuousenginecoolanttemperatureinformationtotheECM.
Astemperatureincreases,sensorresistancedecreases.
"Withharnessconnectordisconnected,checkresis-
tanceacrosssensorterminals.
"ComparetestsresultstovaluesinTabled.
FUELINJECTION

130-15
0011984
Fig.22.M42enginecoolanttemperature(ECGsensor(arrow).
Tabled.EngineCoolantTemperatureSensoror
IntakeAirTemperatureSensorTestValues
(DME1.7)
Testtemperatures

Resistance(kohms)',
14±2°F(-10t1°C)

7-11.6
68±2°F(20t1°C)

2.1-2.9
176±2°F(80tVC)

0.27-0.40
TheECTsensorislocatedundernumberoneintakerun-

'
ner.SeeFig.22.
NOTE-
1.CheckECMreferentevoltagetosensor:

Thetestvalueslistedrepresentonlythreetestpoints
fromacontinuousresistanceNTCsensor.Checkthe
"DisconnectharnessconnectorfromECTsensor.

fulllinearresponsetoincreasingtemperatureasthe
"Turnignitionkeyon.

enginewarmsup.
"Checkfor5voltsbetweensupplyvoltage(brown/red)
wireofharnessconnectorandground.

3.IfECTsensorfailsthesetests,itisfaultyandshouldbe
"Turnignitionkeyoff.

replaced.Ifnofaultsarefound,reconnectelectrical
"Ifvoltageisnotpresentorincorrect,checkwringfrom

harness.
ECMandcheckECTsensorreferencevoltageoutput
atECM.SeeTableh.
NOTE-
2.CheckECTsensorresistance:

Useanewcoppersealingwasherwheninstallingsen-
sor.Reptaceanylostcoolant.
WARNING -
DonotreplacetheECTsensorunlesstheengineis
cold.Hotcoolantcanscald.
TighteningTorque
"ECTsensortocylinderhead.......13Nm(10ft-Ib)
BOSCHDMEM1.7COMPONENT TESTSANDREPAIRS

130-16

FUELINJECTION
Throttiepositionsensor(TPS),

Idiespeedcontrolvalve,
testingandreplacing

testingandreplacing
Thethrottiepositionsensor(TPS)ismountedonthesideof

¡diespeedismaintainedbytheECMviathe¡diespeedcon-
thethrottiehousingandisdirectlyconnectedtothethrottie

trolvalve.SeeFig.24.¡diespeedisadaptivethroughthe
valveshaft.TheECMsendsavoltagesignaltothepotentiom-

ECMandno¡diespeedadjustmentscanbemade.Before
eter-typesensorandmonitorsthevoltagethatcomesback.

testingthevalve,confirmthatthethrottiepositionsensor
(TPS)isworkingcorrectly.
CheckTPSfunctionbydisconnectingtheharnessconnec-
torandcheckingreferencevoltageandsensorresistance.
SeeTableeandFig.23.Ifvoltageisnotpresent,checkthe
outputvoltagesignalfromtheECMandcheckthewiringbe-
tweenthesensorandtheECM.Ifthesensorresistanceisin-
correct,replacethethrottiepositionsensor.
NOTE-
Thethrottiepositionsensorisnotadjustable.Iftestre-
sultsareíncorrect,thesensorshouldbereplaced.
Tablee.ThrottlePositionSensorTests
(DME1.7)
Testconditions

1Terminais

1Testvalue
Harnessconnec-

(1andgroundin

15VDC(approx.)
tordisconnected,

harnessconnector
ignitionon
0013235
Fig.23.ThrottiepositionsensorterminalidentificationonM42engine.
Harnessconnec-

I1and3atsensor

(4kohms(approx.)
tordisconnected,

terminais
ignitionoff
Connectordis-

1and2atsensor

Continuouslyvari-
connected,igni-

terminais

ablefrom1-4k
tionoff.Throttle

ohms(approx.)with
rotatedfrom¡die

outinterruption
tofui]position
BOSCHDMEMl.7COMPONENT TESTSANDREPAIRS
Fig.24.¡diespeedcontrolvalve(arrow)onM42engine.
NOTE-
"Thetestsgivenbelowareelectricalchecksonly.They
donotcheckthemechanicaloperationofthevalveor
ifthevalveisstickingorworn.Ifthevalveissuspect,
substitutingaknowngoodvalveisthebestwayto
checkforamechanicalfault.
1.Checkbattery(+)voltagetovalve:
0013226
"Disconnectharnessconnectorfromvalve.
"Checkforbatteryvoltageatterminal2(red/whitewire).
"Ifvoltageisnotpresentcheckwiringbetweenvalve
andmainrelay(terminal87).
2.CheckthatECMsignalisreachingvalve:
"Withenginerunning,checkthat¡diespeedcontrol
valveisaudiblybuzzing.
"Ifvalveisnotworking,disconnectwiringharnesscon-
nector.
"Connect12Vprobelightacrossconnectorterminais.
"Turnignitionkeyon;probeshouldlight.lfprobedoes
noflight,checkthewiringfromtheECM(pin29)tothe
valve.SeeTableh.lfprobedoeslightbut¡diequality
ispoor,thevalveismostlikelystickingandorworn
andshouldbereplaced.

BOSCHDMEMMANDM33.1
COMPONENT TESTSANDREPAIRS
ConsultTableaforengineapplicationinformationforthe
BoschDME3.1and3.3.1systems.
TheDME3.1andDME3.3.1systemsaresimilarinopera-
tion,withknockcontrolandVANOSoperationbeingthekey
differences.DME3.1enginesarenotequippedwithVANOS
orknockdetectors,whiletheDME3.3.1systemis.
CAUTION-
Useontyadigitalmultimeterwhentestingwiring.
UseofananalogVOMmaydamagetheengine
controlmodule.
Fig.25.Massairflowsensor.HotwiresensorusedoncarswithDME
Electricaltestsofthemainandfuelpumprelaysandthe

3.1(19926-cylindermodels).
DMEenginecontrolmodule(ECM)arecoveredearlierinthis
section.Fuelpumptestsarecoveredin160FuelTankand

CAUTION-
FuelPump.
Useonlyadigitalmultimeterwhencheckingthe
massairflowsensor.Ananalogmetercandam-
MassAirFlowSensor

agetheairflowsensor.
Therearetwotypesofmassairflowsensorsusedonthe

1.Disconnectairflowsensorfromaircleaneronly.Leave
carscoveredbythissection.Testingproceduresvaryde-

itconnectedtoductleadingtointakemanifoldand
pendingontypeinstalled.Theairflowsensorisnotadjustable

leavewiringharnessconnected.
andmustonlybetestedwithadigitalmultimeter.
MassAirFlowSensorVariants
"1992M50engine
DMEM3.1.........massairflowsensor-hotwire
"1993-1995M50andS50US
DMEM33.1)........massairflowsensor-hotfilm
Massairflowsensor(hotwire),
testingandreplacing
Whentheengineisrunning,acurrentisusedtoheatathin
wireinthecenterofthesensor.SeeFig.25.Thecurrentinthe
wireisregulatedtomaintainatemperatureof100°Cmore
thantheairpassingoverit.Thecurrentusedtoheatthewire
iselectronicallyconnecedintoavoltagemeasurementcorre-
spondingtothemassofintakea¡r.
Tokeepthewireclean,itisheatedtoatemperatureofabout
1,000°C(1,830°F)foronesecond.This"burn-off"cycletakes
placeautomatically,foursecondsaftertheengineistumedoff.
lfthehotwirebreaksorifthereisnooutputfromtheairflow
sensor,theECMautomaticallyswitchestoa"limp-home"
modeandtucosontheCheckEnginelight.Theenginecan
usuallybestartedanddriven.Theairflowsensorhasnointer-
nalmovingpartsandcannotbeserviced.
FUELINJECTION

130-17
2.Startengineandrunittonormaloperatingtemperature.
3.Revenginetoatleast2,500rpm,thenshutitoff.Look
throughmeterathotwire.Afterapproximatelyfoursec-
ondswireshouldglowbrightlyforaboutonesecond.
NOTE-
Ifthewireglowsasspecified,thentheairflowmeter
andECMareprobablyoperatingcorrectly.lfthewire
doesnotglow,continuetesting.
4.lfthewiredoesnotglow,removeairflowsensorand
lookthroughittoseeifwireisbroken.lfwireisbroken,
meterwillhavetobereplaced.
5.Reinstallairflowsensorandharnessconnector.Peel
backrubberbootfromharnessconnector.Working
fromrearofconnector,connectdigitalvoltmeteracross
terminals1and4.SeeFig.26.
6.Startandrevenginetoatleast2,500rpm,thenshutit
off.Afterabout4seconds,voltageshouldrisetoabout
4voltsforaboutonesecond.lfvoltageispresent,but
wiredoesnotglow,airflowsensorisfaultyandshould
bereplaced.
7.lfvoltageisnotpresentinstep6,turnignitionkeyon
andcheckforvoltageandgroundatsensor.There
shouldbegroundatpin4.Thereshouldbepositive(+)
batteryvoltageatpin2.
BOSCHDMEM3.1ANDM32.1COMPONENT TESTSANDREPAIRS

130-18

FUELINJECTION
Theenginecoolanttemperature(ECT)sensorsendscon-
tinuousenginecoolanttemperatureinformationtotheECM.
Fig.26.MassairflowsensorterminalidentifcationoncarswithDME

Astemperatureincreasessensorresistancedecreases.
M3.1fuelinjection.
Massairflowsensor(hotfilm),
testingandreplacing
MOTE-
Aburn-offcycleisnotusedonhotfilmsensors.
8.Withignitionoff,disconnectharnessconnectorfromair

ECTSensorLocation
flowsensor.Usingadigitalmultimeter,checkresis-

"M50/S50USengine............leftsideofcylinder
tanceatterminalslisted.

headunderintakemanifold
AirFlowSensorTestValues(DMEM3.1)
"Terminals5and6.....................3-4ohms
Ifanyfaultsarefound,checkwiringloandfromtheECM.
MakeECMpinouttestaslistedinSeeTablei.Mainpowerto
airflowsensorcomesfromDMEmainrelay.
OncarswithDMEM3.3.1ahotfilmmassairflowsensoris
used.Whentheengineisrunning,acurrentisusedloheata
thinfilminthecenterofthesensor.Thiscurrentiselectroni-
callyconvertedintoavoltagemeasurementcorrespondingto
themassofintakeair.
Ifthehotfilmbreaksorifthereisnooutputfromtheairflow
sensor,theECMautomaticallyswitchestoa"limp-home"
modeandtucosontheCheckEnginelight.Theenginecan
usuallybestartedanddriven.Theairflowsensorhasnointer-
nalmovingpartsandcannotbesenricedoradjusted.
CAUTION-
Useonlyadigitalmultimeterwhencheckingthe
massairflowsensor.Ananalogmetercandam-
agetheairflowsensor.
BOSCHDMEM3.1ANDM32.1COMPONENT TESTSANDREPAIRS
1.Disconnectharnessconnectorfromairflowsensor.
2.Turnignitiononandcheckforvoltageandgroundat
connector.Thereshouldbegroundatpin1.There
shouldbepositive(+)batteryvoltageatpin3.Ifany
faultsarefound,checkwiringtoandfromECM.Make
ECMpinouttest.SeeTablej.
NOTE-
Positive(+)batteryvoltagetoairflowsensorcomes
fromDMEmainrelaywhentheignitionisswitchonor
enginerunning.
Enginecoolanttemperature(ECT)sensor,
testingandreplacing
0012704
Fig.27.Enginecoolanttemperature(ECT)sensor(A)islocatedbe-
neathtopenginecover(B)andcrankcaseventhose(C).M52
engineshown.M50issimilar.
1.CheckECMreferencevoltagetosensor:
"DisconnectharnessconnectorfromECTsensor.
"Turnignitionkeyon.
"Checkfor5voltsbetweensupplyvoltagewire
(brown/red)wireofharnessconnectorandground.
"Turnignitionkeyoff.
"Ifvoltageis'notpresentorincorrect,checkwiringfrom
ECMandcheckreferencevoltageoutputatECM(pin
78).SeeTablei(DME3.1)orTablej(DME3.3.1)
2.CheckECTsensorresistance:
"Withharnessconnectordisconnected,checkresis-
tanceacrosssensorterminals.
"ComparetestsresultstovaluesinTablef.

Tablef.EngineCoolantTemperatureSensoror
IntakeAirTemperatureSensorTestValues
(DME3.113.3.1)
Testtemperatures

Resistance(kohms)
14±2°F(-10±
1'C)

7-11.6
68±2°F(20±1'C)

2.1-2.9
17612°F(80tVC)

0.27-0.40
NOTE
Thetestvalueslistedrepresentonlythreetestpoints
fromacontinuousresistanceNTCsensor.Checkthe
fulllinearresponsetoincreasingtemperaturesasthe
enginewarmsup.
3.IfECTsensorfailsthesetests,itisfaultyandshouldbe
replaced.Ifnofaultsarefound,reconnectelectrical
harness.
WARNING -
DonotreplacetheECTsensorunlesstheengineis
cold.Hotcoolantcanscald.
NOTE-
Use"

anewcoppersealingwasherwheninstalling
sensor.Replaceanylostcoolant.
TighteningTorque
"Enginecoolanttemperaturesensor
tocylinderhead.................13Nm(10ft-lb)
Intakeairtemperature(IAT)sensor,
testingandreplacing
Theintakeairtemperature(IAT)sensorsignalisusedasa
correctionfactorforfuelinjectionandignitiontiming.Thissen-
sorismountedintheintakemanifoldbehindthethrottleposi-
tionswitch.SeeFig.28.
CheckTPSfunctionbydisconnectingtheharnessconnec-
1.CheckthatECMreferencevoltageisreachingIATsen-

torandtestingcontinuityacrosstheterminalswhilechanging
sor:

thethrottleposition.Resistancetestvaluesarelistedbelow.If
"DisconnectIATsensorharnessconnector.

theresuitsareincorrect,replacethethrottlepositionsensor.
"Turnignitionkeyon.

SeeFig.29.
"Checkfor5voltsbetweensupplyvoltagewireofhar-
nessconnectorandground.
NOTE-
"Turnignitionkeyoff.
Thethrottlepositionsensorisnotadjustable.Iftestre-
sultsareincorrect,thesensorshouldbereplaced.
IATSensorSupplyVoltage
"M50/S50USengines.........greywireandground
FUELINJECTION

130-19
Fig.28.IntakeairtemperaturesensorlocationonM50/S50USengine
(arrow).
Ifvoltageisnotpresentorincorrect,checkwiringfromECM
andcheckreferencevoltagesignalatECM(pin77).SeeTa-
bleiorTablej.
2.CheckIATsensorresistance:
"Withharnessconnectordisconnected,checkresis-
tanceacrosssensorterminals.Comparetestsresuits
tovaluesinTablefgivenearlier.
"IfIATsensorfafsthistestitisfaultyandshouldbere-
placed.
3.Ifnofaultsarefound,reconnectelectricalharness.
Throttlepositionsensor(TPS),
testingandreplacing
Thethrottlepositionsensor(TPS)ismountedonthesideof
thethrottlehousingandisdirectlyconnectedtothethrottle
valveshaft.TheECMsendsavoltagesignaltothepotentiom-
eter-typesensorandmonitorsthevoltagethatcomesback.
BOSCHDMEM3.1ANDM32.1COMPONENT TESTSANDREPAIRS

130-20

FUELINJECTION
Fig.29.ThrottlepositionsensorterminalidentificationonM50engine.
Tableg.ThrottlePositionSensorTests
(DME3.113.3.1)
Testconditions

ITerminals

ITestvalue
Harnessconnector

13andground

15VDC(approx.)
disconnected,igni-

inharness
tionon

connector
Harnessconnector

1and3atsen-14kohms(approx.)
disconnected,igni-

sorterminals
tionoff
Throttleplaterotat-

1and2atsen-

Variablefrom1-4k
edfrom¡dietofull

sorterminals

ohms(approx.)with-
throttleposition

outinterruption

¡dieSpeedControlValveCoilResistanceValues
"M50/S50USengine
NOTE-

Terminals1and2...................20t5ohms
Oncarswithtractioncontrol,donotconfusethethrottle

Terminals2and3...................20t5ohms
positionsensoronthemainthrottlebodywiththethrot-

Terminals1and3.....:.............40t5ohms
tlepositionswitchonthesecondarythrottlebody,
whereapplicable.
¡diespeedcontrolvalve,testing
¡diespeedismaintainedbytheECMthroughthe¡diespeed
controlvalve.The¡diecontrolfunctioncompensatesforengine
loadandengineoperatingconditions.¡diespeedisadaptive
throughtheECMandno¡diespeedadjustmentscanbemade.
NOTE-
Beforetestingthevalve,confirmthatthethrottleposition

Theidlespeedcontrolvalvereceivespositive(+)bat-
sensorisworkingcorrectly.

teryvoltagefromthemainrelay.
BOSCHDMEM3.1ANDM3.3.1COMPONENTTESTSANDREPAIRS
NOTE-
"Thetestsgivenbelowareelectricalchecksonly.They
donotcheckthemechanicaloperationofthevalve.If
thevalveissuspectedofcausingpooridie,substitut-
ingaknowngoodvalveisthebestwaytocheckfora
mechanicalfault.
1.Withenginerunning,checkthat¡diespeedcontrol
valveisbuzzing.
2.TurnonA/Corshiftcarfintodrive.¡dieshouldremain
steadyorincreaseslightly.
3.Ifvalveisnotbuzzing,orif¡diedecreasesinstep2,
stopengineanddisconnectharnessconnectorfrom
valve.Checkresistanceofvalveacrossitsterminals.
SeeFig.30.Testvaluesarelistedbelow.
NOTE-
Ifyoususpectanintermittentfault,lightlytapthevalve
whiletestingresistance.
11250
Fig.30.¡diespeedcontrolvalveterminalidentification.
4.Withvalveharnessconnectordisconnected,checkfor
batteryvoltageatred/whitewireinconnectorwithigni-
tiontumedon.
"Ifthereisnovoltage,checkwiringbetweenconnec-
torandmainrelayterminal87.SeeElectricalWiring
Diagrams.
5.Ifvoltageispresentasdescribedabove,checkwiring
betweenECMandvalve.Ifnowiringfaultsarefound,
checkECMsignaltovalve.

NOTE-

NOTE-
"TheOlespeedcontrolvalvesignalcanbechecked

Theintakemanifoldisheldinplacewith7nutsfrom
usingadutycyclemeter(ordwellmeter).Connectthe

aboveand2supportbracketboltsfromundemeath.On
metertothevalvefollowingthemanufacturer'sin-

DME3.1cars,carefullydisconnecttheidleairhosefrom
structions.TurnontheWCorcreatealargaairleak

theintakemanifoldwhenliftingthemanifoldoff.Formore
andcheckthatthemeterreadingreactswhiletheidle

information,sea113CylinderHeadRemovalandIn-
speedremainssteady.

stallation.
"Therearesomeadditionalinputstothecontrolmod-
ulethataffectidlespeed(Le.throttleposition,AIC-on

5.Disconnectal¡necessaryhosesandremoveidlespeed
signals,andAITDriveposition).Checkthesesignals

controlvalve.
ifidleproblemspersist.SeeTablaiorTablej.
Idlespeedcontrolvalva,replacing
Theidlespeedcontrolvalveismountedbeneaththeintake
manifold.Accessingthevalvaisbestaccomplishedbyfirstre-
movingtheintakemanifold.
NOTE-
¡tisrecommendedthattheintakemanifoldgasketsbe
replacedwhenevertheintakemanifoldisremoved.
1.Removetopenginecoversfromengine.SeeFig.31.
FUELINJECTION

130-21
6.InstallationisreverseofRemoval.Usenewgaskets
wheninstallingintakemanifold.
NOTE-
Poordriveabilitymaybenoticedafterinstallingare-
placementidlespeedcontrolvalve.Afterabout10min-
utesofdriving,thesystemwilladaptthebasesettingof
thevalvaandtheidlespeedshouldretumtonormal.
TighteningTorque
"Intakemanifoldto
cylinderhead(M7)...........15±2Nm(11tift-Ib)
BOSCHDMEM5.2
COMPONENT REPLACEMENT
On-BoardDiagnostics11(OBDII)isincorporatedintothe
BoschDMEM5.2enginemanagementsystemsusedonthe
M44engine.OBDIIiscapableofdetectingafullrangeof
faults.Whenfaultsaredetected,aDiagnosticTroubleCode
(DTC)isstoredinthesystemECM.TheCheckEnginewarn-
inglightwillalsocomeonifanemissions-relatadfaultisde-
tected.
ThemostefficientwaytodiagnosetheBoschOBDIIsys-
temisbyusingaspecializedscantool.TheOBDIIsystemis
capableofstoringhundredsoffaults,makingdiagnosticswith
ascantooltheonlyviablemethod.Therefore,systemdiag-
nosticsisnotcoveredhere.
Fi

31.Removetoeninecoversb

inoutcaPsandremovin

NOTE-
nuts(A)
9.

P

g

y
Pryg

g

"TheOBD11faultmemory(includinganiiluminated
Note
14L-teatcoveredge(arrows).
CheckEnginelight)canonlyberesetusingthespe-
cialscantool.RemovingtheconnectorfromtheECM
2.Removetwoholddownnutsfromfuelinjectorwiring

ordisconnectingthebatterywillnotarasethefault
duct.Prybackinjectorconnectorretainersandliftoff

memory.
wiringduct.

"The16-pinOBDIldiagnosticconnectorislocatedon
thelowerleftdashpanel.RefertoFig.1.
3.Disconnectintakeairbootfromthrottlehousing.Where
applicabledisconnectacceleratorcableandcruise

"BMWspecialscantoolora`generic"OBDIIscantool
controlcablefromtheirbrackets.

mustbeusedtoaccessDTCs.
4.Unboltintakemanifoldandmoveitoutofwayenough
toaccessidlespeedcontrolvalva.
"Tablaklistsenginecontrolmodule(ECM)pinoutsfor
theDMEM5.2system
BOSCHDMEM5.2COMPONENTREPLACEMENT

130-22

FUELINJECTION
Massairflowsensor,replacing
1.Disconnectharnessconnectorandintakeairbootfrom
airflowsensor.SeeFig.32.
Fig.32.Todetachairflowsensor,disconnectharnessconnector(A);

3.Installationisreverseofremoval.
unclipretainíngclipstoaírfilterhousing(B);andremovelarge
hoseclampatairintakebellows(C).M44enginewithtraction

"Useanewcoppersealingwasherwheninstallingsen-
controlshown.

sor.
"Replaceanylostcoolant.
2.Detachtwolargeclipsatairfilterhousingandworkair
flowsensoroutofrubbersealinfilterhousing.
TighteningTorque
3.Installationisreverseofremoval.

"Enginecoolanttemperature
"Foreaseofinstallation,lubricatelargerubbersealin

tocylinderhead.................13Nm(10ft-Ib)
airfilterhousingwithsiliconelubricantorequivalent.
"Noadjustmenttoairflowsensorispossible.
"Carefullycheckthatallhosesandsealsareseated

Intakeairtemperature(IAT)sensor,
properly.

replacing
Enginecoolanttemperature(ECT)sensor,
replacing
Theenginecoolanttemperature(ECT)sensorisadual
temperaturesensor.Onecircuítprovidescoolanttemperature
informationtotheECMwhiletheothercircuítprovidescoolant
temperatureinformationtotheinstrumentcluster.
WARNING -
DonotreplacetheECTsensorunlesstheengineis
cold.Hotcoolantcanscald.
1.DisconnectharnessconnectorfromECTsensor.See
Fig.33.
2.Unscrewtemperaturesensorfromcylinderheadand
remove
BOSCHDMEM5.2COMPONENT REPLACEMENT
U1111bis4a
Fig.33.M44enginecoolanttemperature(ECT)sensorlocatedabove
oilfilter(arrow).
Theintakeairtemperature(IAT)sensoroncarswithM44
engineismountedinthetopsectionoftheintakeairfilter
housing.SeeFig.34.
1.RemoveelectricalharnessconnectorfromIATsensor.
2.Uncliptemperaturesensorandremovefromairfilter
housing.
3.Installationisreverseofremoval.
Throttlepositionsensor(TPS),replacing
Thethrottlepositionsensorislocatedonthesideofthe
throttlehousing.SeeFig.35.
1.Unplugharnessconnectorfromsensor.

001ía4i
Fig.34.Intakeairtemperature(IAT)sensorintopsectionofairfilter
housing.
¡diespeedcontrolvalve,replacing
sideofthethrottlebody.SeeFig.35.
1.Disconnectharnessconnectorfrom¡dievalve.
0012725
Fig.35.M44engine:Throttlehousingshowing(A)throttleposition
sensor(fPS)and(B)¡diespeedcontrolvalve.
2.Removetwomountingscrewsholdingsensortothrottle
housing.
The¡diespeedvalveontheM44engineislocatedonthe
FUELINJECTION

130-23
2.Disconnectvacuumhoseandretainingscrews.
3.Pull¡diespeedcontrolvalvefromitsfittings.
4.Installationisreverseofrémoval.Alwaysreplace0-
ringsandseals.
NOTE
Poordriveabilitymaybenotícedafterinstallingare-
placement¡diocontrolvalve.Afterabout10minutesof
driving,theidiespeedshouldretumtonormal.
SIEMENSMS41.1
COMPONENTREPLACEMENT
On-BoardDiagnosticsII(OBDII)isincorporatedintotheSi-
emensMS41.1enginemanagementsystemsusedinthe
M52andS52USengine.RefertoFig.36.
OBD11iscapableofdetectingafui¡rangeoffaults.When
faultsaredetected,aDiagnosticTroubleCode(DTC)is
storedinthesystemECM.TheCheckEnginewarninglight
willalsocomeonifanemissions-relatedfaultisdetected.The
mostefficientwaytodiagnosetheSiemensOBDIIsystemis
byusingaspecializedscantool.TheOBDIIsystemiscapa-
bleofstoringhundredsoffaults,makingdiagnosticswitha
scantooltheonlyviablemethod.Therefore,systemdiagnos-
ticsisnotcoveredhere.
NOTE-
"The
OBD 11faultmemory(includinganilluminated
CheckEnginelight)canonlyberesetusingthespe-
cialscantool.RemovingtheconnectorfromtheECM
ordisconnectingthebatterywillnoterasethefault
memory.
"The16-pinOBD 11diagnosticconnectorislocatedon
thelowerleftdashpanel.RefertoFig.1.
"BMWspecialscantoolora"generic"OBD 11scantool
mustbeusedtoaccessDTCs .
3.Installationisreverseofremoval.Noadjustmentisnec
essary.

"Table1listsenginecontrolmodule(ECM)pinoutsfor
theMS 41.1systems.
SIEMENSMS41.1COMPONENT REPLACEMENT

130-24

FUELINJECTION
Jo'0
o_A
í1
RELAY
.
. .
.
CAMSHAFT POSITIONSENSOR
' . ~'

~ :UhI~IIUH~W~`bY~7~d~t~II7
.
.
.,
1111111
~ilf
ASC
TERMINAL15
MEMORY POWER
CRANKSHAFT
POSITION
qtcMSENSOR
THROTTLE
POSITION
ENGINE
COOLANT
TEMP
FUELTANKPRESSURESENSOR
S-EML
S-MSR
S-ASC
VEHICLESPEED
LOWFUELLEVEL
A/CSWITCHON(AC)
E36
IHKA

COMPRESSOR "ON"
SIGNAL(KO)
INDIVIDUALSERIALNUMBER
SIEMENSMS41.1COMPONENT REPLACEMENT
FUELPUMP
RELAYCONTROL
AUXGROUND
P
MAINGROUND
ACCOMPRESSOR
RELAYCONTROL

~®
SECONDARY AIR
INJECTIONAIRPUMP
RELAYCONTROL -
M
PRECAT

POSTCATmnXYGENSENSOR
ys
U
~4

,HEATING
FUELINJECTORCONTROL(
MS41.1

(
MS
PURGECONTROL
VALVE

//

PURGE'
CANISTER
SHUT-OFF
VALVE
ECM
RELAY
CONTROL
IGNITIONCOILS
CONTROL
1ASC
oayi
THROTTLE
POTENTIOMETER
POWER
,
al;.
.
i
r71a
.
"afn7111,/

r
Fig.36.SiemensMS41.1OBDIIenginemanagementsystemusedonM52engine.BoschM5.2systemusedonM44engineissimilar.

Massairflowsensor,replacing
1.Disconnectharnessconnectorandintakeairboots
fromairflowsensor.SeeFig.37.
Fig.37.Massairflowsensor(arrow)onM52engine.
2.Installationisreverseofremoval.
"Noadjustmenttoaírflowsensorispossible.
"Checkintakehosesforcracksandvacuumleaks.
Enginecoolanttemperature(ECT)sensor,
replacing
TheECTsensorisadualtemperaturesensor.Onecircuit
providescoolanttemperatureinformationtotheECMwhile
theothercircuitprovidescoolanttemperatureinformationto
theinstrumentcluster.
1.Removeleft-sidetopenginecover.
4.Removesensor.
5.Installationisreverseofremoval.
"Replaceanylostcoolant.
0012703
"Useanewcoppersealingwasherwheninstallingnew
TighteningTorque
"Enginecoolanttemperature
tocylinderhead.................13Nm(10ft-Ib)
FUELINJECTION

130-25
0012704b
Fig.38.M52engine:Enginecoolanttemperature(ECT)sensor(A)is
locatedbeneathtopenginecover(8)andcrankcasevent
hose(C).
Intakeairtemperature(IAT)sensor,
replacing
Theintakeairtemperature(IAT)sensorfortheM52/S52US
engineismountedonthebottomoftheintakemanifold.SeeFig.
39.
2.Unclipcrankcaseventinghosefromcylinderheadcov-
er.SeeFig.38.

Fig.39.M52/S52USengine:Intakeairtemperaturesensorlocationin
bottomofintakemanifold(arrow).Throttlehousingshownre
3.Underintakemanifold,disconnectharnessconnector

moved.
fromsensor.
1.Disconnectintakeairbootfromthrottlehousing.Unbolt
throttlehousingand¡ayaside.(Itisnotnecessaryto
disconnectthrottlecableorelectricalharnessconnec-
torsfromthrottlehousing.)
sensor.

2.RemoveelectricalharnessconnectorfromIATsensor.
3.Uncliptemperaturesensorandremovefromintake
manifold.
4.Installationisreverseofremoval.Useanewgasketat
thethrottlehousing.
SIEMENS MS41.1COMPONENT REPLACEMENT

130-26

FUELINJECTION
Throttlepositionsensor(TPS),replacing
Thethrottiepositionsensorislocatedonthesideofthe
throttiehousing.SeeFig.40.
Fig.40.M52engine:Throttlepositionsensor(arrow).
1.Unplugharnessconnectorfromsensor.
NOTE-
Oncarswithtractioncontrol,donotconfusethethrottie
positionsensoronthemainthrottiebodywíththethrot-
tiepositionswitchonthesecondarythrottiebody,
whereapplicable.
3.Installationisreverseofremoval.
¡diespeedcontrolvalve,replacing
0012700b
The¡diespeedcontrolvalveismountedontheundersideof
theintakemanifoldadjacenttothedipsticktubebracket.Ac-
cessingthevalveisbestaccomplishedbyfirstremovingthe
throttiehousing.
1.Disconnectintakeairbootfromthrottiehousing.Unbolt
throttiebodyand¡ayaside.(Donotdisconnectthrottie
cableorelectricalharnessconnectorstothrottiebody.)
2.Unboltdipsticktubebracketfromintakemanifold.
3.Workíngunderintakemanifold,disconnectelectrical
harnessconnectorfrom¡diespeedcontrolvalve.
4.Removetwoboltsretaining¡diespeedcontrolvalveto
undersideofintakemanifold.Removevalvefromintake
manifold.Removehoseclampanddisconnecthose.
ECMPINASSIGNMENTS
matelyoneminute.
Vacuum
seal
Mounting
bracket
Electrical
connector
0013185
Fig.41.M52engine:¡diespeedcontrolvalve(locatedunderintake
manifold).
5.Installationísreverseofremoval.Usenewgaskets
wheninstalling.
NOTE-
Poordriveabilítymaybenoticedatterinstallingare-
placementidlespeedcontrolvalve.Afterabout10min-
utesofdrívingtheidlespeedshouldreturntonormal.
ECMPINASSIGNMENTS
2.Removetwomountingscrewsholdingsensortothrottie
housing.

Enginecontrolmodule(ECM),accessing
1.Disconnectnegative(-)batterycable.Waitapproxi-
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevüi.
2.Removeenginecontrolmodule(ECM)compartment
coverfromrightsideofenginecompartmentrearbulk-
head.Coverisretainedwithfourcaptívescrews.See
Fig.42.
3.Disconnectcontrolmoduleharnessconnectorbyre-
leasingfastenerandpivotingconnectorupandoff
ECM.
4.RemoveECMfromretainingbracketsandpullECM
fromitsholder.
5.Installationisreverseofremoval.

0013ZIM
Fig.42.Enginecontrolmodule(ECM)locatedincompartmentin
right-rearofenginecompartment(arrow).
NOTE-
ReplacementECMsmustbecodedwithapplicationin-
formation(Le.enginecode,transmissiontype,etc.)pri-
ortoinstallation.ConsultanauthorizedBMWdealer
beforereplacingtheECM.
ECMpinassignmentsaregiveninTableshthroughTable
I.Thisinformationcanbehelpfulwhendiagnosingfaultstoor
fromtheECM.Ifal¡inputsandwiringareOKbutoperational
problemsstillexist,theECMitselfmaybefaulty.
Fig.43.ECMpinnumbersasseenfrombackofECMconnector.
FUELINJECTION

130-27
Generally,absenceofvoltageorcontinuitymeansthereisa
wiringorconnectorproblem.Testresultswithincorrectvalues
donotnecessarilymeanthatacomponentisfaulty:Checkfor
loose,brokenorcorrodedconnectionsandwiringbeforere-
placingcomponents.Iftheresultsarestillincorrect,testthe
componentitself.Forenginemanagementsystemelectrical
schematics,seeElectricalWiringDiagrams.
CAUTION-
Alwayswaitatleast40secondsaftertuniingoff
theignitionbeforeremovingtheconnectorfrom
theenginecontrolmodule(ECM).Iftheconnec-
torisremovedbeforethistime,residualpowerin
thesystemrelaymaydamagetheECM.
"Alwaysconnectordisconnectthecontrolmodule
connectorandmeterprobeswiththeignitionoff.
WhenmakingchecksattheECMitself,abreakoutbox
shouldbeusedtoallowteststobemadewiththeconnector
attachedtotheECM.Thisalsopreventsdamagetothesmall
termínalsintheconnector.Asanalternative,theharnesscon-
nectorhousingcanbeseparatedsothatelectricalcheckscan
bemadefromthebackoftheconnector.ECMpinnumbering
isshowninFig.43.
NOTE-
Oncarswithtractioncontrol,donotconfusethethrottle
positionsensoronthemainthrottlebodywiththethrot-
tlepositionswitchonthesecondarythrottlebody.
27
Lb
2L4 LJ22©©®®17 ©©®©©~©©®©~~rui~~ru
®®®®®®®®®®®®®®®IZA®®®®®®®®®®®®®®®®®
1
>I-
0013211
ECMPINASSIGNMENTS

130-28

FUELINJECTION
Tableh.ECMPinAssignment-Bosch DMEM1.7
Pin Signal Componenttfunction

Signal
1

Output

Fuelpumprelaycontrol

Fuelpumprelay,terminal85
2

Notused
3

Output

Cyl.2andcyl.4fuelinjectionvalvecontrol

Cyl.2andcyl.4fuelinjectionvalves
4

Notused
5

Notused
6

Ground

Ground,fuelinjectionvalveoutputstages

Groundpoint
7

Notused
8

Output

"Checkengine"indicatorcontrol

Instrumentcluster
9

Notused
10

Notused
11

Output

DKVpotentiometersignal

Transmissioncontrolmodule(EGS)
12

Input

Throttlepositionsensor

ThrottlepositionSignal
13

Notused
14

Input

Volumeairflowsensor

Volumeairflowsensor(signalground)
15

Input

Cyl.1-2knocksensor

Cyl.1-2knocksensor
16

Input

Camshaftpositionsensor(cylinderidentification)

Camshaftpositionsensor(cylinderidentification)
17

Output

timeasurementsignal(fuelconsumption)

Instrumentcluster
18

Output

Intakeairresonancechangeovervalve(DISA)

Intakeairresonancechangeovervalve
19

-

Notused
20

Notused
21

Notused
22

Notused
23

Notused
24

Output

Cyl.3ignitioncoilcontrol

Cyl.3ignitioncoil
25

Output

Cyl.1ignitioncoilcontrol

Cyl.1ignitioncoil
26

Input

Batteryvoltage

B+junctionpoint
27

Output

Enginecontrolmodulerelaycontrol

Enginecontrolmodulerelay,terminal85
28

Ground

Groundforelectronicsandshieldingofsensors

Groundpoint
29

Output

Idlespeedcontrolvalvecontrol

Idlespeedcontrolvalve
30

Notused
31

Notused
32

Output

Cyl.1andcyl.3fuelinjectionvalvecontrol

Cyl.1andcyl.3fuelinjectionvalves
33

Notused
34

Ground

Ground,outputstages(exceptforignitionandfuel

Groundpoint
injectionvalves)
35

Notused
36

Output

Evaporativeemissionvalvecontrol

Evaporativeemissionvalve
37

Output

Oxygensensorheatercontrol

Oxygensensorrelay,terminal85
38

Notused
39

Notused
40

INotused
41

IInput

,VolumeAirFlowsensor

Volumeairflowsensor(voltagevarieswithengineload)
42

1Input

1Cyl.3-4knocksensor

1Cyl.3-4knocksensor
43

Ground

Groundforsensors

Enginecoolanttemperaturesensor,cyl.1-2knocksensor,cyl.3-4knock
sensor,andthrottlepositionsensor
44

1Input

1Camshaftpositionsensor(cylinderidentification)

1Camshaftpositionsensor(cylinderidentification)
ECMPINASSIGNMENTS

Tableh.ECMPinAssignment--BoschDMEM1.7
Pin

1Signal

1Component/function

1Signal
45 Notused
46 Notused
47 Notused
48

Output

A/Ccompressorcut-out

Compressorcontrolrelay,terminal85
49 Notused
50 Notused
51

Output

Cyl.4ignitioncoilcontrol

Cyl.4ignitioncoil
52

Output

Cyl.2ignitioncoilcontrol

Cyl.2ignitioncoil
53

Notused
54

Input

Batteryvoltagefromenginecontrolmodule

Enginecontrolmodulerelay,terminal87a
55

Ground

Ground,ignition

Groundpoint
56

Input

Ignitionswitch,terminal15

Ignitionswitch,terminal15
57 Notused
58

Notused
59

Output

Throttlepositionsensorandvolumeairflowsensor

Referencevoltage(5VDC)
60

Input

Programmingvoltage

Datalinkconnector
61 Notused
62 Notused
63 Notused
64

Input

Ignitiontimingintervention

Transmissioncontrolmodule(EGS)
65

Input

DriverangeP/N

Automatictransmissionrangeswitch
66 Notused
67

Input

CrankshaftpositionRPMsensor

CrankshaftpositionRPMsensor
68

Input

CrankshaftpositionRPMsensor

CrankshaftpositionRPMsensor
69 Notused
70

Input

Oxygensensorsignal

Heatedoxygensensor
71

Ground

Oxygensensorsignalground

Heatedoxygensensor
72 Notused
73

Input

Vehiclespeedsignal

Instrumentcluster
74

Output

Enginespeedsignal

Instrumentcluster
75

Notused
76

Input

Volumeairflowsensor

Volumeairflowsensor
77

Input

Intakeairtemperaturesensor(IAT)

Intakeairtemperaturesensor(IAT)
78

Input

Enginecoolanttemperature

Enginecoolanttemperaturesensor
79 Notused
80

Notused
81

Input

Drive-awayprotectionsignal(code)

On-boardcomputer
82

Notused
83 Notused
84

Notused
85

Input

A/Cpressure

Pressureswitch
86

Input

A/Cswitch

Integratedclimateregulationcontrolmodule
87

Output

RxDdiagnosisdataline

Datalinkconnector
88

Output-Input

TxDdiagnosisdataline

lDatalinkconnector
FUEL INJECTION

130- 29
ECMPINASSIGNMENTS

130- 30

FUEL INJECTION
Pin Signal Component/function

Signal
ECMPINASSIGNMENTS
Table1.ECMPinAssignment-BoschDMEM3.1
1

output

Fuelpumprelaycontrol

Fuelpumprelayswitcheswithenginerunningorcranking(crankshaftposition
Signalmustbepresentforrelayswitchover)
2

1
output

1Idlespeedcontrolvalve

1Pulsadground-closesignal(seealsopin29)
3

output

Fuelinjectorcontrol,cyl.1

Pulsedground(injectionpulsewidthinms)withenginerunning
4

output

Fuelinjectorcontrol,cyl.3

Pulsedground(injectionpulsewidthinms)withenginerunning
5

output

Fuelinjectorcontrol,cyl.2

Pulsedground(injectionpulsewidthinms)withenginerunning
6

ground

Ground

Groundforfuelinjectoroutputstages
7 vacant -

-
8

output

CheckEngine

Checkénginelampcontrolground
9 vacant -

-
10 vacant -

-
11

output

Throttlevalveposition

Loadsignaltotransmissioncontrolmodule
12

input

Throttlepositionsensor

Voltagevarieswiththrottleposition
13

output

Massairflowsensor

Airflowsensorhotwireburnoff(voltagefor0.5secondsaftershutdown)
14

ground

Massairflowsensor

Groundforairflowsensor
15 vacant -

-
16

input

Cylinderidentificationsensor

A/Cvoltagepulsepercamshaftrevolution(betweenpin16and44)
17

output

Fuelconsumption(ti)

Fuelconsumptionoutput(KVASignal)toinstrumentcluster
18 vacant -

-
19 vacant -

-
20 vacant -

-
21 vacant -

-
22 vacant -

-
23

output

Ignitioncontrol(terminal1),cyl.no.2

PrimarySignal,ignitioncoilcyl.no.2
24

output

Ignitioncontrol(terminal1),cyl.no.3

Primarysignal,ignitioncoilcyl.no.3
25

output

Ignitioncontrol(terminal1),cyl.no.1

Primarysignal,ignitiohcoilcyl.no.1
26

input

Powersupply(terminal30)

Batteryvoltage(B+)atal¡times(terminal30)
27

output

Mainrelaycontrol

Mainrelayactivation(torelayterminal85)
28

ground

Ground

GroundforECMandsensorshielding
29

output

Idlespeedcontrolvalve

Pulsedground-opensignal(seealsopin2)
30 vacant -

-
31

output

Fuelinjector,cyl.no.5

Pulsedground(injectionpulsewidthinms),cyl.no.5
32

output

Fuelinjector,cyl.no.6

Pulsedground(injectionpulsewidthinms),cyl.no.6
33

output

Fuelinjector,cyl.no.4

Pulsedground(injectionpulsewidthinms),cyl.no.4
34

ground

Ground

Groundforoutputstages
35 vacant
36

output

Evaporativepurgevalvecontrol

Pulsedgroundwithengineatnormaltemperatureandvaryingengineload
37

output

Oxygensensorheaterrelaycontrol

Oxygensensorheaterrelayactivation(groundatterminal85)
38 vacant -

-
39 vacant -

-
40 vacant

-
41

input

Massairflowsensor

Voltage(+)
42 vacant -

-
43

ground

Ground

Groundfortemperaturasensors(ECTsensor,IATsensor,TPsensor)
44

input

Cylinderidentificationsensor

A/Cvoltagepulsepercamshaftrevolution(betweenpin16and44)

Tablei.ECMPinAssignment-Bosch DMEM3.1
Pin

Signal

Component/function

2
ignal
FUELINJECTION

130-31
45 vacant -
46 vacant -

-
47 vacant -

-
48

output

A/Ccompressorcontrol

A/Ccompressordisabledviacompressorcontrolrelay
49 vacant -

-
50

output

Ignitioncontrol(terminal1),cyl.no.4

Primarysignal,ignitioncoilcyl.no.4
51

output

Ignitioncontrol(terminal1),cyl.no.6

Primarysignal,ignitioncoilcyl.no.6
52

output

Ignitioncontrol(terminal1),cyl.no.5

Primarysignal,ignitioncoilcyl.no.5
53 vacant

-
54

input

Powersupply

Batteryvoltage(+)frommainrelayterminal87
55

ground

Ground

Groundforignitioncontrol
56

input

Powersupply(terminal15)

Batteryvoltage(+)withkeyonorenginerunning
57 vacant -

-
58 vacant -

-
59

output

Throttlepositionsensor

Throttlepositionsensorsupplyvoltage(5VDC)
60

input

Datalinkconnector

Programmingvoltage
61 vacant -

-
62 vacant -

-
63 vacant -

-
64

input

Ignitiontimingintervention

fromA/Tcontrolmodule(onlyactiveduringgearshift)
65

input

Automatictransmission(A/T)rangeswitch

Transmissionparkorneutralsignal
66 vacant -

-
67

input

Enginespeed/crankshaftpositionsensor

Crankshaftposition/rpm(voltage(VAC)betweenpins67and68)
68

input

Enginespeed/crankshaftpositionsensor

Crankshaftposition/rpm(voltage(VAC)betweenpins67and68)
69 vacant -

-
70

input

Oxygensensor

Oxygensensorsignal(0-1VDCfluctuatingwithenginerunning)
71

ground

Oxygensensor

Oxygensensorsignalground
72 vacant -

-
73

input

Roadspeed

Roadspeedsignalfrominstrumentcluster
74

output

Enginespeed(TD)

Enginespeed(TD)signaltoinstrumentcluster
75 vacant -

-
76 vacant -

-
77

input

Intakeairtemperature(IAT)sensor

Intakeairtemperature(0-5V,temperaturedependent)
78

input

Enginecoolanttemperature(ECT)sensor

Enginecoolanttemperature(0-5V,temperaturedependent)
79 vacant -

-
80 vacant -

-
81

input

On-boardcomputer

Drive-awayprotectionenable
82 vacant -

-
83 vacant -

-
84 vacant -

-
85

input

A/Cpressureswitch

FromIntegratedclimatecontrolmoduleviaA/Cpressureswitch
86

input

A/Ccompressoron

FromIntegratedclimatecontrolmodule
87

input

Diagnosticconnector(RxD)

DiagnosticRxD(receive)signaltopin15inDatalinkconnector
88

input/output

Diagnosticconnector(TxD)

DiagnosticTxD(transmit)signaltopin20inDatalinkconnector
ECMPINASSIGNMENTS

130-32

FUELINJECTION
Pin

1Signal

1Component/function

1Signal
1

output

Fuelpumprelaycontrol

Fuelpumprelayswitcheswithenginerunningorcranking(crankshaftposition
signalmustbepresentforrelayswitchover)
2

output

Idlespeedcontrolvalve

Pulsedground-closesignal(seealsopin29)
3

output

Fuelínjectorcontrol,cyl.5

Pulsedground(injectionpulsewidthinms)cyl.5
4

output

Fuelinjectorcontrol,cyl.6

Pulsedground(injectionpulsewidthinms)cyl.6
5

output

Fuelinjectorcontrol,cyl.4

Pulsedground(injectionpulsewidthinms)cyl.4
6

ground

Ground

Groundforfuelinjectoroutputstage
7

output

Camshaftactuator(VANOSsolenoid)control

Camshaftactuator(VANOSsolenoid)
8

output

CheckEngine

Instrumentcluster,CheckEnginelamp
9 vacant -

-
10 vacant -

-
11

output

Throttleposition

ThrottleanglesignaltoA/Tcontrolmodule
12 vacant -

-
13

input

Oxygensensor

Oxygensensorsignal(0-1VDCfluctuatingwithenginerunning)
14

input

Massairflowsensor

Massairflowsensor
15 ground Ground

Ground
16

input

Crankshaftposition/rpmsensor

Voltagepulse(VAC)betweenpin16and43(crankposition/rpmsensor)
17

input

Camshaftpositionsensor

Halleffectcamshaftsensor
18 vacant -

-
19 vacant -

-
20 vacant -

-
21 vacant -

-
22 vacant -

-
23

output

Ignitioncoilcontrol,cyl.4

Ignitioncoil4
24

output

Ignitioncoilcontrol,cyl.6

Ignitioncoil6
25

output

Ignitioncoilcontrol,cyl.5

Ignitioncoil5
26

input

Powersupply(terminal30)

Batteryvoltage(B+)atalltimes
27

input

Mainrelaycontrol

Mainrelayactivation(terminal85)
28

ground

Ground

GroundforECMandsensorshielding
29

output

Idlespeedcontrolvalve

Pulsedground-opensignal(seealsopin2)
30 vacant -

-
31

output

Fuelinjectorcontrol,cyl.3

Injectionpulsewicithinms-cyl.3
32

output

Fuelinjectorcontrol,cyl.2

Injectionpulsewicithinms-cyl.2
33

output

Fuelinjectorcontrol,cyl.1

Injectionpulsewidthinms-cyl.1
34

ground

Ground

Groundforremainingoutputstages
35 vacant -

-
36

output

Evaporativepurgevalvecontrol
37 vacant -

-
38

output

Oxygensensorheaterrelaycontrol

Oxygensensorheaterrelayswitchover(terminal85)
39 vacant -

-
40

ground

Oxygensensor

Oxygensensorsignalground
41

input

Massairflowsensor

Massairflowvoltagesignal
42

input

Vehiclespeed

Vehiclespeedsignalfrominstrumentcluster
43

input

Crankshaftposition/rpmsensor

Voltagepulse(VAC)betweenpin16and43
44

ground

Ground

Groundforintakeairtemp.sensor,enginecoolanttemp.sensor,throttle
positionsensor
ECMPINASSIGNMENTS
Tablej.ECMPinAssignment-Bosch DMEM3.3.1

Tablej.ECM PinAssignment-Bosch DME M3.3.1
Pin

~Signal

1Componentffunction

1signal
FUELINJECTION

130-33
45

ground

Ignitioncircuitshield

Groundshieldforignitioncircuitmonitoring
46

output

Fuelconsumption(KVAsignal)

Toinstrumentcluster
47

output

Crankshaftrpm

Enginespeed(TD)signaltoinstrumentcluster
48

output

A/Ccompressorcontrol

A/Ccompressorrelayterminal85
49 vacant -

-
50

output

Ignitioncoilcontrol,cyl.1

Primarysignal,ignitioncoil1
51

output

Ignitioncoilcontrol,cyl.2

Primarysignal,ignitioncoil2
52

output

Ignitioncoilcontrol,cyl.3

Primarysignal,ignitioncoil3
53 vacant -

-
54

input

Powersupply

Batteryvoltagefrommainrelay(terminal87a)
55

ground

Ground

Groundforignitioncontrol
56

input

Powersupply(terminal15)

Batteryvoltagewithkeyonorenginerunning
57

input

Ignitiontimingintervention

FromA/Tcontrolmodule
58 vacant -

-
59

output

Throttlepositionsensor(TPS)

VoltagesupplytoTPS(5VDC)
60

input

Programmingvoltage

Datalinkconnector
61 vacant -

-
62 vacant -

-
63 vacant -

-
64

input

A/Consignal

Fromintegratedclimatecontrolmodule
65

input

A/Cpressuresignal

FromintegratedclimatecontrolmoduleviaA/Cpressureswitch
66

input

On-boardcomputer

Drive-awayprotectionenable(starterimmobilizationrelay)
67 vacant -

-
68 vacant -

-
69

input

Knocksensor#2(cyl.4,5,6)

Knocksensor#2signal
70

input

Knocksensor#1(cyl.1,2,3)

Knocksensor#1signal
71

ground

Ground

Groundforknocksensorsandshields
72 vacant -

-
73

input

Throttlepositionsensor(TPS)

Throttlepositionsignal
74 vacant
-
75 vacant -

-
76 vacant
-
77

input

Intakeairtemperatura

Intakeairtemperaturasensor(0-5VDC)
78

input

Enginecoolanttemperature

Enginecoolanttemperaturesensor(0-5VDC)
79 vacant -
80 vacant -

-
81

input

Automatictransmissiongearpositionlneutral

A/Tparkorneutralpositionsignal
safetyswitch
82 vacant -

-
83 vacant -

-
84 vacant -

-
85 vacant -

-
86 vacant -

-
87

input

Diagnosticconnector(RxD)

DiagnosticRxD(receive)signaltopin15inDatalinkconnector
88

input/output

Diagnosticconnector(TxD)

DiagnosticTxD(transmit)signaltopin20inDatalinkconnector
ECMPINASSIGNMENTS

130-34

FUELINJECTION
Pin

iSignal

1Component/function

1Signal
1

output

Oxygensensor(monitoringsensor)heater

Oxygensensorheatercontrol(switchedground)
2

output

Idlespeedcontrolvalve

Pulsedground-closesignal(seealsopin29)
3

output

Fuelinjectorcontrol,cyl.1

Pulsedground(injectionpulsewidthinms)cyl.1
4

output

Fuelinjectorcontrol,cyl.4

Pulsedground(injectionpulsewidthinms)cyl.4
5

notused

-

-
6

ground

Ground

Groundforfuelinjectoroutputstage
7

notused

-
8

1output

1CheckEngine

1Instrumentcluster,CheckEnginelamp
9

notused

-

-
10

input

Electronicimmobilizercontrol(EWSII)

Electronicimmobilizercontrol(EWSII)module
11

output

Automaticclimatecontrol

Automaticclimatecontrol,toevaporatorcontrolier
12

notused

-

-
13

notused

-

-
14

notused

-

-
15

notused

-

-
16

input

Intakeairtemperature

IntakeairtemperatureSignal
17

input

Massairflowmeter

Intakeairsignal
18

notused

-

-
19

input

Oxygensensor(monitoringsensor)

Oxygensensorcontrol
20

output

Crankshaft/rpmsensor

Crankshaft/rpmsensorcontrol
21

input

Camshaftpositionsensor

Camshaftpositionsignal
22

output

Ignitioncoilcontrol,cyl.3

Primarysignal,ignitioncoil3
23

output

Ignitioncoilcontrol,cyl.4

Primarysignal,ignitioncoil4
24

notused

-

-
25

notused

-

-
26

input

Powersupply(terminal30)

Batteryvoltage(B+)atal¡times
27

input

Mainrelaycontrol

Mainrelayactivation(terminal85)
28

ground

Ground

GroundforECMandsensorshielding
29

output

Idlespeedcontrolvalve

Pulsedground-opensignal(seealsopin2)
30

output

Oxygensensor(monitoringsensor)heater

Oxygensensorheatercontrol(switchedground)
31

output

Fuelinjectorcontrol,cyl.3

Pulsedground(injectionpulsewidthinms)cyl.3
32

output

Fuelinjectorcontrol,cyl.2

Pulsedground(injectionpulsewidthinms)cyl.2
33

Inotused
40

input

Knocksensor#2(cyl.3,4)

Knocksensor#2signal
41

notused

-

-
42

input

Vehiclespeed

Vehiclespeedsignalfrominstrumentcluster
43

notused

-

-
44

output

Throttlepositionsensor(TPS)

Throttlepositionreferencesignal
ECMPINASSIGNMENTS
Tablek.ECMPinAssignment-Bosch DMEM5.2
34

ground

Ground

GroundforECM/outputstages
35

notused

-

-
36

input

A/Ccompressorrelay

A/Ccompressorrelaycontrol
37

notused

-

-
38

notused

-

-
39

notused

-

-

Tablek.ECMPinAssignment-Bosch DMEM5.2(continued)
Pin

ISignal

1Componentltunction

1Signal
45

Ioutput

IMassairflowmeter

IIntakeairSignal
46

output

Oxygensensor(monitoringsensor)

Oxygensensorcontrol
47

notused

-
48

notused

-
49

output

Ignitioncoilcontrol,cyl.1

Primarysignal,ignitioncoil1
50

output

Ignitioncoilcontrol,cyl.2

Primarysignal,ignitioncoil2
51

notused

-
52

notused

-
53

input

Throttlepositionsensor

ThrottlepositionSignal
54

input

Powersupply

Batteryvoltagefrommainrelay(terminal87)
55

ground

Ground

GroundforECM
56

input

Powersupply(terminal15)

Batteryvoltagewithkeyonorenginerunning
57

output

Activatecoolingfan(man.trans.)control

Normalspeedrelay
58

notused

-

-
59

notused

-

-
60

input

Programmingvoltage

Programmingvoltageviadatalinkconnector,pin18
61

output

Evaporativeemissionvalve

Evaporativeemissionvalvecontrol
62 vacant -

-
63

output

Fuelpumprelay

Fuelpumprelaycontrol
64

notused

-
65

notused

-

-
66

notused

-

-
67

notused

-

-
68

input

Signalabove80°C(man.tran.)

Doubletemperatureswitch
69

input

Automaticclimatecontrol

Automatícclimatecontrol
70

input

Knocksensor#1(cyl.1,2)

Knocksensor#1Signal
71

ground

Ground

Groundforanalogsignalsandknocksensors
72

notused

-

-
73

notused

-

-
74

input

Enginecoolanttemperaturesensor

EnginecoolanttemperaturaSignal
75

notused

-

-
76

notused

-

-
77

output

Oxygensensor(regulatingsensor)

Oxygensensorcontrol
78

input

Crankshaft/rpmsensor

Crankshaftposition/rpmSignal
79

input

ABSortractioncontrol

ABSorASTcontrol
80

input

Enginespeed

EnginespeedSignal
81

notused

-

-
82

notused

-

-
FUEL INJECTION

130- 35
83

input

On-boardcomputar

FromOn-boardcomputer(terminal4)
84

notused

-

-
85

notused

-

-
86

notused

-

-
87

input

Diagnosticconnector(RxD)

DiagnosticRxD(receive)signaltopin15inDatalinkconnector
88

output

I
Diagnosticconnector(TxD)

DiagnosticTxD(transmit)signaltopin17inDatalinkconnector
ECMPINASSIGNMENTS

130- 36

FUEL INJECTION
Pin

1Signal

1Componentffunction

1Signal
1

output

Ignitioncoilcontrol,cyl.2

Primarysignal,ignitioncoil2
2

output

Ignitioncoilcontrol,cyl.4

Primarysignal,ignitioncoil4
3

output

Ignitioncoilcontrol,cyl.6

Primarysignal,ignitioncoil6
4 ground Ground

Ground
5

output

Fuelinjectorcontrol,cyl.2

Pulsedground(injectionpulsewidthinms)cyl.2
6

output

Fuelinjectorcontrol,cyl.1

Pulsedground(injectionpulsewidthinms)cyl.1
7

output

Massairflowmeter

Massairmetersignal
8

input

Massairflowmeter

Massairmetersignal
9

output

Instrumentcluster

Fuelconsumptionsignal
10

output

Enginecoolanttemperature(ECT)sensor

ECTsignal
11

output

Fueltankpressuresensor

Fueltankpressuresensorcontrol
12

input

Throttlepositionsensor(TPS)

Throttlepositionsignal
13 -
14

input

Intakeairtemperature(IAT)sensor

Intakeairtemperaturesignal
15

Tractioncontrol

ASTmodule
16

input

Automaticclimatecontrol

Automaticclimatecontrol
17
18

input

Electronicimmobilizercontrol(EWSII)

Electronicimmobilizercontrol(EWSII)module
19

Automaticclimatecontrol

Automaticclimatecontrol
20

-

Instrumentcluster

Instrumentcluster
21

output

Camshaftactuator(VANOSsolenoid)control

Camshaftactuator(VANOSsolenoid),switchedground
22

output

Fuelinjectorcontrol,cyl.3

Pulsedground(injectionpulsewidthinms)cyl.3
23

Fuelinjectorcontrol,cyl.6

Pulsedground(injectionpulsewidthinms)cyl.6
24

Fuelinjectorcontrol,cyl.4

Pulsedground(injectionpulsewidthinms)cyl.4
25

output

Oxygensensorheatercontrol

Oxygensensorheaterground
26

input

Powersupply(terminal30)

Batteryvoltage(B+)atalltimes
27

output

Idlespeedcontrolvalve

Pulsedground-opensignal(seealsopin53)
28 ground Ground

Ground
29

output

Ignitioncoilcontrol,cyl.1

Primarysignal,ignitioncoíl1
30

output

Ignitioncoilcontrol,cyl.3

Primarysignal,ignitioncoil3
31

output

Ignitioncoilcontrol,cyl.5

Primarysignal,ignitioncoil5
32 ground Ground

Ground
33

output

Fuelinjectorcontrol,cyl.5

Pulsedground(injectionpulsewidthinms)cyl.5
34 ground Ground

Ground
35

output

Secondaryairinjection

Secondaryairinjectionpumprelaycontrol
36

output

Enginespeedoutput

Enginespeedsignal
37 -
38

ground

Knocksensor

Shieldingforknocksensors
39

output

Intakeairtemperaturesensor(IATSensor)

VoltagesupplytoIATsensorandECTsensor
Enginecoolanttemperature(ECT)sensor
40

output

Crankshaftpositionsensor(Halleffect)

Crankshaftpositionsensorcontrol
41

ground

Camshaftposition(CMP)sensor

ShieldingforCMPsensor
42

output

Throttlepositionsensor(TPS)

TPSground
43

input

Camshaftposition/rpmsensor

Camshaftposition/rpmsensorcontrol
44

output

Throttlepositionsensor(TPS)

VoltagesupplytoTPS(5VDC)
45

Tractioncontrol

ASTmodule
46

-

Instrumentcluster

Instrumentcluster
ECMPINASSIGNMENTS
TableI.ECMPinAssignment-Siemens DME MS41.1

TableI.ECMPinAssignment-Siemens DMEMS41.1(continued)
Pin

ISignal

IComponent/function

1Signal
FUEL INJECTION

130- 37
47 -
48

input

Crankshaftpositionsensor(Halleffect)

Crankshaftpositionsensorcontrol
49

input

Powersupply(terminal15)

Batteryvoltagewithkeyonorenginerunning
50

output

Solenoidvalve(runninglosses)

Runninglosses
51

output

Carboncanistervalve

Carboncanistervalvecontrol
52 vacant -
53

output

Idlespeedcontrolvalve

Pulsedground-closesignal(seealsopin29)
54

input

Powersupply

Batteryvoltagefrommainrelay(terminal87)
55 vacant -
56 -
57

input

Knocksensor(cyl.1-3)

KnocksensorinputSignal
58

output

Knocksensor(cyl.1-3)

Knocksensorcontrol
59

input

Knocksensor(cyl.4-6)

KnocksensorinputSignal
60

input/output

Diagnosticconnector(TxD)

DiagnosticTxD(transmit)signaltopin18inDatalinkconnector
61

output

Oxygensensorheater(monitoringsensor)

Oxygensensorheaterground
62

output

Secondaryairinjection

Secondaryairinjectioncontrolvalve
63

output

Knocksensor(cyl.4-6)

Knocksensorcontrol
64

input

Camshaftposition/rpmsensor

Camshaftposition/rpmsensorcontrol
65

input

Camshaftposition/rpmsensor

Camshaftposition/rpmsensorcontrol
66 -
67

output

Oxygensensor

Oxygensensorreferencevoltage
68

output

Evaporativepurgevalvecontrol

Pulsedgroundwithengineatnormaltemperatureandvaryingengineload
69

output

Fuelpumprelaycontrol

Fuelpumprelayswitcheswithenginerunningorcranking(crankshaftposition
signalmustbepresentforrelayswitchover)
70 vacant -

-
71

output

Oxygensensorheater(regulatingsensor)

Oxygensensorheaterground
72

output

Oxygensensor(monitoringsensor)

Oxygensensorreferencevoltage
73

input

Mainrelaycontrol

Mainrelayactivation(terminal85)
74

output

A/Ccompressorcontrol

A/Ccompressorrelaycontrol
75

input

Oxygensensor

Oxygensensorsignal
76

notused

-

-
77

input

Oxygensensor(regulatingsensor)

Oxygensensorsignal
78

input

Oxygensensor(monitoringsensor)

Oxygensensorsignal
79

output

Oxygensensor(regulatingsensor)

Oxygensensorreferencevoltage
80

Tractioncontrol

ASTmodule
81

Tractioncontrol

ASTmodule
82

Tractioncontrol

ASTmodule
83

output

Crankshaftpositionsensor(Halleffect)

Crankshaftpositionsensorcontrol
84 vacant -

-
85

output

Automatictransmission

Automatictransmissioncontrolmodule
86

input

Automatictransmission

Automatictransmissíoncontrolmodule
87

input

Powersupply

Batteryvoltagefrommainrelay(terminal87)
88

input/output

Diagnosticconnector(TxD)

DiagnosticTxD(transmit)signaltopin17inDatalinkconnector
ECMPINASSIGNMENTS

160FuelTankandFuelPump
GENERAL............................160-1

Operatingfuelpumpfortests..............160-6
FuelPumpElectricalTests...............160-7
FUELTANKANDLINES...............160-2

Fuelpumpelectricalcircuit,testing.........160-7
Fueltank,draining.....................160-2

Fuelpumppowerconsumption,testing......160-7
Fueltank,removingandinstalling.........160-3

FuelDeliveryTests.....................160-8
FuelTankEvaporativeControlSystem.....160-4

Relievingfuelpressureandconnecting
fuelpressuregauge...................160-8
FUELLEVELSENDERS...............160-4

Systempressure,testing.................160-9
Fuellevelsenders,testing...............160-5

Fueldeliveryvolume,testing.............160-10
Fuelleve¡senderandfuelpump
(rightside),emovingandinstalling......160-5

TABLES
Fuelleve¡sender(leftside),

a.FuelLeve¡SenderResistances................160-5
removingandinstalling................160-6

b.FuelPumpCurrent.........................160-8
c.FuelPressureSpecifications.................160-10
FUELPUMP..........................160-6

d.FuelPumpDeliverySpecifications............160-10
FuelPumpFuseandRelay..............160-6
GENERAL
Thisrepairgroupcoversserviceinformationspecificallyfor

Thecautionsandwarningsonthispageshouldbeob
thefuelsupplysystem.Informationonthefue¡injectionsys-

servedwhenservicingthefuelsystem.
temiscoveredin130FuelInjection.
NOTE-
Fue¡filterreplacementiscoveredin020Maintenance
Program.
WARNING -
"Thefuelsystemisdesignedtoretainpressure
evenwhentheignitionisoff.Whenworkingwith
thefuelsystem,loosenthefuellinesslowlytoal-
lowresidualfuelpressuretodissipategradually.
Avoidsprayingfuel.
"Beforebeginninganyworkonthefuelsystem,
placeatireextinguisherinthevicinityofthework
area.
"Fuelishighlyflammable.Whenworkingaround
fuel,donotdisconnectanywiresthatcouldcause
electricalsparks.Donotsmokeorworknear
heatersorothertirehazards.
"Alwaysunscrewthefueltankcaptoreleasepres-
sureinthetankbeforeworkingonthetankor
fines.
"Donotuseaworklightnearanyfuel.Fuelmay
sprayontothehotbulbcausingatire.
"Makesuretheworkareaisproperlyventifated.
FUELTANKANDFUELPUMP

160-1
CAUTION-
"Priortodisconnectingthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviü.
"Beforemakinganyelectricaltestswiththeignition
tumedon,disabletheignitionsystemasde-
scribedin120IgnitionSystem.Besurethebat-
teryisdisconnectedwhenreplacingcomponents.
"Topreventdamagetotheignitionsystemorthe
electronicfuelsystemcomponents,includingthe
controlunit,aiwaysconnectanddisconnectwires
andtestequipmentwiththeignitionoff.
"Cleanlinessisessentialwhenworkingwiththe
fuelsystem.Thoroughlycleanthefuelfineunions
beforedisconnectinganyofthefines.
"Useonlycleantools.Keepremovedpartsclean
andsealedorcoveredwithaclean,lint-freecloth,
especiallyifcompletionoftherepairisdelayed.
"Donotmovethecarwhilethefuelsystemis
open.
"Avoidusinghighpressurecompressedairto
blowoutfinesandcomponente.Highpressure
canruptureinfernalsealsandgaskets.
"AlwaysreplacesealsandO-rings.
GENERAL

160-2

FUELTANKANDFUELPUMP
0011943
1.Fillerpipe

10.Fuelcompensatingsiphonpumpandhoseassembly
2.Fillerpipegroundingtab

(modelsbuiltfrom1/95)
3.Ventpipe

11.Fueltank
4.Threadedcollar

12.Tanksupportstrap
5.Rubberringseal

13.Bolt-tightento23Nm(17ft-Ib)
6.Fuelpump

14.Fuelexpansiontank
7.Leftsidefuelleve¡sender(modelsbuiltfrom1/95)

15.Fueltankpressuresensor(OBDII)
8.Rightsidefuelleve¡sender
9.Leftsidefuelleve¡senderwithfuelcompensatingsiphonpump
(modelsbuiltupto1/95)
Fig.1.

E36fueltankassembly.
FUELTANKANDLINES

Fueltank,draining
Theplasticfueltankismountedbeneaththecenterofthe
car(beneathrearseat).Mountedinthefueltankarethefuel
pumpandfuelleve¡sendingunits.Connectinglinesforthe
evaporativeemissioncontrolsystemandexpansiontankare
alsoattachedtothetank.Whenperformingtheprocedures
thatfollow,refertoFig.1.
FueltankcapacityforE36modeis
"Allex.1996M3(3.0L)..........65liters(17.0gal)
"1996M3(3.0L)modeis.........62liters(16.4gal)
FUELTANKANDLINES
Thefueltankshouldbedrainedintoanapprovedstorage
unitoranothercar'sfueltank.
WARNING-
"Beforeremovingthetank,besurethataflhot
componentssuchastheexhaustsystem,are
completelycooleddown.
"Fuelmaybespilled.Donotsmokeorworknear
heatersorotherPirehazards.
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagavi¡¡.

2.Removefueltankfillercap.
3.Removerearseatcushionandpullbackinsulation
matstoexposefueltankaccesscovers.SeeFig.2.
uui3140
Fig.2.

Rightsidefueltankaccesscoverunderrearseatcushion.
4.Removerightandleftaccesscoverstoexposefuel
hosesandelectricalconnectionsattank.
5.Labelfuelhoses.Thendisconnecthosesandharness
connectorsfromfuelsendingunitsandfuelpump.See
Fig.3.
FUELTANKANDFUELPUMP

160-3
NOTE-
"Ifnecessary,pushfuellevelsenderarmtowardfuel
pumpassemblytofacilitateremoval.
"BMWspecialtoolno.161020shouldbeusedtore-
moveandinstallthethreadedcollar.Damagetothe
collarmayresultifthespecialtoolisnotused.
"Pumpoutcontentsofeachtanklobeusingapproved
pumpinglextractionequipmentandflexiblefuel-grade
hose.
WARNING -
Fuelmaybespilled.Donotsmokeorworknear
heatersorotherfirehazards.
7.Installationofsendingunitsisreverseofremoval,not-
ingthefollowing:
"Usenewsealingringswheninstallingpump/sending
unitassemblies.
"Besurethatfuellineconnectionspointinsamedirec-
tionastheycarneout.
"Filltankandcheckforleaksbyrunningengine.
CAUTION-
Beforestartingtheengine,fillthefueltankwithat
least1.5gallons(5liters)offuel.Thepumpwillbe
damagedifyourunitwithoutfuel.
Fueltank,removing andinstalling
1.Disconnectnegative(-)cablefrombattery:
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removefueltankfillercapanddraintankasdescribed
earlier.
3.Workinginleftaccesstankaccesshole(underrear
seatcushion),removeventpipefromtank.
4.Workinginsidecar,disconnectparkingbrakecable
endsfromparkingbrakelever.See340Brakes.
5.Workingunderneathcar,gentlypryfuellinesaway
fromretainingbracketinfrontoftank.Removeclamps
anddisconnectfuelhosesasshowninFig.4.
6.Removeexhaustsystemandheatshieldasdescribed
ooisiai

in180ExhaustSystem.SeeFig.5.
Fig.3.

Fuelpump/fuellevelsenderassemblyintopoffueltank(right
sideshown).Disconnectsupplyhose(A),returnhose(B)and

7.Removedriveshaft.See260Driveshaft.
harnessconnector(C).
8.Pullparkingbrakecablesbackwardawayfrombottomof
6.Unscrewthreadedcollarsfromfueltank.Slowlywith-

fueltank,disengagingthemfrombracketsasneeded.
drawfuelsenderassembliesfromtank,allowingfuelto
drainoff.
FUELTANKANDLINES

160-4

FUELTANKANDFUELPUMP
Fig.4.

Pinchoffsupplyandretumfuelhoses(arrows)beforedis-
connectingfromrigidmetallines.
0013143
Fig.5.Afterremovingexhaustsystem,removeheatshieldscrews
(arrows)andheatshield.
9.Workingunderneathcar,loosenhoseclampanddis-
connectfillerhose.
10.Supporttankfrombelow.Removetankstrapmounting
bolts.Lowerandremovetank,disconnectingrightside

TheE36modelusesatwo-lobedfueltankandeachlobeof
ventandotherhoses/electricalconnectorsasneces-

thetankhasitsownfuellevelsendingunit.
sary.
11.Installationisreverseofremoval.
"Alwaysusenewseals,gaskets,O-rings,andhose
clamps.
"Inspecthosesandreplaceanythatarechafed,dried
outorcracked.
"Inspectheatshieldandreplaceifcorroded.
"Inspectrubberbuffersandlinersonfueltank,support
strapsandonundersideofbody.Replacerubber
partsthatarehardenedordamaged.
FUELLEVELSENDERS
CAUTION-
"Beforestartingtheengine,fillthefueltankwith
atleast1.5gallons(5liters)offueltoprevent
damagingadryfuelpump.
"Ifthefillerneckhasbeenremovedfromthebody,
besuretoreattachtheneck'sgroundingscrew
(whereapplicable).Checkelectricalresistance
betweenthegroundtabandwheelhub.There-
sistanceshouldbenohigherthan0.6ohms.
TighteningTorques
"Fueltanktobody................23Nm(17ft-Ib)
"Hoseclamps(10mm-16mmdía.)..2.0Nm(18in-lb)
FuelTankEvaporativeControlSystem
Thefueltankevaporativecontrolsystemisusedtoventthe
fueltanktoacharcoalcanister,whichisthenpurgedbyen-
ginevacuumduringnormalengineoperatíon.Thiscontrols
emissionofrawhydrocarbons(fuel)totheatmosphere.See
Fig.1.
Afuelexpansiontank,locatedundertherightrearfender,
trapsoverflowfuelandincorporatesextrafueltankplumbing.
Startingwith1996models,OBDIIstandardsrequirethat
thefueltankevaporativecontrolsystembemonitoredfor
leaks.Thisisaccomplishedusingthefueltankpressuresen-
sor,theventshutoffvalve,andtheevaporativepurgevalve.
NOTE-
Onmostearlycars(1992-1995),thecharcoalcanister
isintheenginecompartment.Onlatercars,thechar-
coalcanisterisunderthesparetireintheluggagecom-
partment.
FUELLEVELSENDERS
Therightsidefuelleve¡senderisintegratedwiththefuel
pump.Eachsenderhasafloatconnectedtoavariableresis-
tanceforfuelleve¡.Whenreplacingthesender/pumpassem-
blyalwaysreplacehoseclamps,gasketsandO-rings.
WARNING -
Whenremovingthefuellevelsenderorthefuel
pump,thefueltankshouldbeemptied.

Fuelleve¡senders,testing

Fuelleve¡sender(rightside)
Theleftandrightfuelleve¡sendingunitsarewiredinseries.

andfuelpump,removingandinstalling
Thefuelgaugereceivesasignalthatistheaverageofthetwo

1.Disconnectnegative(-)cablefrombattery.
inputvalues.
1.Removerearseatcushion,liftupinsulationmats,and
removebothfueltankaccesscovers.
2.Disconnectwhiteplugoneachsendingunit.SeeFig.6.
3.Checkresistancevalueofeachsendingunit.Values
shouldbethesame.
5.Ifvaluesaredifferent,removesendingunitsasdescribed
below,andcheckresistancevaluésacrossterminals.Tablea
listsresistancevaluesforsendersatvariousfloatpositions.
Tablea.FuelLeve¡SenderResistances
Floatposition

Testresult(ohms)
Rightsideempty

10ohmt2
Rightsidefull

250ohm±5
Leftsideempty

10ohmt2
Leftsidefui¡

250ohm±5
FUELTANKANDFUELPUMP

160-5
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsglvenatthefrontofthis
manualonpageviii.
2.Drainfuelfromtankasdescribedearlier.
WARNING -
Alwaysunscrewthefueltankcaptoreleasepres-
sureinthetankbeforeworkingonthetankorfines.
3.Removerearseatcushionandpullbackinsulationpad
underrightside.
4.Removescrewsholdingrightfueltankaccesscover.
Removecover.
5.Labelfuelhoses.Disconnecthosesandharnesscon-
nectorsfromfuelsendingunitandfuelpump.
6.Unscrewthreadedcollarfromfuelpumplfuelleve¡
sender.Slowlywithdrawassemblyfromtank,allowing
fueltodrainoff.SeeFig.7.
0013187&0013194
Fig.6.

Fuelpump/leve¡senderterminalidentification.Checkresis-
tanceatterminalsofwhiteconnectors(arrows).

"Ifnecessary,pushleve¡senderarmtowardfuelpump
assemblytofacilitateremoval.
NOTE-
BMWspecialtoolno.161020shouldbeusedtore-
moveandinstallthethreadedcollar.Damagetothe
collarmayresultifthespecialtoolisnotused
WARNING -
NOTE-

Fuelmaybespilled.Donotsmokeorworknear
Thecompensatingsiphonpump(Fig.1)maintainsthe

heatersorotherfirehazards.
fuelleve¡betweentherightandlefttanklobes.Ifthere-
sistancesaredifferentbetweentheleftandrightsend-
ers,removethesendersandvisuallyinspecttheleve)in

7.Usinganewsealingring,installpumpandsending
eachlobe.Iftheleve¡isdifferent,checkthesiphoncom-

unit,beingsurethatfuellineconnectionspointinsame
pensatingpump.

directionastheycarneout.
8.Reconnectharnessconnectorandhoses.Filltankand
checkforleaksbyrunningengine.Insta¡¡accesscover
anditsmountingscrews.Reconnectnegative(-)cable
tobattery.
CAUTION-
Beforestartingtheengine,fillthefueltankwithat
least1.5gallons(5liters)offuel.Thepumpwillbe
damagedifyourunitwithoutfuel.
FUELLEVELSENDERS

160-6

FUELTANKANDFUELPUMP
Fig.7.

Fuelsenderandpumpassembly.
Tooperatethefuelpumpfortestingpurposeswithouthav-
Fuelleve¡sender(leftside),

ingtoruntheengine,thefuelpumprelaycanbebypassedto
removingandinstalling

powerthepumpdirectly.
Theprocedureforremovingandreplacingtheleftsidefuel

Torunthefuelpump,removetherelayandconnectthe
leve¡senderissimilartothatusedfortherightside.Thereis

socketforrelayterminal30tothesocketforrelayterminalno.
nofuelpumpontheleftside.

87withafusedjumperwire.Relayterminalidentificationis
showninFig.9.Aftercompletingthetests,removethejumper
wire.
FUELPUMP
Theelectricfuelpumpísmountedinthefueltankintandem
withtherightsidefuelleve¡sender.Thefuelpumpdelivers
fuelathighpressuretothefuelinjectionsystem.Apressure
regulatormaintainssystempressure.Thequantityoffuelsup-
pliedexceedsdemand,soexcessfuelretumstothefueltank
viaaretumlíne.See130FuelInjectionformoreinformation
onsystempressureandthefuelpressureregulator.
NOTE-
Fuelpumpremovalproceduresaregivenearlierunder
Fuelleve¡sender(rightside)andfuelpump,remov-
íngandinstalling.
FuelPumpFuseandRelay
Thefuelpumpisoperatedbyafuelpumprelaylocatedín
thepowerdistributionbox.Thefuelpumpcircuitisprotected
byfuseno.18locatedinthepowerdistributionbox.SeeFig8.
FUELPUMP
0013142
Fuel

DME
PUMP main
reay

relay
0
aooo~a
aaoó
Fig.8.

Fuelpumprelaylocationinpowerdistributionbox.
TheDMEenginecontrolmodule(ECM)andtheDMEmain
relaysupplypowertothecoi¡sideofthefuelpumprelay.Dur-
ingstarting,thefuelpumprunsaslongastheignitionswitchis
inthestartpositionandcontinuestorunoncetheengine
starts.Ifanelectricalsystemfaultinterruptspowertothefuel
pump,theenginewillnotrun.
Operatingfuelpumpfortests
CAUTION-
Relaylocationsmayvary.Usecarewhenidentify-
ingrelaysandwhentroubleshootingtheelectrical
systematthefuselrelaypanel.Thefuelpumpre-
¡ayisafourpinrelayandhasa1.5mm2redwire
atterminal30intherelaysocket,lfindoubt,con-
sultanauthorizedBMWdealer.
NOTE-
Thejumperwireshouldbe1.5mm2(14ga.)andin-
cludeenin-finefuseholderwitha16ampfuse.To
avoidfuselrelaypaneldamagefromrepeatedconnect-
ínganddisconnecting,alsoincludeatoggleswitch.A
heavy-dutyjumper,BMWtoolno.613050,fsalso
availablefromenauthorizedBMWdealer.
0013034,
Ifthepumpdoesnotrunwiththejumperinstalled,thefault
couldbeinthefuelpumporthewiringtothepump.Checkthe
pumpanditswiringasdescribedbelow.

Fig.9.

Fuelpumprelayterminalidentification.
FuelPumpElectricalTests
Troubleshootingofanyfuelpumpfaultshouldbeginwith
checkingthefuelpumpfuseandthefuelpumprelay.The
DMEmainrelayshouldalsobechecked.
NOTE-
Specialtoolsarerequíredforsomeofthetestsde-
scribedhere.
Fuelpumpelectricalcircuit,testing
ThefuelpumpelectricalcircuitdiagramisshowninFig.10.
3.Iffuelpumpdoesnotrun,disconnectblackharness
connectorfromtanksenderunit.Withjumperwirecon-
nectedasdescribedinstep2above,checkforpositive
(+)batteryvoltageatharnessconnectorterminals.See
Fig.11.
FUELTANKANDFUELPUMP

160-7
FromMainRelay
(+15powerwithkeyinrun

FromB+juretionpoint
orstartposition)
(batteryvoRageatalltirnes)
'.5RD/Nrr

1.5RD
1.5GNNI
FromEngine

2.5GNNI
ControlModule

15
2.5GNNI
Ground
(belowcenterconsole)
Fig.10.Fuelpumpelectricalcircuit.
30
-~
Relay
FuelPump
8~T
I

1
s
ám61FrontPower
I

a
1DistributionBox
I_
16
WIRING
COLORCODE
BK-BLACK
BR-BROWN
FuelPump

RD

-

RED
(in-tank)
M YL YELLOW
GN-GREEN
BU-BLUE
1 VI-VIOLET
GY-GREY
WT-WHITE
PK-PINK
0011946
4.Ifvoltageandgroundarepresent,fuelpumpisproba-
blyfaulty.Ifthereisnovoltage,checkwiringFromfuel
pumpReayandmakesureReayisfunctioningcorrectly.
CAUTION-
Fuseandrelaylocationsmayvary.Usecarawhen

Fuelpumppowerconsumption,testing
troubleshootingtheelectricalsystematthe
fuselrelaypanel.Toresolveproblemsinidentify-

NOTE-
ingarelay,seeenauthorízedBMWdealer.

"Toachieveaccuratetestresults,fhebatteryvoltage
attheconnectorshouldbeapproximately13volts.
1.Removerearseatcushion,pullrightsideinsulationmat

Chargethebatteryasnecessary.
backtoexposefueltankaccesscover.Removecover

.qhigherthannormalpowerconsumptionusuallyfin-
toexposewiringconnections.

dicatesawornfuelpump,whichmaycauseintermit-
tentfuelstarvationduelopumpoverheatingand
2.Removefuelpumprelayandopératefuelpumpasde-

seizure.Theonlyremedyispumpreplacement.Be
scribedunderOperatingfuelpumpfortestsearlier.

suretocheckthatthereturnfineandthepumppickup
Pumpshouldrun.Disconnectjumperwirewhenfin-

arenotobstructedbeforereplacingthepump.
ished.
1.Removerearseatcushion,pullrightsideinsulationmal
backtoexposefueltankaccesscover.Removecover
toexposewiringconnections.
2.Disconnect(black)harnessconnectorfromfuelpump.
3.Connectanammeterandaninsulatedjumperwirebe-
tweenterminalsinconnectorandcorrespondingpump
terminals.SeeFig.12.
FUELPUMP

160-8

FUELTANKANDFUELPUMP
UU131tst5
Fig.11.Voltagesupplytofuelpumpharness(black)connectorbeing
checked(arrow).
00131ts7
Fig.12.Testfuelpumpforcurrentdrawbyattadhingammeterand
jumperwireasshown.
CAUTION-
Donotallowthetestleadstoshorttoground.
NOTE-
See600ElectricalSystem-Generalforinformation
onelectricaltestsusingadigitalmultimeter(DMM).
4.RunpumpasdescribedinOperatingfuelpumpfor
tests.
FUELPUMP
5.Compareammeterreadingwithspecificationlistedin
Tableb.
Maximumcurrent

5.0amps
consumption
FuelDeliveryTests
Tableb.FuelPumpCurrent
Checkingfueldeliveryisafundamentalpartoftrouble-
shootinganddiagnosingtheDMEsystem.Fuelpressuredi-
rectlyinfluencesfueldelivery.Anaccuratefuelpressure
gaugewillbeneededtomakethetests.
Therearethreesignificantfueldeliveryvaluestobemea-
sured:
"Systempressure-createdbythefuelpumpandmain-
tainedbythepressureregulator.
"Fueldeliveryvolume-created bythefuelpumpandaf-
fectedbyrestrictions,suchascloggedfuelfilter.
"Residualpressure-thepressuremaintainedinthe
closedsystemaftertheengineandfuelpumpareshut
off.
Proceduresformeasuringthefirsttwoquantitiesarede-
scribedhere.
Residualfuelpressureischeckedusingtheprocedurede-
tailedin130FuelInjection.
Relievingfuelpressureandconnecting
fuelpressuregauge
WARNING -
"Gasolineishighlyflammableanditsvaporsare
explosive.Donotsmokeorworkonacarnear
heatersorotherfirehazardswhendiagnosing
andrepairingfuelsystemproblems.Haveafire
extinguisheravailableincaseofanemergency.
"Whenworkingonanopenfuelsystem,wearsuit-
ablehandprotection.Prolongedcontactwithfuel
cancauseiflnessesandskindisorders.
CAUTION-
Cleanlinessisessentialwhenworkingwithfuel
circuitcomponents.Thoroughlycleantheunions
beforedisconnectingfuelfines
Topreventfuelfromsprayingonahotengine,systemfuel
pressureshouldberelievedbeforedisconnectingfuellines.
Onemethodistotightlywrapashoptowelaroundafuellinefit-
tingandloosenordisconnectthefitting.
Measuringfuelpressurerequiresspecialtools.Earliercars
usepressurehosewithclampsforfueldelivery.Thesecanbe
attachedtoafuelpressuregaugebelowtheintakemanifold.

NOTE-

NOTE-
On1996andlater4-cylindercars,useBMWspecial

"UseBMWpressuregaugePartNo.133060,oran
tool136051(hosewithquickreleasecoupling)toat-

equivalent.Thefuelpressuregaugeshouldhavea
tachpressuregaugetoShraedervalvefittingontopof

rangeof0to5bar(0to75psi)andmustbesecurely
theM44fuelrail.SeeFig.13.

connectedtopreventitfromcominglooseunderpres-
sure.
u012503a
Fig.13.FuelrailshowinglocationofShradervalvefittingonM44en-
gine(arrow).
Latermodel6-cylinderfuelsystemsrequireBMWspecíal
tool161050toreleasefittingsandconnectthefuelgauge.
SeeFig.14.
0012699
Fig.14.FuellinesatrearofíntakemanifoldonM52engine.UseBMW
specialtool161050toreleasefittings.
Ifthespecialtoolsarenotavailable,alengthoffuellineand
aT-fittingcanbeinstalledtotheinletfuellineandconnected
toafuelgauge.
FUELTANKANDFUELPUMP

160-9
"Oncarswith6-cylinderengine,thetopleft-sideen-
Binecoverwillhavetoberemovedtoaccessthefuel
rail.
Systempressure,testing
Systempressureisthepressurecreatedbythefuelpump
andmaintainedbythepressureregulator.SeeFig.15.Sys-
tempressureisnotadjustable.
1.Removefueltankfillercap.
Fig.15.Fuelpressureregulator.Fuelpressuredeflectsdiaphragmto
retumfueltotankwhenpressurereachesdesiredlimit.
CAUTION-
Thefuelpumpiscapableofdevelopingahigher
pressurethanthatregulatedbythepressurereg-
ulator.Intheeventthefuelpumpcheckvalveis
faulty(stuckclosed),makesurethefuelpressure
doesnotriseaboye6.0bar(87psi).Damageto
thefuelfinesorfuelsystemcomponentscouldre-
sult.
2.Connectin-fineaTfittingandfuelpressuregaugeto
outlethoseatfuelpump.
FUELPUMP

160-10

FUELTANKANDFUELPUMP
3.OperatefuelpumpasdescribedearlierunderOperat-
ingfuelpumpfortests.Checkthatfuelpressurecor-
respondstospecificationslistedinTablec.
"Ifsystempressureislow,repeattestwhilegradually
pinchingoffreturnhose.Pressureshouldriserapidly.
Ifnot,fuelpumpismostlikelyfaulty.
"Ifsystempressureistoohigh,checkreturnlinefrom
pressureregulatortotank.Checkforkinksinhose.
Blowcompressedairthroughlinetocheckforblock-
ages.Ifnofaultycanbefound,pressureregulatoris
mostlikelyfaulty.See130FuelInjectionfortesting
andreplacementprocedures.
Tablec.FuelPressureSpecifications
Engine

1Fuelpressure
4-cylinder
M42/M44

3.0:e0.06bar(43.5±0.9psi)
6-cylinder
M50/S50US

3.0:j-0.06bar(43.5t0.9psi)
M52/S52US

3.5t0.06bar(51t0.9psi)
CAUTION-
Donotusecompressedairabove40psitoblow
outfinesorcomponents.Interna¡damagetocom-
ponentsmayresult.
4.Whenfinished,disconnectpressuregauge.
FUELPUMP
Fueldeliveryvolume,testing
1.Disconnectreturnlinefromfuelrailinenginecompart-
ment.
2.Connectalengthofhosetofittingonfuelrailandplace
openendofhoseinasuitablecontainerforcatching
fuel(2-quartcapacity).
3.Runfuelpumpforexactly30secondsasdescribed
earlierunderOperatingfuelpumpfortestsandmea-
surefuelcollected.RefertoTabled.
WARNING-

Tabled.FuelPumpDeliverySpecifications
Fuelunderpressureispresentduringthetest.UseI

Engine

Deliveryrate(30seconds@12V)
hoseclampsatallconnections.
4-cylinder
M42/M44

0.875fter(0.93qt)
6-cylinder
M50/S50US

0.875fter(0.93qt)
M52/S52US

~

1.12liter(1.16qt)
4.Whenfinishedtesting,reconnectfuelline.Tightenall
hoseclamps.
NOTE-
Itiscommonpracticetoreplacethefuelfilteranytime
thefuelpumpunitisreplaced.

170RadiatorandCoolingSystem
GENERAL............................170-1
CoolantPumpandThermostat............170-1
RadiatorandExpansionTank.............170-1
CoolingFans..........................170-2
WarningsandCautions..................170-2
TROUBLESHOOTING..................170-2
CoolingSystemPressureTest............170-3
ThermostatQuickCheck................170-3
TemperatureGaugeQuickCheck.........170-3
Coolingfan,testing.....................170-4
COOLINGSYSTEMSERVICE..........170-5
Coolant,drainingandfilling...............170-5
Coolingsystem,bleeding
(radiatorwithintegralexpansiontank).....170-6
GENERAL
Thissectioncoversrepairandtroubleshootinginformation
fortheenginecoolingsystem.Forheatercoreandrelated
heatingandairconditioningcomponents,see640Heating
andAirConditioning.
CoolantPumpandThermostat
Acentrifuga¡-typecoolantpumpismountedtothefrontof
theengíne.Thebelt-drivenpumpcirculatescoolantthrough
thesystemwhenevertheengíneisrunning.Athermostatcon-
trolstheflowofcoolantintotheradiator.
Whentheengíneiscoldthethermostatisclosedsocoolant
bypassestheradiator,recirculatingfromtheengínedirectly
backtothepump.Whentheengínereachesoperatingtem-
perature,thethermostatopensandcoolantcirculatesthrough
thewholesystemincludingtheradiator.
RadiatorandExpansionTank
Theradiatorisacrossflowdesign.Atranslucentexpansion
tankprovidesforcoolantexpansionathighertemperaturesand
easymonitoringofthecoolantleve¡.
On4-cylindermodeis,theradiatorexpansiontankisintegral
withtheradiator.SeeFig.1.
RADIATORANDCOOLING SYSTEM

170-1
Belt-drivencoolingfan,replacing...........170-7
Electriccoolingfan,replacing.............170-8
Auxiliarycoolingfan,replacing............170-8
Thermostat,replacing...................170-9
Coolantpump,replacing................170-10
RADIATORSERVICE..................170-11
Radiator,removingandinstalling..........170-11
TABLES
a.CoolantTemperatureSensorWireColors........170-3
b.AuxiliaryCoolingFanSwitchingTemperatures.:..170-4
c.AuxiliaryCoolingFanTemperature
SwitchTests..............................170-5
d.CoolingSystemCapacities...................170-6
A.Expansiontank

C.Dualtemperaturefanswitch
B.Radiatordrainscrew
Fig.1.Radiatorassemblywithintegralexpansiontank(4-cylinder
engine).
On6-cylindermodels,astandaloneexpansiontankisused.
Oncarswithautomatictransmission,ATFiscirculated
throughanadditionalheatexchanger(ATFcooler).
GENERAL

170-2

RADIATORANDCOOLING SYSTEM
CoolingFans

TROUBLESHOOTING
Belt-drivencoolingfan.Theprimarycoolingfanisbelt-
driven.Itismountedtothefrontofthecoolantpumpthrougha
fanclutch.Thefanclutchisaviscousfluidcouplingthatcon-
trolsthespeedofthefanbasedonenginecompartmenttem-
perature.
Electriccoolingfan.ModelswithM44engineandstan-
dardtransmissionsubstituteanelectricfanforthebelt-driven
viscousfan.Thisisattachedtotherearoftheradiatorand
controlledviatheDME5.2enginemanagementsystem.
NOTE-
Theelectriccoolingfaninthesemodelsisactivatedby
theenginecontrolmodule(ECM).
Auxiliarycoolingfan.Inal¡modelsatwo-speedelectric
auxiliarycoolingfanismountedbehindthefrontgrillandin
frontoftheradiator.ThisfanisprimarilyusedfortheA/Csys-
tem,butalsooperateswhenthecoolanttemperatureex-
ceedsapredeterminedleve¡.
WarningsandCautions
ThefollowingwarningsandCautionsshouldbeobserved
whenworkingonthecoolingsystem.
WARNING -
"Atnormaloperatingtemperaturethecoolingsys-
temispressurized.Allowthesystemtocoolas
longaspossiblebeforeopening-aminimumof
anhour-thenreleasethecapslowlytoallow
salereleaseofpressure.
"Releasingthecoolingsystempressurelowers
thecoolantsboilingpointandthecoolantmay
boílsuddenly.Useheavyglovesandweareye
andlaceprotectiontoguardagainstscalding.
"Useextremecarewhendraininganddisposingof
enginecoolant.Coolantispoisonousandlethal
tohumansandpets.Petsareattractedtocoolant
becauseofitssweetsmellandtaste.Consulta
veterinarianimmediatelyifcoolantisingestedby
ananimal.
CAUTION-
"Avoidaddingcoldwatertothecoolantwhilethe
engineishotoroverheated.Ifitisnecessaryto
addcoolanttoahotsystem,dosoonlywiththe
enginerunningandcoolantpumptuming.
"Priortodisconnectingthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
TROUBLESHOOTING
Mostcoolingsystemfaultscanbegroupedintooneofthree
categories:
"Coolingsystemleaks
"Poorcoolantcirculation
"Radiatorcoolingfanfaults
Wheninvestigatingthecauseofoverheatingorcoolant
loss,beginwithavisualinspection.Besuretocheckthecon-
ditionandtensionofthecoolantpumpdrivebelt.Checkhoses
forcracksorsoftness.Checkclampsforlooseness.Check
thecoolantleve¡andcheckforevidenceofcoolantleaksfrom
theengine.
Checkthattheradiatorfinsarenotblockedwithdirtorde-
bris.Cleantheradiatorusinglow-pressurewaterorcom-
pressedair.Blowoutward,fromtheenginesideout.
Inspectthecoolantpumpbyfirstremovingthedrivebelt
fromthepump.Firmlygraspoppositesídesofthepulleyand
checkforplayinalldirections.Spinthepulleyandcheckthat
theshaftrunssmoothly.
NOTE-
Thecoolantprovideslubricationforthepumpshaft,so
anoccasionaldropofcoolantleakingfromthepumpis
acceptable.Ifcoolantdripssteadilyfromtheventhole,
thepumpshouldbereplaced.
Thecoolingsystembecomespressurizedatnormaloperat-
ingtemperature,whichraisestheboilingpointofthecoolant.
Leaksmaypreventthesystemfrombecomingpressurized,
allowingthecoolanttoboilatalowertemperature.Ifvisualev-
idenceisinconclusive,acoolingsystempressuretestcan
helptopinpointhard-to-findleaks.
Ifthecoolingsystemisfullofcoolantandholdspressure,
thenextmostprobablecauseofoverheatingare:
"Faultyradiatorfan
"Looseorworndrivebelt
"Failedthermostatorcoolantpump
"Clogged/pluggedradiatororcoolantpassages.
NOTE-
"Someearlystylecoolantpumpswerefittedwíthfi-
berlplastictypeimpellers.Overtime,thisimpellercan
wearawayandresultinoverheating.Theplasticim-
pellercanalsosliporfree-wheelonthepumpshaft.If
theengineoverheatsandnootherfaultscanbe
found,theoldstyleimpellermaybethecauseofthe
problem.
"Onlypumpswiththeupdatedmetalimpellershould
beusedforreplacement.

CoolingSystemPressureTest

Iftheengineoverheatsandnoothercoolingsystemtests
indicatetrouble,theradiatormayhavesomepluggedpassag-
Acoolingsystempressuretestisusedtocheckforinternal

esthatarerestrictingcoolantflow.
leaks.Someofthecommonsourcesofinternalleaksarea
faultycylinderheadgasket,acrackedcylinderhead,ora

TemperatureGaugeQuickCheck
crackedcylinderblock.
Thecoolanttemperaturesensorislocatedontheintake
Todoacoolingsystempressuretest,aspecialpressure

manifold(left)sideofthecylinderhead,undertheintakeman-
testerisneeded.

ifoldrunners.SeeFig.2.
WARNING -
Atnormaloperatingtemperature-thecoolingsys-
temispressurized.Allowthesystemtocoolbefore
opening.Releasethecapslowlytoallowsalere-
teaseofpressure.
Withtheenginecold,instanapressuretestertotheexpan-
siontank.Pressurizethesystemtothespecificationlistedbe-
low.Pressureshouldnotdropmorethan0.1bar(1.45psi)for
atleakttwominutes.Ifthepressuredropsrapidlyandthereis
nosignofanexterna¡leak,thecylinderheadgasketmaybe
faulty.Consideracompressiontestasdescribedin100En-
gine-General.
Thescrew-ontypeexpansiontankcapshouldalsobetest-
edusingapressuretesterandthecorrectadapter.
CoolingSystemTestPressure
"Radiatortestpressure..........1.5bar(21.75psi)
"Radiatorcaptestpressure...........2bar(29psi)
CAUTION-
Exceedingthespeclfiedtestpressurecoulddam-
agetheradiatororothersystemcomponents.
Carefullyinspecttheradiatorcapfordamage.Replacea
faultycaporadamagedcapgasket.
ThermostatQuickCheck

Inlatermodels,theECTsensorandthegaugesenderare
combinedintoonesenderunit.ForwirecolorsrefertoTablea.
Tocheckifthethermostatisopeningandcoolantiscirculat-
ingthroughtheradiator,allowacoldenginetoreachoperat-
ingtemperature(temperaturegaugeneedieapproximately
centered).Shutoffengine.Feelthetopradiatorhose.Ifthe
hoseishottothetouch,thecoolantisprobablycirculatingcor-
rectly.Ifthereareanycoolareasinthehoseorradiator,cool-
antflowtotheradiatorisprobablyrestricted.Checkforafaulty
thermostatorapluggedradiator.
NOTE-
Athermostatthatisstuckopenwillcausetheengineto
warmupslowlyandrunbelownormaltemperatureat
highwayspeed.Athermostatthatisstuckclosedwillre-
strictcoolantflowtotheradiatorandcauseoverheating.
RADIATORANDCOOLING SYSTEM

170-3
U.¡ig.v
Fig.2.TemperaturegaugesenderonM44engine.Temperature
gaugesenderlocationissimilaronal]engines.
Inearlymodels,theenginecoolanttemperature(ECT)sen-
sorforthefuelinjectionandthecoolanttemperaturegauge
senderarelocatedsidebyside.
Tablea.CoolantTemperatureSensorWireColors
Function

Sensor

Terminal

Wirecolors
locationnumber
Twosensors:
Temperature Rear 1 Brown/violet
gaugesender

2

Brown/yellow
ECTsensor

Front

1

Brown/red
2

Brownor
Brown/black
Onesensor:
Temperature Dual 1 Brown/yellow
gaugesender

sensor

2

Brown/violet
ECTsensor

3

Brown/red
4 Brown/black
orGrey/black
TROUBLESHOOTING

170-4

RADIATORANDCOOLING SYSTEM
Aquicktestatthecoolanttemperaturegaugesendercan

Theauxiliarycoolingfancomesonwhencoolanttempera
determineifthegaugeisfunctioningcorrectly.

tureexceedsapredeterminedleve¡orwhenevertheaircondi-
tioningison.Adual-rangetemperatureswitchforcoolingfan
lfthegaugeneedieremainsattherestpositionwiththeen-

controlismountedontherightsideoftheradiator.SeeFig.3.
ginewarm,removetheharnessconnectorfromthesender
andjumperthecorrectterminalsintheconnectortosimulate
ahighenginetemperature.SeeTablea.Turntheignitionon.
Ifthegaugeneedlemovesupward,thesenderisfaulty.Ifthe
gaugedoesnotrespond,thewiringtothegaugeisbroken
(opencircuit)orthegaugeitselfisfaulty.
WARNING-
1996andlatenmodelsareOBD11compliant.Dis-
connectingelectricalconnectorswíththeignition
turnedonmaysetfaultcodesintheECM.Itisrec-
ommendedthatyouleavethediagnosisoffaultsin
thecoolanttemperaturesensorsystemtotheBMW
dealerservicedepartmentwhichhasspecialized
OBD11scantoolequipment.
Ifthegaugeneedlereadstoohighwhentheengineiscold,
removetheharnessconnectorfromthesender.Turntheigni-
tionon.lfthegaugeneedlepositiondoesnotchange,thewir-
ingorthegaugeisshortedtoground.Ifthegaugeneedle
drops,thesenderisfaultyandshouldbereplaced.Whenre-
placingafaultycoolanttemperaturesender,thegasketring
onthesendershouldalsobereplaced.
TighteningTorque
"Temperaturegaugesendertoengine18Nm(13ft-Ib)
Coolingfan,testing
NOTE-
OnM44engineswithmanualtransmission,theprimary
electriccoolingfanismountedontheenginesideofthe
radiatorandiscontrolledbytheenginecontrolmodule
(ECM).Troubleshootingthiscircuitshouldbelefttoan
authorizedBMWdealerwiththeproperdiagnostic
equipment
Anotherwisesoundcoolingsystemmaystilloverheat,par-
ticularlywithprolongedidling,duetoafailureofthecoolíng
fan(s).
Thebelt-drivencoolingfaniscontrolledbyatemperature
dependentviscousclutch.Afailedfanclutchmayaffectair
flowthroughtheradiatorresultinginoverheatingorpossibly
overcooling.
Speed
Lowsp
Highs
Withtheengineoff,checkthefanclutchbyspinningthefan.

eed
Thefanshouldspinontheclutchwithsomeresistance.

peed
Checkforsignsofleakingfluidfromtheclutch.Ifthefanfree-
wheelswithnoresistance,cannotbeturnedbyhand,orthere
aresignsofoilleakage,theclutchshouldbereplaced.
TROUBLESHOOTING
Fig.3.

Radiatorcoolingfantemperatureswitch(arrow).
WARNING-
"Usecautionwhentestingtheelectriccooling
fan(s)andcoolanttemperatureswitch.Keep
handsandwiresclearofthefanblades.Thecool-
ingfan(s)canrunanytimetheignitionisON.
"Forgreatestsafety,coolíngfanandcoolanttem-
peratureswitchtestsshouldbeperformedona
coldenginewiththeairconditioningoff.
Tableb.AuxiliaryCoolingFanSwitching
Temperatures
Switchingtemperature
196°F(91°C)
210°F(99°C)
0012506
Ifafaultythermostat,trappedair,orarestrictioninthesys-
temisnotallowingthecoolanttocirculatethroughtheradia-
tor,thetemperatureswitchwillnotcloseandtheauxiliary
coolingfanwillnotrun.Beforemakingthetestsdescribedbe-
low,makesurethethermostatisoperatingcorrectlyasde-
scribedearlier.Thenormalswitchingtemperaturesforthe
dual-speedswitcharelistedinTableb.

NOTE-
Somecarscoveredbythismanualmayhaveanalter-
natecoolingfanswitchwithswitchingtemperaturesof
176%190W(80%88°C).Whenreplacingtheswitch
checktheswitchingspecifications,whichshouldbe
stampedontheswitchbody.
1.Ifcoolantiscirculatingatnormaloperatingtempera-
ture,butauxiliarycoolingfandoesnotrun,disconnect
connectorfromradiatortemperatureswitchandmake
testslistedinTablec.
Tablec.AuxiliaryCoolingFanTemperature
SwitchTests
Wiresjumpered

Test

Testresuits
conditions
Black/green(terminal2)and

IgnitionON

Fanrunson
brown(terminal1)

lowspeed
Black/gray(terminal3)and

IgnitionON

Fanrunson
brown(terminal

I
1)

highspeed
2.Iffanrunsonlywhenpowereddirectlybyjumpered
connectorandhotcoolantiscirculatingthroughradia-
tor,radiatortemperatureswitchismostlikelyfaulty.Use
anewsealingringwhenreplacingswitch
TighteningTorque
"Temperatureswitchtoradiator......15Nm(11ft-Ib)
3.Ifauxiliaryfandoesnotrunwhenpowereddirectly,
checkforbatteryvoltageattemperatureswitchconnec-
tor(black/greenwire)withignitionon.Ifbatteryvoltage
isnotpresent,checkfuses.See610ElectricalCom-
ponentLocations.
RADIATORANDCOOLINGSYSTEM

170-5
~r~nmma
0
0
0
Fig.4.

Auxiliaryradiatorcoolingfanlowspeedrelay(1)andhigh
speedrelay(2)inpowerdistributionbox.(Relaylocationsmay
vary.)
AuxiliaryCoolingFanCircuitFuses

Fig.5.Auxiliaryradiatorfanresistor(arrow).
"Fuse16...............................5amp
"Fuse41(ex.M44w/man.trans)...........30amp
"Fuse48(M44w/man.trans.only)..........40amp

COOLINGSYSTEMSERVICE
0013034
4.Ifnofaultsarefound,removelowspeedrelayandturn

Coolant,drainingandfilling
ignitionON.SeeFig.4.

1.Removeexpansiontankcap.Settemperaturecontrols
"Checkforpoweratterminal30andterminal86ofrelay

tofullwarm.
socket.
"Reinstalllowspeedrelayandrepeattestathighspeed

WARNING -
relaysocket.Fixanywiringfaultsfound.

Allowthecoolingsystemtocoolbeforeopenlngor
Onearlyproductioncars(upto9/92):Iffanoperatesonlyon

drainingthecoolingsystem.
highspeedandnoelectricalfaultshavebeenfounduptothis
point,useanohmmetertocheckthatfanresistorisnotelectri-

2.Place3raallo
ug.

beneathradiatordrainplugandre-
callyopen.Resistorismountedonauxiliarycoolingfanhousing

movedrainplg.SeeFig.6.
behindfrontgrille.SeeFig.5.Wiringdiagramsfortheradiator
coolingfancanbefoundunderElectricalWiringDiagrams.

3.Place3-g

pailbeneathrearofengineblo.Loos-
enandre
mlon
oveengineblockcoolantdrainplug
k
.
COOLINGSYSTEMSERVICE

170-6

RADIATORANDCOOLING SYSTEM
Fig.6.

Radiatordrainplug(arrow).
WARNING -
Coolantispoisonous.Itisespeciallylethaltopets.
Cleanupspillsimmediatelyandrinsetheareawith
water.
NOTE-
Theblockdrainplugislocatedontheexhaustsideof
theengine,nearthereasoftheengine.
4.Reinstallradiatorandengineblockdrainplugsusing
newsealingwashers.Leaveheatercontroisonfull
warm.
5.Usingacoolantmixtureof50%antifreezeand50%dis-
tilledwater,fillsystemslowlyOnradiatorwithintegral
expansiontank,bleedcoolingsystemasdescribedbe-
low.
NOTE-
"Tapwatermaycausecorrosionofradiator,engine
andcoolanthoses.
"Coolantcanoftenbereusedprovideditiscleanand
lessthantwoyearsold.Donotreusecoolantwhenre-
placingdamagedengineparts.Contaminatedcoolant
maydamagetheengineorcoolingsystem.
Tabled.CoolingSystemCapacities
Engine

jCapacity
4-cylinder

16.5liters(6.9qt)
6-cylinder
M50/M52

10liters(10.6qt)
S50US/S52US

10.5liters(11.1qt)
COOLINGSYSTEMSERVICE
TightehingTorques
"Radiatordrainplugtoradiator...2-3Nm(18-27in-lb)
"Engineblockdrainplugtoblock

....25Nm(18ft-Ib)
Coolingsystem,bleeding
(radiatorwithintegralexpansiontank)
NOTE-
Onradiatorswithaseparateexpansiontank,ableed
screwisnotprovided.Thecoolingsystemwithsepa-
rateexpansiontankisselfbleedingviatheventhose
ontheexpansiontank.
Airmaybecometrappedinthesystemduringfilling.
Trappedaircanpreventpropercoolantcirculation.Whenever
thecoolantisdrainedandfilled,thesystemshouldbebledof
trappedair.
1.Withenginecold,addcoolanttoexpansiontankuntil
levelreachesCOLD(KALT)markontank.
2.Loosenbleedscrewonradiatorexpansiontank.See
Fig.7.
0011976
Fig.7.

Coolingsystembleedscrewonradiator(arrow).Notecold
levelmarkonexpansiontank.
3.M3models:Loosenbleedscrewonthermostathous-
ing.
4.Settemperaturecontrolsinpassengercompartmentto
fui¡warmandturnignitiononposition(donotstarten-
gine).

5.Slowlyaddcoolantuntilitspillsfrombleedscrews.
Whencoolantspillíngfrombleedscrewsisfreeofair
bubbies,tightenscrews.
6.Runengineuntilitreachesoperatíngtemperature.Af-
terenginehascooled,recheckcoolantlevelandtopup
asnecessary.
CAUTION-
AlwaysusegenuineBMWcoolantoritsequiva-
lenttoavoidtheformationofharmful,cloggingde-
positsinthecoolingsystem.Useofother
antifreezesolutionsmaybeharmfultothecooling
system.
TighteningTorque
"Radiatorbleedscrew
tothermostathousing.............8Nm(71in-lb)
Belt-drivencoolingfan,replacing
1.Usinga32mmwrenchonfanclutchnut,turnwrench
quicklyinaclockwisedirection(workingfromfrontof
car)toloosen.Spinfanoffpump.SeeFig.8.
NOTE-
"Theradiatorcoolingfannut(32mmwrench)hasleft-
handthreads.
"Thenutmaybedifficulttoloosen.Useatooltohold
thecoolantpumppulleystationary.BMWhasaspe-
cialtoolforthispurpose(BMWspecialtoolno.115
030).
2.Removeexpansionrivetsholdingshroudtoradiator.
SeeFig.9.Removefanandshroudtogether.
NOTE-
Storetheremovedfanclutchassemblyinanupright
(installed)positiontopreventlossofclutchfluid.
RADIATORANDCOOLING SYSTEM

170-7
Fig.8.

Radiatorcoolingfannut(arrow).Nuthasleft-handthreads.
3.Toreplacefanclutch,removefanmountingboltsand
separateclutchfromfan.
Fig.9.

Fanshroudretainingrivet(arrow).Pryoutcenterpinandre
4.Installationisreverseofrernoval.

moverivet.Rivetdesignmayvarydependingonmodeland
modelyear.
TighteningTorques
"Clutchnuttocoolantpump(left-handthreads)
WíthoutBMWtoolno.115040.....40Nm(29ft-lb)
WithBMWtoolno.115040.......30Nm(22ft-Ib)
"Fantoviscousclutch.............10Nm(89in-lb)
0013203
COOLINGSYSTEMSERVICE

170-8

RADIATORANDCOOLING SYSTEM
Electriccoolingfan,replacing
Onlate4-cylindermodels(M44engine)withmanualtrans-
mission,theprimarycoolingfaniselectricallyoperatedandis
mountedontheenginesideoftheradiator.
1.Ifnecessary,removecoverfromtopofradiator.See
Fig.10.
0012505
Fig.10.Aircoverinbackofradiator.Unclipcoverfromfanshroudaf-
terremovingmountingscrews.
2.Disconnectfanharnessconnectoratbottomleftofra-
diator.
3.Removefanshroudmountingscrewsatleftandright
sideofradiator.Liftfanassemblystraightupandoffra-
diator.
4.Installationisreverseofremoval.Besuretoalignside
tabsonfanhousíngwithretainingtabsonradiator
whenreinstallingfan.
Auxiliarycoolingfan,replacing
Theauxiliaryelectriccoolingfanismountedbehindthe
frontbumper,infrontoftheA/Ccondenser.Therearetwover-
sionsofauxiliaryfansinstalled,dependingonmodelanden-
gineinstalled.
TType1(upto9192)
1.Removefrontradiatorairshroud.SeeFig.11.
2.Removefanmountingscrews.SeeFig.12.
3.Tiltfanforward.Disconnectelectricalharnessconnec-
torbeforeliftingfanup.
COOLINGSYSTEMSERVICE
Fig.11.Frontradiatorairshroudfasteners(arrows).
Fig.12.Version1auxiliaryfanmountingscrews(arrows).
NOTE-
Ifnecessary,removefrontbumperorlowerenginecov-
ertoaccesselectricalharnessconnector.
4.Installationisreverseofremoval.
l)Type2(from9192)
2.Removefanmountingscrews.SeeFig.13.
0013137
1.Removefrontbumperandradiatorgrilles.See510Ex-
teriorTrim,Bumpers.
3.Anglefanupandforward,disconnectingelectricalhar-
nessconnectorbehindit.Removeitthroughbumper
opening.

Fig.13.Version2auxiliaryfanmountingscrews(arrows).Front
bumperhasbeenremoved.
4.Installationisreverseofremoval.
Thermostat,replacing
0013146
Thecoolantthermostatisinstaliedinahousingatthefront
ofthecylinderhead.SeeFig.14.
Fig.14.Coolantthermostatandhousíng.
NOTE-
OnM44engines,thethermostatisintegratedintothe
thermostathousíng.Ifthethermostatrequiresreplace-
ment,thecompletethermostathousingmustbereplaced.
RADIATORANDCOOLING SYSTEM

170-9
WARNING -
Allowthecoolingsystemtocoolbeforeopeningor
drainingthesystem.
2.Removebelt-drivencoolingfanandfanshroudasde-
scribedearlier.
3.OnM52/S52USengines:Unclipwiringductretaining
clipsandremoveductfromabovethermostathousing.
Alsoremoveenginefrontliftingbracket.
4.Removethermostathousingfromfrontofengine.See
Fig.15.
Fig.15.Thermostathousíngshownremoved(6-cylinderengine).
NOTE-
Somethermostatshaveadirectionarroworventhole
neartheedge.Installthethermostatsothateitherthe
arroworholeareatthetop.
CAUTION-
Besuretoreconnectgroundwire(s)atthermostat
housingmountingbolt,whereapplicable.
5.Removethermostat.Notethermostatdirectionandori-
entationbeforeremoving.
6.Insta¡¡newthermostatand/orthermostathousingusing
newO-ringandgasket(s)asnecessary.
oo131ss

7.Installationisreverseofremoval.Fillsystemwithcool-
antasdescribedunderCoolant,drainingandfilling.
TighteningTorques
1.DrainradiatorasdescribedaboveunderCoolant,

"Thermostathousingcover
drainingandfilling.

tohousingorcoolantpump........10Nm(89in-lb)
"Engineliftingbracketbolttothermostathousing
(M52/S52USengine)(M8).........22Nm(17ft-Ib)
COOLINGSYSTEMSERVICE

170-10

RADIATORANDCOOLINGSYSTEM
Coolantpump,replacing
Theenginecoolantpumpismountedinthefrontoftheen-
gineonthetimingcover.SeeFig.16.
Fig.16.Coolantpumpmountedontimingcover.
NOTE-
Onlyreplacementcoolantpumpswithmetal¡mpellers
shouldbeinstalled.Pumpswithplasticimpellers
shouldnotbeused.
1.Draincoolingsystemasdescribedearlier.
0013197
WARNING -
Allowcool¡ngsystemtocoolbeforeopen¡ngor
drain¡ngsystem.
2.Removeprimarycoolingfanshroudandcoolingfan
(belt-drivenorelectric)asdescribedearlier.
Fig.17.EnginedrivebelttensionerbeingreleasedonM44engine.Pry
offtensionercoverandthenlevertensionerincounterciock-
wisedirection(asfacingengine)andslipbeltoffpulleys.
Fig.18.DrivebelttensionerbeingreleasedonM52engine.Pryoff
3.Disconnecthosesfromthermostathousing.Unbolt

tensionercoverandthenlevertensionerclockwise(asfacing
thermostathousingfromfrontofcylinderhead.

engine)toreleasebelttension.
4.Removecoolantpumpdrivebelt.SeeFig.17orFig.
18.
NOTE-
-Markdirectionofdrivebeltrotationifreusingbelt.

"The6-cylindercoolantpump¡smountedonstudsand
retainedbynuts.
"Severa¡drivebeltandtensionerconfigurationshave
beenusedinE36models.Referto020Maintenance
Programand640HeatingandAirConditioning.
5.Removecoolantpumppulleyfrompump.
6.Removemountingfastenersfrompump.
COOLINGSYSTEMSERVICE
NOTE-
"The4-cylindercoolantpump¡smountedus¡ngtwodif-
terentlengthbolts.Notewherethelongerboltfitsdur-
ingdisassembly.
0011989
7.Inserttwoscrews(M6)intappedboresandtightenuni-
formlyuntilpumpisfreefromtimingchaincover.See
Fig.19.

Fig.19.Coolantpumpbeingremoved.ThreadtwoM6bolts(arrows)
inevenlytowithdrawpump.(Thermostatandhoseshave
beenremovedtorvisualaccess.)
8.Installationisreverseofremoval.
"BesuretoreplaceO-ringandgaskets.
"CoatO-ringwithlubricantduringinstallation.
TighteningTorque
"Coolantpumptotimingchaincover
M6...........................10Nm(89in-lb)
M8...........................22Nm(17ft-Ib)
"Coolantpumppulley
tocoolantpump.................10Nm(89in-lb)
RADIATORSERVICE
Radiator,removingandinstalling
1.Drainradiatorasdescribedearlier.
WARNING -
Allowcoolingsystemtocoolbeforeopeningor
drainingsystem.
2.Removeprimarycoolingfan(belt-drivenorelectric)as
describedearlier.
3.Disconnectcoolingfanandleve¡sensorharnesscon-
nectorsfrombottomofradiator,whereapplicable
4.Disconnectharnessconnectorfromauxiliaryfandual
temperatureswitch.SeeFig.20.
5.Disconnectallcoolanthosesfromradiator.
RADIATORANDCOOLING SYSTEM

170-11
0012500
Fig.20.Coolingfandualtemperaturaswitch(arrow)onrightsidoof
radiator.
6.Whereapplicable,disconnectautomatictransmission
fluid(ATF)coolerlinesfromradiator.SeeFig.21.
Fig.21.Automatictransmissionfluid(ATF)linosatradiator.
7.Carefullypryoutradiatorretainingclipsfromtopofra-
diator.SeeFig.22.
8.Pul¡radiatorupandoutofcar.
NOTE-
Theradiatorrestsontworubbermounts.Checkthat
themountsdonotsticktothebottomoftheradiator.
RADIATOR SERVICE

170-12

RADIATORANDCOOLING SYSTEM
Fig.22.Radiatorretainingclipbeingremoved.Pushdownandpulí
screwdriverforwardtoreleaseclip.
9.Installationisreverseofremoval.
"Fillradiatorandcoolingsystemasdescribedunder
Coolant,drainingandfilling.
"CheckATFleve¡and,ifnecessary,topup.See240Au-
tomaticTransmission.
RADIATORSERVICE

GENERAL............................180-1

Exhaustsystem,removingandinstalling.....180-3
EXHAUSTSYSTEMREPLACEMENT....180-1

Exhaustmanifolds,removingandinstalling...180-5
GENERAL
Theexhaustsystemisdesignedtobemaintenancefree,al-
thoughregularinspectioniswarrantedduetotheharshoper-
atingconditions.Undernormalconditions,thecatalytic
converterdoesnotrequirereplacementunlessitisdamaged.
On1996andlatercars,apre-andpost-catalyticconverter
oxygensensorisusedateachcatalyticconverter.Besureto
takecarewhenremovingthesystemnottodamagethesen-

EXHAUSTSYSTEMREPLACEMENT
sors.
See130FuelInjectionforinformationontestingoxygen
sensors.
NOTE-
OnM52engines,tworesonatorpípes(shortandlong)
areincorporatedintotherearmufflerassembly.See
Fíg.1.Anexhaustflapisintegratedintotheoutletside
oftheshortpipe.Theflapisoperatedbyavacuumac-
tuatorviatheSiemensMS41.1enginecontrolmod-
ule).Theflapisclosedatenginespeedsbelow2,500
rpm.Thisallowsexhaustgassestoflowthroughthe
longresonatorpipeandreducenoise.Above2,500
rpm,theexhaustflapisopen(novacuumappliedtothe
actuator)andallowsexhaustgassestoflowthrough
theshortpipeformaximumperformance.
180ExhaustSystem
0013101
Fig.1.

Rearmuffler(activesilencerusedonM52engines).Vacuum
operatedflap(A)changesbetweenshortandlongpipes,de-
pendingonenginespeed.
EXHAUSTSYSTEM

180-1
WARNING-
Exhaustgasesarecolorless,odorless,andvery
toxic.Runtheengineonlyínawell-ventilatedarea.
Immediatelyrepairanyleaksintheexhaustsystem
orstructuraldamagetothecarbodythatmightal-
lowexhaustgasestoenterthepassengercompart-
ment.
ExhaustsystemcomponentsaredetailedinFig.2through
Fig.4.
Newfasteners,clamps,rubbermounts,andgasketsshould
beusedwhenreplacingexhaustcomponents.Aliberalappli-
cationofpenetratingoiltotheexhaustsystemnutsandbolts
inadvancemaymakeremovaleasier.
WARNING-
"Theexhaustsystemandcatalyticconverterop-
erateathightemperatures.Allowcomponentsto
coolbeforeservicing.Wearprotectíveclothíngto
preventbums.Donotuseflammablechemicals
nearahotcatalyticconverter.
"Old,corrodedexhaustsystemcomponents
crumbleeasílyandoftenhaveexposedsharp
edges.Toavoidinjury,weareyeprotectionand
heavygloveswhenworkingwitholdexhaust
parts.
EXHAUSTSYSTEMREPLACEMENT
T

180-2

EXHAUSTSYSTEM
a
EXHAUST SYSTEMREPLACEMENT
Fig.2.

Exhaustsystemon1992-19956-cylinderengines.3251(M50)exhaustsystemshown.
E~
)l-,malo m~=
i
32592-95
1.

Frontpipewithcatalyticconvertor

6.

Bracket

11.

Bracket/clamp(2)

16.

Rearpipewithmuffler
2.

Gasket(2)

7.

Bracket(2)

12.

Rubbermountingring(2)

17.

Rubbermount
3.

Exhaustmanifold

8.

Bracket

13.

Flange

18.

Support
4.

Exhaustmanifold

9.

Bracket

14.

Gasket(48mm)

19.

Bracket
5.Manifoldgasket

10.Oxygensensor

15.Gasket(48mm)
eme°"

k :I>-8a
1.

Exhaustmanifold

7.

Frontpipewithcatalyticcon-

9.

Bolt(M8X90)

14.

Brackets(rearmuffier)
2.

Nut(M10)

vertor

10.

Compressionspring

15.

Rearmufflerandpipe
3.Gasket(clty.2)

8.

Oxygensensor(regulating)

11.

Self-lockingnut(M8

16.

Bracket(transmission)
4.Gasket

-tightento55Nm(41ft-Ib)

-alwaysreplace

17.

Brackets(transmission)
5.

Nut

8a.

Oxygensensor(monitoring)

12.

Bracket(rearpipe)
6.

Bolt(M8X55)

-tightento55Nm(41ft-Ib)

13.

Rubbermountingring
(9ty2)
Fig.3.

Exhaustsystemon1996-19984-cylinder(M44)engine.1992-19954-cylinderengineexhaustsystemissimilar.

1.

Gaskets

5.

Frontpipewithcatalyticcon-

8.

Flange
2.

Exhaustmanifold

verter

9.

Bolt(M8x55)
3.Exhaustmanifold

6.Oxygensensor(monitoring)

10.Rubbermountingring(48mm)
4.

Oxygensensor(regulating)

7.

Nut(M8)

11.

Rearpipewithmufflers
Fig.4.

Exhaustsystemon1996-19986-cylinderengines.M3(S50US)
exhaustsystemshown.
Exhaustsystem,removingandinstalling

NOTE-
Theautomatictransmissionwillbesupportedbythe
Thissectioncoversremovingtheexhaustsystemasacom-

rearcrossmemberoncethebraceisremoved.
pleteunit.Oncethesystemisremovedfromthecar,individual
pipesandmufflerscanbemoreeasilyreplaced.
1.Withexhaustsystemfullycold,raiseandsupportcar
foraccesstoexhaustsystem.
WARNING -
Donotworkunderaliftedcarunlessitissolidly
supportedonjackstandsdesignedforthatpur-
pose.Neverworkunderacarthatissupported
solelybyajack.
2.Disconnectoxygensensorconnector(s).
NOTE-
On1996andlatercarswithmultipleoxygensensors,
labeltheoxygensensorconnectorsbeforedisconnect-
ing.
4.Whereapplicable,removesupportbracefromtrans-
mission.SeeFig.5.
EXHAUSTSYSTEM

180-3
3.Loosenandremoveboltsholdingfrontexhaustpipesto
exhaustmanifolds.

transmission.SeeFig.6.
0011940
Fig.5.

Crossbracemountingbolts(arrows).
5.Disconnectexhaustsupportbracketassemblyfrom
6.Supportexhaustsystemfrombelowanddísconnect
rubbersupports/rubberringsfromexhaustsystem.Re-
moveexhaustsystemfrombelow.SeeFig.7.
EXHAUSTSYSTEMREPLACEMENT

180-4

EXHAUSTSYSTEM
Fig.6.

Exhaustsystemsupportbracketon6-cylinderengine.Re-
movebolts(arrows)toseparatefromexhaustpipe.
Fig.7.

Rubberexhaustsystemhangers.Removehangerbyprying
offbracket(arrows).
EXHAUSTSYSTEMREPLACEMENT
7.Installationisreverseofremoval.
"Wherenecessary,transferpartsfromoldsystemtore-
placementsystem.
"Coatmanifoldstudswithcopperpastebeforeinstalling
nuts.
"Whereapplicable,tightenfrontpípewithsemi-flexible
compensatorlastwheninstallingfrontpipetomani-
folds.
"Makesurethereisatleast20mm(3/4in.)ofclearance
betweenexhaustsystemandcarbodyateverypoint.
"Looselyinstallallexhaustsystemmountinghardware
andhangersbeforetighteningfastenerstotheirfinal
torque.
"On4-cylinderengines:Tightencentermountingflange
nutsevenlyuntilcorrectdimensionisobtained.See
Fig.8.
ri
J%JJ
w
~~~JJJJ
1
Fig.8.

On4-cylinderengines,tightennutsevenlysothatspríngsare
preloadedtoDimensionA.
NOTE-
Topreventexhaustsystemrattlesandvibration,pre-
loadtherearclampingbracketsintheíonaarddirection.
SeeFig.9.
0011937
TighteningTorques
"Crossbracetochassis

...........21Nm(17ft-Ib)
"Exhaustsupportbracket
totransmission................,.21Nm(17ft-Ib)
"Exhaustsystemmountingclamps...15Nm(11ft-Ib)
"Frontexhaustpipetoexhaustmanifold
M10nut.......................30Nm(22ft-Ib)
"Frontexhaustpipetorearpipe
M8bolt/nut.....................22Nm(16ft-Ib)
withcompressionspring................SeeFig.8
"Oxygensensortoexhaustpipe.....55Nm(41ft-Ib)

DimensionA=15mm(0.60in.)
Fig.9.

Preloadrearclampingbracketasspecifíedtohelpprevent
systemrattling.
Exhaustmanifolds,removingand
installing
WARNING -
Donotworkunderaliftedcarunfessitissolidly
supportedonjackstandsdesignedforthatpur-
pose.Neverworkunderacarthatissupported
solelybyajack.
EXHAUSTSYSTEM

180-5
2.On1996andlater6-cylinderengines,disconnectthe
secondaryaircheckvalveandeipefromtheexhaust
manifold.
3.Unboltfrontexhaustpipe(s)fromexhaustmanifold(s).
4.Removeexhaustsupportbracketfromtransmission.
5.Loosenandremovenutsfromexhaustmanifoldsand
removemanifolds.Discardnutsandgaskets.
NOTE-
Oncarswíthoxygensensorsmountedintheexhaust
manifolds,usecarewhenremovingmanifolds.Tobe
safe,removethesensorsfromthemanifoldsbeforere-
movingmanifolds.
6.Installationisreverseofremoval.
"Coatexhaustmanifoldmountingstudswithcopper
pastebeforeinstallingnewnuts.
"Insta¡¡manifoldgasketswitharchedsidefacingmani-
folds.
Alwaysusenewretainingnutsandgasketswhenremoving

TighteningTorques
andinstallingtheexhaustmanifolds.

"Exhaustmanifoldtocylinderhead
4-cylinderengine(M7nut)........15Nm(11ft-Ib)
1.Withexhaustsystemcold,raiseandsupportcarforac-

6-cylinderengine(M7nut)........20Nm(15ft-Ib)
cessloexhaustsystem.
EXHAUSTSYSTEMREPLACEMENT

GENERAL .............................
200-1
ManualTransmission...........'........
200-1
AutomaticTransmission.................200-1
TransmissionIDCodes..................200-2
GENERAL
E36modelsareequippedwithalongitudinaldrivetrain.The
transmissionisbolteddirectlytotherearoftheengine.A
driveshaftconnectstheoutputshaftofthetransmissiontothe
finaldrive.Thefinaldriveismountedlotherearsuspension
andthebody.Individualdriveaxleswithintegratedconstant
velocityjointstransferrotationalpowertotherearwheels.
ManualTransmission
Duetodifferentpowercharacteristicsandperformancere-
quirements,fourdifferentmanualtransmissionsareusedin
themodelscoveredbythismanual.Manualtransmissionap-
plicationsaregiveninTablea.
TRANSMISSION-GENERAL 200-1
200Transmission-General
TABLES
a.ManualTransmissionApplications.............200-1
b.AutomaticTransmissionApplications...........200-1
Fig.1.

ZF-manufacturedmanualtransmission.
Fortransmissiongearratioinformationandrepairinforma-
tion,see230ManualTransmission.

AutomaticTransmission
E36carswithstandardtransmissionuseasingle-disc
clutchwithdual-massflywheel.Forfurtherinformation,see
210Clutch.
Tablea.ManualTransmissionApplications
Model Year Engine Transmission
318ifisfC

1992-1995

M42

GetragS5D200G'
1996-1998

M44

GetragS5D250G
323is/iC

1998

M52

GetragS5D250G
325ifsriC

1992-1995

M50

GetragS5D250G
3281/isfC

1996-1998

M52

ZFS5D320Z
M3

1995

S50US

ZFS5D310Z
1996-1998

S52US

ZFS5D320Z
'The1992M42enginemaybefittedwitheithertheGetragSSD200Gtrans-
missionorS5D250Getrag.TheS5D200Gwasdiscontinuedinproductionin
asof9/92.ThistransmissionisinterchangeablewithGetragS5D250G.
Fourdifferentautomatictransmissionsareused,depend-
ingonmodelandmodelyearand/orproductiondate.Allofthe
automatictransmissionsareelectrohydraulicallycontrolled
witheitherfourorfiveforwardspeeds.Automatictransmis-
sionapplicationsaregiveninTableb.
Forautomatictransmissionrepairinformation,see240Au-
tomaticTransmission.
Tableb.AutomaticTransmissionApplications
Model 1 Year 1Engine 1Transmission
318i1is/1C

1992-1995~M42
323isfiC

1998

M52

A4S310R
3251/is/1C 1992-1995 M50
3181/isfC

11996-1998

M44

A4S270R
328i/is/1C 1996-1998 M52
M3

1996-1998

S50US

IA5S310Z
S52US
GENERAL

200-2TRANSMISSION-GENERAL
TransmissionIDCodes
Onbothmanualandautomatictransmissions,thecodelet-
terandtransmissiontypenumbersshouldbelocatedonanID
plateattachedtothesídeofthetransmission.Donotrelyon
numberscastonthetransmissioncaseforidentification.
Inaddition,thetransmissionlubricantvariesbetweentrans-
missionsandmodelyears.Fluidapplicationinformation
shouldbeclearlymarkedonalabelonthetransmission.
Onmanualtransmissions,eitherATF(orangelabelreads
ATF-Oil!)oraspecialBMWlubricant(yellowlabelreadsMTF-
LT1)areused.See230ManualTransmission.
AutomatictransmissionsarefilledwitheitherDexronIII
ATF(blacktrans.typeplatereadsATF-Oil!),aspecialffe-
timeoil(greentrans.typeplatereadingLife-Timeó1).See
240AutomaticTransmission.
GENERAL
CAUTION-
lfindoubtastothetypeoffluidinstalledinapar-
ticulartransmission,consultandauthorizedBMW
dealerservicedepartmentforthelatestinoperat-
ingfluids.
Fig.2.

TypicallocationofIDpíateonautomatictransmissionhousing
(arrow).A4S310R(THM-R1)

GENERAL............................210-1

CLUTCHMECHANICAL ................210-3
CLUTCHHYDRAULICS................210-1

Clutch,removing.......................210-4
Clutch,inspectingandinstalling............210-5
Clutchhydraulicsystem,

Transmissionpilotbearing,replacing.......210-6
bleedingandflushing..................210-2
Clutchmastercylinder,replacing..........210-2

Table
Clutchslavecylinder,replacing...........210-3

a.ClutchDiscDiameter........................210-3
GENERAL

CLUTCHHYDRAULICS
Thisrepairgroupcoversreplacementoftheclutchmechan-

TheClutchishydraulicallyactuatedbythemasterandslave
¡calandhydrauliccomponents.Specialtoolsmayberequired

cylinders.Clutchdiscwearisautomaticallytakenupbythe
forsomeoftheprocedures.Readtheprocedurethroughbe-

pushrodtraveloftheslavecylinder,makingperiodicadjust-
forebeginningajob.

mentsunnecessary.
NOTE-
See200Transmission-Generalfortransmission
applicatíoninformation.
Themajorcomponentsoftheclutchsystemareshownin
Fig.1.
Engine

Pressureplate
flywheel,,assembly
Clutch
Flywheel
bolt
Pressureplate
releaselever

Releaselever
Fig.1.

Clutchassemblyandhydraufcs.
210Clutch
Release
bearing
Pushrod
Asoftorspongyfeeltotheclutchpedal,longpedalfree-
play,orgrindingnoisesfromthegearswhileshiftingcanallin-
dicateproblemswiththeClutchhydraulics.Inthesecircum-
stancesitisbesttostartwithaclutchfluidflush,followed,if
necessary,byreplacementofthehydraulicparts.
Frombrakefluidreservoir
CLUTCH 210-1
0
0
Transmission
inputshaft
Clutch
master
cylinder
Bulkhead
Slavecylinder
6535
CLUTCHHYDRAULICS

210-2 CLUTCH
Clutchhydraulicsystem,
bleedingandflushing
Iftheclutch/brakefluidismurkyormuddy,orhasnotbeen
changedwithinthelasttwoyears,thesystemshouldbe
flushed.Flushingtheoldfluidfromtheclutchlinesisdoneus-
ingabrakesystempressurebleeder.
1.Removebrakefluídreservoircap.Usingacleansy-
ringe,removebrakefluidfromreservoir.Refillreservoir
withcleanfluid.
2.Attachpressurebrakebleedertofluidreservoír.
CAUTION-
Donotexceed2bar(29psi)pressureatthefluid
reservoirwhenbleedingorflushingthehydraulic
system.
3.Connectalengthofhosefromclutchslavecylinder
bleedervalveloacontainer.SeeFig.2.
0012003
Fig.2.

Clutchslavecylinderbleedervalveonleftsideoftransmission
(arrow).
4.Openbleedervalveandallowbrakefluidtoexpeluntil
cleanfluidcomesoutfreeofairbubbles.
5.Closebleedervalveanddisconnectpressurebleeding
equipmentfromfluidreservoir.Hoseonbleedervalve
remainsconnected.
6.Slowlyoperateclutchpedalabout10times.Fillreser-
voirwithcleanfluidasnecessary.
7.Unboltslavecylinderfromtransmission.
8.Positionslavecylindersothatbleedervalveisfacingup
(highestpoint).
CLUTCHHYDRAULICS
9.Openbleedervalveandslowlypushslavecylinder
pushrodal¡thewayin.Closebleedervalveandslowly
releasepushrod.Repeatprocedureuntilfluidrunsout
clearandwithoutbubbles.
10.Disconnectbleederhose.Instanslavecylinderlotrans-
mission.Addcleanbrakefluidtoreservoirasneces-
sary.Checkclutchoperation.
TighteningTorques
"Clutchslavecylinder
totransmission..................22Nm(17ftlb)
Clutchmastercylinder,replacing
Theclutchmastercylinderismountedtothepedalassem-
bly,directlyabovetheclutchpedal.
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removebrakefluidreservoircap.Usingacleansy-
ringe,removebrakefluidfromreservoir.
CAUTION-
Brakefluidispoisonous,highlycorrosiveanddan-
geroustotheenvironment.Wearsafetyglasses
andrubbergloveswhenworkingwithbrakefluid.
Donotsiphonbrakefluidwithyourmouth.Imme-
diatelycleanawayanyfluidspilledonpaintedsur-
facesandwashwithwater,asbrakefluidwill
removepoint.
3.Disconnectfluidsupplyhosefrommastercylinder.
Placeapanunderhosetocatchanyexcessfluid.
4.Workinginenginecompartment,disconnectfluidline
fittingfrommastercylinder.
5.Workinginpassengercompartment,removelowerin-
strumentpaneltrimabovepedalcluster.
6.Disconnectclutchpedalfromclutchmastercylinder
pushrodbyremovingclevispinlockingclipandslide
outclevispin.
7.Removemastercylindermountingbolts.SeeFig.3.
8.Installationisreverseofremoval.Fillfluidreservoirwith
cleanfluid.Bleedclutchhydraulicsasdescribedearlier.
Connectnegativecabletobatterylast.

Fig.3.

Clutchmastercylindermountingbolts.
Clutchslavecylinder,replacing
0012589
TighteningTorques
"Clutchmastercylindertobulkhead..22Nm(17ft-Ib)
"Fluidlinetomastercylinder
orslavecylinder.................16Nm(12ft-1b)
Theclutchslavecylinderismountedontheleftsideofthe
transmission.

CLUTCHMECHANICAL
1.Removebrakefluidreservoircap.Usingacleansy-
ringe,removebrakefluidfromreservoir.
2.Disconnectfluidhosefromslavecylinder.Placeapan
underhosetocatchanyexcessfluid.
3.Unboltslavecylinderfromtransmission.SeeFig.4.
4.Installationisreverseofremoval,notingthefollowing:
"Checkforwearonpushrod.Anyotherwearexcepton
tipiscausedbymisalignmentofclutchcomponents.
"Lightlycoatpushrodtipwithmolybdenumdisulfide
grease(Molykote0Longterm2orequivalent).
"Duringinstallationbesurepushrodtipengagesrecess
inclutchreleaselever.
"Fillfluidreservoirwithcleanfluid.
"Bleedclutchhydraulicsasdescribedearlier.
CLUTCH 210-3
Fig.4.

Clutchslavecylindermountingbolts(arrows).
Tablea.ClutchDiscDiameter
Model

Diameter
3181/is/iC

215mm(8.46in)
325i/is/iC

228mm(8.98in)
323is/iC
328i/is/iC

240mm(9.45in)
M3
0012715
TighteningTorques
"Clutchslavecylinder
totransmission..................22Nm(17ftlb)
"Fluidlinetoslavecylinder.......17Nm(10-12ftlb)
Thetransmissionmustberemovedfromtheenginetoac-
cesstheclutchmechanicalcomponents.Itisrecommended
thattheclutchdisc,pressureplateandreleasebearingbere-
placedduringaclutchoverhaul.Besuretocheckthebottom
ofthebellhousingforoil.Ifengineoilisfound,checkfora
faultyrearcrankshaftoilseal.
CLUTCHMECHANICAL

210-4CLUTCH
Clutch,removing
1.Removetransmissionfromengine.See230Manual
Transmission.
2.Removereleasebearingfromtransmissioninputshaft.
3.Removeclutchreleaseleverbyslidingitoutfromunder
springclip.SeeFig.5.
Fig.5.

Removeclutchreleaseleverbypullingawayfromspringclip
indirectionofarrow.
4.Lockflywheelinposítionusingasuitablelockingtool
(BMWSpecialtoolno.112170,orequivalent).See
Fig.6.
Fig.6.

Flywheellockingtool(arrow)installedtorearofcylinderblock.
CLUTCHMECHANICAL
0011581
0012008
5.Installaclutchcenteringtoolthroughclutchassembly
topreventclutchdiscfromfallingoutwhenremoving
pressureplate.SeeFig.7.
Fig.7.

Clutchcenteringtool(arrow)showninstalledthroughclutch
discandflywheel.
6.Removesixboltsfromperimeterofpressureplate.Re-
movepressureplateandclutchdisc.SeeFig.8.
Fig.8.

Clutchpressureplatemountingbolts(arrows).
0012009
6529

Clutch,inspectingandinstalling
1.Inspectclutchdiscforwear,cracks,looserivets,con-
taminationorexcessiverunout(warping).Replaceif
necessary.
2.Inspectflywheelforscoring,hotspots,cracksorloose
orwornguidepins.Replaceflywheelifanyfaultsare
found.
WARNING -
Ifflywheelisremovedfromvehicle,usenewbolts
durínginstallation.Theoldstretch-typeboltsshould
notbereused.
3.Inspecttransmissionpilotbearinginendofcrankshaft.
Thebearingshouldrotatesmoothlywithoutplay.Ifnec-
essary,replaceasdescribedlater.
4.Inspectandcleanreleasebearinglever.Applyathin
coatofgreasetoreleasebearínglevercontactpoints.
SeeFig.9.Also,lightlylubricateclutchdiscsplinesand
transmissioninputshaftsplínes.
5.Installpressureplateandclutchdisc.Donotfullytight-
enbolts.
6.Centerclutchdisconflywheelusingcenteringtool
(BMWspecialtoolno.212130orequivalent).Referto
Fig.7.
NOTE-
Besureclutchdíscisfacingthecorrectway.Thenew
discshouldbemarkedenginesfdeortransmission
side.SeeFig.10.
7.Tighteneachboltoneturnatatimeuntilpressureplate
isfullyseated,andthentorquetospecification.
8.Removeclutchdisccenteringtool.Removeflywheel
lockingtool.
Fig.9.

Clutchreleaseleverlubricationpoints(arrows).
CLUTCH210-5
Clutch
Clutch
pressure
disc plate
0012026
Fig.10.ClutchassemblyNoteclutchdischubpositionduringinstal-
lation.
CLUTCHMECHANICAL

210-6CLUTCH
9.Cleanandinspectreleasebearingguidesleeveon
transmission.Installreleaseleverandreleasebearing.
SeeFig.11.
A
0011582
Fig.11.Clutchreleasebearingcorrectlyinstalledonguidesleeve(A).
Bearingtabs(B)alignwithcontactpoints(C)onreleaselever.
10.Insta¡¡transmission.See230ManualTransmission.
TighteningTorques
"Flywheeltocrankshaft(usenewbolts)
M42/M44engines..............120Nm(89ft-Ib)
Allothers.....................105Nm(77ft-Ib)
"Pressurepíatetoflywheel
M88.8grade...................24Nm(18ft-Ib)
M810.9grade..................34Nm(25ft-Ib)
CLUTCHMECHANICAL
Transmissionpilotbearing,replacing
1.Removeclutchasdescribedearlier.
2.Removetransmissionpilotbearingfromendofcrank-
shaftusingBMWspecialtoolno.112340,orequiva-
lent.
3.PressnewbearingfintoplaceusingBMWSpecíalTool
no.112350,orequivalent.

230ManualTransmission
MANUALTRANSMISSION

230-1
GENERAL ............................230-1

Outputshaftsea¡,replacing
(transmissioninstalled).................230-4
TRANSMISSION FLUIDSERVICE.......230-1

Inputshaftsea¡,replacing
Transmissionfluidleve¡,checking.........230-2

(transmissionremoved)................230-5
Transmissionfluid,replacing.............230-2

TRANSMISSION REMOVAL AND
TRANSMISSION SERVICE.............230-2

INSTALLATION ........................230-5
Back-uplightswitch,replacing............230-2

Transmission,removingandinstalling.......230-6

_
Selectorshaftsea¡,replacing
(transmissioninstalled)................230-3

TAB
a.ManualTransmissionGearRatios.............230-1
GENERAL

TRANSMISSION FLUIDSERVICE
Thisrepairgroupcoversexternaltransmissionservice,in-

ThemanualtransmissionsinstalledintheE36modelsare
cludingremovalandinstallationofthetransmissionunit.Inter-

normallyfilledwithautomatictransmissionfluid(ATF),al-
naltransmissionrepairisnotcovered.Specialpresstoolsand

thoughalternativelubricantsmayhavebeenusedfromthe
proceduresarerequiredtodisassembleandservicetheinter-

factory,dependingontransmissiontypeandmodelyear.For
nalgeartrain.

example,transmissionsfittedtotheM3modelsarenormally
filledwitha"lifetime"manualtransmissionfluid(BMWMTF
Manualtransmissionsusedarebasedonengineapplica-

LT-1)anddonotrequireperiodicfluidchanges.
tion.Consult200Transmission-Generalfortransmission
applicationinformation.Tablealistsgearratiospecifications.

NOTE-
Thetransmissionlubricanttypecanbefoundonalabel
NOTE-

onthesideofthetransmission.Consultanauthorized
Donotrelyonforgedcastingnumbersfortransmission

BMWdealerforaltematefluiduseandthemost-up-to-
codeidentification.

dateinformationregardingtransmissionoperatingfluids.
Tablea.ManualTransmissionGearRatios
Transmission

1

GetragS5D200G

1

GetragSSD250G

1

ZFS5D310Z

1

ZFS5D320Z
GearRatios:
1st

4.23

4.23

4.20

4.20
2nd

2.52

2.52

2.49

2.49
3rd

1.66

1.66

1.66

1.66
4th

1.22

1.22

1.24

1.24
5th

1.00

1.00

1.00

1.00
reverse

4.04

4.04

3.89

3.89
TRANSMISSION FLUIDSERVICE

230-2

MANUALTRANSMISSION
Transmissionfluidleve¡,checking
Checkingthetransmissionoillevelinvolvessimplyremov-
ingthesidedrainplugandinsertingafingerintotheholeto
checkthefluidleve¡.lfthefluidleve¡isuptothebottomofthe
drainhole(fingeriswettedbytransmissionfluid),theleve¡is
correct.
Transmissionfluid,replacing
NOTE-
Manualtransmissionfluidtypeshouldbeprintedona
labelonthesideofthetransmission.Ifindoubt,consult
anauthorizedBMWdealerfortheup-to-dateinforma-
tiononoperatingfluids.
1.Drivevehicleforafewmilestowarmtransmission.
2.Raiseandsafelysupportvehicletoaccessdrainplug.
WARNING -
"Whenraisingthecaruslngafloorjackorahy-
drauliclift,carefullypositionthejackpadtopre-
ventdamagingthecarbody.Asuitableliner
(wood,rubber,etc.)shouldbeplacedbetween
thejackandthecartopreventbodydamage.
"Watchthejackclosely.Makesureitstaysstable
anddoesnotshíítortilt.Asthecarisraised,the
carmayrollslightlyandthejackmayshift.
3.Placeadrainpanundertransmissionandremovedrain
plugatbottomoftransmission.SeeFig.1.
Fig.1.

Manualtransmissionfill(1)anddrainplugs(2).
TRANSMISSION SERVICE
4.Installandtorquedrainplug.
5.Removefillplugfromsideoftransmission.Slowlyfill
transmissionwithfluiduntilfluidoverflowsfillhole.
6.Installandtorquefluidfillplug.
FluidCapacity
"Getragtransmission...........1.0liter(1.1USqts)
"ZFtransmission.............1.2liters(1.3USqts)
TighteningTorque
"Transmissiondrainorfillplug.......50Nm(37ft-Ib)
TRANSMISSION SERVICE
Back-uplightswitch,replacing
1.Raiseandsafelysupportvehicletoaccessback-up
lightswitch.
NOTE-
"Theback-uplightswitchonGetragtransmissionsisin
theleftrearofthetransmission.
"Theback-uplightswitchonZFtransmissionisinthe
rightfrontofthetransmission.
2.Unscrewswitchfromtransmission.
3.Installnewswitch.
TighteningTorque
"Back-uplightswitch
totransmission..................20Nm(15ft-ib)
4.Checktransmissionfluidleve¡beforeloweringvehicle.

Selectorshaftseal,replacing
(transmissioninstalied)
1.Raiseandsafelysupportvehicletoaccessdrainplug.
2.Supporttransmissionwithtransmissionjack.
3.Removedriveshaft.See260Driveshaft.
4.Removetransmissioncrossmemberandtiltdownrear
oftransmission.
CAUTION--
Tiltingtheenginetolowerthetransmissioncan
leadtodamagetovariouscgmponentsduetolack
ofclearance.
-OncarswithAST(tractioncontrol)removethrot-
tlebodybeforetiltlngengine.
-Removebrakefluidreservoirlfnecessary.
Lockingpin
á

Lockingclip
8.Reinstallshiftlinkagetoselectorshaft.
7.Coatnewsealwithtransmissionfluid.Drivenewsealin
flushwithhousing.UseBMWspecialsealinstallation
toolno.232260orequivalentandasoft-faced(plastic)
hammer.SeeFig.4.
9.Fiaisetransmissionandreinstallcrossmember.
MANUALTRANSMISSION

230-3
Seal Selector
_shaft
5.Workingatrearofselectorshaft,disconnectshiftlink-

Fig.3.

Selectorshaftoilsea¡beingpriedoutwithscrewdriver.
agefromselectorshaft.SeeFig.2.
Fig.4.

Selectorshaftsealbeinginstalled.
6542
0012020
Fig.2.

Disconnectshiftlinkagefromtransmissionselectorshaftby
pryingbacklockingclipandpushinglockingpinout.

10.Installdriveshaftusingnewnuts.See260Driveshaft.
6.Carefullyprysea¡outwithanarrowsealremoveror

11.Checktransmissionoillevel,toppingupasnecessary.
smallscrewdriver.SeeFig.3.
TighteningTorques
"Driveshafttoflexdisc/
finaldriveflange..............See260Driveshaft
"Transmissioncrossmembertochassis
M8......................22-24Nm(16-17ft-1b)
M10..........................42Nm(31ft-Ib)
TRANSMISSION SERVICE

230-4

MANUALTRANSMISSION
Outputshaftsea¡,replacing
(transmissioninstalled)
1.Raiseandsafelysupportvehicle.Supporttransmission
withtransmissionjack.
WARNING -
"Whenraisingthecarusingafloorjackorahy-
drauliclift,carefullypositionthejackpadtopre-
ventdamagingthecarbody.Asuitableliner
(wood,rubber,etc.)shouldbeplacedbetween
thejackandthecartopreventbodydamage.
"Watchthejackclosely.Makesureitstaysstable
anddoesnotshiftortilt.Asthecarisraised,the
carmayrollslightlyandthejackmayshift.
2.Removedriveshaft.See260Driveshaft.
3.Removetransmissioncrossmemberandlowertrans-
missionatrear.
CAUTION-
Tiltingtheenginetolowerthetransmissíoncan
leadtodamagetovariouscomponenteduetolack
ofclearance.
-OncarswithAST(tractioncontrol)removethrot-
tlebodybeforetiltingengine.
-Removebrakefluidreservoirifnecessary.
4.Bendbackandremovecollarnutlockplate.
5.Holdflangesteadyandremovecollarlocknut(use
30mmthin-walleddeepsocket.)SeeFig.5.
Fig.5.

Useholdingtoolwhenlooseningoutputshaftcollarnut.
6.Removeflange.Ifnecessary,useapuller.
7.Useasea¡pullertoremovesealfromtransmission
housing.SeeFig.6.
8.Coatnewsea¡wíthtransmissionfluidanddriveintopo-
sitionuntilitisflushwithhousing.SeeFig.7.
TRANSMISSION SERVICE
Fig.6.

Pullerusedtoremovetransmissionseal.
Fig.7.

Outputshaftsealbeinginstalledusingsealdriver(BMWspe-
cialtoolno.232300).
9.Reinstalloutputflange(andshims,ifapplicable)toout-
putshaft.
NOTE-
OnGetragS5D200GandS5D250Gtransmissions
BMWrecommendsheatingtheoutputflangetoabout
176°F(80°C)toaidininstallation.Thiscanbedoneby
placingtheflangeinhotwater.
10.Coatbearingsurfaceofcollarnutwithsealerandinstall
nut.Tightencollarnutintwostages.Insta¡¡newlock-
plate.Bendtabsintoflangegrooves.
NOTE-
BMWrecommendstheuseofasealersuchasLoctite®
242wheninstallingtheflangecollarnuttopreventoil
fromleakingpastthethreads.

11.Raisetransmissionandreinstalltransmissioncross-
member.
12.Installdriveshaftusingnewnuts.See260Driveshaft.
13.Checktransmissionoilleve¡,toppingupasnecessary.
TighteningTorques
"Transmissioncrossmembertochassis
M8......................22-24Nm(16-17ft-Ib)
M10..........................42Nm(31ft-Ib)
"Transmissionoutputflangetooutputshaft

O

0012022Z:ZZZZ~%_j
StageI......................190Nm(140ft-Ib)
StageII(afterloosening).........120Nm(89ft-Ib)

Fig.9.

Indentatoilsealhousing(1).Punchholesinsealhousingat
Inputshaftsea¡,replacing
(transmissionremoved)
Replacementoftheinputshaftsea¡requirestheremovalof
thetransmissionfromthevehicleasdescribedlaterinthisre-
pairgroup.
5.Lubricatenewsea¡withtransmissionoilanddriveinto
1.Removeclutchreleasebearingandreleaseleverfrom

placeusingBMWSpecialToolno.232430orequiva-
insidebellhousing.

lent.
2.Removeboltsforclutchrelease-bearingguidesleeve,

6.Thoroughlycleanguidesleevemountingbolts,sealin
notingboltlengths.Removesleeveandanyspacers

surfaces,andthreadsincase.Applysealer(Loctite
(shims)under¡t.SeeFig.8.

242orequivalent)toguidesleevesealingsurfaceand
bolts.Reinstallguidesleeveandspacer(s).
0011640
Fig.8.

Clutchreleasebearingguidesleevebolts.(Getragtransmis-
sionshown).
3.Withtransmissiononaworkbench,removeinputshaft
sea¡coverfrominsidebel¡-housing.
4.Locatetwoindentsinsealhousing.Useapunchor
scribetopunchholesinhousingatindents.Threadtwo
sheetmetalscrewsintoholesandpulísealoutusing
screws.SeeFig.9.
MANUALTRANSMISSION

230-5
indentsandusesheetmetalscrew(2)topul¡sea¡fromtrans-
mission.
NOTE-
Usecarenottoscratchordamageinputshaft.Usea
protectivesleeveortapetheshaftwhenremovingand
installingthesea¡.
TighteningTorque
"Guidesleevetotransmission
M6xl2bolt.....................10Nm(89in-lb)
TRANSMISSIONREMOVAL
ANDINSTALLATION
Removalandinstallationofthetransmissionisbestaccom-
plishedonaliftusingatransmissionjack.Theenginemustbe
supportedfromaboveusingappropriatesupportequipment.
Thisallowstheenginetopivotonitsmountstoaccesstheup-
perTorx-headboltsatthebellhousing.
WARNING -
"Makesurethecarisstableandwellsupportedat
alltimes.Useaprofessionalautomotiveliftor
jackstandsdesignedforthepurpose.Afloorjack
isnotadequatesupport.
"Theremovalofthetransmissionmayupsetthe
balanceofthevehicleonalíft.
TRANSMISSION REMOVAL ANDINSTALLATION

230-6

MANUALTRANSMISSION
Transmission,removingandinstalling
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Insta¡¡enginesupportacrossenginebay.Raiseengine
sothatweightofengineíssupported.SeeFig.10.
Fig.10.Enginesupportequipmentusedtosupportenginefrom
abovebeforeremovingtransmission.
3.Raisevehicletogainaccesstoundersideofcar.
4.Supporttransmissionwithtransmissionjack.lfapplica-
ble,removereinforcingcrossbracefrombelowen-
gine/transmission.
5.Disconnectharnessconnectorfromreverselightswitch
ontransmission.
6.Removecompleteexhaustsystemandheatshield.
See180ExhaustSystem.
NOTE-
Disconnectoxygensensorhamessconnector(s)be-
foreloweringexhaustsystem.
7.Removedriveshaft.See260Driveshaft.
8.Disconnectshiftrodfromtransmissionselectorshaft.
SeeFig.11.
9.Disconnectshiftconsolefromtopoftransmission.See
250GearshiftLinkage.
TRANSMISSIONREMOVALANDINSTALLATION
Washers
Shift

Shiftrod
rod

retainingclip
00,
Fig.11.Shiftlevertotransmissionconnection.
Shiftconsole
0012024
10.Unboltclutchslavecylinderfromsideoftransmission.
Donotdisconnectfluidhose.Suspendslavecylinder
fromchassisusingstiffwire.
CAUTION-
Donotoperateclutchpedalwithslavecylinderre-
movedfromtransmission.
11.Supporttransmissionfrombelowwithjack.Removerear
supportcrossmemberfromtransmission.SeeFig.12.
Fig.12.Reartransmissioncrossmember(arrow).
12.Lowertransmission/engineassemblyuntilitrestson
frontsuspensioncrossmember.
CAUTION-
Tiltingtheenginetolowerthetransmissioncan
leadtodamagetovariouscomponenteduetolack
ofclearanceatrearofengine
-OncarswithASTremovethrottlebodybeforetilt-
ingengine.
-Removebracefluidreservoirifnecessary.
0013135

13.Removetransmissionmountingbolts(Torx-head).
Notelengthandlocationofbolts.SeeFig.13.
Fig.13.Transmissionmountingbolts.
0611642
CAUTION-
Atnotimeshouldtheweightofthetransmission
besupportedbythetransmissioninputshaft.
NOTE-
WashersshouldalwaysbeusedwithTorx-headbolts.
Installingboltswithoutwasherswillmakethemdifficult
toloosen.
MANUALTRANSMISSION

230-7
Fig.14.Bellhousingalignmentdowels(arrows).
16.Installdriveshaftandpreloadcenterbearingbracket.
Usenewnutswhenmountingdriveshafttotransmis-
síon/flexdiscandfinaldrive.See260Driveshaft.
17.Refilltransmissionwithappropriatelubricantbefore
startingortowingthecar.SeeTransmissionFluid
Serviceearlierinthisrepairgroup.
14.Removetransmissionbypullingbackwarduntilthetrans-

TighteningTorques
missioninputshaftclearstheclutchdiscsplines,then

"Reinforcingcrossbrace
pulídownwards.Lowerjackandremovetransmission.

tochassis(M10).................42Nm(31ft-Ib)
"Rubbermounttotransmission
15.Installationisreverseofremoval,keepinginmindthe

orbracketnut(M8)...............21Nm(16ft-Ib)
following:

"Slavecylindertotransmission......22Nm(16ft-Ib)
"Wheninstallingexchangetransmission,transferparts

"Transmissioncrossmembertochassis
fromoldunittoexchangeunit

M8......................22-24Nm(16-17ft-Ib)
"Thoroughlycleaninputshaftandclutchdiscsplines.

M10..........................42Nm(31ft-Ib)
Lightlylubrícatetransmissioninputshaftbeforein-

"Transmissiontoengine(Torx-head)
stalling.-

M8...........................22Nm(16ft-Ib)
"Besurebellhousingdowelsarecorrectlylocated.See

M10..........................43Nm(32ft-Ib)
Fig.14.

M12..........................72Nm(53ft-Ib)
"Centerrearoftransmissionindriveshafttunnelbefore

"Transmissiondrain/fillplugs........50Nm(37ft-Ib)
tighteningtransmissionsupportbracket.
TRANSMISSIONREMOVALANDINSTALLATION

AUTOMATICTRANSMISSION

240-1
240Automatic Transmission
GENERAL............................240-1

TRANSMISSION REMOVAL AND
INSTALLATION .......................240-4
TRANSMISSION SERVICE .............240-1

Transmission,removingandinstalling.......240-4
ATFleve¡,checking.....................240-1
ATF,drainingandfilling.................240-2

TABLE
a.AutomaticTransmissionGearRatios...........240-1
GENERAL

TRANSMISSIONSERVICE

lo
Automatictransmissionsareidentifiedbycodeletters

ATFleve¡,checking
foundonadataplatelocatedonthesideofthetransmission
case,behindthemanualvalvelever.See200Transmis-

TheautomatictransmissionsinstalledintheE36models
sion-Generalforapplicationinformation.Forgearratiospec-

arenormallyfilledwithDexronIIIautomatictransmissionfluid
ifications,seeTablea.

(ATF),althoughalternativefluidshavebeeninstalledfromthe
factory,dependingontransmissiontypeandmodelyear.
CAUTION-

SometransmíssionsarefilledwithaspecialBMW"lifetime"
ATFdoesnotcirculateunlesstheengineisrun-

automatictransmissionfluid,whichdoesnotrequireperiodic
ning.Whentowinganautomafictransmissionve-

fluidchanges.
hicle,useaflat-bedtruckorralsetherearwheels
offtheground.

CAUTION-
Mixingdifferenttypesoftransmissionfluidswill
Theelectronictransmissioncontrolmodule(TCM)monitors

leadtotransmissionfailure.
transmissionoperationforfaultsandalertsthedriverbyillumi-
natingthetransmissionfaultindicatorontheinstrumentpan-
el.On-boarddiagnosticcodesstoredintheTCMmustbe

NOTE-
downloadedandinterpretedbytrainedtechniciansusingspe-

Thetransmissionlubricantinstafedcanbefoundona
cialBMWdiagnosticequipment.

typeplateonthesideofthetransmission.Inaddition,
astickermaybelocatedonthefluidsumpindicating
thetypeoftransmissionlubricantused.Ifindoubt,con
NOTE-

sultanauthorizedBMWdealerforaltematefluiduse
Internalrepairstotheautomatictransmissionrequire

andcurrentinformationregardingtransmissionoperat-
specialserviceequipmentandknowledge.Ifitisdeter-

ingfluids.
minedthatinterna¡serviceisrequired,consultenau-
thorízedBMWdealeraboutafactoryreconditionedunit

Thetransmissionisnotequippedwithadipstick.Checking
oratransmissionrebuild.

theATFleve¡requiresmeasuringandmaintainingaspecified
ATFtemperatureduringthecheckingprocedure.Thecheck-
ingtemperatureisnotfullywarmorcold(theATFsump
shouldbeapproximatelywarmtothetouch).
Tablea.AutomaticTransmissionGearRatios
Transmission

MS310R(THM-R1)

MS310R(THM-Rl)

MS310Z(5HP18)

I

MS270R(THM-R1)
(1992-1993) (1993-on)
Gearratios:
1st

2.40

2.86

3.67

2.86
2nd

1.47

1.62

2.00

1.62
3rd

1.00

1.00

1.41

1.00
4th

0.72

0.72

1.00

0.72
5th

-

-

0.74

-
Reverse

2.00

2.00

4.10

2.00
TRANSMISSIONSERVICE

240-2

AUTOMATICTRANSMISSION
WARNING-
Iftheappropriatetemperaturemeasuringequip-
mentisnotavailable,ATFleve¡checkingshouldbe
lefttoanauthorizedBMWdealerThecheckingpro-
cedureshouldbedoneonaliftwiththeenginerun-
ninginneutral.Inaddition,thetransmissionfluid
temperaturemustbemaintainedwithinanarrow
rangeduringthecheckingprocedure.
1.Placevehicleonalift.
WARNING-
Toliftthevehiclesafely,see010Fundamentalsfor
theDo-it-YourselfOwner.
2.WarmupdrivetrainbyrunningengineuntilATFreach-
esspecifiedtemperature.Applybrakeand,whileidling
engine,shiftthroughallgearssevera¡times.Turnen-
gineoff.
ATFLevelChecking
"Fluidtemperature.............30-55°C(86-131°F)
3.RemoveATFfillplug.Placetransmissioninneutraland

ATF,drainingandfilling
restartengine.SeeFig.1orFig.2.
Fig.1.

ATFfillplug(A)onMS270R/A4S310Rtransmissions.
4.WithATFatspecifiedtemperature,add(luiduntilit
spilisfromfillhole.
WARNING-
HotATFcanscald.Weareyeprotectionandprotec-
tiveclothingandglovesduringthecheck.Ifthe
transmissionwasoverfilled,hotATFwillspillfrom
thefillerholewhenthefillplugisremoved.
5.Reinstallfillplugusingnewsealingring.
TRANSMISSIONSERVICE
011743
0011742
Fig.2.

ATFdrainplug(A)andfillplug(B)onA5S310Ztransmission.
TighteningTorques
"ATFfillplugtoATFsump
MS270R/A4S31OR.............33Nm(24ft-Ib)
MS310Z(M30plug)............100Nm(74ft-Ib)
Theproceduregivenhereincludesremovalandinstallation
oftheATF(luidstrainer(filter).
1.Removedrainpluganddrainfluidintocontainer.See
Fig.3orFig.2givenearlier.
0~
0
/\1--Z.IZ
~~
A

~"o

15/
Fig.3.

ATFdrainplug(A)onA4S270R/A4S310R.
WARNING-
TheATFmustnotbehotwhendraining.Donot
draintheATFiftheengineandlortransmissionIs
hot.HotATFcanscald.Weareyeprotection,pro-
tectiveclothingandgloves.
0011595

2.OnMS270R/A4S310Rtransmissions:Removefront

5.InstallationisreverseofRmoval.
andrearoilsumpmountingboltsandremovesumps

"Alwaysreplacesea¡fordrainplugandal¡gasket(s)and
andsumpgaskets.

O-rings.
"Cleansumpandsumpmagnet(s)usingalint-free
NOTE-

cloth.
TheMS270R/A4S310Rtransmissionsmaybefitted

"OnMS270R/A4S310Rtransmissions:Usenewbolts
withASE(inch)bolts.

atsumpandtightenboltsin-line,oneafterother(do
nottightenboltsinacross-wisepattern).
3.OnA5S310Ztransmission:Removeoilsumpmount-

"OnMS310Ztransmission,besuretoinstanrounded
ingboltsandbrackets,notingpositionofbrackets.Re-

sumpclampingbracketsatcornersofsump.
move

"Filltransmissionwithapprovedfluid.
sumpandsumpgasket.

"CheckfluidlevelasdescribedunderATFleve¡,
4.RemoveATFotra¡nermount¡ngscrewsandremove

checking.
strainertogetherwithgasketorO-ring.SeeFig.4or
Fig.5.
Fig.4.

A4S270R/A4S310Rfluidstrainermountingboits(arrows).
Fig.5.

A5S310Zfluidstrainermountingboits(arrows).
0013230
AUTOMATIC TRANSMISSION

240-3
NOTE-
UsenewsumpboltspurchasedfromBMW.Alternative-
ly,cleanoldboltsandcoatwithLoctite®threadlocking
compoundorequivalent
AutomaticTransmissionFluidCapacity(refillonly)
"MS270R/A4S310R
Removaloflargesumponly........3.0liters(3.2qt)
Removalofbothsumps...........5.0liters(5.3qt)
"MS310Z......................3.3liters(3.5qt)
TighteningTorques
"ATFdrainplugtoATFsump
MS270R/A4S310R............25Nm(18ft-Ib)
MS310Z(M10plug)............16Nm(12ft-Ib)
"ATFfillplugtoATFsump
MS270R/A4S310R............33Nm(24ft-Ib)
MS310Z(M30plug).........:.100Nm(74ft-Ib)
"ATFstrainertovalvebody
MS270R/A4S310R............20Nm(15ft-Ib)
MS310Z......................6Nm(53in-lb)
"ATFsumptotransmission
MS270R/A4S310R(M6).........12Nm(9ft-¡b)
MS310Z(M6)..................6Nm(53in-¡b)
TRANSMISSIONSERVICE

240-4

AUTOMATIC TRANSMISSION
TRANSMISSION REMOVALAND
INSTALLATION
Removalandinstallationofthetransmissionisbestaccom-
plishedonaliftusingatransmissionjack.Usecautionand
safeworkshoppracticeswhenworkingbeneathcarandlow-
eringtransmission.
WARNING-
Toliftthevehiclesafely,see010Fundamentalsfor
theDo-it-YourselfOwner.
CAUTION-
"Besurethevehicleisproperlysupported.The
removalofthetransmissionmayupsetthebal-
anceofthevehicleonalift.
"Tiltingtheenginetoremovethetransmissioncan
leadtodamagetovariouscomponentsdueto
lackofclearance.
-OncarswithASTremovethrottlebody.
-Removebrakefluidreservoirifnecessary.
Torx-headboltsareusedtomountthetransmissiontothe
bellhousing.Besuretohaveappropriatetoolsonhandbefore
startingthejob.
2.Installenginesupportacrossenginebay.Raiseand
safelysupportvehicle.SeeFig.6.
WARNING-
"Whenraisingthecarusingafloorjackorahy-
drauliclift,carefullypositionthejackpadtopre-
ventdamagingthecarbody.Asuitableliner
(wood,rubber,etc.)shouldbeplacedbetween
thejackandthecartopreventbodydamage.
"Watchthejackclosely.Makesureitstaysstable
anddoesnotshiftortilt.Asthecarisraised,the
carmayrollslighttyandthejackmayshift.
CAUTION-
Removaloftransmissionwillcauseenginetotip
unlessenginesupportisused.
TRANSMISSION REMOVAL ANDINSTALLATION
Fig.6.Enginesupportequipmentusedtosupportenginefromabove
beforeremovingtransmission.
3.Raisevehicletogainaccesstoundersideofcar.
4.DrainATFfromtransmissionasdescribedearlier.
5.Disconnectoxygensensorharness.Removeexhaust
system,andexhaustheatshield.See180Exhaust
System.
Transmission,removingandinstalling

6.Removedriveshaft.See260Driveshaft.
1.Disconnectnegative(-)cablefrombattery.

7.WithselectorleverinPark,disconnectshiftselectorle-
vercablefromleverandremovecablebracket.Hold
CAUTION-

linkageclampingboltstationarywhenloosening
Priortodisconnectiogthebattery,readthebattery

clampingnut.SeeFig.7.
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
Fig.7.

Selectorlevercableclampingnut(A).Loosencableclamping
nut(B)andremovecablefrombracket.Alwayscounterhold
clampingboltwhenlooseningnut.

8.Disconnectmainharnessconnectorfromtransmission
byturningitsbayonetlockringcounterclockwise.Re-
movewiringharnessfromtransmissionhousing.See
Fig.8.
Fig.8.

Harnessconnectoratautomatictransmission.
9.Whereapplicable,disconnectharnessconnectorfrom
speedsensorattopóftransmission.
10.Disconnecttransmissioncoolerlineclampsfromen-
gine.Disconnectlinesfromtransmission.
11.Supporttransmissionwithtransmissionjack.Remove
reinforcingcrossbrace(ifapplicable)andtransmission
supportcrossmember.
NOTE-
Noteinstallationpositionofsupportcrossmember.
12.Removeaccessplugincoverplateonrightsideofen-
gineblockandremovetorqueconverterbolts.Turn
crankshafttoaccessboits.SeeFig.9.
AUTOMATIC TRANSMISSION

240-5
Bellhousingaccess
hole
Socketwrench
Fig.9.

Accessandremovetorqueconverterboitsthroughholein
bellhousingcover.
0
A
fij
13.Removebellhousing-to-enginemountingbolts.See

Fig.10.Transmission-to-engineTorx-headmountingbolts.
Fig.10.
0012592
TRANSMISSIONREMOVALANDINSTALLATION

240-6

AUTOMATIC TRANSMISSION
14.Removetransmissionbypullingbackanddown.Lower
jacktoallowtransmissiontoclearvehicle.

TighteningTorques
"ATFdrainplugtoATFsump
CAUTION-

MS270R/A4S310R.............25Nm(18ft-Ib)
Donotallowthetorqueconvertertofatioffthe

ASS310Z(M10plug).............16Nm(12ft-Ib)
transmissioninputshaft.

"ATFfillplugtoATFsump
MS270R/A4S310R.............33Nm(24ft-Ib)
15.Installationisreverseofremoval,notingthefollowing:

MS310Z(M30plug)............100Nm(74ft-Ib)
"Blowoutofcoolerlineswithlow-pressurecompressed

"ATFcoolerlines(A4S270R/A4S310R)
airandflushcoolerwithcleanATFtwicebeforereat-

Couplingnuts...................20Nm(15ft-Ib)
tachinglinestotransmission.

Hollowbolts....................37Nm(28ft-Ib)
"Reinforcingcrossbrace
CAUTION-

tochassis(M10).................42Nm(31ft-Ib)
"Wearsafetyglasseswhenworkingwithcom-

"Torqueconverter
pressedair.

todriveplate(M10)..............45Nm(33ft-Ib)
"Transmissionsupportcrossmembertochassis
"DonotreuseATFafterflushing.

M8......................22-24Nm(16-17ft-1b)
M10..........................42Nm(31ft-Ib)
"Installnewsealingwashersonhollowbolts.

"Transmissíontoengine(Torx-headwithwasher)
"Insta¡¡newO-ringsontransmissioncoolerlines,where

M8...........................21Nm(15ft-Ib)
applicable.

M10..........................42Nm(31ft-Ib)
"Inspectdriveplateforcracksorelongatedholes.Re-

M12..........................72Nm(53ft-Ib)
placeifnecessary.
"Checktobesuretorqueconverterisseatedcorrectly
intransmissionduringfinalinstallation.
"Whenmountingtransmissiontoengine,thethree
mountingtabsontorqueconvertermustbealigned
withindentationsondriveplate.Useanalignment
doweltolineupboltholes,ifnecessary.
"FilltransmissionwithcleanATFuntiloilleve¡iseven
withfillhole.Thencheckfluidleve¡asdescribedear-
lier.
"Adjustgearshiftmechanism.See250Gearshiftlink-
age.
NOTE-
Torx-headmountingboltsshouldalwaysbeusedwith
washerstopreventdifficultremoval.
TRANSMISSIONREMOVALANDINSTALLATION

GENERAL............................250-1

AUTOMATIC TRANSMISSION
GEARSHIFT...........................250-3
MANUALTRANSMISSION

Gearshiftmechanism,adjusting
GEARSHIFT..........................250-1

(automatictransmission)................250-3
Gearshiftlever,removing

Gearposition/neutralsafetyswitch,replacing
(manualtransmission).................250-1

(automatictransmission)................250-4
Gearshiftlever,installing

Automaticshiftlock,checkingfunction
(manualtransmission).................250-2

(automatictransmission)................250-5
Shiftinterlock,checkingfunction
(automatictransmission)................250-6
GENERAL
Thisrepairgroupcoverstransmissiongearshiftandlinkage
service.
Specialservicetoolsarerequiredforsomeoftheproce-
duresgivenhere.Togainaccesstothecompletegearshift
mechanismítisnecessarytoremovetheexhaustsystemand
thedriveshaftasdescribedin180ExhaustSystemand260
Driveshaft.
MANUALTRANSMISSION GEARSHIFT
Gearshiftlever,removing
(manualtransmission)
ThemanualtransmissiongearshiftlinkageisshowninFig.
1.Usethisillustrationasaguidewhenremovingandinstalling
thelinkage.
1.Pullstraightuponshiftknobloremoveitfromshiftlever.
NOTE-
Removaloftheshiftknobwillrequireabout90lbs.of
force.
2.Pryuponrearofshiftboottounclip,thenremoveboot
fromfrontretainers.
3.Raisevehicletogainaccesstoundersideofvehicle.
WARNING -
Makesurethecarisstableandwellsupportedatafl
times.Useaprofessionalautomotiveliftorjack
standsdesignedforthepurpose.Afloorjackisnot
adequatesupport.
250GearshiftLinkage
GEARSHIFTLINKAGE

250-1
Fig.1.

Manualtransmissiongearshiftlinkage.
4.Disconnectoxygensensorharnessconnectors.Re-
movecompleteexhaustsystem.See180Exhaust
System.
MANUAL TRANSMISSION GEARSHIFT

250-2

GEARSHIFTLINKAGE
5.Removedriveshaft.See260Driveshaft.

9.Releasegearshiftleverretainingringfrombelowby
turningspecialtool90°(1/4turn)counterclockwise.See
6.Supporttransmissionwithtransmissionjack.Remove

Fig.4.
crossmemberfromrearoftransmission.SeeFig.2.
Fig.2.

Reartransmissioncrossmember(arrow).
7.Lowerrearoftransmissiontoaccessgearshiftlinkage.
CAUTION-
Tiltingtheenginetolowerthetransmissioncan
leadtodamagetovariouscomponenteduetolack
ofclearance.
-OncarswithASTremovethrottlebody.
-Removebrakefluidreservoirifnecessary.
0013135
8.Workingbelowtransmission,disconnectshiftrodfrom
gearshiftlever.Notewashersoneithersideofshiftrod
end.SeeFig.3.
v
clip
Shiftrod
Fig.3.

Pulloffshiftrodretainingclipindirectionofarrow(t);disen-
gageshiftrodfromgearshiftlever(2).
MANUALTRANSMISSIONGEARSHIFT
BMWTool
No.251110
orequivalent
Fig.4.

ShiftleverretainingringbeingremovedusingBMWspecial
tool251110.
10.Raisetransmissionandtemporarilyinstantransmission
crossmember.
11.Lowervehicle.Workingfrominsidepassengercom-
partment,pullupongearshiftlevertoremoveittogeth-
erwithretainingringandrubbergrommet.
Gearshiftlever,installing
(manualtransmission)
6532
1.Instanshiftlever,aligninglockingtabswithopeningsin
shiftconsole.Pressdownonretainingringuntilitclicks
intoplace.SeeFig.5.
\Retaining
Fig.5.

Shiftleverretainingring.Fitplastictabsintoslotsofshiftcon-
sole(arrows).

2.Installrubbergrommetwitharrowpointingforward.In-

AUTOMATicTRANSMISSION
stallshiftrodandshiftboot.

GEARSHIFT
NOTE-
Installrubbergrommetcorrectlysothatissealsoutwa-
ter.
4.Installdriveshaftandheatshield.See260Driveshaft.
Manualvalveleven
(attransmission)
Fig.6.

Automatictransmissiongearshiftassembfy.
Shiftcable
GEARSHIFTLINKAGE

250-3
Theautomatictransmissionshiftmechanismisshownin
Fig.6.Usetheillustrationasaguidewhenservícingthegear-
shiftmechanism,includingshiftcablereplacement.
3.Connectshiftrodtoshiftlever.Installtransmission
crossmember.Lifttransmissionandtightencrossmem-

Gearshiftmechanism,adjusting
berbolts.

(automatictransmission)
NOTE-

1.PositionselectorleverinPark.
Beforeconnectingtheshiftrodtothelever,besurethe

2.Raisevehicletogainaccesstoshiftlinkage.
gearshiftlevenisfacingthecorrectwayasillustratedin
Fig.1.
WARNING -
Makesurethecanisstableandwellsupportedatall
times.Useaprofessionalautomotiveliftorjack
standsdesignedforthepurpose.
5.Reinstallexhaustsystem.See180ExhaustSystem.
Connectoxygensensorharnessconnectors.

3.Loosenselectorcableclampingnut.SeeFig.7.
6.Lowervehicle.Insta¡¡shiftbootcover.Pushshiftknob

4.Pushshiftleverforwardtowardengine(Parkposition)
ontolever.

whileapplyinglightpressureoncableend.Tightenca-
bleclampingnut.
TighteningTorques

NOTE-
"Driveshafttofinaldrive

Donotovertightenthenutsothatittwiststhecable.
flange(withU-joint)...........See250Driveshaft
"Flex-disctodriveshaftor
transmissionflange...........See250Driveshaft

TighteningTorque
"Transmissioncrossmember

"Shiftcableclampingnut.......10-12Nm(75-9ft-Ib)
tobody(M8)....................21Nm(16ft-Ib)
/Sr\11
Gearposition/
neutralsafety
switch
Automatic
shilo
solenoidid
AUTOMATICTRANSMISSIONGEARSHIFT

250-4

GEARSHIFTLINKAGE
r%;
5
(((((C "~;
Fig.7.

Selectorlevercableclampingnut(A).Counterholdclamping
boltwhenlooseningnut.
Gearposition/neutralsafetyswitch,
replacing(automatictransmission)
NOTE-
Thegear-positionlneutralsafetyswitchisalsosome-
timesreferredtoastheautomatictransmissionrange
switch.
Failureofthegearpositionlneutralsafetyswitchcancause
ano-startcondition.Inacidition,sinceitsignalsgearshiftposi-
tiontothetransmissioncontrolunit,afaultyswitchcancause
erratictransmissionoperation.
1.Removehex-headscrew(3mmallenkey)fromshiftle-
verhandleandremovehandle.Carefullypryupcover
fromgearshiftleverconsole.
2.Disconnectharnessconnectorfromgearpositionlneu-
tralsafetyswitchandremovemountingscrews.See
Fig.8.
3.Removegearpositionlneutralsafetyswitchbymoving
selectoruntilpinonleveralignswithslotonswitch.Pull
switchstraightupandoff.SeeFig.9.
4.Installationisreverseofremoval,notingthefollowing:
"Beforeinstallingswitch,alignplasticcontactslidein-
sideswitchwithslotinswitch.SeeFig.10.
"Instanswitchsothatcontactslideonswitchalignswith
slotonswitch.Thenpositiongearshiftleverpintoslot
onswitchandinstallswitch.
"Wheninstallingshiftleverhandle,engagepínonre
leasebuttontoholeinpulírod.SeeFig.11.

Fig.9.

Contactslideinswitchalignstoslotonswitchandpinonle-
ver.
TighteningTorques
"Consoletobody..................7Nm(62in-lb)
"Gearpositionlneutralsafetyswitch
toshiftconsole..................4.5Nm(40in-lb)
AUTOMATIC TRANSMISSION GEARSHIFT
Fig.8.

Disconnectharnessconnectortogearposition/neutralsafety
switchbypressingconnectorretainingclipstogether(ar-
rows).Switchmountingscrewsshownat1.

Fig.10.Aligncontactslide(1)withslotinswitchhousing(2)beforein-
stallinggearposition/neutralsafetyswitch.
Fig.11.Engagereleasebuttonpintoholeinpullrodbeforeinstalling
Theautomaticshiftlockusesanelectrícsolenoidtolockthe
selectorleverinPorN.Depressingthefootbrakewiththeig-
nitiononenergizesthesolenoid,allowingthelevertobe
movedintoadrivegear.Thesolenoidisenergizedonlywhen
theenginespeedisbelow2,500rpmandthevehiclespeedis
below3mph.Thesolenoidísmountedintheright-handside
oftheselectorleverhousing.SeeFig.12.
1.Withenginerunningandcarstopped,placeselectorle-
verinPorN.
2.Withoutdepressingbrakepedal,checkthatselectorle-
verislockedinpositionPorN.
3.Depressbrakepedalfirmly.Solenoidshouldbeheard
toenergize.
GEARSHIFTLINKAGE

250-5
Fig.12.Automaticshiftlockpreventsdrivegearselectionuntilthe
brakepedalisdepressed.
4.CheckthatselectorlevercannowbemovedoutofPorN.
NOTE-
Thenexttestshouldbeperformedinanopenareawith
theparkingbrakeonandwithextremecaution.
5.WithselectorleverinPorNandbrakepedalde-
pressed,raiseengineabove2,500rpm.Checkthatse-
lectorlevercannotbemovedoutofPorN.
shiftleverhandle.

Ifanyfaultsarefoundchecktheelectricaloperationofthe
shiftlocksolenoidandcheckforwiringfaultstoorfromthe
Automaticshiftiock,checkingfunction

transmissioncontrolmodule(TCM).See610Electrical
(automatictransmission)

ComponentLocationsandElectricalWiringDiagrams.
NOTE-
ThesolenoidiscontrolledviatheTCM,usingbrake
pedalposition,enginespeed,androadspeedascon-
trollinginputs.
AUTOMATIC TRANSMISSION GEARSHIFT

250-6

GEARSHIFTLINKAGE
Shiftinterlock,checkingfunction

1.Shiftselectorlevertopark(P)positionandturnignition
(automatictransmission)
Theshiftinterlockusesacablebetweentheignitionswitch
andtheshiftlevertolocktheshiftleverintheparkposition
whenthekeyisintheoffpositionorremoved.Thisfeature
alsopreventsthekeyfrombeingremovedfromtheignition
lockuntiltheselectorleverisinP.Fig.13.
Fig.13.Shiftinterlockservestwosafetyfunctions:1)itlocksshiftle-
verinpark(P)whenthekeyisremoved,and2)itpreventsre-
movalofkeyuntilshiftleverismovedintoP.
AUTOMATICTRANSMISSIONGEARSHIFT
LatchirigGate
0012714
keytothe"zero"(off)position.
2.Removeignitionkey.Checkthatselectorlevercannot
beshiftedoutofPposition.
NOTE-
"ltmustonlybepossibletoremoveignitionkeywith
selectorleverinPposition.
"Shiftinterlockcablemustnotbekinked.
3.Turnignitionkeyonanddepressbrakepedal.Check
thatselectorlevermovesfreelyfromgeartogear.
4.WiththeselectorleverinagearpositionotherthanP,
attempttomovethekeytothezeroposition.Thekey
shouldnotgointothezeroposition.
Ifanyfaultsarefoundcheckthecableforkinksandtheca-
bleattachmentpointsfordamageorfaults.

DRIVESHAFTSERVICE................260-3
Driveshaft,aligning.....................260-3
Driveshaft,removing....................260-4
260Driveshaft
DRIVESHAFT260-1
GENERAL............................260-1

Driveshaft,installing.....................260-4
Flex-disc,replacing.....................260-5
TROUBLESHOOTING..................260-1

Centerbearingassembly,replacing........260-6
Frontcenteringguide,replacing...........260-7
TABLE
a.DriveshaftTroubleshooting....................260-2
GENERAL

NOTE-
Forreardriveaxlerepairinformation,see330Rear
Thetwo-piecedriveshaftisjoinedinthecenterbyasliding

Suspension.
splinedcoupling.Thiscouplingcompensatesforforeandaft
movementofthedriveline.Thedriveshaftísconnectedtothe

Driveshaftnoiseorvibrationmaybecausedbywornor
transmissionbyarubberflex-discandtothefinaldrivebya

damagedcomponents.Checktheuniversaljointsforplay.
universaljoint.Itissupportedinthemicidlebyacentersupport

Withthedriveshaftinstalled,pullandtwistthedriveshaftwhile
bearing.Thebearingismountedinrubbertoisolatevibration.

watchingthejoint.TheBMWspecificationforplayisvery
SeeFig.1.

small,soalmostanynoticeableplaycouldindicateaproblem.
TROUBLESHOOTING

Checkthetorqueofthefastenersattheflangeconnections.
Checktherubberoftheflex-discandcenterbearingfordete
Thesourceofdrivelinevibrationsandnoisecanbedifficult

riorationortearíngandcheckforpreloadatthecenterbearing
topinpoint.Engine,transmission,rearaxle,orwheelvibra-

withavisualinspection.Checkthedriveshaftforbrokenor
tionscanbetransmittedthroughthedriveshafttothecar

missingbalanceweights.Theweightsareweldedtabsonthe
body.Noisesfromtherearofthecarmaybecausedbyfinal

driveshafttubes.Inadditiontoinspectingforfaultydriveshaft
driveproblems,orbyfaultywheelbearings,driveaxies,or

parts,theinstalledanglesofthedriveshaftshouldalsobe
evenwornorimproperlyinflatedtires.

considered.
Flex-disc
Center
universaljoint
Fig.1.

Driveshaftandfinaldriveassembly.
Rearsection
Splinedshaft

ofdriveshaft
Centersupport

`

Clampingsleeve
bearíngassembly
Differentialinputflange
0013110
TROUBLESHOOTING

260-2 DRIVESHAFT
Furtherinspectionrequiresremovalofthedriveshaft.
Checkthefrontcenteringguideonthetransmissionoutput
flangefordamageormisalignment.Alsocheckrunoutatthe
transmissionoutputflangeandoutputshaft,andatthefinal
driveinputflange.Checktheboltholeboresintheflangefor
wearandelongation.
Driveshaftflangerunout(max.allowable)
"Transmissionoutputflange
axialplay...................0.10mm(0.004in.)
radialplay...................0.07mm(0.003in.)
"Finaldriveinputflangeradialplay(measuredat
driveshaftcenteringlip)........0.07mm(0.003in.)
Spinthecenterbearingandcheckforthesmoothoperation
withoutplay.Checkthatthesplinesoftheslidingcoupling
movefreely.Cleanandlubricatethesplineswithmolybdenum
disulfidegrease(Molykote®Longterm2orequivalent).
Checktheuniversaljointsforwearorbinding.Ifanyjointisdif-
ficulttomoveorbinds,thedriveshaftsectionshouldbereplaced.
Tablea.DriveshaftTroubleshooting
NOTE-
Withthedriveshaftinstalled,theactualamountthatthe
universaljointspivotislimited.Forthemostaccurate
test,checkuniversaljointsintheirnormalrangeof
movement.
Ifinspectionrevealsnothingwrongwiththedriveshaft,it
mayneedtoberebalanced.Thiscanbedonebyaspeciality
driveshaftrepairshop.Also,checkthealignmentofthedrive-
shaftasdescribedbelow.
NOTE-
Minordriveshaftvibrationscanoftenbecorrectedsim-
plybydisconnectingthedriveshaftatthefinaldrive,
andrepositíoningthedriveshaft90°,180°or270°inre-
lationtothefinaldriveinputflange.
Tablealistssymptomsofdriveshaftproblemsandtheir
probablecauses.Mostoftherepairinformationiscontained
withinthisrepairgroup.
Symptom

Probablecause

Correctiveaction
1.Vibrationwhen

a.Incorrectpreloadofcenterbearing.

a.Checkpreloadofcenterbearing.Readjustpreload.SeeFig.6.
startingoff(forward

b.Centerbearingrubberdeteriorated.

b.Inspectcenterbearingandrubber.Replaceifnecessary.
orreverse).

c.

Flex-discdamagedorworn.

c.

Inspectflex-disc.Replaceifnecessary.
TROUBLESHOOTING
d.Engineortransmissionmountsfaulty.Id.Inspectengineandtransmissionmounts.Alignorreplace,ifnec-
essary.
e.Frontcenteringguideworn,or

e.Checkfrontcenteringguideandreplaceifnecessary.Check
driveshaftmountingflangesoutof

runoutofdriveshaftflanges.
round.
f.

Universaljointswornorseized.

f.

Checkuniversaljointplayandmovement.Replacedriveshaftif
necessary.
g.Slidingcouplingseized.

g.Removedriveshaftandcheckmovementofslidingcoupling.
Cleancouplingsplinesandreplacepartsasnecessary.
h.Driveshaftmisaligned.

h.Checkdriveshaftalignment.
2.Noiseduringon/off

a.Finaldrivecomponentswornor

a.Removefinaldriveandrepair.
throttleorwhen

damaged(excessivepinion-to-ring-
engagíngclutch.

gearclearance).
b.

DriveaxleorCVjointfaulty.

b.

InspectdriveaxlesandCVjoints.Repairorreplaceasneces-
sary.
c.Slidingcouplingseized.

c.Removedriveshaftandcheckmovementofslidingcoupling.
Cleancouplingsplinesandreplacepartsasnecessary.
3.Vibrationat25to30

a.Frontcenteringguideworn,or

a.Checkfrontcenteringguideandreplaceifnecessary.Check
mph(40to50

driveshaftmountingflangesoutof

runoutofdriveshaftmountingflanges.
km/h).

roundordamaged.
b.Universaljointswornorseized.

b.Checkuniversaljointplayandmovement.Replacedriveshaftif
necessary.
c.

Flex-discdamagedorworn.

c.

Inspectflex-disc.Replaceifnecessary.
d.Centerbearingrubberdeteriorated.

d.Inspectcenterbearing.Replaceifnecessary.
e.Slidingcouplingseized.

e.Removedriveshaftandcheckmovementofslidingcoupling.
Cleancouplingsplinesandreplacepartsasnecessary.
f.

Misalignedinstalledposition.

f.

Checkdriveshaftalignment.

Symptom

1

Probablecause
4.Vibration,audible

a.Frontcenteringguideworn,or

a.Checkfrontcenteringguideandreplaceifnecessary.Check
rumbleover35mph

driveshaftmountingflangesoutof

runoutofdriveshaftmountingflanges.
(60km/h).

roundordamaged.
b.Mountingflangeboltslooseorholes

b.Removedriveshaftandchecktransmissionoutputflangeand
worn.

finaldriveinputflange.Replaceifnecessary.
c.Driveshaftunbalanced.

c.Checkdriveshaftforlooseormissingbalanceweights.Have
driveshaftrebalancedorreplaceifnecessary.
DRIVESHAFT SERVICE
Driveshaft,aligning
d.Universaljointswornorseized.

d.Checkuniversaljointplayandmovement.Replacedriveshaftif
necessary.
e.Slidingcouplingseized.

e.Removedriveshaftandcheckmovementofslidingcoupling.
1

Cleancouplingsplinesorreplacepartsasnecessary.
f.

Incorrectpreloadofcenterbearing.

f.

Checkpreloadofcenterbearing.Readjustifnecessary.
g.Centerbearingfaulty.

g.

Replacecenterbearing.
h.Finaldriverubbermountfaulty

h.Inspectfinaldriverubbermountandreplaceifnecessary.
i.

Driveshaftmisaligned.

i.

Checkdriveshaftalignment.
Repairkitsfortheuniversaljointsarenotavailable,anditis
notcommonpracticetorepairtheuniversaljointsonBMW
driveshafts.Wornordamageduniversaljointsusuallyrequire
replacementofthatsectionofthedriveshaft.
Thedriveshaftisbalancedtocosetolerances.Wheneverit
istoberemovedordisassembied,themountingflangesand
driveshaftsectionsshouldbemarkedwithpaintorapunch
beforeproceedingwithwork.Thiswillensurethatthedrive-
shaftcanbereassembledorinstalledinexactlythesameori-
entation.
Universaljointplay
"Maximumallowable...........0.15mm(0.006in.)
Thealignmentofthedriveshaftdoesnotnormallyneedto
becheckedunlesstheengine/transmissionorthefinaldrive
havebeenremovedandinstalled.If,however,allotherparts
ofthedriveshafthavebeeninspectedandfoundtobeokay,
butthereisstillnoiseorvibration,driveshaftalignmentshould
bechecked.
Therearetwoimportantdriveshaftalignmentchecks.The
firstistomakesurethatthedriveshaftrunsstraightfromthe
transmissiontothefinaldrive;withoutanyvariationfromside-
to-sidecausedbymisalignmentoftheengine/transmissionin
itsmounts.Makeabasiccheckbysightingalongthedrive-
shaftfrombacklofront.Anymisalignmentshouldbeapparent
fromthecenterbearingforward.Toadjusttheside-to-side
alignment,loosenthetransmissionorenginemountstorepo-
sitionthem,thenretightenthemounts:Thedriveshaftshould
beexactlycenteredinthedriveshafttunnel.SeeFig.2.
Tablea.DriveshaftTroubleshooting(continued)
DRIVESHAFT 260-3
Correctiveaction
b:izó
Fig.2.

Driveshaftside-to-sidealignment.Driveshaftshouldbecen-
teredindriveshafttunnel.
Thesecondimportantdriveshaftalignmentcheckismore
complicated.Itcheckstheamountthedriveshaftisangled
verticallyatthejoints.Thisangleisknownasdriveshaftde-
flection.
Ingeneral,thereshouldbelittledeflectioninthedriveshaft
betweentheengine,thecenterbearing,andthefinaldrive.
Precisechecksrequiretheuseofalargeprotractororsome
othermeansofmeasuringtheangleoftheengineandthefi-
naldriveandcomparingtheseanglestotheangleofthedrive-
shaftsections.
Tochangethedeflectionangle,shimscanbeplacedbetween
thecenterbearingandthebodyorbetweenthetransmission
andítsrearsupport.Whenusingshimstochangeadeflection
angle,keepinmindthattheangleofadjacentjointswillalso
change.Deflectionanglesshouldbeassmallaspossible.
DRIVESHAFT SERVICE

260-4DRIVESHAFT
CAUTION-
Themaximumallowablechangeinheightofthe
centerbearingortransmissionsupportusing
shimsis3mm(0.12in.).
Driveshaft,removing
WARNING -
"Besurethewheelsareoffthegroundbeforere-
movingthedriveshaft.Settheparkingbrakebe-
foreremovingthedriveshaft.
"Oncethedriveshafthasbeenremoved,thevehi-
clecanrollregardlessofwhetherthetransmis-
sionisingearornot.
"Thedriveshaftfsmountedtothetransmission
andfinaldrivewithself-lockingnuts.Thesenuts
aredesignedtobeusedonlyonceandshouldbe
replacedduringreassembly.
1.Disconnectoxygensensorelectricalconnectorsand
removecompleteexhaustsystem.See180Exhaust
System.
4.Removedriveshaftmountingbolts.SeeFig.3.Discard
oldnuts.
JG
Fig.3.

Frontdriveshafttotransmissionmountingboltbeingre-
moved.Noteopen-endwrench(arrow)beingusedtocoun-
terholdbolt.
5.Loosenthreadedclampingsleeveondriveshaftafew
tucos.SeeFig.4.
DRIVESHAFTSERVICE
Fig.4.

Threadedclampingsleevenutbeingloosened.
0012037
6.Supportdriveshaftandremovecentersupportbearing
mountingbolts.
7.Removedriveshaftbutdonotseparatetwohalves.Pull
downoncenterofdriveshafttofacilitateremoval.
2.Removeexhaustheatshieldandheatshieldcross-
member.

NOTE-
Ifdriveshafthalveswereseparateandnotmatch-
3.Matchmarkfrontandreardriveshaftconnectionsat

marked,assembledriveshaftasshownindrawing.Ifa
transmissíonandfinaldrive.

vibrationoccurs,disassembledriveshaftandrotateone
section180°.SeeFig.5.
Driveshaft,installing
Fig.5.

Driveshaftalignment.Centerlinesofuniversaljoints(arrows)
mustbeparallelorat90°toeachother
1.Aligndriveshaftmatchmarksatfinaldriveandthenat
transmissionflange.Startattachingnuts.Usenewself-
lockingnuts.
2.Positioncentersupportbearingandstartattaching
nuts.Usenewself-lockingnuts.
3.Tightenflangenutswhilepreventingboltsfromtwisting
incoupling.Tightenfinaldriveflangefirst,thentighten
couplingattransmission.
4.Preloadcentersupportbearingbypushingbearingfor-
ward4-6mm(0.16-0.24in.)fromcenter.SeeFig.6.
Tightenattachingbolts.

Fig.6.

Preloadcenterbearingtowardfront4-6mm(arrow).
5331
5.Tightenthreadedsleeveondriveshafttopropertorque .
6.Insta¡¡heatshieldandheatshieldcrossmember.
TighteningTorques
"Driveshaftcentermounttobody....21Nm(16ft-Ib)
"Driveshaftclampingsleeve........10Nm(89in-lb)
"Driveshafttofinaldriveflange
WithCVjoint(M8)...............32Nm(23ft-Ib)
WthU-joint(M10ribbednut).......80Nm(59ft-Ib)
WithU-joint(M10compressednut)..60Nm(44ft-Ib)
"Flex-disctodriveshaftortransmissionflange
M10(8.8grade).................48Nm(35ft-Ib)
M10(10.9grade)................64Nm(47ft-Ib)
M12(8.8grade).................81Nm(60ft-Ib)
M12(10.9grade)...............100Nm(74ft-Ib)
M12(10.9grade)(M3models).....115Nm(85ft-Ib)
"Transmissioncrossmember
tobody(M8)....................21Nm(16ft-Ib)
NOTE-
Boltgradeismarkedonthebolthead.Whenreplacing
bolts,onlyuseboltsofthesamestrengthandhardness
astheoriginalsinstalled.
Flex-disc,replacing
Theflex-discbetweenthefrontsectionofthedriveshaftand
theoutputflangeofthetransmissionshouldbecheckedfor
cracks,tears,missingpieces,ordistortion.Checkforworn
boltholeboresintheflange.
1.RemovedriveshaftasdescribedinDriveshaft,remov-
ing.
NOTE-
¡tispossibletoonlypartiallyremovethedriveshaft,
leavingitconnectedtothefinaldrive.Thedriveshaft
canbetilteddowninthecenterandslidoffthetrans-
missionflangeoncetheclampingsleeveisloosened
andthecenterbearingbracketisunbolted.Suspend
thedriveshaftusingstiffwireinasclosetotheinstalled
positionaspossible.Ifthedriveshafthangsunsupport-
ed,therearuniversaljointmaybedamaged.
2.Unboltflex-díscfromdriveshaft.
DRIVESHAFT 260-5
7.Installexhaustsystem.See180ExhaustSystem.
Connectwiringharnesstooxygensensors.

NOTE-
Removalandinstallationoftheboltsmaybemadeeas-
8.Roadtestvehicletocheckfornoiseorvibration.

ierbyplacingalargehoseclamparoundtheflex-disc,
andtighteningtheclampslightlytocompressthecou
WARNING -

pling.
"Donotreuseself-lockingnuts.Thesenutsare
designedtobeusedonlyonce.

3.Insta¡¡newflex-discusingnewself-lockingnuts.Mold-
"Avóidstressingtheflex-discwhentorquingthe

edarrowsoncouplingshouldfaceflangearms.See
boltsDothis

holdingthebolts

Fig.7.
steadyand.

uy
turningthenutsontheflangeside.
5:132
Fig.7.

Whenattachingflex-disc,moldedarrowsmustpointtoward
flangearms.
DRIVESHAFT SERVICE

260-6DRIVESHAFT
4.Insta¡¡driveshaftasdescribedinDriveshaft,install-
ing.
TighteningTorques
"Driveshaftcentermounttobody....21Nm(16ft-Ib)
"Driveshaftclampingsleeve........10Nm(89in-lb)
"Driveshafttofinaldriveflange
WithCVjoint(M8)...............32Nm(23ft-Ib)
WthU-joint(M10ribbednut).......80Nm(59ft-Ib)
WithU-joint(M10compressednut)..60Nm(44ft-Ib)
"Flex-disctodriveshaftortransmissionflange
M10(8.8grade).................48Nm(35ft-Ib)
M10(10.9grade.................64Nm(47ft-Ib)
M12(8.8grade).................81Nm(60ft-Ib)
M12(10.9grade)...............100Nm(74ft-Ib)
M12(10.9grade)(M3models).....115Nm(85ft-Ib)
"Transmissioncrossmember
tobody(M8)....................21Nm(16ft-Ib)
5.Removecenterbearingcirclipanddustguard.SeeFig.
Centerbearingassembly,replacing

10.Removebearingfromdriveshaftusingpuller.
Toreplacethecenterbearingassembly,thedriveshaft
mustberemovedfromthecar.Thecenterbearingassembly
consistsofagroovedballbearinginarubbermount.The
bearingassemblyispressedontothefrontsectionofthe
driveshaftandsecuredbyacirclip.SeeFig.8.
Circlip
NOTE-
Torqueonlythenutswhileholdingtheboltheads.Thís
willpreventdamagingorfatiguingtherubber.
Dustcap
Fig.8.

Explodedviewofdriveshaftsupportbearingassembly.
1.Removedriveshaft.SeeDriveshaft,removing.
DRIVESHAFT SERVICE
0012594
5333
Fig.9.

Beforepullingapartdriveshaftsections,makematching
marksasshown.
4.Inspectconditionofrubberbushingforsplinedcou-
pling.Replacewornordamagedparts.
2.Makematchingmarksonfrontandreardriveshaftsec-

NOTE-
tions.SeeFig.9.

Installpullersothatitpullsoninnerhubofbearing.
Pullingonouterringofmountmaytearrubber,anden
3.Loosenclampingsleevefullyandpulldriveshaftsec-

tirebearingassemblywillneedtobereplaced.
tionsapart.Removerubberbushing,washer,and
clampingsleevefromfrontsection.
5334
Fig.10.Centerbearingcirclip(arrow)toberemoved.Driveshafl
showninstalled.

6.Beforeinstallation,makesuredustguardisondrive-

2.Packcavitybehindcenteringguidewithheavygrease
shaft,andthenpresscentermountontodriveshaft

untilgreaseisflushwithbottomedgeofguide.
flushwithdustguard.
3.Insert14mm(approximately%zin.)diametermandrel
7.Placeclampingsleeve,washer,andrubberbushingon

ormetalrodfintoguide.Strikeguidewithhammerto
frontdriveshaftsection.Lubricatesplineswithmolyb-

forcecenteringguideout.
denumdisulfidegrease(Molykote0Longterm2or
equivalent)andthenreassembledriveshaft.

NOTE-
Themandrelshouldfitsnuglyinthecenteringguideso
NOTE-

thatthegreasecannotescapearoundthesidesofthe
Donotretightenclampingsleeveuntildriveshaftisin-

mandrel.
stalled.
4.Removeoldgreasefromdriveshaft,lubricatenewcen
8.Insta¡¡dríveshaft.SeeDriveshaft,installing.

tering

guide

with

molybdenum

disulfide

grease
(Molykote®Longterm2orequivalent)anddriveitfinto
9.Tightenclampingsleeve.

driveshaft.
NOTE-
TighteningTorque

Thesealinglipoftheguideshouldfaceoutwardandit
"Clampingsleeve.................10Nm(7.5ft-Ib)

shouldbedrivenintothedriveshafttoaspecified
depth.SeeFig.11.
Frontcenteringguide,replacing
Thefrontcenteringguidecentersthedriveshaftinrelation
tothetransmission.Theguideispress-fitfintoacavityinthe
frontofthedriveshaftandslidesontothetransmissionoutput
shaft.
Nospecificationsaregivenforwearoftheguide,butgener-
allytheguideshouldfitsnuglyonthetransmissionoutput
shaft.
NOTE-
Somedriveshaftshaveadustcapinstalledontheend
ofthedriveshaft,overthecenteringguide.Thedust
capmaybecomebentordistortedwhenthedriveshaft
isremovedorinstalled.Damagetothedustcapshould
notaffectthecenteringguideandshouldnotbemistak-
enforguidewear.
1.Removedriveshaft.SeeDriveshaft,removing.
®RIVESHAFT 260-7
~)I~4.5mm
(.177")B313
Fig.11.Wheninstallingnewdriveshaftcenteringguide,driveguide
inuntilitsprotrusiondepthisasshown.
5.Installdriveshaft.SeeDriveshaft,installing.
DRIVESHAFTSERVICE

SUSPENSION,STEERINGANDBRAKES-GENERAL

300-1
300Suspension,Steering
andBrakes-General
GENERAL ............................300-1

M3SUSPENSION ANDBRAKES...........300-7
FrontSuspension......................300-1
Steering..............................300-2

SUSPENSION ANDSTEERING
RearSuspension......................300-2

TROUBLESHOOTING ..................300-7
Brakes..............................300-2
Tiresandwheeis.......................300-2

TABLE
a.ASTIndicatorLampFunction.................300-5
INTEGRATED SYSTEMS ...............300-2

b.SuspensionandSteeringTroubleshooting.......300-8
AntilockBrakeSystem(ABS).............300-2
Al¡SeasonTraction(AST)...............300-4
GENERAL

FrontSuspension
Thissectioncoversgeneralinformationforfrontandrear

Thelowercontrolarmsconnectthefrontsuspensionstruts
suspension,thesteeringsystem,andthebrakíngandtraction

tomountingpointsonthesubframecrossmemberandthe
controlsystems.

body.SeeFig.2.
TheBMWE36suspensionandsteeringsystemsareengi-
neeredtoprovideacompromisebetweentaut,responsive
handlingandridecomfort.Althoughthefrontandrearsuspen-
sionassembliesareindependentsubsystems,theyworkto-
gethertoachieveBMW'soverallcombinationofprecise
handlingandcomfort.SeeFig.1.
Fig.1.

BMWE36frontandrearsuspensionsystems.
Eachfrontstrutassemblyincludesashockabsorbercar-
tridgeinsidethetubularstruthousingandalargecoilspring.
Theupperstrutmountbearingallowsthestruttoturnwiththe
wheels.Thelowerendofthestrut,whichincludesthestub
axleforthefrontwheel,connectstoaball-jointonthecontrol
arm.
0013098
GENERAL

300-2

SUSPENSION,STEERINGANDBRAKES-GENERAL
Steering
INTEGRATEDSYSTEMS
Thesteeringlinkageconnectstherack-and-pinionunit
throughtierodstothesteeringarms.Thetierodendsallow
thewheelstopivotandreacttosuspensiontravel.
RearSuspension
Therearaxlecarrieristhemainmountingpointforthefinal
drivehousingandtherearsuspensioncomponents.
Trailingarmslocatetherearwheelsandanchorthesprings,
shocksandstabilizerbar.Driveaxieswithconstant-velocity
(CV)jointsatbothendstransferpowerfromthedifferentialto
theroadwheels.Thedifferentialismountedtotherearaxle
carrierthroughrubbermountsandbushingstoheleisolate
drivetrainnoiseandvibration.
Brakes
E36carsareequippedwithpowerdiscbrakeswithaninte-
gralantilockbrakes(ABS).Theparkingbrakeisadual-drum
systemintegratedwiththerearbrakerotors.SeeFig.3.
Powerassistisprovidedbyavacuumboosterwhentheen-
gineisrunning.Thebrakepedalpushrodisconnecteddirectly
tothemastercylinder,sofailureofthevacuumboosterdoes
notnormallyresultintotalbrakefailure.
0012124

Eachdiscbrakeusesacaliperwithasinglehydrauliccylin-
Fig.2.

Frontsuspensioncontrolarm(arrow).

der.Brakepadsintheleftfrontandrightrearcontainwear
sensors.Whenthepadsneedreplacement,thesensorsillu-
Thefrontsuspensionisdesignedwithminimumpositive

minatealightonthedashboard.
steeringoffset.Thisgeometrycontributestostabilitywhen
tractionisunequalfromsidetoside.Suspensiontravelislim-

TiresandWheels
itedbyrubberbumpstops.
ThethreepointmountingofeachL-shapedcontrolarmere-

Tiresizeiscritica¡totheproperoperatíonoftheE36ABSor
ciselycontrolsthefront-to-rearandside-to-sidepositionofthe

ABS/ASTsystem.Severa¡differentstylesofwheels,in15,16
strut,whiletheflexibilityofthejointsandmountsalsoallows

and17inchdiameters,areavailablefromanauthorizedBMW
themovementnecessaryforsuspensiontravel.Thecontrol

dealer.
armmountingpointsaredesignedwithanti-divegeometry.
Thesuspensionreducesthenormaltendencyforthefrontof

NOTE-
thevehicletodiveunderhardbraking.

Aftermarketwheelsshouldbeselectedwlthcare.Im-
properlyfittedwheelscancontactanddamagesus
Controlarmpositionisfixed,withnoadjustmentprovisions

pension,brakeorbodycomponentsandmayadversely
onthecontrolarmsforalter¡ngfrontwheelalignment.Astabi-

affectvehiclestability.
lizerbarmountedtobothcontrolarmshelestoreducebody
rol¡whencomering.

INTEGRATEDSYSTEMS
AntilockBrakeSystem(ABS)isstandardonallE36cars.
Thevariable-assistpowersteeringsystemconsistsofan

Standardonsomemodelsandinstalledasoptionalequipmenton
engine-drivenhydraulicpump,arack-and-piniontypesteer-

others,isAllSeasonTraction(AST).
inggear,andconnectinglinkagetotheroadwheels.TheE36
utilizesanengine-speeddependentvariableeffortsteering

AntilockBrakeSystem(ABS)
system.Atlowspeeds,maximumpowerassistisprovidedto
easeparkingandcitydriving.Athighspeeds,assistisre-

Theelectronically-controlledABSmaintainsvehíclestabili
ducedtoensurestability.

tyandcontrolduringemergencybrakingbypreventingwheel
lock-up.ABSprovidesoptimumdecelerationandstabilitydur-

Wheelbrake
caliper
Electronic
controlmodule
Fig.4.

SchematicrepresentationofABS.
SUSPENSION,STEERINGANDBRAKES-GENERAL

300-3
Fig.3.

Schematicviewofdualcircuitbrakeswith4-channelABS.
ingadverseconditions.Itautomaticallyadjustsbrakesystem
hydraulicpressureateachwheeltopreventwheellock-up.
Thesystem'smaincomponentsarethewheelspeed
(pulse)sensors,theABScontrolmodule,andthehydraulic
controlunit.SeeFig.4.
Warning
lamp
u
Master
Whee
_
lspeed

I-lydraulic

cylinder
sensor

controlunit

0012135
UNI
Thewheelspeedsensorscontinuouslysendwheelspeed
signalstothecontrolmodule.SeeFig.5.Thecontrolmodule
comparesthesesignalstodetermine,infractionsofasecond,
whetheranyofthewheelsareabouttolock.Ifanywheelis
nearingalock-upcondition,themodulesignalsthehydraulic
unittomaintainorreducepressureattheappropriate
wheel(s).Pressureismodulatedbyelectrically-operatedsole-
noidvalvesinthehydraulicunit.
Fig.5.

ABSwheelspeedsensor.
0006563
INTEGRATEDSYSTEMS

300-4

SUSPENSION,STEERINGANDBRAKES-GENERAL
Three-channelABSísusedonal[E36carsequippedwith

Al¡SeasonTraction(AST)
standardABS.Eachfrontwheelhasaseparatesolenoid
valvetomodulatehydraulicpressuretothatbrakecaliper.

ThetractioncontrolsystemworksinconjunctionwithABS
Therearwheelsaremodulatedasapair,controlledbyasin-

andtheenginemanagementsystemtoenhancevehiclecon
glesolenoidvalve.

trol.ThemainfunctionoftheASTsystemistomaintaintherolling
contactbetweenthetiresandtheroadsurfaceunderal¡driving
E36carsequippedwithABS/ASTutilizeafourchannelsys-

conditions.Thisisachievedthroughexactapplicationand
tem,whichfunctionsexactlyasthethreechannelsystem

managementofbrakinganddrivetrainforces.
above,exceptthattherearwheelsaremodulatedindividually.
IDLESPEED
CONTROLVALVE
HROTTLE
PLATE
6.
Í
II
I
i

ADSACTUATOR
THROTTLEPLATE
POSITIONSENSOR
DME
Fig.6.AllSeasonTraction(AS)workswithotherdrivetrainsystemstoenhancevehiclecontrol.
INTEGRATED SYSTEMS
ThethrottlecontrolsystemusedinASTisillustratedinFig.
MASSAIRFLOWSENSOR
JADS THROTTLEPLATE
POSITIONSENSOR
0013006

NOTE-
ThetractioncontrolsystemreferredtoasAST(allsea-
sontraction)mayalsobereferredtoasASC(Automat-
icStabilityControl)andASC+T(AutomaticStability
Control+Traction).
TheASTsystemimprovestractionbyelectronicallyapply-
ingtherearbrakeswhenthereardrivewheelsarespinningat
afasterratethanthefrontwheels.ThecombinedABS/AST
controlmodule,operatingthroughtheABShydrauliccontrol
unit,modulatesbrakingforceattherearwheels.
Inaddition,ASTusesretardedignitiontimingandanauxil-
iaryenginethrottleplatetoreduceenginetorqueandmaintain
vehiclestability.
Theauxiliarythrottleplateisheldopenbyspringpressure.
TheASTsystemactívatestheauxiliarythrottiepositionmotor
(ADS)tocosetheASTthrottleasneeded.Thisreducesthe
volumeofengineintakeair.Duetothethrottleclosingvery
rapidlyduringASToperationthedrivercannotincreasethe
enginepoweroutputregardlessofhowfartheaccelerator
pedalispushedtothefloor.
Theauxiliarythrottleplateisplacedaheadoftheconven-
tionalthrottleplateinthethrottlebody.
Tractioncontrolalsocomesintooperationduringdecelera-
tion.Deceleratingonsnowyoricyroadsurfacescanleadto
rearwheelslip.Ifarearwheelstartstodragorlockupwhen
thethrottleisclosedrapidlyorduringdownshifting,theAST
systemcanlimittheproblembyadvancingtheignitiontiming.
AswitchonthecenterconsoleisusedtotoggletheASTon
oroff.
TheASTsystemisdesignedtobemaintenancefree.There
arenoadjustmentsthatcanbemade.Repairandtrouble-
shooting
oftheASTsystemrequiresspecialtestequipment
andknowledgeandshouldbeperformedonlybyanautho-
rizedBMWdealer.Tablealiststheconditionsindicatedby
theASTindicatorlightintheinstrumentcluster
SUSPENSION,STEERINGANDBRAKES-GENERAL

300-5
Table a.AST Indicator
Lamp Function
Indicatorlamp

1Condition

1Comment
Lighton

NormalASTstart-

AutomaticAST
up

self-test
Lightoff

ASTmonitoring

AutomaticASTop-
mode

eration
PressASTbutton,

ASToff(disabled)

Rockingthecarto
lightcomeson

getoutofsnowor
otherloosesurface
Drivingwithsnow
chains
PressASTbutton:

ASTmonitoring

AutomaticASTop-
lightgoesout

Imode

eration
Lightflashes

ASTactivemode

INormalASToper-
ationasitcontrols
wheelspeed
Lightstaysonaf-

DefectinAST

ConsultBMW
terstartupor

dealerfordiagno-
comesonwhile

sis/repair
driving

(Vehicleoperation
remainsnormal)
WARNING-
EvenacarwithASTissubjecttothenormalphysi-
callaws.Avoidexcessivespeedsfortheroadcon-
ditionsencountered.
CAUTION-
"Ifthetiresonthecarareofdifferentmakes,the
ASTsystemmayover-react.Onlyfittiresofthe
samemakeandtreadpattem,
"Inadverseconditions,suchastryingtorockthe
caroutofdeepsnoworanothersoftsurface,or
whensnowchainsarefitted,itisadvisableto
switchoffASTandallowthecarsdrivelinetoop-
erateconventionally.
INTEGRATED SYSTEMS

300-6

SUSPENSION,STEERINGANDBRAKES-GENERAL
BATTERY
KL30
ECM
MAIN
C~RELAY

KL15
DSCSWITCH
LF
1;1~lZZ~

nSLn
l'zsJ

WHEEL
RF
c_.
LR
r_.
>
RR
ELECTRONIC
BRAKELIGHT
SWITCH
SPEED
SENSORS
Fig.7.

SchematicofAIISeasonTraction(AST)system.
INTEGRATEDSYSTEMS
EDC
POWERSUPPLY

SOLENOID
RELAY
GROUNDCONTROL
POWERSUPPLYI'1
ABS
PUMP
GROUNDCONTROLÍ
F

f
iJ
RELAY
INLET(4X)
wxxuw
OUTLET(4X)

-=-=--

AST
AST
INTAKE
IHYDRAULIC-=-
SWITCHING =---
!99001!J
WHEELSPEEDX4
DMEII
000001-f

1UNIT
AGS
IKE&
DMEI
PARKBREVE
771SWITCH
M
ALTERNATOR

AUXILIARYTHROTTLE
r`

INDICATOR

POSITIONMOTOR
(ADS)
ABSPUMP

DIAGNOSIS
RELAY

lu~~~b
0013027

increasedpoweroutputandroad-handlingdemands.
Thesteeringgeometryismodifiedbychangingthecast-
er/camberanglesslightly.Thisisaccomplishedbyreposition-
ingtheupperstrutmountingholesinthefrontstruttowersand
throughdifferentfrontandrearcontrolarms.
M3BrakeSystemImprovements
"Venteddirectionalfront
rotors:315mmdia.x28mmthick.
"Venteddirectionalrear
rotors:312mmdia.x20mmthick.
"Largerbrakepadsandcalipers.
"ModifiedTevesABSsystem.
SUSPENSION,STEERINGANDBRAKES-GENERAL

300-7
M3SUSPENSIONANDBRAKES

NOTE-
M3brakerotorsaredirectional,havingadifferentpart
TheE36M3wasintroducedinlate1994asa1995model.

numberforeachside.Rotorswithanoddpartnumber
ThedesignoftheM3suspension,steeringandbrakesisa

goontheleftwhilerotorswithenevenpartnumbergo
modificationofexistingE36systemswhichaccommodates

ontheright.
M3FrontSuspensionImprovements
"Reinforcedspringplates,controlarms,controlarmbush-
ings,steeringarms.
"Recalibratedstruts,firmersprings.
"Stifferstabilizerbar,largerstabilizerbarbushings.
"Frontstabilizerlinkedtostruts.
M3Wheels/Tires
"Frontwheels1992-1998:.....7.5Jx17in.lightalloy
"Rearwheel1992-1997.......7.5Jx17in.lightalloy
"Rearwheel(option).........8.5Jx17in.lightalloy
"Frontandreartire
1992-1997......................235/40x17in.
"Fronttire1998only...............225/45x17in.
"Reartire1998only................245/40x17in.
CAUTION-
Inenemergency,anM3frontwheel/tireassembly
maybemountedontherearaxle.Howeverarear
wheel/tireassemblymustnotbemountedonthe
frontaxle.
M3RearSuspensionImprovements
"Reinforcedtrailingarms.
"Recalibratedshockabsorbers,firmersprings.

SUSPENSIONANDSTEERING
TROUBLESHOOTING
Stablehandlingandridecomfortbothdependontheinteg-
rityofthesuspensionandsteeringcomponents.Anysymp-
tomofinstabilityorimpreciseroadfeelmaybecausedby
wornordamagedsuspensioncomponents.
Whentroubleshootingsuspensionandsteeringproblems,
alsoconsidertheconditionoftires,wheels,andtheiralign-
ment.Tirewearandincorrectinflationpressurescandramati-
callyaffecthandling.Subtieirregularitiesinwheelalignment
anglesalsoaffectstabílity.Mixingdifferenttypesorsizesof
tires,particularlyonthesameaxle,canaffectalignmentand
mayunbalanceacar'shandling.
Tablebliststhesymptomsofcommonsuspensionand
steeringproblemsandtheirprobablecauses,andsuggests
correctiveactions.Boldtypeindicatestherepairgroups
whereapplicabletestandrepairprocedurescanbefound.
SUSPENSIONANDSTEERINGTROUBLESHOOTING

300-8

SUSPENSION,STEERINGANDBRAKES-GENERAL
Tableb.SuspensionandSteeringTroubleshooting
Symptom

1

Probablecause
Repairs
(RepairGroupsshowninbold)
Carpulístooneside,wanders

a.Incorrecttirepressure

a.Checkandcorrecttirepressures.020
b.Incorrectwheelalignment

b.Checkandadjustwheelalignment.320
c.Faultybrakes(pullsonlywhenbraking)

Ic.Checkforsticking/damagedfrontcaliper.340
Steeringheavy,poorreturn-

a.Wornupperstrutbearing(s)

a.Replacestrutbearings.310
to-center

b.Incorrecttirepressure

b.Checkandcorrecttirepressures.020
c.Powersteeringsystemfaulty

c.Checkpowersteeringfluidlevel.Testsystem
pressure.320
Front-endorrear-endvibra-

a.Wornstrutcartridgesorshockabsorbers

a.Replacestrutcartridges.310,330
tionorshimmy

b.Wornsuspensionbushings(controlarmortrail-

b.Replacewornbushings.310,330
ingarm)
c.Wornfrontsuspensionballjoints(controlarm,

c.Replacewornballjoints.310
steeringarmorsteeringtie-rodend)
d.Unbalancedorbentwheels/tires

d.Balancetires.Checktiresforunevenwearpat-
terns.Checkwheelsfordamage.
e.Loosewheellugboits

e.Tightenlugboitstopropertorque.
Poorstability,repeatedbounc-Ia.Wornstrutcartridgesorshockabsorbers

Ia.Replacestrutcartridges.310,330
ingafterbumps,suspension
bottomsouteasily
Suspensionnoise(especially

a.Wornfrontupperstrutbearings

a.Replaceupperstrutbearings.310
overbumps)

b.Loosefrontstrutcartridge

b.Check/tightenstrutcartridgecollarnut.310
c.Wornsuspensionbushings(controlarmortrail-

c.Replacewornbushings.310,330
ingarm)
d.Wornstabilizerbarrubbermounts

d.Replacestabilizerbarrubbermounts.310,330
e.Loosesuspensioncrossmember

e.Checkcrossmemberfordamage.Tighten
mountingboits.
Unevenrideheight

a.Incorrectcoilsprings

a.Measurerideheightandreplacespringsasre-
quired.310,330
b.Bentordamagedsuspensioncomponents

b.Inspect,repair/replaceasnecessary.310,330
c.Saggingcoilsprings

c.Measurerideheightandreplacespringsasre-
quired.310,330
Wheelnoise,continuous

Ia.Wornwheelbearing

Ia.Replacewheelbearing.310,330
growling,maybemorenotíce-
ablewhenturning
Steeringloose,imprecise

a.Incorrecttirepressure

a.Checkandcorrecttirepressures.020
-

b.Loosesteeringgearmountingbolt(s)

b.Inspectandtightenboits.320
c.Worntierodend(s)

c.Replacetierod(s)andalignwheels.320
d.Faultyfrontwheelbearing

d.Replacewheelbearing.310
e.Wornordamagedsteeringgear

e.Adjustorreplacesteeringgear.320
f.Worntires

f.Replacetires.010
SUSPENSION ANDSTEERING TROUBLESHOOTING

GENERAL
310FrontSuspension
GENERAL ............................310-1

FRONTWHEELBEARINGS ............310-8
SHOCKABSORBERS ANDSPRINGS...310-2

Frontwheelbearing,replacing.............310-8
Strutassembly,removingandinstalling.....310-2

STABILIZERBAR......................310-9
Strutassembly,disassembling

Stabilizerbar,removingandinstalling.......310-9
andassembling......................310-4
RideHeight...........................310-4

SUBFRAME CROSSMEMBER ...........310-9
Subframecrossmember,
CONTROL ARMS.....................310-5

removingandinstalling.................310-9
Controlarm,removingandinstalling....

..310-5
Outercontrolarmballjoint,replacing

Table
excetM3models

310-6

a.FrontRideHeightSpecifications...............310-5
Controlarmbushing,replacing............310-7
TheE36frontsuspensionisshowninFig.1.Forageneral

Specialservicetoolsarerequiredformostoftheworkde-
descriptionofthefrontsuspensionandcomponents,see300

scribedinthisrepairgroup.Readtheproceduresthroughbe-
Suspension,SteeringandBrakes-General.

forebeginninganyjob.
Stabilizerbar
Powersteering
fluidcooler
Control

Strutassembly
arm
Tierod
Fig.1.

BMWE36frontsuspension.(M3suspensionshown.Othersaresimilar.)
FRONTSUSPENSION

310-1
Steering
arm 0012132
GENERAL

310-2

FRONTSUSPENSION
WARNING-
"Physicalsafetycouldbeimpairedifprocedures
describedhereareundertakenwithouttheproper
servicetoolsandequipment.Besuretohavethe
righttoolsonhandbeforebeginninganyjob.
"Donotreuseself-lockingnutsorbolts.Theyare
designedtobeusedonlyonceandmayfailifre-
used.Alwaysreplaceself-lockingfastenersany
timetheyareloosenedorremoved.
"Donotinstallboltsandnutscoatedwithunder-
coatingwax,asthecorrecttighteningtorquecan-
notbeassured.Alwayscleanthethreadswith
solventbeforeinstallation,orinstallnewparts.
"Donotattempttoweldorstraightenanysuspen-
sioncomponents.Replacedamagedparts.
SHOCKABSORBERS ANDSPRINGS
ThecompletefrontstrutassemblyisshowninFig.2.Most
strutassemblycomponentsareavailableasreplacement
parts.
NOTE-
Strutsandlorspringsshouldalwaysbereplacedin
parts.
Strutassembly,removingandinstalling
1.Raisecarandremovefrontwheel.
WARNING-
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispointDonot
placejackstandsundersuspensionparts.
2.Unboltbrakecaliperassembly,keepingbrakehose
connected.Detachbrakehosefromstrutassembly.
Suspendbrakecaliperfromchassisusingstiffwire.Re-
movebrakerotor.See340Brakes.
SHOCKABSORBERS ANDSPRINGS
0011191
Fig.2.

Frontstrutassemblywithsteeringarm,fronthub,frontspring
andstrutuppermount.
3.RemoveABSwheelspeedsensor.SeeFig.3.
4.DisconnectABSsensorwireharnessandbrakepad
wearsensorwireharness(leftsideonly)fromstrut
housing.
5.OnM3modeis:Disconnectstabilizerbarlinkfromstrut.

Fig.3.

ABSwheelspeedsensormountingbolt(arrow).
NOTE-
Noteflatsonstabilizerbarlinkballjointforplacement
ofopenendwrench.
CAUTION-
Donotremovecenterstrutretainingnut.
8.Lowerstrutassemblyfromcar.
NOTE-
Storetheremovedstrutassemblyupríght.Donotallow
ittolíehorizontallyorupside-downforanylengthof
time.Ifíncorrectstoragehasoccurred,placethestrut
assemblyupríghtwíththerodfullyextendedforatleast
24hours.
0012117
FRONTSUSPENSION

310-3
6.Unboltsplashshieldandsteeringarmfromstrut.Sus-

Fig.4.

Strutandsteeringarmassembly.
pendsteeringarmassemblyfromchassisusingstiff
wire.SeeFig.4.
1.Nut

6.Bolt
2.Strut

7.Bolt
3.ABSwheelspeedsensor

8.Flatwasher
4.Cableholder

9.Self-lockingnut
5.Steeringarm

10.Washer
11.Bolt
9.Installationisreverseofremoval.Besuretousenew
CAUTION-

self-lockingnutsandbolts.
Thesteeringarmballjointcanbedamagedifthe

"Usenewsteeringarmmountingbolts,orcleanbolts
armisallowedtohangunsupported.

anduseLocktite®270orequivalentthread-locking
compound.
7.Supportstrutassemblyfrombelow.Fromabove,re-

"OnM3models:Whenattachingstabilizerlinktostrut,
movethreestrutmountingnutsonstruttower.

useathinwrenchtoholdflatsonlinkparalleltostrut.
"HavecarprofessionallyalignedWhenjobiscomplete.
TighteningTorques
"Brakecalipertosteeringarm......110Nm(81ft-lb)
"Roadwheeltohub.........100±10Nm(74t7ft-Ib)
"Stabilizerbarlinktostrut(M3)......59Nm(44ft-lb)
"Steeringarmtostruthousing
"(encapsulatedbolts-alwaysreplace)107Nm(78ft-lb)
"Strutassemblytostruttower
(self-lockingnuts)................24Nm(16ft-Ib)
SHOCKABSORBERS ANDSPRINGS

310-4

FRONTSUSPENSION
Strutassembly,
disassemblingandassembling
-Besureupperspringpadiscorrectlyinstalledtoupper
NOTE-

springplateandspringendiscorrectlyseatedinup-
Springsandlorstrutsshouldalwaysbereplacedin

perandlowerspringplates.
pairs.

"Useanewself-lockingtop(center)nut.Tightennutfui-
¡ybeforereleasingspringcompressor.
Replacingtheupperstrutmount,springandstrutrequires

"Havecarprofessionallyalignedwhenjobiscomplete.
thatthestrutfirstbedisassembled.Foraguidetotheparts
duringstrutreplacement,seeFig.5.
TighteningTorques
WARNING-

"Upperstrutmounttostrutshaft(seif-lockingnut)
Donot,attempttodisassemblethestrutswithouta

shaftwithexternalhexagon........65Nm(48ft-1b)
springcompressordesignedspecificallyforthisjob.

shaftwithinterna¡hexagon.........44Nm(32ft-Ib)
"Roadwheeltohub.........100±10Nm(74±7ft-lb)
1.Removestrutassemblyasdescribedearlier.Placein
securesupport.
RideHeight
2.Usingspringcompressor,compressspringuntilspring
forceonuppermountisrelieved.

Rideheightismeasuredfromtheloweredgeofthewheel
archtothebottomedgeofthewheelrim.SeeFig.6.
WARNING -
Makesurethespringcompressorgrabsthespring

lftherideheightisoutsidethespecificationlisted,new
fullyandsecurelybeforecompressingit.

springsshouldbeinstalled.Besuretohavetheoldspring
codenumberonhandwhenorderingnewspring.
3.Pryprotectivecoverofftopofstrutassembly,thenre-
movetop(center)nutandwasherwhileholdingstrut

NOTE-
shaftstationary

Thespringpartnumberisstampedneartheendofthe
springcofls.
4.Removeupperstrutmountandrelatedcomponents.
5.Releasespringcompressorcarefullyandevenly,allow-
ingspringloexpandslowly
1
Self-lockinghexnut

Absorber/
Flatwasher

bumpstop
Nut
Cover
Upper

~
strut
mount

PinZ

Pistonbellows
Flatwasher

r
i
t1

~

1
Upperspringplate
1

1

1
Upperspringpad

I

1
-

,

Lowerspringpad
-Í

0012136
Fig.5.

Frontspring,springplateandrelatedparts.
SHOCKABSORBERS ANDSPRINGS
6.Assemblyisreverseofdisassembly,notingthefollow-
ing:
Tablealistsfrontsuspensionrideheightspecifications.
Thesespecificationsapplytoacarinanormallyloadedposi-
tion.Whencheckingrideheightorinstallingsuspensioncom-
ponentsthatrequirethecartobe"normallyloaded,"loadthe
carasfollows:

Fig.6.

Rideheightmeasurement(A)istakenfromcenterofwheel
archtobottomofwheelrim.
Normalloadedposition
"Eachfrontseat...................68Kg(150Ibs)
"Rearseat(center)................68Kg(150Ibs)
"Trunk...........................21Kg(46lbs)
"Fueltank.................................fuf
Tablea.FrontRideHeightSpecifications
318,323,325,
Wheelsize

M3models
328models
15inch
std.suspension

576mm(22.67in)

1555mm(21.85in)
sportsuspension

~
561mm(22.09in)

530mm(20.87in)
16inch
std.suspension

589mm(23.19in)

1570mm(22.44in)
sportsuspensíon

~
574mm(23.52in)

545mm(21.46in)
17inch
std.suspension

604mm(23.77in)

585mm(23.03in)
sportsuspension

~
589mm(23.19in)

~
560mm(22.05in)
Maximumvariationbetweensides:10mm(0.4in)
Maximumdeviationfromspecifications:10mm(0.4in)
FRONTSUSPENSION

310-5
CONTROLARMS
Onal¡modelsexceptMas,theoutermountingbushingand
theouterballjointonthecontrolarmareavailableasreplace-
mentparts.Ifthecontrolarmcenterballjointisworn,thecom-
pletecontrolarmwillneedtobereplaced.SeeFig.7.
Fig.7.

Controlarm.Outerballjointandbushingareavailableasre-
placementparts(exceptM3).Centerballjointisintegralwith
controlarm.
Specialpresstoolsarerequiredtoremovethecontrolarms
andtoreplacethecontrolarmbushings.Readtheprocedure
throughbeforebeginningthejob.
Controlarm,removing andinstalling
1.Raisecarandremovewheel.
WARNING-
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Removestabilizerbarlinkmountingnutandseparate
linkfromcontrolarmasdescribedlaterinthisrepair
group.
NOTE-
OnM3models,thestabilizerbarlinkattachestothe
strut.
CONTROLARMS

310-6

FRONTSUSPENSION
3.Workingatsteeringarm,removecontrolarmballjoint
nut.SeeFig.8.Pressballjointoutofsteeringarm.
Fig.8.

Controlarmballjointnutatsteeringarm(arrow).
4.Removecontrolarmtosubframecrossmemberball
jointnut.Separateballjointfromcrossmember.Work-
ingatotherendofcontrolarm,removeboltsattaching
controlarmbushingcarriertobody.SeeFig.9.
Fig.9.

Controlarmbushingcarrierbolts(arrows).
0012117
0011960
5.Installationisreverseofremoval.Makesureal¡thread
bores,bolts,nutsandmatingsurfacesareclean.Use
newself-lockingnutsorbolts,whereapplicable.
WARNING-
"Donotreuseself-lockingnutsorbolts.Theyare
designedtobeusedonlyonceandmayfailifre-
used.
"Boltsandnutscoatedwithafockingcompound
fromthefactoryshouldnotberefnstalled.Always
replace`micro-encapsulated"fastenerssuchas
thesteeringarm-to-strutbolts.
CONTROL ARMS
TighteningTorques
"Controlarmballjointto
subframecrossmember...........85Nm(62ft-Ib)
"Controlarm'balljointtosteeringarm.65Nm(48ft-Ib)
"Controlarmbushingcarriertobody..47Nm(34ft-Ib)
"Stabilizerbarlinktocontrolarm(M8).42Nm(31ft-Ib)
"Roadwheeltohub.........100±10Nm(74±7ft-Ib)
Outercontrolarmballjoint,replacing
(exceptM3models)
OnallmodelsexceptMas,theouterballjointisavailableas
areplacementpart.Theballjointcanbereplacedwiththe
controlarminstalled.
Specialtoolsarerequiredtoreplacetheballjoínt.Readthe
procedurethroughbeforebeginningthejob.
1.Disconnectstabilizerbarlinkfromcontrolarmasde-
scribedlaterinthisrepairgroup.
NOTE-
OnM3models,thestabilizerbarlinkattachestothe
strut.ttfsnotnecessarytodisconnectthestabilizerbar
linkonM3modelsforthfsrepairprocedure.
2.Loosennutforballjointuntilitcontactssteeringarm.
3.Usingasuitableballjointtool,separatejointfromsteer-
íngarm.Removeballjointmountingnutandpullball
jointoutofsteeringarm.
4.Markpositionofballjointguidetocontrolarm.SeeFig.
10.
0012718
Fig.10.Markinstalledpositionofballjointguidetocontrolarm(sr-
row).
5.Movesuspensionstrutoutofwayandpressballjoint
outofcontrolarm.

6.Installationisreverseofremoval.
"Makesurecontrolarmballjointtaperboreiscleanand
freeofanycorrosion.
"Pressnewballjointintoposition,makingsuretoalign
balljointguidewithmarkmadeearlier.
"Verifythatlockingcliponnewballjointfacestowards
centerofvehicle.
TighteningTorques
"Controlarmballjointtosteeringarm.65Nm(48ft-Ib)
"Stabilizerbarlinktocontrolarm(M8)42Nm(31ft-Ib)
"Roadwheeltohub.........100±10Nm(74t7ft-lb)
Controlarmbushing,replacing
Controlarmbushingsshouldaiwaysbereplacedinpairs
andthetwobushingsandbushingcarriersshouldhavethe
samemarkings,indicatingsamemanufacturer.
1.Raisecar.
WARNING-
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Unboltcontrolarmbushingcarrierfrombody.
3.Markinstalledpositionofbushingtocontrolarm.SeeFig.
11.
assemblyoffcontrolarm.
lnl~
0012145
FRONTSUSPENSION

310-7
NOTE-
Thekerosene-likespeciallubricantisusedonlyasan
aidininstallingthebushingtothecontrolarmstub.
Workmustbecarriedoutinasshortatimeaspossible.
Within30minutesthecontrolarmbushingwillbe
`glued"inpositiononthecontrolarm.
CAUTION-
BMWpartnumbersareprovidedforreference
onlyandaresubjecttochange.Alwaysrelyonan
authorizedBMWdealerpartsdepartmentforthe
mostup-to-dateinformation.
6.Pressnewrubbercontrolarmbushingassemblyonto
theendofcontrolarmtoproperdepth(asmarked).
NOTE-
Besuretoreinstallthebushingcarriertothecontrol
armcorrectly.Thecarrierhascenteringboresonside.
Thissidemustfaceuptowardsbody.SeeFig.12.
Fig.12.Controlarmbushingcarriercenteringboresmustfaceup.
7.Immediatelyboltcontrolarmbushingcarriertobody,
torqueboitsandlowercartoground.
TighteningTorques
"Controlarmbushingcarriertobody..47Nm(34ft-ib)
Fig.11.Beforeremovingbushingfromcontrolarm,markinstalledpo-
sitionofoldbushingtocontrolarm.Insta¡¡newbushingin
sameposition.

8.Withcarloweredtogroundandloadedasdescribed
earlier,bouncesuspensionafewtimes,thenleavecar
4.Usingappropriatepresstools,pullcontrolarmbushing

undisturbedforaminimumof30minutes.
CAUTION-
5.CoatendofcontrolarmwithBMWspeciallubricant

IFailuretofollowtheaboveproceduremayimpair
partno.81229407284.

thecar'shandlingandstability.
CONTROLARMS

310-8

FRONTSUSPENSION
FRONTWHEELBEARINGS
Thefrontwheelbearingsarepermanentlysealedandre-
quirenomaintenance.Thebearingisintegralwiththewheel
hubandpressedontothesteeringarmstubaxle.
Specialpresstoolsarerequiredtoreplacethefrontwheel
bearings.Readtheprocedurethroughbeforebeginningthe
job.
Frontwheelbearing,replacing
1.Raisecarandremovewheel.
WARNING-
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Pryoffdustcapfromcenterofwheelhub.Bendback
stakedpartofwheelhub(axle)collarnut.SeeFig.13.
Fig.13.Stakedpartofwheelhubcollarnuttobebentback(arrow).
3.Remountwheelandlugbolts.
4.Lowercantoground.Withanassistantapplyingbrakes,
loosencollarnut.Donotremovecompletely.
NOTE-
Thewheelhubcollarnutistightenedtoatorqueof290
Nm(214ft-Ib).Makesurethecarisfirmlyonthe
ground.
FRONTWHEELBEARINGS
6.RemoveABSwheelspeedsensor.RefertoFig.3.
7.Removebrakecaliperassemblyandbrakerotorasde-
scribedin340Brakes.Leavebrakehoseconnectedto
caliper.Suspendcaliperassemblyfromchassisusing
stiffwire.
8.Removewheelhubcollarnut.
9.Removewheelhubwithintegralwheelbearingfrom
steeringarmusingapuller.SeeFig.14.
0011200
Fig.14.Wheelhubwithintegralwheelbearingbeingremovedusinga
puller.
NOTE-
Ifbearinginnerracestaysonsteeringarm,remove
splashguardandusetwojawpullertoremoverace.
10.Insta¡¡splashguardandnewdustshieldbehindbear-
ing.Pressnewwheelhub/bearingassemblyonusing
appropriatepresstools.
NOTE-
Whenpressingthewheelhublbearingon,applyforce
onlytothebearinginnerrace.
11.Installnewcollarnut.Donottightennuttoitsfinal
torqueatthistime.
"Installbrakerotorandbrakecaliper.See340Brakes.
"Mountwheelandlugboits.Lowercantogroundtogain
leverage.
12.Withanassistantapplyingbrakes,tightencollarnut
andthenstakenuttoaxle.
5.Raisecarandremovewheel.

13.Raisecarandremovewheel.

STABILIZERBAR
Stabilizerbar,removingandinstalling
Stabilizerbarlinkarrangementsdifferslightlyamongmod-
els.Inmostmodelsthelinksattachlothecontrolarmsnear
theoutboardend.OnM3modelsthelinksattachlothestrut
assemblies.
1.Raisecarandremovebothfrontwheels.
WARNING -
Makesurethatthecarisfirmlysupportedonjack
standsdesígnedforthepurpose.Placethejack
standsbeneathastructuralchassíspoint.Donot
placejackstandsundersuspensionparts.
uul
Fig.15.Disconnectstabilizerbarconnectinglinkatbar(arrow).(3181
modelshown.M3stabilizerlinkattacheslostrut.)
FRONTSUSPENSION

310-9
14.Insta¡¡anewgreasecap,usingLoctite©638sealantor

3.Removetwostabilizerbarbushingbracketsonleftand
equivalent.Insta¡¡wheelandlowercar.

rightsides.Removebar.
4.Installationisreverseofremoval.Usenewseif-lockíng
TighteningTorque

nútsonconnectinglinks.
"Brakerotorlowheelhub..........16Nm(12ft-Ib)

"OnM3models:Whenattachingstabilizerlinklostrut
"Collarnutlostubaxle..........290Nm(214ft-Ib)

orlobar,useathinwrenchloholdflatsonlinkparallel
"Brakecaliperlosteeringarm......

110Nm(81ft-Ib)

lostrut.
"Roadwheellohub.........100±10Nm(74t7ft-Ib)
NOTE-
Installationofthestabilizerbariseasiestwiththecar
leve¡(frontwheelsatthesameheight),andasnearto
normalrideheightaspossible.
TighteningTorques
"Stabilizerbarbushingbrackets
losubframecrossmember.........22Nm(16ft-Ib)
"Stabilizerbarlinkbracketlo
controlarm.....................42Nm(31ft-1b)
"Stabilizerbarlinklo
stabilizerbar(M10)..............42Nm(31ft-Ib)
"Stabilizerbarlinklostrutorbar(M3).59Nm(44ft-Ib)
SUBFRAME CROSSMEMBER
Thesubframecrossmemberprovidesrigidmounting'poínts
2.Removestabilizerbarconnectinglinkfromstabilizer

fortheengine,suspension,andsteeringcomponents.The
baronleftandrightsides.SeeFig.15.

crossmemberisnotnormallysubjectlowearandshouldohly
bereplacedifstructurallydamaged.
Removingthesubframecrossmemberrequiresenginelift-
ingequipmentlosupporttheweightoftfheenginefromabove
sothatthesubframecanberemovedfrombelow.
WARNING-
Removalorreplacementofthesubframecross-
membermayaffectsuspensionandsteeringgeom-
etry,includingfrontwheelafignment.Make
appropriatematchingmarksduringremovaland
havethefrontendalignedoncerepairsarecom-
plete.
Subframecrossmember,
removingandinstalling
1.Usingenginesupportequipment,raiseengineuntil
weightofengineissupported.See110EngineRe-
movalandInstallation.SeeFig.16.
2.Raisecarandremovefrontwheels.
WARNING-
Makesurethatthecarisfirmlysupportedonjack
standsdesígnedforthepurpose.Placethejack
standsbeneathastructuralchassíspointDonot
placejackstandsundersuspensionparts.
SUBFRAME CROSSMEMBER

310-10

FRONTSUSPENSION
Fig.16.Supportequipmentusedtosupportenginefromaboye.
SUBFRAMECROSSMEMBER
Fig.17.Rightsidecrossmember-tobodymountingbolts.
3.Workingbeneathcar,removeleftandrightnutsfrom

10.Installationisreverseofremoval,notingthefollowíng:
enginemounts.

"Makesureallbolts,boltholes,andmatingsurfacesare
cleantoensurepropertighteningandalignment.Use
4.Removecontrolarmbushingcarrierfrombody.Referto

newself-lockingnutsorbolts,whereapplicable.
Fig.9.

"Onvehiclesproducedup9-92only:
-Removepaintfromcontactsurfacesbeforeínstall-
5.Removecontrolarmballjointfromcrossmember.Sep-

ingcrossmember.
aratejointwithaplastichammer.Suspendcontrolarm

-Install4newtoothedlockwashersbetweensub-
fromchassisusingstiffwire.

frameandchassis(installnewwashersregardless
ofwhetherwasherswereoriginallyfitted).
WARNING-

-Replaceall4mountingbolts.
Donotallowthecontrolarmtohangfromtheball

-LubrícatesuspensioncrossmemberboltswithLM48
¡oint.Thiscandamagetheball¡oint.

pasteorequivalentanti-seizecompoundbeforeín-
stalling.
6.Unboltsteeringrackfromsubframe.See320Steering

"Lowerengineontoenginemounts,allowingittosettle
andWheelAlignment.Suspendsteeringrackfrom

fullybeforetighteningenginemountbolts.
chassisusingstiffwire.Usingatransmissionjackor

"Whenthejobiscompletedhavefrontendprofession-
equivalent,supportcrossmemberfrombelow.

allyaligned.
7.Removereinforcingbracebelowoilpan,whereappli-
cable.

TighteningTorques
"Subframecrossmembertobody
8.Unboltcrossmemberfrombodyonbothsides.SeeFig.

M12-8.8bolts...................77Nm(56ft-Ib)
17.

M12-10.9bolts.................110Nm(81ft-Ib)
M12-12.9bolts.................105Nm(77ft-Ib)
9.SlowlyLowercrossmember,makingsureallelectrical

"Steeringgeartosubframecrossmember
teads,suspensioncomponentsandheatshieldsare

(M10-10.9self-lockingbolts).......42Nm(31ft-Ib)
clearduringremoval.

"Controlarmballjointto
subframecrossmember...........85Nm(62ft-Ib)
"Controlarmbushingcarrier
tobody........................47Nm(34ft-Ib)

320SteeringandWheelAlignment
GENERAL ............................320-1

Outertierodend,replacing...............320-4
Tierod,replacing.......................320-5
STEERINGWHEEL

320-1
Steeringwheel,removingandinstalling.....320-1

WHEELALIGNMENT...................320-5
POWERSTEERINGSYSTEM...........320-2

FrontToe-inandToeDifferenceAngle......320-6
Powersteeringpump,

RearToe-in...........................320-6
removingandinstalling................320-2

WheelAlignmentSpecifications............320-6
Powersteeringsystem,bleedingandfilling..320-3
STEERINGGEAR.....................320-3
Steeringgearrack,
removingandinstalling..................320-3
GENERAL

STEERING WHEEL
Thisrepairgroupcoversservicingofthemechanicaland

TheBMWE36isequippedwithanSRSairbagmountedin
hydrauliccomponentsofthesteeringsystem,includingwheel

thesteeringwheel.Improperhandlingoftheairbagcould
alignmentinformation.

causeseriousinjury.Theairbagisanexplosivedeviceand
shouldbetreatedwithextremecaution.Alwaysfollowtheair-
Thevariable-assistpowersteeringsystemconsistsofan

bagremovalprocedureasoutlinedin721AirbagSystem
engine-drivenhydraulicpump,arack-and-pinionsteering

(SRS).
gearassemblywithanintegralhydrauliccontrolvalve,and
connectinglinkagetotheroadwheels.

WARNING-
"TheBMWSupplementalRestraintSystem(SRS)
Atlowspeeds,maximumpowerassistisprovidedtoease

iscomplexandspecialprecautionsmustbeob-
parkingandcitydriving.Athighspeeds,assistisreducedto

servedwhenservicing.Seriousinjurymayresult
ensurestability.Thepowersteeringsystemvariesassist

ifsystemserviceisattemptedbypersonsunfa-
basedonenginespeed.

miliarwiththeBMWSRSanditsapprovedser-
viceprocedures.BMW specifiesthatall
ING-

inspectionandserviceshouldbeperformedby
WARN
anauthorizedBMWdealer.
"Donotreuseself-lockingnuts.Theyarede-
signedtobeusedonlyonceandmayfailifre-

"BMWSupplementalRestraintSystems(SRS)
used.Alwaysreplacethemwithnewlockingnuts.

areequippedwithaback-uppowersupplyinside
theSRScontrolmodule.A10minutewaiting
"Donotínstallboltsandnutscoatedwithunder-

shouldbeobservedafterthebatterycablehas
coatingwax,ascorrecttighteningtorquecannot

beendisconnected.Thiswillallowthereserve
beassured.Alwayscleanthethreadswithsol-

powersupplytodischarge.
ventbeforeinstallation,orinstallnewparts.
"Donotattempttoweldorstraightenanysteering
components.Alwaysreplacedamagedparts.
NOTE-
Forinformationonsteeringcolumn-mountedswitches
andtheignitionlock,see612SwitchesandElectrical
Accessories.
STEERINGANDWHEELALIGNMENT

320-1
CasterandCamber.....................320-5
TABLES
a.FrontWheelAlignmentSpecifications...........320-6
b.RearWheelAlignmentSpecifications...........320-6
Steeringwheel,removingandinstalling
1.Centersteeringwheel.Makesurefrontwheelsare
pointedstraightahead.
2.Disconnectnegative(-)cablefrombatteryandcover
terminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
STEERINGWHEEL

320-2

STEERINGANDWHEELALIGNMENT
3.Carefullyremoveairbagfromfrontofsteeringwheel.
See721AirbagSystem(SRS).Storeairbagunitina
safeplace.
WARNING-
Improperhandlingoftheaírbagcouldcauseseri-
ousínjury.Storetheaírbagwiththehornpadfacing
up.Ifstoredfacingdown,accidentaldeployment
couldpropelitvlolentlyintotheair,causíngínjury.
4.Removesteeringwheelcenterbolt.Lightlypunchmark
orscribepositionofsteeringwheeltosteeringcolumn
shaft.SeeFig.1.
0012687
Fig.1.Steeringwheelcenterbolt(arrow).

Powersteeringpump,
removingandinstalling
POWERSTEERINGSYSTEM
5.Unlocksteeringwheelbyturningignitionkeyon.Re-
movesteeringwheel.
WARNING-
TheSRScontactreelísmountedtotherearofthe
steeringwheelhub.Thecontactreelísawoundcoil
ofwirethatensurescontinuouselectrícalcontactfor
theairbagunitOncethesteeringwheelmounting
nutorboltisremovedthecontactreelislockedin
thecenterpositionanditspositionmustnotbeal-
tered.
6.Insta¡¡steeringwheelwhilealigningmatchingmarks.
Makesureairbagcontactringlockingpinengagescut
outincontactreel.Insta¡¡steeringcolumncenternut.
Donotover-torque.SeeFig.2.
7.Theremainderofinstallationisreverseofremoval.
Carefullyinstallairbagfromfrontofsteeringwheel.See
721AirbagSystem(SRS).
TighteningTorque
"Steeringwheeltosteering
columnspindle..................63Nm(46ft-Ib)
Fig.2.

Insta¡¡steeringwheelsothatlockingpinincolumnalignswith
cutoutincontactreel(arrow).Contactreelonlatemodel
steeringwheelmayvaryfromthatshown.
POWERSTEERINGSYSTEM
Powerassistisprovídedbyabelt-drivenpumponthelower
leftfrontoftheengine,justbelowthealternator.Thepower
steeringfluidresenroirislocatedonthelowerleftfrontofthe
engine.
1.Emptypowersteeringfluidreservoirusingcleansy-
ringe.Donotreusefluid.
2.Raisefrontofcar.
WARNING
Makesurethecarisfirmlysupportedonjackstands
designedforthepurpose.Placethejackstandsbe-
neathastructuralchassispoint.Donotplacejack
standsundersuspensionparts.
3.Removefluidhosesfrbmpump.Plugopeningsinpump
andinhoseends.
4.Removedrivebeltfrompowersteeringpump.See020
MaintenanceProgram.
5.Removepumpmountingboltsandremovepump.See
Fig.3.

Fig.3.

Powersteeringpumpandpulleymountingbolts.
6.Installationisreverseofremoval,notingthefollowing:
"Makesureal¡threadbores,bolts,nuts,fluidcouplings
andmatingsurfacesareclean,andthatinsidesurface
ofmulti-ribbed-beltisfreeofgreaseanddirt.
"Usenewsealingwasherswhenreattachingpower
steeringpressurelines.
"Makesurehoseshaveadequateclearancefromchas-
sis.Donotover-torquebanjobolts.
"Fillandbleedpowersteeringsystemasdescribedbe-
low.
Powersteeringsystem,
bleedingandfilling
1.Wíthengineoff,fillpowersteeringfluidreservoirwith
cleanfluid.FillleveltoMAXmarkondipstick.
STEERINGANDWHEELALIGNMENT

320-3
STEERINGGEAR
Acutawayofthepower-assistedrack-and-pinionpower
steeringgearisshowninFig.4.Therackisdesignedtobe
maintenancefree.
Pinion
Fig.4.

Cutawayofrack-and-pinionsteeringgear.
TighteningTorques
"Hydraulichosestopowersteeringpump

?hesteeringgearandlinkagerequirenomaintenanceoth-
M10banjobolt...................12Nm(9ft-Ib)

erthanalignmentandaperiodicinspectionforworncompo
M14banjobolt..................35Nm(26ft-Ib)

nents.
M16banjobolt..................40Nm(30ft-Ib)
"Powersteeringpumptobracket

Steeringgearrack,removingandinstalling
(self-lockingnuts)................22Nm(16ft-Ib)
"Powersteeringpumpbrackettoengine

1.Emptypowersteeringfluidreservoirusingcleansy-
blockoroilpan(self-lockingnuts)...22Nm(16ft-lb)

ringe.Donotreusefluid.
2.Disconnectnegative(-)cablefrombatteryandcover
terminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Startengine.Slowlyturnsteeringwheelfromlockto
lockaminimumoftwotimes.

3.Carefullyremoveairbagfromfrontofsteeringwheel.See
721AirbagSystem(SRS).Storeairbagunitinasale
3.Turnengineoffandcheckfluidleve¡,addingfluidifnec-

place.
essary.
4.Makesurefrontwheelsarepointedstraightahead.
5.Removeoutertierodballjoíntnuts,thenseparateouter
tierodendsfromsteeringarmsusingappropriate
presstools.
6.Disconnectpowersteeringhosefromfluidreservoir.
STEERINGGEAR

320-4

STEERINGANDWHEELALIGNMENT
7.Removefluidlinebanjoboltfromsteeringgear.See

9.Removesteeringgearmountingbolts.SeeFig.7.Re
Fig.5.

movesteeringgearfromsubframecrossmemberby
pullingitforward.
CAUTION-
Plugtheopeningsinthepumpandhoseendsto
preventdirtfromenteringthehydraulicsystem.
NOTE-
Itmaybenecessarytoremoveothercomponentsto
gainaccesstothesteeringgear.
"Makesureal¡threadbores,bolts,nuts,splinesand
matingsurfacesareclean.Usenewself-lockingnuts
whereverapplicable.
"Usemarksmadeduringremovaltoreassemblesteer-
ingcolumnuniversaljointtosteeringstubshaft.Make
surewheelsarestraightahead.
"Useanewsealingwasheronbanjofitting.Donotover-
Fig.5.

Fluidhosesandbanjoboltsatsteeringgear(arrows).

torquebanjobolt.
"Installairbagtothesteeringwheelasdescribedin721
AirbagSystem(SRS).
8.Removelowersteeringshaftuniversaljointpinchbolt,

"Fillandbleedpowersteeringsystemasdescribedear-
thenpulluniversaljointhalfwayoffsteeringgearshaft.

lier.
Markrelationshipbetweenshaftanduniversaljoint,

"Havethecarprofessionallyaligned.
thenremoveuniversaljointfromsteeringgear.SeeFig.
6.
0013231
Fig.6.

Steeringcolumnuniversaljointpinchbolt(arrow).MarkU-
jointtoshaftbeforedisconnecting.Withwheelsinstraight
aheadposition,markonsteeringgear(A)shouldalignwith
splitseaminuniversaljoint(B).
STEERINGGEAR
Fig.7.

Steeringgearmountingbolts(arrows).
Outertierodend,replacing
10.Installationisreverseofremoval,notingthefollowing:
TighteningTorques
"Outertierodendtosteeringarm....45Nm(33ft-Ib)
"Steeringcolumnuniversaljointtosteering
gearshaft(self-lockingnut)........19Nm(14ft-Ib)
"Steeringgeartosubframecrossmember
M10bolt.......................42Nm(32ft-Ib)
"Steeringfluídlines
M10banjobolt...................12Nm(9ft-Ib)
M14banjobolt..................35Nm(26ft-lb)
M16banjobolt..................40Nm(30ft-Ib)
1.Raisecar,removeoutertierodballjointnut,andpress
outoutertierodendballjointasdescribedabove.
2.Makeareferencemeasurementofoutertierodendto
tierod.SeeFig.8.Recordmeasurement.
NOTE-
Accuratemeasuringofthetierodendinreferenceto
thetierodwillhelpapproximatecorrectwheelalign-
mentwhennewpartsareinstalled.

Fig.8.

Measuringtierodendposition(forreferenceonly).
3.Loosenoutertierodendlocknut.SeeFig.9.
Locknut
4.Unscrewtierodendfromsteeringgear.
0012143
"Makesureallthreadedpartsareclean.Replaceself-
lockingnutsandinnertierodlockplate.
"Installoutertierodendtonewtierodusingreference
measurementrecordedearlier.
Fig.9.

Outertierodendlocknut(arrow).

"Havecarprofessionallyaligned.
5.Installationisreverseofremoval.Makesureallthread-
edpartsareclean.Havethecarprofessionallyaligned.
TighteningTorques
"Outertierodendlosteeringarm....45Nm(33ft-Ib)
"Outertierodendlocknut..........35Nm(26ft-Ib)
Tierod,replacing
1.Raisecar,removeoutertierodendballjointnut,and
pressoutoutertierodendballjointasdescribed
above.
2.Makeareferencemeasurementofoutertierodendto
tierod.SeeFig.8.Recordmeasurement
NOTE-
Accuratemeasuringofthetíarodendinreferenceto
thetierodwillhelptoapproximatewheelalignment
whennewpartsareinstalled.
STEERINGANDWHEELALIGNMENT

320-5
3.Loosenrackbootbellowsclampandslidebellows
back.Inspectbootforanysignofdamage.Replaceif
necessary.
4.Unlockinnertierodendlockplateusingpliers.
5.Usingspecialtool,unscrewinnertierodendfrom
steeringrack.SeeFig.10.
WHEELALIGNMENT
CasterandCamber
Fig.10.Specialtool(arrow)installedoninnertierodend.
6.Installationisreverseofremoval,notingthefollowing:
TighteningTorques
"Outertierodendtosteeringarm....45Nm(33ft-Ib)
"Outertierodendlocknut..........35Nm(26ft-Ib)
"Innertierodtosteeringgear.......71Nm(52ft-Ib)
Properhandling,stability,tirewear,anddrivingeasede-
penduponthecorrectalignmentofal¡fourwheels.Thefront
axleisalignedinrelationtotherearaxie,thenthefrontwheels
arealignedinrelationtooneanother.Thisisknownasafour-
wheelorthrust-axisalignment.
TheBMWE36usesasophisticatedmulti-linksuspension
atthefrontandrearofthecar.Properalignmentrequires
computerizedalignmentequipment.
FrontandrearcasterandCamberarebothfixedbythede-
signofthecar.Anydeviationsareusuallytheresultofwornor
damagedsuspensionorbodyparts.
WHEELALIGNMENT

320-6

STEERINGANDWHEELALIGNMENT
FrontToe-inandToeDifferenceAngle

WheelAlignmentSpecifications
Toe-inisthedifferenceinthedistancebetweenthefrontof

AlignmentspecificationsfortheE36arelistedinTablea
thefrontwheelsandtherearofthefrontwheels.Itisadjusted

andTableb.Thespecificationsonlyapplyunderthefollowing
byalteringthelengthoftheoutertierods.

conditions:
Toe-inadjustmentsshouldonlybemadeonalignment
equipmentwiththecarinnormalloadedpositionasdescribed
belowunderWheelAlignmentSpecifications.
Toedifferenceangledeterminestheprogressivelydifferent
pathstakenbythefrontwheelsasthecaristurning.Itisfixedby
thesteeringgear,butdependsonaccuratesettingofthetoe-in.
RearToe-in
Thereisnoprovisionforroutinerearwheeltoe-inadjust-
ment.Ifanyalignmentanglesdeviatefromspecifications,
carefullyinspectthereartrailingarms,rearsuspensionsub-
frameandal¡associatedbushingsandflexiblemountsfor
wearordamage.Afterreplacinganypartsthatappearwornor
damaged,re-checkthetoemeasurements.
WHEELALIGNMENT
Tablea.FrontWheelAlignmentSpecifications
"Correctwheelsandtiresareinstalled,ingoodcondition,
andareatthecorrectinflationpressures.
"Al¡steeringandsuspensionpartsandbushingsareun-
damagedandshownosignsofabnormalwear.
"Wheelbearingsareingoodcondition.
"Rideheightisinaccordancewithspecifications.
See310FrontSuspensionand330Rearsuspension.
"Carisinnormalloadedposition.
Normalloadedposition
"Eachfrontseat.....:.............68Kg(150lb)
"Rearseat(center)................68Kg(150lb)
"Trunk............................21Kg(46lb)
"Fueltank.................................full
3181325
Model

3181325

sport

M33.0liter

M33.2liter
suspension
Toeangle(total)

0°18'±8'

0°18'±8'

0°10'±5'

0°10't5'
Camber
To1995

-0°40'±30'

-0°58'±30'

-0°55'±30'

-
1995on

-0°30'±30'

-0°51'±30'

-0°55'±30'

-0°46'±30'
Caster
10°wheellock

3°41'±30'

3°50'±30'

6°38'±30'

9°35'±30'
20°wheellock

3°52'±30'

3°57't30'

6°52'±30'

7°50'±30'
FrontWheelDisplacement

0°t15'

0°t15'

0°±15

0°±15'
Tableb.RearWheelAlignmentSpecifications
3181325
Model

3181325

sport

M33.0liter

M33.2liter
suspension
Toeangle(total)

0°24't6'

0°24'±6'

0'30'.-t6'

0°30't6'
Camber

-l'40't15'

-2°0't15'

-1°45't10'

-1'45'±10'
Maximumallowabledeviationbetweensides

0°±3'

0°±3'

0°t3'

0°t3'

GENERAL............................330-1

CVboot,replacing......................330-8
RIDEHEIGHT.........................330-1

REARSUSPENSIONARMS............330-9
Trailingarm,removingandinstalling.......330-10
SHOCKABSORBERS ANDSPRINGS...330-2

Trailingarmbushing,replacing...........330-11
Rearshockabsorber,removingandinstalling330-3

Uppercontrolarm,removingandinstalling..330-12
Coilspring,removingandinstalling........330-4

Lowercontrolarm,removingandinstalling..330-12
REARWHEELBEARINGS.............330-4
Rearwheelbearing,replacing............330-5

Finaldrivecarrier,removingandinstalling..330-12
DRIVEAXLES........................330-6

TABLE
a.RearRideHeightSpecifications...............330-1
Driveaxle,removingandinstalling.........330-6
GENERAL
Specialservicetoolsarerequiredforsomeoftheworkde-
scribedinthisrepairgroup.Readtheproceduresthroughbe-
forebeginninganyjob.
NOTE-
Ageneraldescriptionoftherearsuspensionanda
troubleshootingguidecanbefoundin300Suspen-
sion,SteeringandBrakes-General.
RIDEHEIGHT
Rearsuspensionrideheightiscontrolledbytherear
springs.Iftherearrideheightisnotwithinthespecifications
listed,therearspringsshouldbereplaced.
Rideheightismeasuredfromtheloweredgeofthewheel
archtothebottomedgeofthewheelrim.SeeFig.1.
Tablealistsrearsuspensionrideheightspecifications.

ooy98
Thesespecificationsapplytoacarinanormallyloadedposi-
tion.Whencheckingrideheightorinstallingsuspensioncom-

Fig.1.

Rideheightmeasurement(A)istakenfromcenterofwheel
ponents,loadthecarasfollows:

archtobottomofwheelrim.
Normalloadedposition
"Eachfrontseat....................68kg(150lb)
"Rearseat(center).................68kg(150lb)
"Trunk............................21kg(46lb)
"Fue¡tank

.....

...

...................

.

.....full
NOTE-
M3rideheightismeasuredwiththecarunladen.
330RearSuspension
REARSUSPENSION

330-1
FINALDRIVECARRIER...............330-12
Tablea.RearRideHeightSpecifications
Wheelsize

318,323,325,

M3modeis
328modeis
15inch
std.suspension

518mm(20.39in)
sportsuspension

~
507mm(19.96in)
16inch
std.suspension

531mm(20.91in)
sportsuspension

~
520mm(20.47in)
Continued
RIDEHEIGHT

330-2

REARSUSPENSION
Tablea.RearRideHeightSpecifications
Wheelsize

318,323,325,

M3modeis
328modeis
17inch
std.suspension

546mm(21.69in)
sportsuspension

~
535mm(21.06in)

1540mm(21.26in)
Maximumvariationbetweensides:10mm(0.4in)
Maximumdeviationfromspecifications:10mm(0.4in)
SHOCKABSORBERS ANDSPRINGS
TheBMWE36independentrearsuspensionisshownin
Fig.2.Refertothisillustrationwhileperformingrepairson
componentscoveredinthisrepairgroup.
NOTE-
Shockabsorbersandlorspringsshouldalwaysbere-
placedinpairs
i
Stabilizerbarlink
Trailing
arm-
bushing
Fig.2.

BMWE36rearsuspension.
SHOCKABSORBERS ANDSPRINGS
Lowercontrolarm
Trailingarm
frontbracket
WARNING -
"Donotreuseself-lockingnuts.Theyarede-
signedtobeusedonlyonceandmayfailifre-
used.Alwaysreplacethemwithnewself-locking
nuts.
"Personalinjurymayresultifproceduresde-
scribedhereareundertakenwithouttheproper
servicetoolsandequipment.Besuretohavethe
righttoolsonhandbeforebeginningthejob.
"Donotinstallboltsandnutscoatedwithunder-
coatingwax,ascorrecttighteningtorquecannot
beassured.Alwayscleanthethreadswithsol-
ventbeforeinstallation,orínstallnewparts.
"Donotattempttoweldorstraightenanysuspen-
sioncomponents.Replacedamagedparts.

Rearshockabsorber,
removingandinstalling
1.Raisecarandremoverearwheels.
WARNING -
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Removerearspeakers.See650Radio.
3.Pryoutluggagecompartmentlinerretainingclipsand
peelbacklinertogainaccesstouppershockabsorber
mountingnuts.SeeFig.3.
Fig.3.

Rearshockuppermountingnuts(arrows)inluggagecom-
partment.Linerhasbeenpeeledback.
NOTE-
Onconvertiblemodels,theuppershockabsorber
mountisintheconvertibletopcompartmentbehindthe
rearseat.
4.Supporttrailingarmfrombelowusingatransmission
jackorequivalent.SeeFig.4.Removeshockabsorber
uppermountingnuts.
CAUTION-
Theshockabsorberprevenísthedriveaxleand
trailingarmfromdroopingtoofar,soalwayssup-
portthetrailingarmbeforeremovingtheshock.
DamagetodriveaxleCVjointscanresult.
0013224
5.Whilesupportingshockabsorber,carefullyremove
lowermountingbolt.Lowershockabsorberoutof
wheelwell.
Fig.4.

Supportreartrailingarmfrombelowbeforeremovingupper
orlower(arrow)shockmounting.
6.Transfershocktopmountingplate,dustcoverandrelat-
edcomponentstonewshockabsorber.SeeFig.5.
'Protectivecap
Uppermountingnut
14Nm(10ft-Ib)
1120

Shockuppermount
,~,--~to bodynuts(renew)

I
-

'

~

24Nm(17ft-Ib)

I
1
-Gasket(renew)

I
1
ppermount

I

Rear
Ishock
Iabsorber
I
I
---spacer
REARSUSPENSION

330-3
Rubberbumper
Dustshield
Fig.5.

Rearshockabsorberassembly.
Lower
mounting
bolt
77Nm
I

(57ft-Ib)
i
I
I
1
I
0013220
0013236
SHOCKABSORBERS ANDSPRINGS

330-4

REARSUSPENSION
7.Installationisreverseofremoval,notingthefollowing:
"Makesureallthreadedbolts,nutsandmakngsurfaces
areclean.
"Instanshockabsorberfintoshocktowerusinganew
uppermountinggasketandnewself-lockingnuts.
"Tightenlowerbolttoitsfinaltorqueoncecarison
ground.
TighteningTorques
"Roadwheeltohub.........100±10Nm(74±7ft-Ib)
"Shockabsorbertotrailingarm
(carinnormalloadedposition)......77Nm(57ft-Ib)
"Shockabsorbertouppermount.....14Nm(10ft-Ib)
"Shockabsorberuppermounttobody
(M8self-lockingnuts).............24Nm(17ft-Ib)
Coilspring,removingandinstalling
WARNING -
"Thecoilspringisundercompressiveforceandís
extremelydangerousuntilcompressionisre-
moved.
"ltisrecommendedthatarestrainingchainbein-
stalledbetweenthebottomofthecoilspringand
theuppercontrolarmtoretainthespringincase
ofaccidentalrelease.Personalinjurycanresultif
thecompressedcoilspringisnotreleasedslowly
andcarefully.
"Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
1.Raisecarandremoverearwheel.
2.Supportsuspensionarmfrombelowusingatransmis-
sionjackorequívalent.
TighteningTorques
3.Removedriveaxlefromfinaldrive.SeeFig.6.Suspend

"Driveaxletofinaldriveflange
driveaxlefromchassisusingstiffwire.

M8Torxbolt....................64Nm(47ft-Ib)
M10Torxbolt...................83Nm(62ft-Ib)
4.Disconnectshockabsorberfromtraílingarm.

"Roadwheeltohub.........100±10Nm(74±7ft-Ib)
"Shockabsorbertotrailingarm......77Nm(57ft-Ib)
5.Lowersuspensionslowlyandcarefullyuntilthecom-
pressedcoilspringisfullyunloaded.
CAUTION-
Theshockabsorberpreventsthedriveaxleand
trailíngarmfromdroopingtoofar,soalwayssup-
portthetrailingarmbeforeremovingtheshock.
DamagetodriveaxleCVjointscanresult.
6.Removerestrainingchainandremovecoi¡spring.
REARWHEELBEARINGS
Fig.6.

Driveaxletofinaldrivemountingbolts(arrows).
0012103
7.Ifspringistobereused,carefullyinspectitforanysur-
facedamageorcorrosion.Inspectspringmountsfor
anysignsofdamage.Replaceanypartsshowingevi-
denceofwearordamage.
8.Fitcoilspringtospringmountsandinsta¡¡restraíning
chaina
9.Slowlyliftsuspensionbackintoposition,makingsure
coilspringiscorrectlyseatedinupperandlowercoil
springmounts.
10.Whensuspensionhasbeenliftedsufficiently,instan
shockabsorbertotrailingarm.Removerestraining
chain.
11.Theremainderofinstallationisreverseofremoval.
REARWHEELBEARINGS
Therearwheelbearingisaunitizedassemblyandisnotre-
pairableseparately.SeeFig.7.
Specialpresstools,tobeusedwiththetrailingarmat-
tachedtothecar,arerequiredtoreplacethewheelbearings.
Readtheprocedurethroughbeforebeginningthejob.

Wheelbearing
Fig.7.

Rearwheelbearingassembly.
Circlip

Driveflange

Collarnut
0012152
Rearwheelbearing,replacing
1.Raisecarandsupportsafely.Removerearwheel.
2.Removedriveaxleasdescribedlater.

6.Removebearíngretainercirclipfromtrailingarm.
3.Removebrakecaliperassemblyandrotorasdescribed

7.Usingappropriatepresstools,pullbearingassembly
in340Brakes.Leavebrakehoseconnectedtocaliper.

outoftrailingarmbearinghousing.
Suspendcaliperassemblyfromchassísusingstiffwire.
8.Inspectbearinghousingforanydamageorcontamina
4.RemoveABSpulsesensor.SeeFig.8.

tion.Cleanhousingborethoroughlybeforeinstalling
newbearing.Makesureal¡threadbores,bolts,nuts
andmatingsurfacesareclean
Fig.8.

ABSpulsesensorbeingremoved.
5.Removedriveflangefrombearingassembly.SeeFig.
9.
NOTE-
Iftheinnerbearingraceremainsattachedtothedrive
flange,useBMWspecialtoolnos.007500and331
312orequivalentstoseparateinnerracefromflange.
REARSUSPENSION

330-5
0013125
Fig.9.

Driveflangebeingremovedfrombearingassemblyusingim-
pactstylepuller.
9.Installnewbearingassemblyusingpresstools.Apply
forceonlytoouterracewheninstallingbearing.
WARNING -
M3installation:redsealingríngonrearwheelbear-
ingmustfaceoutward.OtherwíseABSwillnotfunc-
tion.
10.Insta¡¡newcirclip.Theoldcirclipshouldneverbere-
used.
CAUTION-
Makesurethatthebearingispressedinfar
enoughtocontacttheshoulderatthebacksideof
thehousingandthatthecirclipisfullyseatedinits
groove.
11.Drawdriveflangeintobearingusingappropriatepress
tools.Supportbearinginnerracewhenpressingin
0013223

driveflange.
NOTE-
BMWspecifiesspecialtoolstopullthedrivefiange
throughthewheelbearingintoposition.Ifusingalter-
nativetools,besuretosupportthebearinginnerrace
whenpressingorpullingthedriveflangefintoplace.
REARWHEELBEARINGS

330-6

REARSUSPENSION
12.Installbrakecaliperassemblyandrotorasdescribedin
340Brakes.
13.Installdriveaxieasdescribedbelow.
TighteningTorques
"Brakerotortodriveflange.........

16Nm(12ft-ib)
"Brakecalipertotrailingarm........67Nm(50ft-Ib)
"Driveaxiecollarnutto
driveflange...................250Nm(184ft-Ib)
M3.........................300Nm(221ft-Ib)
"Roadwheeltohub.........100±10Nm(74±7ft-Ib)
DRIVEAXLES
Thedriveaxlesuseconstant-velocity(CV)jointsonboth
ends.ToreplaceaCVjointordustboot,thedriveaxiemustbe
removedfromthecar.Thecomponentsofthedriveaxieare
illustratedinFig.10.
Driveaxie,removingandinstalling
1.Raiserearofcar.Removerearwheel.
Dustcover
Fig.10.Driveaxieassembly.
DRIVEAXLES
InnerCV
bootkit
-Reinforcement
WARNING -
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Pryoffdustcapfromcenterofwheelhub.
3.Remountwheelandlugboits.
4.Lowercartoground.Withanassistantapplyingbrakes,
loosencollarnut.Donotremovecompletely.SeeFig.
11.
Thedriveflangecollarnutistightenedtoatorqueof
250Nm(184ft-Ib).Makesurethecarisfirmlyonthe
ground.
5.Raisecarandremovewheel.
6.Removebrakecaliperassemblyandrotorasdescribed
in340Brakes.Leavebrakehoseconnectedtocaliper.
Suspendcaliperassemblyfromchassisusingstiffwire.
7.Removedriveaxiefromdriveflange.SeeFig.12.Sus-
penddriveaxiefromchassisusingstiffwire.
OuterCV
bootkit
Driveaxle
Outer
CVjoint

Fig.11.Driveflangecollarnut(arrow).
0012111
8.Supporttrailingarmfrombelow,usingatransmission
jackorequivalent.Removeshockabsorbertotrailing
armbolt.
WARNING -
Itisrecommendedthatarestrainingchainbein-
stalledbetweenthebottomcoilofthecoilspring
andtheuppercontrolarmtoretainthespringin
caseofaccidentalrelease.Personalinjurycanre-
sultifthecompressedcoilspringisnotreleased
slowlyandcarefully.
REARSUSPENSION

330-7
9.Lowertrailingarmsufficientlytogainclearanceforre-
movingdriveaxle.Ifnecessaryuseanappropriate
pullertoRmovedriveaxlefromwheelbearinghousing.
SeeFig.13.
10.Installationisreverseofremoval.
Fig.13.Pressdriveaxlefromwheelbearinghousingusingpuller.
"Applyalightcoatingofoiltocontactfaceofcollarnut,
andinstallitloosely.
"Installroadwheelandlowercartoground.
"Withanassistantapplyingbrakes,tightendriveaxle
collarnuttoitsfinaltorque.
"Installanewcollarnutretainingplate.
TighteningTorques
"Brakecalipertotrailingarm........67Nm(50ft-Ib)
"Brakerotortodriveflange.........16Nm(12ft-Ib)
"Driveaxlecollarnutto
driveflange...................250Nm(184ft-Ib)
M3.........................300Nm(221ft-Ib)
"Driveaxietofinaldriveunitmountingflange........
M8Torxbolt....................64Nm(47ft-Ib)
M10Torxbolt..................100Nm(74ft-Ib)
Roadwheeltohub100±10Nm(74t7ft-Ib)
0012103

"Shockabsorberto
Fig.12.Driveaxletofinaldrivemountingbolts(arrows).

trailingarm.....................77Nm(57ft-Ib)
DRIVEAXLES

330-8

REARSUSPENSION
CVboot,replacing
NOTE-
"TheouterCVjointcannotberemovedfromtheaxle
shaft.InordertoreplacetheouterCVboot,itisnec-
essarytoremovetheinnerjointandbootfirst.
"IftheCVjointsarewornordefective,acompletere-
builtaxleshaftisavailablefromanauthorizedBMW
dealerpartsdepartment.
1.Removedriveaxlefromcarasdescribedabove.
2.RemoveinnerandouterCVbootclampingbandsand
cutoldbootsoffjointsandshaft.Cleangreasefrom
joints.
3.LiftoffdustcoverfrominnerCVjointandremovecirclip

5.Cleanalloldlubricantoffshaftsplinesandinnerjoint's
retainingjointinnerhubtoaxleshaft.SeeFig.14.

splines.
DRIVEAXLES
-01,11,11L"ICOYA
Driveaxle-"e:>,

)

0006560
CVjoint
Fig.15.SupportCVjointatinnerhubduringpressingoperation(ar-
rows).
NOTE-
ToinspectaCVjoint,cleanawaythegreaseandlook
forgalling,pittihgandothersignsofwearorphysical
damage.Polishedsurfacesorvisibleballtracksalone
arenotnecessarilycauseforreplacement.Discolora-
tionduetooverheatingindicateslackoflubrication.
6.PlacenewclampingbandsandCVbootsoverdriveax-
le.
NOTE-
WhenreplacingCVjointboots,usecompleteCVjoint
bootrepairkits.Akitwillincludeanewboot,clamping
bands,speciallubricant,andanewinnerCVjointcir-
clip.ThekitisavailablefromanauthorizedBMWdealer
partsdepartment.
7.ApplyLoctite®270oranequívalentheavy-dutylockíng
compoundtodriveaxlesplines.PositionnewCVjoint
onshaftsothatraisedortallersideofhubisfacing
shaft.
WARNING -
Fig.14.DustcovershownremovedfrominnerCVjoint.Cleanaway

Donotletthelockingcompoundcontacttheballsin
greaseandremovecirclip(arrow)fromshaftend.

thejoint.Applyonlyathincoattocoverthesplines.
4.Whilesupportinginnerhub,pressaxleshaftoutofjoint.

8.Whilesupportingaxleshaft,pressinnerhubofCVjoint
SeeFig.15.

ontoshaft.Installnewcirclip.
NOTE-
Donotlettheballhubpivotmorethan20°intheouter
ringofthejoint.Thehallswillfalloutifthehubíspivoted
toofar.

9.PackeachCVjointandrubberbootwithspecified

REARSUSPENSIONARMS
amountoflubricantsupplied.Applyadhesivetolargeend
ofbootandmountitonjoint.Securebootwithclamps.

Thetrailingarms,controlarmsandtheirmountingbushings
ApplysealertoinnerCVjointdustcoverandinstan.

controlthepositionoftherearwheels.Adamagedsuspen-
sionarmorwornbushingswillchangetherearwheelalign
NOTE-

mentandmayadverselyaffecthandlingandstability.
"Beforeinstallingeachsmallbootclampbesureto
"burp"thebootbyflexingtheCVjointasfaroverasit

WARNING
willgo.Asmallscrew-driverinsertedbetweenthe

Donotattempttostraightenadamagedsuspension
bootandtheaxle-shaftwillhelptheprocess.

arm.Bendingorheatingmayweakentheoriginal
"BMWrecommendsBostil101513orEppleC4851ad-

part.Ifthesuspensionarmshowsanysignsof
hesive,andEpple®39orCuril©Tsealer

damageorexcessivecorrosion,itmustbere-
placed.
CVJointLubricantCapacity
"Wheelhubend
ex.M3.......................80gram(2.8oz.)
M3.........................100gram(3.5oz.)
"Finaldriveend.................85gram(3.0oz.)
10.Installdriveaxleasdescribedearlier.
1.

Finaldrivecarrier
2.

Stabilizerbar
3.

Uppercontrolarm
4.

Lowercontrolarm
5.

Trailingarm
6.

Trailingarmfrontbracket
Fig.16.Reartrailingarms,controlarmsandfinaldrivecarrier.
Iftherearbrakecineisdisconnectedtoremoveatrailing
arm,thecompletebrakingsystemmustbebledaspartofthe
installationprocedure.
Whenperformingrepairstorearsuspensioncomponents,
refertoFig.16.
REARSUSPENSION

330-9
0013112
REARSUSPENSIONARMS

330-10

REARSUSPENSION
Trailingarm,removingandinstalling
1.Raiserearendofcarandremovewheel.
WARNING-
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Removedriveaxleasdescribedearlier.
3.Removebrakerotorandcaliperasdescribedin340
Brakes.Donotremovebrakelinefromcaliper.Hang
caliperfrombodywithwire.
4.Removeparkingbrakecablefrombrakeshoeexpand-
er.See340Brakes.
5.Removerearbrakelinebracketfromtrailingarm.See
Fig.17.
Fig.17.Brakelinebracketboltsontrailingarm(arrow).
WARNING-
Itisrecommendedthatarestrainingchainbein-
stalledbetweenthebottomcoilofthecoilspring
andtheuppercontrolarmtoretainthespringin
caseofaccidentalrelease.Personalinjurycanre-
sultifthecompressedcoilspringisnotreleased
slow1yandcarefully.
REARSUSPENSIONARMS
6.Supporttrailingarmfrombelowwithatransmission
jackorequivalent.
7.Removeshockabsorbertotrailingarmbolt.SeeFig.
18.Slowlylowersuspensionuntilcoilspringcanbe
safelyremoved.
0013220
Fig.18.Supporttrailingarmbeforeremovinglowershockbolt(ar-
row).
8.Unboltupperandlowercontrolarmsfromtrailingarm,
asdescribedlater.
9.RemoveABSwheelspeedsensorfromrearwheel
bearinghousing.Unclipsensorwiríngfromtrailingarm.
Ifremovingrighttrailingarm,separatebrakepadwear
sensorconnector.SeeFig.19.
0012104
Fig.19.BrakepadwearsensorandABSwheelspeedsensorcon-
nectors(arrow).
10.Removethreeboltsholdingtrailingarmfrontbracketto
body.SeeFig.20.Removetrailingarm.

Fig.20.Trailingarmfrontbracketbolts(arrows).
NOTE-
BMW-suppliedreplacementtrailingarmscomewiththe
bushingsinstalled.Anewwheelbearingwillhavetobe
installed.
0013222
11.Iftrailingarmisbeingreplaced,transfertrailingarm
frontbracket.Transferattachedbrakesystemcompo-
nentstonewarmasdescribedin340Brakes.Insta¡¡a
newwheelbearingasdescribedearlierunderRear
WheelBearings.
12.Installationisreverseofremoval.
"Alwaysusenewself-lockingnuts.
"Havecarprofessionallyalignedwhenjobiscomplete.
TighteningTorques
"Driveaxle#ofinaldriveunitmountingflange
M8Torxbolt....................64Nm(47ft-Ib)
M10Torxbolt..................100Nm(74ft-Ib)
"Roadwheeltowheelhub....100±10Nm(74t7ft-Ib)
"Shockabsorbertotrailingarm......77Nm(57ft-Ib)
"Trailingarmtofrontbracket.......110Nm(81ft-Ib)
"Trailingarmbrackettobody........77Nm(57ft-Ib)
"Trailingarmtoupper
orlowercontrolarm(M12bolt)....110Nm(81ft-Ib)
REARSUSPENSION

330-11
Trailingarmbushing,replacing
NOTE-
Whenreplacinganybushinginthereartrailingarm,
measureandrecordtheorientationandprotrusionof
thebushingfromitsboss.Pressinnewbushingto
matchthepositionoftheoldone.
1.Removetrailingarmasdescribedabove.
2.Pressbushingoutoftrailingarmusingappropriate
presstools.
3.CoatnewbushingwithCircolight9lubricantorequiva-
lent.
4.Usingappropriatepresstools,drawnewbushinginto
trailingarmuntilpreviouslymeasuredprotrusionis
achieved.
5.Iffrontbracketbushingwasreplaced,alignfrontbrack-
etbeforetighteningbolt.SeeFig.21.
A
B=8mm
measuredupfromcast-
ingmarkontrailingarm. 0013237
Fig.21.Wheninstallingtrailingarmfrontbracketuising8mmbar
stock.
6.Installationisreverseofremoval.
"Havecarprofessionallyalignedwhenjobiscomplete.
TighteningTorques
"Trailingarmtofrontbracket.......110Nm(81ft-Ib)
"Trailingarmbrackettobody........77Nm(57ft-Ib)
REARSUSPENSIONARMS

330-12

REARSUSPENSION
Uppercontrolarm,
removingandinstalling
1.Raiserearendofcarandremovewheel.
WARNING -
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Removedriveaxleasdescribedearlier.
3.Removestabilizerbarlinkfromuppercontrolarm.
4.Supporttrailingarmfrombelowwithatransmission
jackorequivalent.
WARNING -
Itisrecommendedthataretainingchainbein-
stalledbetweenthebottomcoilofthecoilspring
andtheuppercontrolarmtoretainthespringin
caseofaccidentalrelease.Personalinjurycanre-
sultifthecompressedcoilspringísnotreleased
slowlyandcarefully.
5.Removelowershockabsorberbolt.RefertoFig.18.
Slowlylowertrailingarmuntilcoilspringisfullyre-
leased.Removerestrainingchainandremovespring.
7.Installationisreverseofremoval.
"Alwaysusenewself-lockingnuts.
"Havecarprofessionallyalignedwhenjobiscomplete.
"Insta¡¡driveaxleasdescribedearlier.
TighteningTorques
"Driveaxletofinaldriveflange
M8Torxbolt...................64Nm(47ft-Ib)
M10Torxbolt.................100Nm(74ft-Ib)
"Shockabsorbertotrailingarm......77Nm(57ft-Ib)
"Uppercontrolarm
tofinaldrivecarrier(M12bolt)......77Nm(57ft-Ib)
"Uppercontrolarm
totrailingarm(M12bolt).........

110Nm(81ft-Ib)
Lowercontrolarm,
1.Raiserearendofcarandsupportitsecurelyonjack-
stands.Removerearwheel.
2.Removebothlowercontrolarmmountingbolts.
FINALDRIVECARRIER
3.Useasofthammertotapcontrolarmoutofitsmount-
ingpoints.
4.Installationisreverseofremoval.
NOTE-
Useanewboltandwasherassemblyatthefinaldrive
carriermountíngpointforthecontrolarm.
TighteningTorque
"Lowercontrolarm
tofinaldrivecarrier(M12bolt)......77Nm(57ft-Ib)
"Lowercontrolarm
totrailingarm(M12bolt).........110Nm(81ft-Ib)
FINALDRIVECARRIER
Finaldrivecarrier,
removingandinstalling
1.Raiserearendofcarandsupportitsecurelyonjack
stands.Removerearwheels.
2.Removedriveshaft.See260Driveshaft.
3.Removebothdriveaxlesasdescribedearlier.
6.Removebothuppercontrolarmmountingbolts.Re-
movecontrolarm.

4.Disconnectstabilizerbarfromuppercontrolarms.Re-
movestabilizerbarmounts.
5.Disconnectspeedometerharnessconnectoronfinal
drive(whereapplicable).
6.Removerearsectionofexhaustsystem.See180Ex-
haustSystem.
NOTE-
Itmaybeeasiertoremovecompleteexhaustasone
piece.See180ExhaustSystem.
7.Removeupperandlowercontrolarmsasdescribed
earlier.
8.Supportfinaldrivecarrierwithtransmissíonjack.Re-
movemountingboltsandnutsatfinaldrivecarrier
bushingmounts.SeeFig.22.
9.Slowlylowerfinaldriveandfinaldrivecarrier,detaching
removingandinstalling

wireharnessandconnectorsasnecessary.
10.Finaldrivemaynowbeunboltedfromfinaldrivecarrier.

Fig.22.Finaldrivecarriermounts(arrows).
11.Installationisreverseofremoval.
uu1J221
"Checkandadjustparkingbrakeasdescribedin340
Brakes.
"Alwaysusenewself-lockingfasteners.
"Havecarprofessionallyalignedwhenjobiscomplete.
TighteningTorques
"Driveaxletofinaldriveflange
M8Torxbolt...................64Nm(47ft-Ib)
M10Torxbolt.................100Nm(74ft-Ib)
"Driveshafttofinaldriveflange...See260Driveshaft
"Finaldrivecarriertobody.........77Nm(57ft-Ib)
"Finaldrivetofinaldrivecarrier(M12bolts)
Frontmount....................95Nm(70ft-lb)
Rearmounts...................77Nm(57ft-Ib)
"Roadwheeltowheelhub....100±10Nm(74t7ft-Ib)
"Upperorlowercontrolarm
tofinaldrivecarrier(M12bolts).....77Nm(57ft-Ib)

GENERAL ............................331-1

FinalDriveOilSeals

....................331-1
Finaldriveflangeoilsea¡,replacing.........331-2
FINALDRIVESERVICE................331-1

Finaldriveinputshaftoilseal,replacing.....331-3
Finaldriveoí¡,drainingandfilling..........331-1

Finaldriveunit,removíngandinstalling......331-3
GENERAL
Thisrepa¡rgroupcoversrepairoperationsthatdonotre-
quirecomplicateddisassemblyofthefinaldrive.Internalre-
pairsandfinaldrivedisassemblyarenotcoveredinthis
manual.
FINALDRIVESERVICE
Al¡finaldriveworkrequiressomemethodofraisingthecar
andsupportingitsecurelywhiletheworkisperformed.Jack
standsandafloorjackcaneasilybeused,butuseextreme
cautionwhenworkingbeneaththecar.See010Fundamen-
taisfortheDo-It-YourselfOwner.
NOTE-
Removaloffinaldrivecarrieriscoveredin330Rear
Suspension.
Finaldriveoil,drainingandfilling
1.Drivecartowarmfinaldrivefluid.
2.Raisecarandsupportsafely.
WARNING-
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
5.Fillfinaldrivewithappropriatetypeandquantityoflu-
bricant.Insta¡¡andtightenfillplug.
331FinalDrive
0
Fig.1.

Finaldrivedrainplug(A)andfillplug(B).
D
NOTE-
Thefinaldrivefluidleveliscorrectwhenthefluidbegins
tospillfromthefillplug.
FinalDriveOilSeals
FINALDRIVE

331-1
0013113
FinalDriveDrainandFill
"Oilspecifications
w/olimitedslip

........BMWSAF-XOSyntheticOil
withlimitedslip.......BMWSAF-XISSyntheticOil
"Finaldriveoilcapacity
4-cylinder......................1.1liters(1.2qt)
6-cylinder......................1.7liters(1.8qt)
3.Placeadrainpailbelowfinaldriveandremovedrain
andfillplugfromfinaldrive.SeeFig.1.

Lowoillevelcausedbyfaultyoilsealsmaybethecauseof
noisyfinaldriveoperationorlimited-slipchatter.Thedrive
NOTE-

flange(side)andinputshaft(front)oilsealscanbereplaced
"Usea14mmalíenbitsockettoremovethedrainplug.

whilethefinaldriveisinstalled.
Alternatively,cutapproximately30mm(1.2in)from
analíenkeyanduseaboxendwrenchonthekey

NOTE-
stub.
DonotmistakeleakingCVjointsforflangesealleaks.
4.Installandtightendrainplug.

Itmaybehelpfultodegreasethefinaldrivetopinpoint
thesourceoftheleakpriortoreplacingseals.
FINALDRIVESERVICE

331-2

FINALDRIVE
Makesurethatthecarisfirm1ysupportedonTjack
..-

":.-

:.n

-
2.Detachdriveaxle(s)fromfinaldrive.See330Rear
Suspension.
CAUTION-
Suspendthedetacheddriveaxlefromthecar
bodywithastiffwirehooktopreventdamageto
theouterCVjoint.
Fig.3.

Driveflangesnapring(arrow)toberemovedfromfinaldrive
3.Prydriveflangefromfinaldrive.SeeFig.2.

housing.
Fig.2.

Driveflangebeingpriedoff.Forleverage,useawoodendowel
asshown.
4.Removewire(snap)ringfromfinaldriveopening.See
Fig.3.
NOTE-
Inspectflangeatthepointwheretheoilsealrideson
theshaft.Replacetheflangeassemblyifthereisa
groovewornintheshaft
FINALDRIVESERVICE
9.Attachdriveaxleandtightenbolts.
10.Topofffinaldrivewithofl.
B315
5.Pryoldoilsea¡fromitsrecessusingahookedsealre-
movaltool,oralargescrewdriver.Usepantocatch
drainingfluid.
CAUTION-
Becarefulnottomarthefinaldrivehousingwhen
removingthesea¡.
6.Dipnewsealinfinaldrivelubricantanddrivesealinto
placeuntilfullyseated.
7.Insta¡¡newsnapringingrooveoffinaldrivehousing.
Makesurebothendsofringarefullyseatedingroove.
8.Insta¡¡driveflangebypressingitinbyhanduntilsnap
ringengages.Itmaybenecessarytoturndriveflange
slightlywhilepushing.
TighteningTorque
"Driveaxletofinaldriveflange
M8Torxbolt....................64Nm(47ft-Ib)
M10Torxbolt..................100Nm(74ft-Ib)

Finaldriveinputshaftoilsea¡,replacing
1.Raisecarandsupportsafely.
2.Drainfinaldriveoilasdescribedearlier.
3.Removedriveshaftfromfinaldriveinputshaftflange.
See260Driveshaft.
4.Makematchingmarksoninputshaftandinputshaft
collarnut.SeeFig.4.
Fig.4.

Makematchingmarksoninputshaftcollarnutandflange.
5.Prylockplatefromnut.Holdinputflangeandremove
collarnut.Ifnecessary,useapullertoremoveinput
flange.
6.Removefinaldrivefrontdustcover.
8.Installnewfinaldrivefrontdustcover.
9.Lightlylubricateinputshaftandpressinputflangeback
on.Insta¡¡collarnutandslowlytightenuntilmatching
markslineup,comingascloseaspossibletospecified
torque.
TighteningTorques
"Finaldriveinputshaftflangetopinion
with4boltsidecovers.

.........175Nm(129ft-Ib)
(oruntilmatchmarkslineup)
"Finaldriveinputshaftflangetopinion
with6boltsidecovers...........185Nm(137ft-Ib)
(oruntilmatchmarkslineup)
CAUTION-
Iftheinputflangenuttorqueisexceeded,orthe
nutistightenedpastthemarks,thecrushablecol-
larsleevebehindtheflangewillneedtobere-
placed.Thisoperationrequiresdisassemblyof
thefinaldriveunit.
10.Installanewlockplateandrefillfinaldrivewithlubri-
cant.
11.Remainingassemblyisreverseofdisassembly.
TighteningTorques
"Driveshafttofinaldríveflange...See260Driveshaft
"Flex-disctodriveshaftor
transmissionflange...........See260Driveshaft
"Finaldrivedrainandfillplugs.......70Nm(52ft-Ib)
Finaldriveunit,
removingandinstalling
FINALDRIVE

331-3
1.Raiserearendofcarandsupportitsecurelyonjack
stands.Removerearwheels.
2.Removedriveshaftfromfinaldriveinputflange.See
7.Pryfaultysea¡fromitsrecessusingahookedsea¡re-

260Driveshaft.
movaltooloralargescrewdriver.Dipnewsea¡infinal
drivelubricantanddriveitintoposition.

3.Removebothdriveaxlesfromfinaldriveunit.Suspend
axleusingstiffwire.See330RearSuspension.
CAUTION-
eecarefulnottomarthehousingwhenremoving

4.Disconnectstabilizerbarfromuppercontrolarms.Re-
theseas.

moveleftandrightstabilizerbarmounts.
5.Disconnectspeedometerharnessconnectoronfinal
drive(whereapplicable).
6.Supportfinaldrivewithtransmissionjack.Remove
mountingboltsatfrontandrear.SeeFig.5.
7.Slowlylowerfinaldriveunitandremovetowardsrear.
FINALDRIVESERVICE

331-4

FINALDRIVE
FINALDRIVESERVICE
0013242
0013243
Fig.5.

Finaldrivetofinaldrivecarrierrear(A)andfrontmounting
bolts(B).
8.Installationisreverseofremoval.
"Checkandadjustparkingbrakeasdescribedin340
Brakes.
"Alwaysusenewself-lockingfasteners.
"Havecarprofessionallyalignedwhenjobiscomplete.
TighteningTorques
"Driveaxletofinaldriveflange
M8Torxbolt....................64Nm(47ft-Ib)
M10Torxbolt..................100Nm(74ft-Ib)
"Driveshafttofinaldriveflange...See260Driveshaft
"Finaldrivecarriertobody..........77Nm(57ft-Ib)
"Finaldrivetofinaldrivecarrier(M12bolts)
Frontmount....................95Nm(70ft-Ib)
Rearmounts....................77Nm(57ft-Ib)
"Roadwheeltowheelhub....100±10Nm(74±7ft-Ib)
"Upperorlowercontrolarm
tofinaldrivecarrier(M12bolts).....77Nm(57ft-Ib))

Brakerotor,removingandinstalling........340-7
MASTER CYLINDER ...................340-7
Mastercylinder,removingandinstalling.....340-7
GENERAL

TROUBLESHOOTING
WARNING-
"Althoughsemi-metallicandmetallicBrakefriction
materialsinBrakepadsorshoesnolongercon-
tainasbestos,theyproducedangerousdust.
"Brakefluidispoisonous,highlycorrosiveand
dangeroustotheenvironmentWearsafety
glassesandrubbergloveswhenworkingwith
Brakefluid.DonotsiphonBrakefluidwithyour
mouth.Immediatelycleanawayanyfluidspilled
onpaintedsurfacesandwashwithwater,as
Brakefluidwillremovepaint.
"AlwaysusenewBrakefluidfromafresh,un-
openedcontainer.Brakefluidwillabsorbmois-
turefromtheair.Thiscanleadtocorrosion
problemsinthebrakingsystem,andwillalsolow-
ertheBrakefluid'sboilingpoint.DisposeofBrake
fluidproperly.
"Donotreuseself-lockingnuts,boltsorfasteners.
Theyaredesignedtobeusedonlyonceandmay
failifreused.Alwaysreplacethemwithnewself-
lockingfasteners.
BMWE36modelsareequippedwithvacuumpower-assist-
edfour-wheeldiscbrakeswithanintegralAntilockBrakeSys-
tem(ABS).Single-pistoncalipersactonsolidorventedfront
rotorsandsolidrearrotors.Abrakepadwearsensorforeach
axleindicateswhenbrakepadsneedreplacement.Thedual
drum-typeparkingbrakesystemisintegratedwiththerear
brakerotors.
NOTE-
M3modelshaveventeddirectionalBrakerotorsonthe
rearaxleaswellasonthefront.
340Brakes
BRAKES340-1
GENERAL ............................340-1

BRAKE BOOSTER .....................340-8
TROUBLESHOOTING ..................340-1

Brakebooster,removingandinstalling......340-8
PARKING BRAKE.....................340-10
BLEEDING BRAKES ..................340-3

Parkingbrake,adjusting................340-10
Pressurebleedingbrakes

Parkingbrakeshoes,removingandinstalling.340-11
(exceptcarswithAST).................340-3

ParkingBrakecable,replacing............340-11
BRAKE PADS,CALIPERS,

ANTILOCK BRAKE SYSTEM (ABS)....340-11
ANDROTORS .........................340-3

ABSSystemInspection.................340-12
Brakepads,replacing...................340-4
ABSwheelspeedsensors,replacing......340-12
Brakecaliper,removingandinstalling......340-6
TABLES
a.BrakeSystemTroubleshooting................340-2
b.BrakeRotorReconditioningSpecifications.......340-7
Brakeperformanceismainlyaffectedbythreethings:the
leve¡andconditionofthebrakefluid,thesystem'sabilítyto
createandmaintainhydraulicpressure,andtheconditionof
thefrictioncomponents.
AirintheBrakefluidwillmaketheBrakepedalfeelspongy
duringbrakingorwillincreasetheBrakepedalforcerequired
tostop.Fluidcontaminatedbymoistureordirtcancorrodethe
system.InspecttheBrakefluidinsidethereservoir.Ifitisdirty
ormurky,orisoverayearold,thefluidshouldbereplaced.
Visuallycheckthehydraulicsystemstartingatthemaster
cylinder.Tocheckthefunctionofthemastercylinderholdthe
brakepedaldownhardwiththeenginerunning.Thepedal
shouldfeelsolidandstaysolid.Ifthepedalslowlyfallstothe
floor,eitherthemastercylinderisleakinginternally,orfluidis
leakingexternally.Ifnoleakscanbefound,themastercylin-
derisfaultyandshouldbereplaced.CheckallBrakefluidlines
andcouplingsforleaks,kinks,chafingandcorrosion.
ChecktheBrakeboosterbypumpingtheBrakepedalap-
proximately10timeswiththeengineoff.Holdthepedaldown
andstarttheengine.Thepedalshouldfa¡¡slightly.Ifnot,check
foranyvisiblefaultsbeforesuspectingafaultybrakebooster.
Checkforstrongvacuumatthevacuumhosefittingatthe
booster,andcheckthenon-retumvalveforone-wayflow.
Wornorcontaminatedbrakepadswillcausepoorbraking
performance.Oil-contaminatedorglazedpadswillcause
stoppingdistancestoincrease.Inspecttherotorsforglazing,
discolorationandscoring.Steeringwheelvibrationwhile
brakingatspeedisoftencausedbywarpedrotors,butcan
alsobecausedbywornsuspensioncomponents.
TROUBLESHOOTING

340-2 BRAKES
Whentroubleshooting,keepinmindthattireinflation,wear
andtemperaturecanaffectbrakingandsuspension.See310
FrontSuspensionformoreinformationonfrontsuspension
partsinspection.
Tablealistssymptomsofbrakeproblems,theirprobable
causes,andsuggestedcorrectiveactions.
Tablea.BrakeSystemTroubleshooting
Symptom

1

Probablecause

1

Repairs
Brakesqueal

a.Incorrectlyinstalledbrakepadsor

a.Checkcomponentinstallation.
parkingbrakeshoes
b.Brakepadcarriersdirtyorcorroded

b.Removebrakepadsandcleancalipers.
c.Brakepadanti-rattlespringsfaultyor

c.Install/replaceanti-rattlesprings.
missing
d.Brakepadsheat-glazedoroil-soaked

d.Replacebrakepads.Cleanrotors.Replaceleaking
calipersasrequired.
e.Wheelbearingsworn(noisemost

e.Replacewornbearings.See310FrontSuspension
pronouncedwhenturning)

or330RearSuspension.
Pedalgoestofloorwhenbraking

a.Brakefluidleve¡lowduetosystem

a.Checkfluidlevelandinspecthydraulicsystemfor
leaks

signsofleakage.Fillandbleedsystem.
b.Mastercylinderfaulty

Ib.Replacemastercylinder.
Lowpedalaftersystembleeding

1a.Mastercylinderfaulty

1a.Replacemastercylinder.
Pedalspongyorbrakesworkonly

a.Airinbrakefluid

a.Bleedsystem.
whenpedalispumped

b.Mastercylinderfaulty(interna¡return

b.Replacemastercylinder.
springweak)
c.Leakinglineorhoseunions

c.Repairorreplacelinesandhoses.Bleedsystem.
Excessivebrakingeffort

a.Brakepadswet

a.Uselightpedalpressuretodrypadswhiledriving.
b.Brakepadsheat-glazedoroil-soaked

b.Replacebrakepads.Cleanrotors.Replaceleaking
calipers.
c.Vacuumboosterorvacuumhosecon-

c.Inspectvacuumlines.Testvacuumboosterandre
nectionstoboosterfaulty

placeasrequired.Testvacuumnon-returnvalvefor
one-wayairflow.
Brakespulsate,chatterorgrab

a.Warpedbrakerotors

a.Resurfaceorreplacerotors.
b.Brakepadsworn

b.Replacebrakepads.
c.Brakepadsheat-glazedoroil-soaked

c.Replacebrakepads.Cleanrotors.Replaceleaking
calipers.
Unevenbraking,carpulístoone

a.Incorrecttirepressuresorworntires

a.Inspecttirecondition.Checkandcorrecttirepres-
side,rearbrakeslock

sures.
b.Brakepadsononesideofcarheat-

b.Replacebrakepads.Cleanrotors.Replaceleaking
glazedoroil-soaked

calipers.
c.Caliperorbrakepadsbinding

c.Cleanandreconditionbrakes.
d.Wornsuspensioncomponents

d.Inspectforwornordamagedsuspensioncompo-
nents.See310FrontSuspensionor330RearSus-
pension.
Brakesdrag,bindoroverheat

a.Brakecaliperorbrakepadsbinding

a.Cleanorreplacecaliper.(
b.Mastercylinderfaulty

b.Replacemastercylinder.
WARNING-
OncarswithAllSeasonTraction(AST),special
BMWserviceequipmentisrequiredtoproperly
bleedtheABS/AST system.Forsafetyreasons,the
brakesystemoncarswithABS/AST mustnotbe
bledusingtheproceduresdescribedinthisrepair
group.
BLEEDINGBRAKES
Brakebleedingisusuallydoneforoneoftworeasons:Ei-
thertoreplaceoídbrakefluidaspartofroutinemaintenance
ortoexpeltrappedairinthesystemthatresultedfromopen-
ingthebrakehydraulicsystemduringrepairs.
BLEEDINGBRAKES
Alwaysusenewbrakefluidfromanunopenedcontainer.It
isimportanttobleedtheentiresystemwhenanypartofthe
hydraulicsystemhasbeenopened.Oncarsnotequipped
withtractioncontrol(AST),brakesystembleedingshouldbe
donewithapressurebleeder.OncarswithAST,brakebleed-
ingshouldbedonebyanauthorizedBMWdealer.
WARNING-
OncarswithAllSeasonTraction(AST),special
BMWserviceequipmentisrequíredtoproperly
bleedtheABS/ASTsystem.Forsafetyreasons,the
brakesystemoncarswithABS/AST mustnotbe
bledusingtheproceduresdescribedinthísrepair
group.

Whenbleedingthebrakes,startatthewheelfarthestfrom

4.Closebleederscrewandreleasebrakepedal.Refill
themastercylinderandprogressinthefollowingorder:

brakefluidreservoirandproceedtorearleftwheel.
"rightrearbrake

5.Proceedwiththeremainingwheelsusingtheorderlist-
"leftrearbrake

edearlier.
"rightfrontbrake
"leftfrontbrake
Pressurebleedingbrakes
(exceptcarswithAST)
1.Topoffbrakefluidinreservoirandconnectpressure
bleedertoreservoir.Connectbleederhoseandbottle
torightrearcaliperbleederscrew.Pressurizesystem
toapproximately1bar(14.5psi).
BRAKES 340-3
TighteningTorques
"Bleederscrews:
7mmscrew......................5Nm(4ft-Ib)
9mmscrew......................6Nm(5ft-Ib)
BRAKEPADS,CALIPERS,ANDROTORS
CAUTION-

TheE36frontbrakecaliperisshowninFig.2.Therear
Donotexceedapressureof2bar(29psi)when

brakecaliperisshowninFig.7.
pressurebleedingthebrakesystem.Excessive
pressurewilldamagethebrakefluidreservoir.

Brakepadscanbereplacedwithoutdisconnectingthe
brakefluidhosefromthecaliperorhavingtobleedthebrakes.
2.Haveahelperholdbrakepedaldown.

Therotorscanbereplacedwithoutdisassemblingthewheel
hubandbearing.Alwaysmachineorreplacerotorsinparts.
3.Openbleederscrew.SeeFig1.Havehelperslowly,

Replacepadsinsets.
pumpbrakesabout10timeswithbleederscrewopen,
holdingpedaldownonthelastpump.Whenescaping

WARNING-
fluidisfreeofairbubbles,closebleederscrew.

"Althoughsemi-metallicandmetallicbrakefriction
materialsinbrakepadsorshoesnolongercon
CAUTION-

tainasbestos,theyproducedangerousdust.
Bleederhosemustalwaysremainsubmersedin

"Treatallbrakedustasahazardousmaterial.
thecleanbrakefluidwheneverthebleedervalve
isopen.

"Donotcreatedustbygrinding,sanding,orclean-
ingbrakefrictionsurfaceswithcompressedair.
"Breathinganybrakedustcancauseseriousdis-
easessuchascancer,andmayresultindeath.
Brakepads,replacing
Thisprocedureisapplicablelobothfrontandrearbrakes.
Frontandrearbrakeassembliesarebasicallythesame,ex-
ceptthattherearbrakerotorshousetheparkingbrakemech-
anism
1.Raisecarandremovewheels.
WARNING-
Makesurethecarisfirmlysupportedonjackstands
designedforthepurpose.Placethejackstandsbe-
neathastructuralchassispoint.Donotplacejack
standsundersuspensionparts.
2.Removeplasticcapsfromguideboltsandthenremove
guidebolts.SeeFig.3.
0012113

3.Ifapplicable,disconnectbrakepadwearsensorcon-
Fig.1.

Brakecaliperbleederscrew(arrow).

nectorandremovewiringfromitsholder.
4.Removeanti-rattleclipfromcaliper.SeeFig.4.
BRAKEPADS,CALIPERS,ANDROTORS

340-4BRAKES
Fig.2.

Frontbrakecaliperassembly.
Bleedervalve
anddustcap
Mounting
bolt
Brakepad
wearsensor
(leftwheelonly)
-Brakepad.
carrier
Anti-rattle
^_ spring-
0012154
Fig.3.

Brakecaliperguidebolts(arrows).
5.Pullcaliperstraightoffrotor.
CAUTION-
Donotletthebrakecafiperhangfromthebrake
hose.Suspendftfromthechassisusingstiffwire.
BRAKEPADS,CALIPERS,ANDROTORS
0012155
Fig.4.

Removinganti-rattleclipbyunhookingattopandbottom.
Usescrewdriverasanaid(arrow).
NOTE-
Ifthereisaridgeontherotoredge,thecafiperpfston
willhavetobepushedbackfintothecafiperbeforethe
cafipercanberemoved.

6.Removebrakepadsfromcaliper.Whereapplicable,
carefullyprypadwearsensorfrompad.SeeFig.5.
Fig.5.

Removingbrakepadwearsensor.
7.Inspectbrakecaliperforsignsofleakage.Checkthat
thecaliperpistonslidessmoothlyintocaliper.Replace
caliperifanyfaultsarefound.
CAUTION-
Withthepadsremoved,residualhydreulicpres-
suremaycausethecaliperpistontoslideout.Use
awoodenblocktoholdthepistoninplace.
8.fnsertbrakepadwearsensorintocutoutinnewpad
whereapplicable.
14.Placeinnerbrakepad(withlocatingspring)ontobrake
NOTE-

caliperpiston.Routepadwearsensorwiringthrough
lfthebrakeliningindicatorlightilluminatedpriorto

caliperopeningandbleederdustcap.
brakepadreplacement,thewearsensorshouldbere-
placed.

15.Theremainderofinstallationisreverseofremoval.
"Donotlubricateguideboits.
9.Slowlypresspistonbackintocaliper.Usecacenotto

"Oncebrakeassemblyisinstalleddepressbrakepedal
damagepistondustsea¡.SeeFig.6.

severa¡timesbeforedrivingvehicle.
NOTE-
"Opencaliperbleederscrewwhenpressingpiston

TighteningTorques
backintocaliper.Catchexpelledfluidinappropriate

"Brakecalipertobrakepad
container.Thisprocedureishighlyrecommendedin

carrier(guidebolt)...............30Nm(22ft-Ib)
thecaseofcarswithABS.

"Roadwheeltohub

........100±10Nm(74±7ft-Ib)
"Openthebleederscrewonlywhenapplyingforceto
thepiston.Donotallowairtobedrawninthroughthe
bleederscrew.
"Pressingthecaliperpistoninmaycausethebrakeflu-
idreservoirtooverflow.Topreventthis,useaclean
syringetofirstremovesomefluidfromthereservoir.
BRAKES 340-5
0012157
Fig.6.

Brakecaliperpistonbeingpressedintocalipertomakeroom
fornewpads.Usearagtoprotectcaliperpistonandseals.
10.Thoroughlycleaninnerandoutersurfacesofbrakero-
tor.Inspectrotorforcracks,signsofoverheatingand
0012156 scoring.
11.Measurethicknessofrotor.SeeTableb.Ifrotordoes
notpassminimumthicknessrequirements,orisdam-
aged,replaceasdescribedlater.
12.Thoroughlycleanallcontactpointsoncaliperand
brakepadcarrier.Cleanguideboltsandmakesure
theyslidefreely
13.Lightlycoatpadcontactpointswithbrakeanti-squeal
paste.Placeouterbrakepadontocaliper.Applyasmall
amountofgreasetothetopandbottomcontactpoints
wherethecalipercontactsthepadcarrier.
BRAKEPADS,CALIPERS,ANDROTORS

340-6BRAKES
bolt~

Guidebolt
caps
covers
Brakecaliper
Shoe
retaining
píns
Parkingbrake
cable
Fig.7.

Rearbrakecaliperassembly.
Caliperguide

Brake

ad
bolts,

Bleedervalve

i
_
~wear sénsor
®

anddustcap

(rightwheelV..,,,
Brakecaliper,removingandinstalling
1.Raisecarandremovewheel.
WARNING-
Makesurethecarisfirmlysupportedonjackstands
designedforthepurpose.
2.Loosenbrakehosefittingatcaliper.Donotremove.
3.Removecalipermountingboltsfromsteeringarm(Font
caliper)orfromtrailingarm(rearcaliper).SeeFig.8.
4.Presspistonbackintocaliperandslidecaliperoffbrake
rotor.Spincaliperoffbrakehose.
5.Inspectbrakecaliperforsignsofleakage.Checkthat
caliperpistonslidessmoothlyintocaliper.Replacecal-
iperifanyfaultsarefound.
6.Installationisreverseofremoval.Bleedentirebrake
systembeforedrivingcar.SeeBleedingBrakes.
TighteningTorques
"Frontbrakecalipertosteeringarm..110Nm(81ft-Ib)
"Rearbrakecalipertotrailingarm....67Nm(50ft-Ib)
"Brakefluidhosetocaliper....17-19Nm(13-14ft-Ib)
"Roadwheeltohub

........100±10Nm(74±7ft-Ib)
BRAKEPADS,CALIPERS,ANDROTÓRS
Cover
Caliper

!

Brakepad
Oringiston

carne- p
Circli
©ot~ AV~:Z

1vo~
Springand
spring
retainer

uustseas

~~

Aniráttle
j),
Brake

spring
Shoe pads _ _
adjuster

perreturn
nf
MIL
Rotorwith
integrated
parkingbrake
drum
6573
0011256
Fig.8.

Frontbrakepadcarriermountingbolts(arrows).Rearcaliper
mountingboltsaresimilar.

Brakerotor,removingandinstalling
Brakerotorsshouldalwaysbereplacedinpairs.
Fig.9.

Brakerotormountingscrew(arrow).
3.Inspectrotorforexcessivegrooving,cracks,andwarp-
ing.Checkrotorthickness.SeeTableb.
4.Installationisreverseofremoval.
"Cleanrotorwithbrakecleanerbeforeinstalling.
"Ifbrakefluidhoseveasremovedorloosened,brake
systemmustbebledasdescribedaboveunder
BleedingBrakes.
BRAKES 340-7
5.Oncebrakeassemblyisinstalind,depressbrakepedal
severaltimestoadjustcaliperandpads.
"Pedalshouldfeelfirmandbeatproperheight.
"Checkfluidleve¡.Topupifnecessary.
NOTE-
M3modelsusedirectionalbrakerotorsandmustbein-

NOTE-
stalledontheproperside.Partnumbesarecastfinto

Wheninstallingnewrearbrakerotors,theparking
therotors.Apartthatendsinanoddnumberisaleft

brakeshouldbeadjusted.SeeParkingBrake.
rotor.Onethatendsinanevennumberisarightrotor.
1.Removecaliperasdescribed-aboveandhangfrom

TighteningTorques
chassisusingstiffwire.

"Brakerotortowheelhub..........16Nm(12ft-Ib)
"Frontbrakecalipertosteeringarm...110Nm(81ft-Ib)
NOTE-

"Rearbrakecalipertotraílingarm....67Nm(50ft-Ib)
Donotloosencaliperbrakehose.

"Roadwheeltohub

......100±10Nm(74t7ft-Ib)
2.Removemountingscrewholdingrotortowheelhub.

,
SeeFig.9.

Tableb.BrakeRotorReconditioningSpecificati*M`
Front Rear
Ventedrotorwear
limit(min.thickness)

20.4mm(0.803in.)
Solidrotorwearlimit
(min.thickness)

8.4mm(0.331in.)
M3modelswearlimit
(min.thickness)

26.4mm(0.977in.)

18.4mm(0.723in.)
Axialrunout(max.)
rotorremoved

0.05mm(0.002in.)

0.05mm(0.002in.)
rotorinstalled

0.20mm(0.008in.)

0.20mm(0.008in.)
CAUTION-
M3brakerotorsmustnotbemachined.
MASTERCYLINDER
Thebrakemastercylinderismountedtothefrontofthevac-
uumboosteronthedriversidebulkhead.
Mastercylinder,removingandinstalling
1.Usingacleansyringe,emptybrakefluidreservoir.
WARNING-
Brakefluidishighlycorrosiveanddangeroustothe
environment.Disposeofitproperly.
NOTE-
Onoriginalequipmentrotors,themínimumallowable

2.Disconnectbrakefluidleve¡senderconnectorfromfluid
thicknessisstampedontherotorhub.Measuretherotor

reservoircap.
brakingsurfacewithamicrometerateighttotendifferent
pointsandusethesmallestmeasurementrecorded.

3.Disconnectbrakefluidlinesfrommastercylinder.See
Fig.10.Disconnecthydraulicclutchsystemsupplyline.
4.Unscrewmountingnutsandremovemastercylinder
frombrakebooster.
5.Makesureallnuts,fluidcouplings,threadbores,and
matingsurfacesareclean.
MASTERCYLINDER

340-8BRAKES
Fig.10.Brakefluidlinesatmastercylinder(arrows).
6.Iffluidreservoirwasremoved,installitcarefullyusing
newsealinggrommets.
7.Mountmastercylindertobrakeboosterusinganew0-
ringandnewself-lockingnuts.
CAUTION-
Usecavenottoover-torquethemastercylinder
mountingnuts.Thiscoulddamagethebrake
boosterandpreventpropervacuumbuild-up.
0012164
8.Connectallbrakefluidlines.Connecthydraulicclutch
hosetobrakefluidreservoir.
9.Reconnectfluidleve¡sender,andbleedentirebrake
systemasdescribedearlier.
BRAKEBOOSTER
BRAKEBOOSTER
Thebrakeboosterismountedtothebulkheadonthedriver
sideoftheenginecompartment,directlybehindthebrake
mastercylinder.SeeFig.11.
0015225
Fig.11.Brakebooster(arrow).Aisvacuumhosefromintakemani-
fold.Bisone-wayvalve.Intakemanifoldvacuumactsona
largediaphragminthebrakeboostertoreducebrakepedal
effort.
Brake booster, removing andinstalling
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
TighteningTorque
"Brakemastercylinderto

2.Usingacleansyringe,emptybrake(luidreservoir.
brakebooster...................26Nm(18ft-Ib)

WARNING-
"Brakefluidhosetocaliper....17-19Nm(13-14ft-Ib)

Brakefluidishighlycorroslveanddangeroustothe
environment.Disposeofitproperly.
3.Removebrakefluidlevelsenderconnectorfromreser-
voircap.
4.Disconnectbrakefluidlinesfrommastercylinder.Plug
openings.
5.Disconnectenginevacuumhosefrombrakebooster.

6.DisconnectABSelectricalconnectors.Labelandthen
disconnectbrakelinesfromhydraulicbrakeunit.Plug
openíngs.SeeFig.12.
~
~ A1/B
'1vC~F
lu 11-riJ.
0013244
A.Rightfront

F

Frontfrommastercylinder
B.Leftfront

R.Rearfrommastercylinder
C.Rear
Fig.12.BrakefluidlinesatABShydraulicunit.
WARNING-
"OncarswithAllSeasonTraction(AST),special
BMWserviceequipmentisrequiredtoproperly
bleedtheAntilockBrakeSystem(ABS).Removal
oftheABShydraulicunitisnotrecommendedun-
lessthisequipmentisavailable.Forsafetyrea-
sons,thebrakesystemoncarswithABSmust
notbebledusingtheproceduresdescribedinthis
repairgroup.
"DonotmixupthefluidfinesattheABShydraulic
unitLabelallconnectionsbeforedisconnecting.
7.RemoveABShydraulicunitfromenginecompartment.
8.Workinginsidecar,removepanel(s)frombeneath
steeringcolumntoaccesspedalassembly.See513In-
teriorTrim.
12.Makesureal¡nuts,fluidcouplings,threadboresand
matingsurfacesareclean.
BRAKES340-9
0011261
Fig.13.Brakepedalclevispinandretainingclip(A).Brakebooster
mountingnutsshownatarrows.
13.Ifnecessary,mountmastercylindertovacuumbooster
usinganewO-ríngandnewself-lockingnuts.
CAUTION-
Donotover-torquethemastercylindermounting
bolts.Thiscoulddamagethebrakeboosterand
preventpropervacuumbuild-up.
14.InstallationisreverseofRmoval.
"Bleedbrakesasdescribedearlier.
"Checkand,ifnecessary,adjustbrakelightswitch
abovebrakepedal.
TighteningTorques
"Brakemastercylinderto
brakebooster...................26Nm(18ft-Ib)
"Brakeboostertobulkhead.........22Nm(16ft-Ib)
"Brakefluidlinetomastercylinderor
ABShydraulicunit..........17-19Nm(13-14ft-lb)
9.Removeclipandclevispinfrombrakeboosterpushrod
anddisconnectitfrombrakepedal.Removebrake
boostermountingnuts.SeeFig.13.
NOTE-
10.Workinginenginecompartment,removebrakebooster

Whenreplacingthebrakeboosterone-wayvalveor
togetherwithmastercylinder.

vacuumhose,installthevalvesothatthemoldedarrow
ispointingtowardtheintakemanifold.Usenewhose
11.IfboosterormastercylinderO-ringisbeingreplaced,

clamps.
disconnectmastercylinderfrombrakebooster.
BRAKEBOOSTER

340-10 BRAKES
PARKINGBRAKE
Theparkingbrakeisabrakedrumsystemintegratedinto
therearbrakerotors.SeeFig.14.
Adjustmentoftheshoesmaybenecessarycompensatefor
wear.Theparkingbrakeshouldalsobeadjustedanytimethe
cable,therearbrakerotor,ortheparkingbrakeshoesarere-
placed.
Lower
Parkingbrake

Parkingbrake

retum
shoe actuator spring
Fig.14.Parkingbrakeshoeassembly.
Parkingbrake,adjusting
2.Raiserearofcar.
PARKINGBRAKE
Shoeretainer

Rotorwith
andspring

integrated
parkingbrake
Shoe

drumI
adjuster

Upperreturn
spring
-í<~
::
Rotormounting
screw
WARNING-
Makesurethecarisfirmlysupportedonjackstands
designedforthepurpose.Placethejackstandsbe-
neathastructuralchassispoint.Donotplacejack
standsundersuspensionparts.
0011265
3.Removeonelugboltfromeachrearwheel.Turnroad
wheeluntillugboltholelinesúpwithparkingbrakead-
juster(approximately65°torearofwheelcenterline).
SeeFig.16.
4.Usingascrewdriver,turnadjustertoexpandbrake
shoesuntilroadwheelcannolongerturn,thenback
adjusteroff.Repeatprocedureonotherrearwheel.
Fig.15.Parkingbrakecableadjustingnuts(arrows).
Theparkingbrakecanbeadjustedwiththewheelsin-
stalled,althoughtherearwheelswillhavetoberaisedoffthe

1

fl

i\a
ground.
1.Liftparkingbrakeleverbootoutofconsole.Whilehold-
ingcablesstationary,loosenparkingbrakecablenuts
untilcablesarecompletelyslack.SeeFig.15.
0011263
0012727
Fig.16.Accessparkingbrakeshoeadjusterapproxímately65°torear
ofvertical.Useflat-bladedscrewdrivertoturnadjuster.Onleft
wheel,turnadjusterindirection1toexpandshoes.Onríght
wheel,turnadjusterindirection2toexpandshoes.
ParkingBrakeAdjusting(initial)
"Backoffadjusterthroughwheellugbolthole
ex.M3models......................18notches
M3models..........................8notches
5.Workinginsidecar,setparkingbrakeseveraltimesto
seatcable.Thenpullparkingbrakeleverupfournotch-
es.Tightencableadjustingnutsuntilitisjustpossible
toturnrearwheelswithslightresistance.
6.Releaseleverandmakesurerearwheelsturnfreely.

7.Turnonignition.Checkthatlightcomesonassoonas

4.Removeparkíngbrakeshoesasdescribedabove.
leverispulledup.
5.Disconnectcablefromparkingbrakeactuatorandthen
8.Installparkingbrakeleverboot.Installroadwheellug

removeparkingbrakecablefromcableholderontrail-
bolts.

ingarm.SeeFig.17.
TighteningTorque
"Roadwheeltohub.........100±10Nm(74±7ft-Ib)
Parkingbrakeshoes,
removingandinstalling
1.Raiserearofcarandremoveroadwheels.
WARNING-
Makesurethecarisfirmlysupportedonjackstands
designedforthepurpose.Placethejackstandsbe-
neathastructuralchassispoint.Donotplacejack
standsundersuspensionparts.
2.Withoutdisconnectingbrakefluidhose,removerear
brakecalipersfromtrailingarms.Removerearbrake
rotors.SeeBrakePads,CalipersandRotors.
CAUTION-
Donotletthebrakecaliperassemblyhangfrom
thebrakehose.Supportcaliperfromchassiswith
strongwire.
3.Unhookupperreturnspringfrombrakeshoes.Remove
shoeretainersbypushingtheminandrotating1/4turn.
BMWspecialtoolno.344000canbeusedtoremove
retainers,ifneeded.
4.Spreadshoesapartandliftthemout.

7.Installationisreverseofremoval.Adjustparkingbrake
asdescribedearlier.
NOTE-
Whenremovingthebrakeshoestheshoeexpander
pivotpininthebrakeactuatormayfallout.
TwoversionsoftheAntilockBrakeSystem(ABS)arein-
5.Inspectshoeexpandertomakesureitfunctionsprop-

stalledonthecarscoveredbythismanual.Earlycarsusethe
erly.Applyathincoatofgreasetoslidingpartsand

TevesMarkIVGABS.LatercarsusetheTevesMark20-I
pins.

ABS.Themaindifferencebetweenthetwosystemsisthatthe
Mark20-IsystemintegratestheABScontrolmoduleintothe
6.Installationisreverseofremoval.Besuretoadjust

hydraulicunitasasinglecomponent.
parkingbrakecablesasdescribedearlier.
ABSisdesignedtobemaintenancefree.Therearenoad
Parkingbrakecable,replacing

justmentsthatcanbemadetothesystem.Repairandtrouble-
shootingofthemajorABScomponentsrequiresspecialtest
1.Raiserearofcarandremoveroadwheels.

equipmentandknowiedgeandshouldbedonebyanautho-
rizedBMWdealer.
2.Removerearbrakecaliperandrotor.SeeBrakePads,
CalipersandRotors.
3.Workinginsidecar,liftparkingbrakeleverbootoutof
console.Removecableadjustingnut.RefertoFig.15.
Fig.17.Parkingbrakecableinsertionpointinreartrailingarm(arrow).
6.Slidecableoutofhousing.
NOTE-
BRAKES 340-11
Onsomemodelsitmaybenecessarytoremoverear
mufflertoaccessthebrakecabes).
ANTILOCKBRAKESYSTEM(ABS)
0013209
ANTILOCKBRAKESYSTEM(ABS)

340-12BRAKES
ABSisself-testedbytheABSdiagnosticuniteachtimethe
carisstarted.Oncethetestiscomplete,theABSdashboard
lighttucosoff.Ifthelightremainslitorcomesonatanytime
duringdriving,asystemfaulthasoccurredandABSiselec-
tronicallydisabled.Theconventionalbrakingsystemremains
fullyfunctioning.
ABSInspection
AvisualinspectionoftheABSmayhelptolocatesystem
faults.IfnovisualfaultscanbefoundandtheABSlightre-
mainson,havethesystemdiagnosedbyanauthorizedBMW
dealer.
CarefullyinspecttheentireABSwiringharness,particularly
thepulsesensorharnessesandconnectorsneareachwheel.
Lookforchafingordamageduetoincorrectlyroutedwires.
Carefullyremovethewheelspeedsensors.Cleanthesen-

Fig.18.FrontABSpulsesensormountingbolt(arrow).
sortips.Inspectthetoothedwheelonthewheelhub.Check
formissing,cloggedorcorrodedteeth,orotherdamagethat
couldaltertheclearancebetweenthesensortipandthe
toothedwheel.
NOTE-
Ifatoothedringisdamaged,theentirewheelhubmust
bereptaced.See310FrontSuspensionor330Rear
Suspension.
ABSwheelspeedsensors,replacing
1.Raiseapplicableendofcar.
WARNING-
Makesurethecarisfirmlysupportedonjackstands
designedforthepurpose.Placethejackstandsbe-
neathastructuralchassispointDonotplacejack
standsundersuspensionparts.
2.Unscrewwheelspeedsensormountingbolt.Remove
sensorfromitshousing.SeeFig.18.Removeharness
fromretainingmounts.
3.FrontABSsensor:Workinginfrontwheelhousing,dis-
connectandremovesensor.SeeFig.19.
4.RearABSsensor:Workinginrearwheelhousing,dis-
connectandremovesensor.
5.Duringinstallation,applythincoatofMolykote0Long-
term2oranequivalentgreasetopulsesensorand
housing.
ANTILOCKBRAKESYSTEM(ABS)
0012122
Fig.19.FrontABSwheelspeedelectricalconnector(arrow)inwheel
well.
6.Installationisreverseofremoval.

GENERAL............................400-1

INTERIOREQUIPMENT................400-4
SeatsandSeatbelts.....................400-4
BODYASSEMBLY.....................400-2

InstrumentsandControls.................400-4
ExteriorandAerodynamics...............400-2

CentralBodyElectronics.................400-5
CoupeModels.........................400-3

ElectronicImmobilizationSystem..........400-5
ConvertibleModels.....................400-3

HeatingandAirConditioning..............400-6
GENERAL
Thissectioncoverssystemdescriptionsandgeneralser-
viceinformationfortherepairgroupsfoundin4Bodyand5
BodyEquipment.
WhenworkingorservicingcarsequippedwithSRSair-
bag(s),thefollowingprecautionsmustbeobservedtoprevent
injury.
F19.1.TheBMWE36coupe.
400Body-General
BODY-GENERAL 400-1
WARNING -
"Airbagsareinflatedbyanexplosivedevice.Han-
dledimproperlyorwithoutadequatesafeguards,
airbagunitscanbeverydangerous.Specialpre-
cautionsmustbeobservedpriortoanyworkator
nearthedriver'ssideairbag,thepassenger's
sideairbag(whereapplicable),ortheside-impact
aírbags(whereapplicable).See721AirbagSys-
tem(SRS).
"Alwaysdisconnectthebatteryandcovertheneg-
ative(-)batteryterminalwithaninsulatorbefore
startingdiagnostic,troubleshootingorservice
workoncarsfittedwithSRS,andbeforedoíng
anyweldingonthecar.
0013098
GENERAL

400-2BODY-GENERAL
4-doorSedan
Coupe
-saas3.7""
351/

37.3
O

Ix`-193

267
o oa
'3281model
"M3 model
Convertible
BODYASSEMBLY
55
ass
.e
iss""
-66.9-
Fig.2.

E36bodydimensíons.
BODYASSEMBLY
29.4
29
4
TheBMW3Serieschassisisaunibodydesignconstructed
ofhighstrengthsteel.Attachingparts,suchasthefrontfend-
ers,rearquarterpanels,doors,trunklidandhoodarealso
constructedofsteel.
706.31108.7"

I 38.5
174.5
174.5
O

oo
196.3/106.7'"

35_5

1..
55 .9,566".
106.3/196.7""

i. 358
-1745-
559/563'/566"
- J
0013099
Windowsbondedflushtothebodyandtheguidedflowof
coolingairintotheenginecompartmentprovideagoodcoeffi-
cientofdrag(CD).TheE36carshavea
CDofapproximately
0.30forthesedanandcoupemodels,and0.35forthecon-
vertiblemodels:
Theexteriorpanelsarecorrosion-resistantzinccoated
steel.Thefrontfendersareboltedonandeasilyreplaceabie.
ThebodystylesofE36carscoveredbythismanualarethe

See410Fenders,EngineHood.
4-doorsedan,2-doorcoupeandconvertible.Bodydimen-
sionsvaryslightlybetweenmodels.SeeFig.2.

Thefrontandrearbumpersuseanaluminumframework
withanoverlaidhigh-impact,deformableplasticcover.This
ExteriorandAerodynamics

bumpersystemkeepsdamagetoaminimuminhead-oncolli-
sionsofupto10m.p.h.(15km/h).See510ExteriorTrim,
TheE36canbeimmediatelyrecognizedasatypicalBMW.

Bumpers.
Withitstraditionalstylingfeatures,suchastheBMWkidney
grille,circularheadlightsbehindaglasscover(forreasonsof
streamliníng),andthe"kick"intherearmostroofpillar(C-pil-
lar).

TheE36convertibleisanall-seasonvehiclewithahighlev-
e¡offunctionality,excellentinteriorcomfort,andacousticre-
finement.Interiormaterialsandcolors,thesofttopandthe
light-alloywheelshavebeencarefullymatched.
Variousversionsofmanualandautomaticsofttopshave
beenused,withthefullyautomaticconvertibleroofbeingin-
stalledbeginninginthe1997modelyear.
Ahard-topinbodycolorwithheatedrearwindowisavail-
ableasanoptionforthecoldseason.
BODY-GENERAL 400-3
CoupeModels

Theconvertiblebodystructureincludesmanypassivesafe-
tyrefinementsoveritsfixed-topcounterparts.Someoftheen-
TheE36coupeissimilartothe4-doorsedan,buthasa

hancementsinclude:
morestretchedandsleekerappearance.Thus,withthesame
wheelbaseandidenticallength,itlooksdifferentbutstillfamil-

"Morerígídunderbody.
iar.

"Transverseseatmembers.
"Reinforcedwindshieldframewithbondedwindshield,
The2-doorvariantdiffersfromthe4-doorsedanbya3.12

andtubulardoorreinforcements.
inch(8cm)longerfrontend,aflatterhoodlinewithairslits,

"Rolloverprotectionsystem,whichistrippedintoposition
andaroofalmost1.2inches(3cm)shorter.Additionaldiffer-

inafractionofsecond.Thisisavailableasoptional
encesincludewiderdoorswithframelessWindows,glass-

equipment(standardonthe1998328iC)andmaybefit-
covereddoor-posts(B-pillars)andashorterandlowerlug-

tedtoearlierconvertiblemodels.Withthisfeature,two
gagecompartmentlid.

barsfullyindependentofeachothercomeupbehind
eachrear-seatbackrestwhenthevehicleisindangerof
ConvertibleModels

turningover.
Aconvertiblebodynormallyflexesandvibrates,transfer-
ringoscillationstotheluggagecompartment.IntheE36con-
vertible,BMWutilizesaspecialbatteryintheluggage
compartment,inconjunctionwithauniquebatterytray,asa
vibrationdampeningsystemtocounteractthisoscillation.
CAUTION-
TheE36convertiblerequiresaspecialbattery
whichisdesignedforconstantvibration.
Informationfortheconvertibletopanditsrelatedmecha-
nismscanbefound541ConvertibleTop.
BODYASSEMBLY

400-4 BODY-GENERAL
INTERIOREQUIPMENT
E36interiorshaveauniquecharacter,withacombínationof
sportyfeaturesandinnovativedesign.Al¡bodyversionswere
madeinawidechoiceofinteriorandexteriorcolors.New
colorswithmatchingleatherand/orfabricupholsterywerein-
troducedforeachmodelyear,includinglight-alloywheelsin
newdesigns.
Drivingcomfortisenhancedbypowersteering,tiltsteering
wheel(optional),height-adjustablefrontseats,andelectrical-
lyadjustableandheatedrear-viewmirrors.Insidethecar
therearereadinglightsatfourseatingpositions.
SeatsandSeatBelts

NOTE-
Theseatbaseusedoncarswithpyrotechnicseatbelt
Anatom¡cally-correctseatsareconstructedfrompolyure-

tensionersisnotinterchangeablewiththeearlierseat
thanefoamcontainingareasor"zones"ofdifferentfirmness.

base.
Theseatbaseshavesteelspringsforaddedsupportand
strength.Thepowerseatsareprovidedwithconvenientlylo-

InstrumentsandControls
catedswitchesalongtheoutsideedgeoftheseat.Heated
seatsareanoptioninallmodels.See520Seatsformorede-

Everythingintheinteriorpassengercompartmentessential
tails.

tothedriverislogicallygroupedandeasytoreach.Al¡instru-
mentsandcontrolshavebeenarrangedergonomicallyand
TheM3sportseatisshowninFig.3.

arefullyintegratedintotheoveralldesignofthevehicle.
Fig.3.

M3sportseat.
INTERIOREQUIPMENT
0013195
TheearlyE36carsareequippedwithasingle(driverside)
airbaginthesteeringwheel.Startingwiththe1994models,a
dualairbagSupplementalRestraintSystemhasbeenstan-
dardequipment.Side-impactairbagsinthefrontdoorsareop-
tionalin19974-doorcarsandstandardequipmentinall1998
models.
Through1996,E36seatbeltswereequippedwithBMW's
original-designspringtensioners.In1997,theseatbasede-
signwasmodifiedtoaccommodateapyrotechnic(explosive
charge)seatbelttensioner.Bothtypesoftensionersarede-
signedtoautomaticallytensionthebeltsbyabout2inches(55
mm)intheeventofacollision.
Thepaddeddashboardhousestheinstrumentclusterand
theventilationandheatingsystem.Theinstrumentcluster
useslargeeasy-to-readanaloginstrumentsandisremovable
asaunitwithoutremovingthedashboard.TheServiceInter-
valIndicator(SII)willremindthedriverwhenthecarrequires
service.See620Instruments.
TheMulti-InformationDisplay(MID)unitinthecenterofthe
dashboardcomesinavarietyoffourconfigurations,themost
advancedbeingtheOn-BoardComputer(OBC).SeeFig.4.
Al¡versionsoftheMIDhaveaclockandcalendar.Inaddi-
tion,differentversionsareequippedwitha"checkcontrol,"
displayforfuel-economyinformationandsystemwarnings.
Consulttheowner'smanualforfui¡operatinginstructions.

Ambienttemperaturelclock
MÍMAa.Mi}rm-Mil"IMua~naa~u~itacar"za.~
CentralBodyElectronics
0013028
Fig.4.

DifferentversionsofMulti-informationDisplay(MID)installed
inE36cars.
TheE36carsareequippedwithasophisticatedcentralized
bodyelectric/electronicsplan.Thesystemisself-diagnostic
andincorporatesmanyfunctionsintoasinglecontrolmodule.
Theconsolidationofseveralsystemsintoasinglecontrol
moduleminimizespowerrequirementsandtheincorporation
ofthediagnosticlinkresultsinmoreefficientandaccurate
troubleshooting.
Self-diagnosticcodesareaccessibleelectronicallythrough
thedata-linkconnectorintheenginecompartment.See610
ElectricalComponentLocations.
BODY-GENERAL 400-5
Twoversionsofcentralbodyelectronicsareuseddepend-
ingonmodelyear.
1992and1993modelsareequippedwithacentrallocking
module(ZVM)whichincorporatescontrolofthefollowingsys-
tems:
"Interiorlighting
"Centrallockingwithdoublelockfeature
"Outputrelaysforpowerwindowsandsunroof
"Electronicpowerprotection
E36carssincethe1994modelyearareequippedwithZKE
IV.Thisisanelectroniccomfortandconveniencesystemthat
includesthefollowingadditionalfeatures:
"Onetouchup/downpowerwindowoperation
"Powerwindowandsunroofclosurefromdriverorpas-
sengerdoorlock
"Vehiclelockingorunlockingfromthetrunklock.
Otherfeaturesofthesystemarediscussedin515Central
LockingandAnti-Theft.
ElectronicImmobilizationSystem
Beginninginmodelyear1994,allE36vehiclesincorporate
adriveawayprotectionsystemregardlessofwhetherthevehi-
cleisequippedwithaBMWAlarmSystemoranOn-Board
computer.Twotypesoffactorysystemswereinstalled,de-
pendingonvehicleproductiondate.
Ontheearlysystem(modelyear1994uptoJanuary1995),
theignitionandfuelinjectionfunctionsaredisabledwhenever
thevehicleislockedinthedoublelockmode.Thisisreferred
loasEWSorEWSI.
BeginninginJanuary1995,thedriveawayprotectionsys-
temwasupgradedtoamoresophisticatedsystem,called
EWSII.Thissystemusesawirelesscommunicationlinkbe-
tweenatransponderchipintheignitionkeyandtheringan-
tennasurroundingtheignitionswitch.TheEWSIIcontrol
moduleblocksthestartingofthevehicleunlessthecorrect
codedignitionkeyisused.
Forfurtherinformationaboutdriveawayprotectionsys-
tems,see515CentralLockingandAnti-Theft.
INTERIOREQUIPMENT

400-6BODY-GENERAL
HeatingandAirConditioning
Theelectronicallycontrolledheatingandairconditioning
systemusesanextralarge,infinitelyvariableradialblower
motorforgooddistributionofair.Freshairentersthroughthe
grillebelowtheenginehoodandfintothepassengercompart-
mentviathedashboardandfootwellvents.SeeFig.5.
Repairinformationfortheheatingandairconditioningsys-
temiscoveredin640HeatingandAirConditioning.
Fig.5.

Heatingandairconditioningventilationplan.
INTERIOREQUIPMENT

GENERAL
Thisrepairgroupcoversreplacementofthefrontfenders
andremovalandinstallationoftheenginehood.
NOTE-
Thebodyispaintedatthefactoryafterassembly.Re-
alignmentofbodypanelsmayexposeunpaintedmetal.
Paintallexposedmetaloncetheworkfscomplete.
FRONTFENDERS
Frontfender,removingandinstalling
1.Raisehood.Raiseandsafelysupportfrontofvehicle.
WARNING -
"Whenraisingthecarusingafloorjackorahy-
drauliclift,carefullypositionthejackpadtopre-
ventdamagingthecarbody.Asuitableliner
(wood,rubber,etc.)shouldbeplacedbetween
thejackandthecartopreventbodydamage.
"Watchthejackclosely.Makesureitstaysstable
anddoesnotshiftortilt.Asthecarisraised,the
carmayrollslightlyandthejackmayshift.
2.Removefrontwheel.Removeinnerplasticlinerfrom
wheelwell.
3.Removefrontbumper.See510ExteriorTrim,
Bumpers.
4.Workingatfrontcorneroffender,removefrontgrille
panelbolts(2boltsatleftandright).SeeFig.1.
FENDERS,ENGINEHOOD

410-1
410Fenders,EngineHood
GENERAL............................410-1

ENGINEHOOD........................410-3
Hood,raisingtoserviceposition...........410-3
FRONTFENDERS.....................410-1

Hood,removin

andinstallin

410-3
FrontPender,removingandinstalling.......410-1

Hood,aligning.........................410-4
Hoodreleasecableandlatches,adjusting...410-4
001.145
Fig.1.

Frontgrillepaneltofrontfenderretainingbolts(arrows).Front
bumpershownremoved.
5.Removefrontturnsignalliensassemblyfromapplica-
blefrontcorner.Carefullypryoutsidedirectionalfrom
fender(latercarsonly).See630ExteriorLighting.
6.Removefenderattachingboltsatfrontundersideof
fender.SeeFig.2.
7.Removeboltsalongtopedgeoffender:SeeFig.3.
8.Openfrontdoorandremovefendermountingboltsin
doorjamb.SeeFig.4.
9.Carefullyremovefenderfrombody.
FRONTFENDERS

410-2

FENDERS,ENGINEHOOD
Fig.2.

Fenderattachingbolts,lowerfront(arrows).
Fig.3.

LoosenboltAattopoffender.RemoveboltsB.
FRONTFENDERS
0013104
0013105
0013106
Fig.4.

Frontfenderattachingboltsasviewedthroughdoorjamb(ar-
rows).
10.Installationisreverseofremoval,notingthefollowing:
"Beforeinstallingnewfender,cleanoldsealantandpro-
tectivecoatingfrommountingsurfaces.
"Positionnewfenderandlooselyinstallallmounting
bous.Alignfenderwithdoorpillarandfrontpanel,
thentightenbolts.
"Repairanypaintdamageandpaintanyexposedmet-
al.
"Resealandapplyprotectivecoatingtomountingsur-
faces.
ClearanceSpecification
"Fendertofronthoodortodoor....5.5mm(0.216ín)

ENGINEHOOD
Hood,raisingtoserviceposition
CAUTION-
Donotswitchonthewindshieldwiperswlththe
enginehoodraised.Asaprecaution,removethe
wipermotorfuse.See610ElectricalCompo-
nentLocations.
1.4-doormodels:Openhoodfully.Removeboltfrom
hoodhingebehindhoodsupports(leftandright).Raise
hoodtoserviceposition.SeeFig.5.
2.2-doormodels:Openhoodfully.
Fig.5.

Hoodsupportbracketbolttoberemoved(A)on4-doorcars.
Removeboltsatleftandrighthinges.Swingbracketindirec-
tionofarrowtoraisehoodintoserviceposition.
"Removegroundcableatrighthoodhinge.
"Whileanassistantsupportshood,detachbothhood
supportsfromhood.
"Removedetentscrewsatbackofhoodhinges.See
Fig.6.
"Lifthoodwhilepullinghingeforward.Supporthoodat
higherposition.
3.Whenserviceworkiscomplete,returnhoodtolower
positionandinstafscrewsorbolts.
FENDERS,ENGINEHOOD

410-3
Fig.6.

Torxscrewatbaseofhoodhinge(arrow).
Hood,removingandinstalling
0013147
1.Raisehood.Whereapplicable,partiallyremovehood
acousticinsulationtoaccessrearofhood.SeeFig.7.
Fig.7.

Hoodinsulationretainerbeingpriedout
3.Detachgas-chargedhoodsupportsfromhood.
CAUTION-
Thehoodisheavy.Beforeremovingthehoodsup-
portsorhoodretainingbolts,besuretohavean
assistanthelpsupportthehood.
0013148
2.Disconnectwasherfluidhosesfromwashernozzles.
Whereapplicable,disconnectelectricalharnesscon-
nectorsfromheatednozzles.
ENGINEHOOD

410-4

FENDERS,ENGINEHOOD
4.Withaidofassistant,removehoodhingeboltsfromleft
andRghtsidesofhood.LifthoodoffcarefullySeeFig.8.
Fig.8.

Hoodhingebolts(arrows).Rightsideshown.
5.Installationisreverseofremoval.
NOTE-
Thehoodwasfittedandattachedtoanunfinishedbody
atthefactory.Unfinishedsurfacesexposedbythispro-
ceduremustbetouchedupwfthpafnt.
Hood,aligning
ENGINEHOOD
0013149
6013150
Fig.9.

Hoodpanelgapsshouldbeeven(approx.5.5mm)atall
points(arrows).
Hoodreleasecableandlatches,adjusting
Beforeadjustinghoodlatches,besurethehoodisaligned
evenlytofendersandfrontpanel.Thehoodlatchandcable
assemblyisshowninFig.10.
"Repairanypaintdamageandpaintanyexposedmetal.
"Checkhoodalignmentasdescribednext.

1.Toadjusthoodcables:
Wheninstallingthehood,alignthehingesasclosetothe
originalpaintedsurfaceaspossible.Movementofthehoodon
its'attachinghardwaremayrequiretouch-uppaint.
Thehoodshouldbealignedsothatgapsonallsidesareas
evenaspossible.SeeFig.9.
ClearanceSpecification
"Hoodedgestoadjoiningbody
panel(gap)....................5.5mm(0.216in)
"Removeleftandrightradiatorgrilles.See510Exterior
Trim,Bumpers.
"Removeelectricauxíliarycoolingfan.See170Radia-
torandCoolingSystem.
"Adjustcablesectionbetweentwohoodlatchesso
thereisnoplay(cablesmustnotbeundertensionei-
ther).
2.Loosenhoodlatchesathoodonleftandrightsides.
Loosenboltsonlyenoughtoallowmovementoflatch.
SeeFig.11.
3.Lower(butdonotfullylatch)hoodsevera¡timesso
latchesonhoodcenterthemselvesinlowerlocks.
CAUTION-
Donotlethoodfockwithlatchboltsloose.
4.Tightenhoodlatchboltswhenalignmentiscorrect.
5.Removeonescrewfromeachside,cleanandcoatwith
LoctiteO270orequivalent,andreinstall.

Centerhood

,
00--&---
cable

Hoodlatch
_I

upperleft
Fig.10.Hoodlockingcomponents.Cableadjustingsectionshownatinset.
Fig.11.Hoodlatchmountingbolts(arrows).Leftlatchshown.
Hoodlock

0013160
lowerleft
6.Testhoodforcorrectclosureandopening.Ifhooddoes
notspringopen,lengthenspringpinsatlatches.See
Fig.12.
FENDERS,ENGINEHOOD

410-5
001aio
Fig.12.Tolengthenspringpin,loosenlocknutwithwrenchinserted
throughspring,thenturnpin(arrow)counterclockwise.
ENGINEHOOD

GENERAL
Thisrepairgroupcoversfrontandreardoorrepairinforma-
tion,includingremovalandinstallationoftheinteriordoorpan-
els.
DOORS
WARNING-
LateM3moddishavealuminumdoors.Useextra
careinhandlingaluminumpartsinordertoavoid
damagefromgougingorcorrosión.
NOTE-
"Forinformationonthepowerdoorwindowsanddoor
glassreplacement,sea512DoorWindows.
"Forinformationonthepowerdoorlockingsystem,see
515CentralLockingandAnti-Theft.
WARNING-
Some1997andall1998carsarefittedwithside-im-
pactairbagsinthefrontdoors.Whenservicingdoors
oncarswithfrontside-impactairbags,alwaysdis-
connectthenegative(-)batteryterminal.See721
AirbagSystem(SRS)forcautionsandprocedures
relatingtotheairbagsystem.
Frontorreardoor,removingandinstalling
1.Ifworkingonfrontdoorwithside-impactairbag,discon-
nectnegative(-)batterycable.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevüi.
2.Unboltmainharnessconnectoratdoorpillarandsep-
arateconnector.SeeFig.1.
411Doors
GENERAL............................411-1

DOORPANELS........................411-4
Frontdoortrimpanel,removingandinstalling.411-4
DOORS..............................411-1

Reardoortrimpanel,removingandinstalling.411-5
Frontorreardoor,removingandinstalling...411-1

Rearsidetrimpanel,removingandinstalling
Doorcheck,replacing...................411-3

(coupemodel)........................411-6
DoorAdjustment.......................411-3

Rearsidetrimpanel,removingandinstalling
(convertiblemodels)...................411-6
DOORS 411-1
Fig.1.

Doorharnessconnectorbeingremovedfromdoorpillar.Re-
movemountingscrewsatA,thenseparateconnectorby
pullinguponharnesslock(toparrow).
3.Withdoorfullyopen,removepinboltsfromtopandbot-
tomdoorhinges.SeeFig.2.
0011650
Fig.2.

Doorhingepinbolt(arrow).Tophingeshown.Alsoremove
pinboltfromlowerhinge.
DOORS

411-2DOORS
4.Removeretainerclip(earlymodelsonly)fromdoorcheck
pinonbodypillar.Driveoutdoorcheckpin.SeeFig.3.

DoorAdjustment
"Doorgap
tofender/reardoor.........approx.5mm(0.189in)
"Permíssibledeviationfromparallel..0.5mm(0.020in)
0011651
Fig.3.

Doorcheckpinbeingremoved.Noteretainerclip(A)usedon
earlymodels.
5.Removedoorbyliftingupofflowerhingehalves.
CAUTION-
Becarefulnottodamagedoororotherpainted
bodysurfaces.Makesurenoloadisplacedon
wiringharness.
6.Installationisreverseofremoval.Keepinmindthefol-
lowing:
"Aligndoorsothatpanelgapsareequaloneitherside,
asdescribedlater.Ifnecessary,adjustdoorhingesas
describedlater.
"Adjustdoorstrikersothattrailingedgeoffrontdooris
slightlyhigher(1mm)thanleadingedgeofreardoor.
See515CentralLockingandAnti-Theft.
"Repairanypaintdamageandpaíntanyexposedmet-
al.
CAUTION- .
"In2-doormodels,removingandinstallingthe
doormayupsettheadjustmentandalignmentof
thewindow.Windowadjustment,asdescribedin
512DoorWindows,mustbecarriedoutater
installationtopreventdamagingtheglass.
"Ifbatterypowerislostorthebatteryhasbeen
disconnected,thewindowsmustbere-initialized.
Bothonetouchupldownandpinch-protectionwill
beinactiveuntilwindowsarere-initialized.See
512DoorWindows.
DOORCHECK,REPLACING
Doorcheck,replacing
WARNING-
Some1997andall1998carsarefittedwithside-im-
pactairbagsinthefrontdoors.Whenservicingdoors
oncarswithfrontside-impactairbags,alwaysdis-
connectthenegative(-)batteryterminal.See721
AlrbagSystem(SRS)forcautionsandprocedures
relatingtotheairbagsystem.
1.Closedoorwindowcompletely.
2.Ifworkingonfrontdoorwithside-impactairbag,discon-
nectnegative(-)batterycable.,
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgívenatthefrontofthis
manualonpageviii.
3.Removeinteriordoorpanelandvaporbarrierasde-
scribedlater.
4.Whereapplicable,removeside-impactairbagfrom
door.See721AirbagSystem(SRS).
NOTE-
Insomemodelscoveredinthismanual,ítisnotessen-
tialtoremovetheside-ímpactairbagtoaccessinternal
doorcomponents.However,theprocedureisrecom-
mendedforsafetyreasons.
5.Removeretainerclip(earlymodelsonly)fromdoor
checkpinonbodypillar.Driveoutdoorcheckpin.Refer
toFig.3.
6.Removeboltsandrubbercoverfromdoorchecklock-
plateondoor.
7.Removedoorcheckfrominsidedoor.
8.Installationisreverseofremoval.
"Lubricatedoorcheckbeforeinstalling.
"Usenewmountingboltswhenreinstallingtheside-im-
pactairbagtothedoor(whereapplicable).
"Ifbatterywasdisconnected,re-initializewindowregu-
latormotorsasdescribedin512DoorWindows.

DoorHingeAdjustment
Iftheinstalleddoorisunevenoroutofparallel,shimscan
beusedtocorrectitsposition.Theshimsareplacedbehind
thehingeplateandareavailableintwodifferentthicknesses
(0.5mmand1.0mm).SeeFig.4.
TighteningTorque
"Doorhingetodoor...............21Nm(15.5ft-Ib)
"Doorstrikertodoor..............25Nm(18ft-Ib)
DOORPANELS
0
lo
0013102
Fig.4.

Doorhingeanddoorcheckcomponents.Frontandrear
doorsaresimilar.
WARNING -
Some1997andall1998carsarefittedwithside-im-
pactairbagsinthefrontdoors.Whenservicingdoors
oncarswithfrontside-impactairbags,alwaysdis-
connectthenegative()batteryterminal.See721
AirbagSystem(SRS)forcautionsandprocedures
relatingtotheairbagsystem.
Frontdoortrimpanel,removingandin-
stalling
1.Oncarswithside-impactairbags,disconnectnegative
(-)batterycable.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
Fig.5.

Pryoutsidemirrorswitchfromdoorarmrest.
3.Unscrewdoorlockingknob.
Fig.6.

Pryoffplugs(arrows)andremovescrews.
DOORS 411-3
2.Carefullypryoutmirroradjustmentswitchanddiscon-
nectharnessconnectorfromswitch.Fig.5.
5.Unclipdoorpanelfromdoorperimeter.SeeFig.7.
0013168
4.Pryofftrimcoverforinsídedoorhandle.Pryoffcon-
cealingplugsfromarmrest.Removedoorpanelretain-
ingscrews.SeeFig.6.
UU13169
DOORPANELS

411-4DOORS
6.Disconnectradiospeakerharnessconnector.
Fig.7.

Doorpanelbeingunclippedfromdoor.Pullpanelretaining
clipsoffoneatatime.
7.Installationisreverseofremoval,notingthefollowing:
"Replaceanydamagedplasticpartsorclips.
"Renewvaporbarrierifitisdamaged.
"Usenewmountingboltswhenreinstallingtheside-im-
pactairbagtothedoor(whereapplicable).
"Wheninstallingdoorpanel,alignmetalretainerson
windowsillwithopeningsontopofdoorpanel.See
Fig.8.
"Checkdoor-lockmechanismandwindowforeaseof
movement.
"Ifbatterywasdisconnected,re-initializewindowregu-
latormotorsasdescribedin512DoorWindows.
373
Fig.8.

Metalretainersatbaseofwindowshouldbeinpositionto
matewithopeningsindoortrimpanel.
DOORPANELS
Reardoortrimpanel,
removingandinstalling
1.Opendoorandpryoutpowerwindowswitch.Discon-
nectharnessconnector.
2.Removeashtray.
3.Pryofftrimcoverfrominsidedoorhandle.
4.Pryoffconcealingplugsfromarmrest.Removedoor
panelretainingscrews.SeeFig.9.
Fig.9.

Pryoffplugs(arrows)andremovescrews.
5.Unscrewdoorlockingknob.
6.Unclippanelfromdoorperimeter,startingatthetopof
thedoor.
7.Installationisreverseofremoval.
"Replaceanydamagedplasticpartsorclips.
"Renewvaporbarrierifitisdamaged.
"Alignmetalretainersonwindowsillwithopeningsin
trimpanel.RefertoFig.8.
"Checkdoor-lockmechanismandwindowforeaseof
movement.
Rearsidetrimpanel,removingandinstall-
ing(coupemodels)
1.Removerearseatcushion.Removerearbackrestside
section.See520Seats.
2.Pulloffedgetrimatbottomofrearsidewindow.See
Fig.10.
3.Gentlyuncliptrimpanelandremove.
4.Installationisreverseofremoval.
"Replaceanydamagedplasticpartsorclips.

Fig.10.Paneledgetrimpiecetrimbeingremoved.
Rearsidetrimpanel,removingandinstall-
ing(convertiblemodels)
Toremovetherearsidepanelinconvertiblemodelsitis
necessaryto:
"Removerearseatcushionandrearbackrestsidesec-
tion.
"Lowersidewindow;openconvertibleroof.
"Leftside:Removeconvertibletoplidreleaselevertrim.
"Removepowerwindowswitchanddisconnectharness
connector.
"Removedoorpanelinsetbypullingforward.
"Removecornerprotectorrubbertrim.
"Pulloffsidepanelafterremovingscrewfastener(s).Dis-
engagefromfrontshoulderbelt.

GENERAL
Thisrepairgroupcoverstrunklidremovalandinstallation.
Alsoinciudedherearereplacementproceduresforthegas-
chargedsupportstrutsthatholdthetrunklidintheupposition.
NOTE-
Thebodyíspaintedatthefactoryafterassembly.Re-
alignmentofbodypanelsmayexposeunpaintedmetal.
Paintallexposedmetaloncetheworkiscomplete.
TRUNKLID
Trunklid,removingandinstalling
1.Raisetrunklid.Opentoolkitandremovescrewsat-
tachingtoolkitlotrunklid.
2.Removeinsulatinglinerfromundersideoftrunklid.See
Fig.1.
412TrunkLid
TRUNKLID

412-1
GENERAL............................412-1

Trunklid,aligning.......................412-2
Trunklidsupportstrut,
TRUNKLID...........................412-1

removingandinstalling.................412-2
Trunklid,removinbandinstalling..........412-1
3.Disconnectwiringfromelectricalcomponentsandre-
movecompletewiringharnessfromtrunklid.
4.Whilesupportingtrunklid,loosentophingeboltsand
removelowerboltsfromleftandrightsides.Remove
trunklidwith`aidofhelper.SeeFig.2.
NOTE-
Beforelooseninghingebolts,markhingeandhinge
boltlocationsforreínstallation.
0013163
Fig.2.

Trunklidhingebolts(arrows).Loosenupperboltandremove
lowerbolt.
0013162

5.Installationisreverseofremoval.Ifnecessary,align
Fig.1.

Trunklidlinerretainingscrewsandclips(arrows).

trunklidtobodyasdescribednext.
TRUNKLID

412-2

TRUNKLID
Trunklid,aligning
1.Raisetrunklid.
2.Loosenboitsattrunklidlockuntilitcanjustbemoved.
SeeFig.3.
Fig.3.

Trunklidlockmountingboits(arrows).
0013172
3.Loosenbolisatleftandrighttrunkhingesuntillidcan
justbemoved.
4.Workingatlowercomersoftrunklid,screwinrubber
buffersonleftandrightsidesfully.
5.Propopentrunklidandremovegaspressurestrutas
describedbelow.
WARNING -
"Makesuretosupporttrunklidbeforeremoving
strut.
"Trunklidwithgaspressurestrutremovedwill
dropwithoutdamping.
6.Closetrunklidandalignlidtobodyatrearandfront.
Opentrunklidandtightenhingebolis.
7.Adjustlocksothatclosedtrunklidisapproximately
1mm(0.04in.)belowtopofrearfenders.Tightenlock
bolts.
TRUNKLID
8.Opentrunklidandscrewoutrubberstopssothat
closedtrunklidisflushwithtopofrearfenders.
9.Reinstallgaspressurestrut.
SeamClearanceSpecification
"Trunklidtorearfender
orbumper..........4.3-5.3mm(0.169-0.209in)
"Max.deviationfromparallel.......0.5mm(0.019in)
Trunklidsupportstrut,
removingandinstalling
WARNING -
Makesuretosupporttrunklidbeforeremoving
strut
1.Opentrunklid.Removespringclipfromsupportstrut
andremovestrutfrombodyend.SeeFig.4.
Fig.4.

Supportstrutspringclip(arrow)atbodyend.
2.Removestrutfromtrunklid.
3.Installationisreverseofremoval.Replaceanytrimre-
tainingclipsdamagedduringremoval.

GENERAL.............................510-1

Frontbumperimpactabsorber,replacing....510-4
Rearbumper,removingandinstalling

......510-4
OUTSIDEREARVIEWMIRRORS..........510-1

Rearbumperimpactabsorber,replacing....510-6
Outsidemirrorglass,replacing

...........510-1

Bumperheight,adjusting

................510-6
Outsidemirrorhousing,
removingandinstalling................510-1

EXTERIORTRIM

......................510-6
Outsidemirror,removingandinstalling.....510-2

BMWembiem,removingandinstalling......510-7
Bodysidemolding,replacing

.............510-7
BUMPERS

...........................510-3

Radiatorgrille,removingandinstalling......510-7
Frontbumper,removingandinstalling......510-3

Frontpanel,removingandinstalling........510-7
GENERAL
510ExteriorTrim,Bumpers
Thisrepairgroupincludesrepairinformationfortheoutside
rearviewmirror,frontandrearbumpers,andtheeasilyre-
movableexteriortrimparts.
OUTSIDEREARVIEWMIRRORS
Theremovecontrolledmirrorscomeintwostyles:heated
andunheated.Manyofthemirrorcomponentsareseparately
availablefromanauthorizedBMWdealer,includingtheglass
andoutsideplastichousing.
Outsidemirrorglass,replacing
CAUTION-
Mirrorshouldbeatoraboveroomtemperature
beforeremoval.Otherwise,smallplasticpartsor
glasswillbreak.
1.Insertthinprytool(woodenortape-wrappedscrewdriv-
er)betweenbottommirroredgeandmirrorhousingand
carefullypryoutmirrorglassfromhousing.SeeFig.1.
2.Heatedmirror:removeheatingelementharnesscon-
nectorsfrombackofmirrorglass.
3.Installnewglassintopositionbypressingfirmlyuntilit
snapsintoplace.
EXTERIORTRIM,BUMPERS

510-1
00130..
Fig.1.Pryingmirrorglassoutofmirrorhousing.Notescrewdriver
shaftwrappedwithtape.
Outsidemirrorhousing,
removingandinstalling
1.Removemirrorglassasdescribedabove.
2.Removehousingretainingscrewsandliftoffrearhous-
ing.SeeFig.2.
3.Tiltmirrorhousingforwardandcompressplasticretain-
ersandliftofffronthousing.SeeFig.3.
4.Installationisreverseofremoval.Checkmirrorfunction
beforeinstallingcoveringparts.
OUTSIDEREARVIEWMIRRORS

510-2

EXTERIORTRIIVI,BUMPERS
Fig.2.

Mirrorhousingretainingscrews(arrows).
Fig.3.

Useneed1e-noseplierstoreleaseretainers(arrows).
Outsidemirror,removingandinstalling
0013039
0013040
1.Removetriangulartrimplatebypryingandliftinggently
fromdoorframe.SeeFig.4.Unhookharnesssplice
connectorfrombaseoftrimpíate.
2.Separateharnessconnector.Supportmirrorandre-
movemirrormountingbolts.Liftmirroroffdoor.See
Fig.5.
3.Installationisreverseofremoval.Checkmirrorfunction
beforeinstallingcoveringparts.
TighteningTorque
"Outsidemirrortodoor(M6).........6Nm(4.5ft-Ib)
OUTSIDEREARVIEWMIRRORS
0013041
Fig.4.

Pryplastictrimindirectionofarrow1,thenliftoffindirection
ofarrow2.
0013042
Fig.5.

Mirrormountingbolts(arrows).Two-doorbodystyleshown.

BUMPERS
Frontbumper,removingandinstalling
RefertoFig.6.whenremovingandinstallingthefront
bumper.
1.Raiseandproperlysupportvehicle.
WARNING -
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Uncliplefttrimstripbypryinggentlyunderplastictrim
atfrontofbumper.Similarly,uncliptowingeyecover
fromrightside.
5.Removebumpercoverretainingscrewsinfrontwheel
3.Removefourmountingnutsfrombumpermounts(two

well(leftandrightsides).SeeFig.8.
nutsoneachmount).SeeFig.7.
4.Workingunderneathcar,removescrewsfromleftand
rightsidecornertrim,thenremovetrim.
Sidebrackets
Bumper
cover
Fig.6.

Frontbumperassembly.
EXTERIORTRIM,BUMPERS

510-3
Fig.7.

Frontbumpermountingnuts(arrows).Lefttrimandtoweye
coveronrighthavebeenremoved.
6.Disconnectharnessconnectorsatfoglightsockets(if
applicable).
Sidecornertrim

Supportbracket
Impactabsorber
o

O
Foglight
support
LBumnerbracketbolt
Licenseplata

0011944
bracket
BUMPERS

510-4

EXTERIORTRIM,BUMPERS
Fig.8.

Bumpercoverretainingscrews(arrows)inleftwheelweil.
7.Disconnectharnessconnectorsatoutsidetemperature

0013052
sensoratrearofleftsideofbumperandtemperatura

Fig.9.

Frontbumperimpactabsorbermountingnuts(A)and
switchatrearofrightsideofbumper(ifapplicable).

bumperbrackethardware(B).
8.Slidebumperstraightoffsidabrackets.
9.Installationisreverseofremoval,notingthefollowing:

Whenremovingandinstallingtherearbumperoritscompo-
"Slidesidebracketsonbumperandbodycarefullyto-

nents,refertoFig.10.
gether.
"Makesuretabsontrimstripengageslotsinbumper

1.Raiseandproperlysupportvehicle.
correctly.
TighteningTorque
"Bumpertobumper
bracket(M8nut).................22Nm(16ft-Ib)
2.Workingunderbumper,removescrewsorexpansion
Frontbumperimpactabsorber,replacing

rivetsatcornersandmiddleoflowerbumperpanel.Pull
panelbackward,uncouplingitfrombumpercover.See
Thebumpermountingbracketandimpactabsorbermount-

Fig.11.
inghardwareareaccessiblewiththeFontbumperremoved,
asdescribedabove.SeeFig.9.

3.Removebumpercoverexpansionrivetsandscrewsin-
sideleftandrightrearwheelwells.
NOTE-
Installthebumperbracketboltwiththreadlockingcom-
poundsuchasLoctite8270orequivalent.
TighteningTorques
"Bumperbrackettoimpactabsorber
(M10nut)....................:.55Nm(41ft-Ib)
"Impactabsorbertochassis(M6nut)...9Nm(7ft-Ib)
BUMPERS
Rearbumper,removingandinstalling
WARNING -
Makesurethatthecarisfirmlysupportedonjack
standsdesignadforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
4.Removeleftandrightbumperbracketmountingbolts
andremovebumper.SeeFig.12.
5.Installationisreverseofremoval.
NOTE-
Installthebumperbracketboltwiththreadlockingcom-
poundsuchasLoctite®270orequivalent.

Fig.10.Rearbumperassembly.
0013045
Fig.11.Expansionrivetatcornerofrearbumperlowerpanel(arrow).
Somemodelsusescrews.Pullpanelbackwardtodisengage
frombumpercover.
TighteningTorque
"Bumperbrackettoimpactabsorber
(M10bolt)......................42Nm(31ft-Ib)
EXTERIORTRIM,BUMPERS

510-5
0013047
Fig.12.Inserttoolthroughrearbumpermountborestoremove
mountingbolts(rightsideshown).
BUMPERS

510-6

EXTERIORTRIM,BUMPERS
Rearbumperimpactabsorber,replacing
1.Removebumperasdescribedabove.
2.Removeluggagecompartmentfloorcovering.
Fig.13.Luggagecompartmentfloorpanelfasteners(arrows).(Left
sideshown.Righfsideissimilar)
5.Installationísreverseofremoval.
Bumperheight,adjusting
TighteningTorques
"Bumperbrackettoimpactabsorber
(M10bolt)......................42Nm(31ft-lb)
"Impactabsorbertochassis
(M8nut).......................22Nm(16ft-Ib)
Theadjustmentproceduregivenbelowappliestoeitherthe
frontorrearbumper.A14mmallensocketisneededtomake
theadjustment.
1.Raiseandproperlysupportvehicle.
WARNING -
Makesurethatthecarisfirmlysupportedonjack
standsdesignedforthepurpose.Placethejack
standsbeneathastructuralchassispoint.Donot
placejackstandsundersuspensionparts.
2.Frontbumper:
"Removebumperasdescribedearlier.
"Removebumperbracketbolt.RefertoFig.9.
EXTERIORTRIM
3.Rearbumper:
"RemovelowerbumperpanelasdescribedinRear
bumper,removingandinstalling.
"Removebumperbracketmountingboltatimpactab-
sorber.
3.Rightside:Removebatteryandbatterytray.

4.Usinga12-inchextensionandal4mmAllensocket,
turnadjustingcollarclockwiseorcounterclockwiseas
4.Removefastenersfromleftorrightluggagecompart-

neededtochangeheightofadjustingcollar.SeeFig.
mentfloorpanelsandliftoutpanel.SeeFig.13.Impact

14.
absorbermountingnutscannowbeaccessed.
~4
EXTERIORTRIM
Ratchet
extension
Adjusting
collar
Impact
absorber,
14mmAllen
Socket
Ratchet
0012073
Fig.14.Adjustbumperheightatthreadedadjustingcollarinbumper
impactabsorber.
5.Reinstallmountingboltsandcheckbumperheight.Re-
fitfrontbumper.
TighteningTorques
"Frontbumperto
bumperbracket(M8nut)..........22Nm(16ft-Ib)
"Frontbumperbracketto
impactabsorber(M10bolt)........55Nm(41ft-Ib)
"Rearbumperbracketto
impactabsorber(M10bolt)........42Nm(31ft-Ib)
Muchoftheexteriortrimisretainedtothebodybyplastic
clipsandfastenersthatmaybedamagedduringremoval.Be
suretohavethenecessaryfastenersonhandwhenremoving
exteriortrimpieces.

BMWemblem,removingandinstalling
Theproceduregivenbelowappliestobothfrontandrear
emblems.
1.Wrapandofascrewdriverwithtape.
CAUTION-
Protecthoodpaintbycoveringareaaroundem-
blemwithtape.
2.Carefullypryoutemblem.SeeFig.15.
UVI1'¿.
Fig.15.BMWemblembeingremoved.Pryupemblemcarefullyonei-
therside(arrows).Notetapeonscrewdrivertips.
3.Installationisreverseofremoval.
"Replaceplasticinsertsinbodyifdamaged.
"Ifemblemfitslooselyintoinserts,useasmallamount
ofbodymoldingtapeoradhesivaonrearofemblem
beforeinstalling.
Bodysidemolding,replacing
Toremovebodysidemoldings,carefullyprythemoldings
straightoff.SeeFig.16.
Installationisthereverseofremoval.Replaceanyclipsor
clipcoveringbootsdamagedduringremoval.
Radiatorgrille,removingandinstalling
1.Removeplasticfrontradiatorshroudorairduct,as
needed
2.Lightlytapcenterofgrillatowardradiatorandremove
frompanelopening.Chromeringpulísoutfromfront.
SeeFig.17.
3.Toreplace,snapgrilleandchromepiecetogether.
Pushassemblyintofrontpanel,pressingattopand
bottomuntilitsnapsintoplace.
EXTERIORTRIM,BUMPERS

510-7
Fig.16.Bodysidamoldingretainingclips(arrows).
-

0013048
Fig.17.Radiatorgrillebeingtappedinward.Rightsidefrontpaneltop
retainingscrewisshownatA.
Frontpanel,removingandinstalling
ThefrontpanelisshowninFig.18.
1.Removefrontbumperasdescribedearlier.
2.Removeheadlights.See630ExteriorLighting.
3.Removeradiatorgrilleasdescribedearlier.
4.Withenginehoodopen,removefrontpanelretaining
screwsatleftandrightsidesofradiator.SeeFig.19.
EXTERIORTRIM

510-8

EXTERIORTRIM,BUMPERS
Fig.18.Frontpanelassembly.Notetopretainingscrews(A),retainingscrewsatradiatorsupport(B),andsideretainingscrews(C).
00130~,u
Fig.19.Frontpanelretainingscrewsatradiator(arrows).Rightside
shown.Toremoveleftsidescrewsitmaybenecessarytore-
moveairfilterhousingorduct.
5.Removefrontpaneltopretainingscrewsnearhood
latches.RefertoFig.17.
6.Workingundercar,removeleftandrightsidepanelre-
tainingscrews.SeeFig.20.
7.Removepanelandrepairorreplacewithpaintedpart.
8.Installationisreverseofremoval.
EXTERIORTRIM
0013145
Fig.20.Frontbumpermustbeofftoaccessfarrightandleftfront
panelretainingscrewsfrombelow(arrows).(Rightside
shown.)

GENERAL............................512-1

WINDOWSERVICE,
Frontdoorwindow,initializing.............512-1

2-DOORMODELS.....................512-5
WINDOWSERVICE,

Frontdoorwindow,removingandinstalling
(2-doormodels)

......................512-5
4-DOORMODELS.....................512-2

Frontdoorwindow,adjusting
Frontdoorwindow,removingandinstalling

(2-doormodels)......................512-7
(4-doormodels)......................512-2

Rearventwindoworventlatch,
Frontdoorwindow,adjusting

replacing(2-doormodels)..............512-11
(4-doormodels)......................512-3
Reardoorwindow,removingandinstalling

WINDOWREGULATORSERVICE......512-12
(4-doormodels)......................512-4

Doorwindowregulatorandmotor,
Reardoorfixedglass,removingandinstalling

removingandinstalling................512-12
(4-doormodels)......................512-4
GENERAL

Frontdoorwindow,initializing
Thisheadingcoversdoorglass,windowregulatorandpow-
erwindowmotorrepairinformation.Beforeproceedingwith
windowrepairs,specificallyonlatecarsfittedwithfrontside-
impactairbags,readtheprocedurethroughtodeterminethe
scopeoftherepair.
Thebondedwindshieldandrearglassarereplacedusing
specialadhesivesandtools.Itisrecommendedthatbonded
glassreplacementbedonebyaprofessionalglassinstaller.
WARNING -
"Alwayswearhandandeyeprotectionwhen
workíngwithbrokenglass.
"ffawindowisbroken,alloftheglassbitsshould
bevacuumedoutofthedoorcavity.Useablunt
screwdrivertocleanoutanyremainingglass
piecesfromthewindowguiderails.
CAUTION-
ffbatterypowerislostorthebatteryhasbeendis-
connected,windowsmustbere-initialized.Both
onetouchup/downandpinch-protectionwillbein-
activeuntilwindowsarere-initialized.Seabelow.
512DoorWindows
DOORWINDOWS

512-1
Thefrontdoorwindowsincorporateapinch-protectionfea-
tureaswellasone-touchup/down(1994andlatermodels).In
orderforthesefeaturestoworkcorrectly,themechanicalstop
referencepointmustbere-initializedafterrepairsarecarried
out.
1.Closedoorandturnignitionkeyon.Fullyopenfront
window.
2.Fullyclosefrontwindow.
4.Repeatforremainingwindow.
5.Thewindowsshouldnowbeinitializedandtheanti-
pinchandone-touchup/downfunctionsshouldbeen-
abled.
GENERAL

512-2

DOORWINDOWS
WINDOW SERVICE,
4-DOORMODELS
WARNING -
Whenservicingthedoorwíndows,theharnesscon-
nectortothewindowregulatorshouldalwaysbe
disconnectedtopreventpinchingfingersinclosing
window.
NOTE-
Ifthebatteryisdisconnected,thefrontwindowregula-
tormotorsmustbere-initializedafterrepairsarecar-
riedout.lfthewindowmotorsarenotreinitialized,the
programmedone-touchupldownandanti-pinchfunc-
tionswillbedisabled.SeeFrontdoorwindow,initial-
izing.
Frontdoorwindow,removingandinstalling

0013061
(4-doormodeis)

Fig.1.Liftoffwindowsea¡fromdoor.Notemetalretainer(arrow).2-
doorcarshown.
1.Lowerdoorwindowabout12in.(300mm).
2.Removefrontdoorpanelandvaporbarrierasde-
scribedin411Doors.
WARNING -
"Some1997andall1998carsarefittedwlthside-
impactairbagsinthefrontdoors.Whenservicing
thedoorwíndowsoncarswithfrontside-impact
airbags,alwaysdisconnectthenegative()bat-
terycable.See721AirbagSystem(SRS)for
cautionsandproceduresrelatingtotheairbagsys-
tem.
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpagevi¡¡.
3.Oncarswithside-impactairbags,disconnectnegative
(-)cablefrombattery.Thenremoveairbagunitfrom
door.See721AirbagSystem(SRS).
5.Carefullyremovewindowinnersea¡andpryoffmetal
retainersundersealingliptopreventscratchingglass.
SeeFig.1.
6.Removeretainingclipsfromwindowslides.SeeFig.2.
WINDOW SERVICE,4-DOORMODELS
Fig.2.

Retainingclipsforwindowslides(arrows).
0011696
7.Whilesupportingwindowglass,prywindowliftingarms
outofleftandrightslides.SeeFig.3.
NOTE-

8.Pivotwindowupatrearandoutofdoor.
Insomemodeiscoveredinthismanual,itisnotessen-
tialtoremovetheside-impactairbagtoaccessinternal

9.Installationisreverseofremoval,notingthefollowing:
doorcomponents.However,theprocedureisrecom-

"Usenewmountingboltswhenreinstallingtheside-im-
mendedforsafetyreasons.

pactairbagtothedoor(whereapplicable).See721
AirbagSystem(SRS).
4.Disconnectharnessconnectorfromwindowmotorto

"Adjustwindowasdescribedlater.
preventaccidentaloperation.

"Re-initializewindowregulatormotorsasdescribed
earlier.

0011697
Fig.3.

Windowliftingarmsshownremovedfromslides(arrows).
Frontdoorwindow,adjusting
(4-doormodels)
Wheneverthefrontwindoworwindowregulatorisre-
moved,windowadjustmentshouldbechecked.Theglass
shouldcontactthetopofthewindowsquarelyandshouldseat
againstthewindowsea¡uniformly.
NOTE-
Ifthewindowdoesnotcontactthewindowsealuni-
formly,windnoiseorwaterinfiltrationmayresult
Besuretore-initializethewindowmotorsasdescribedear-
lier.
WARNING -
Some1997andall1998carsarefittedwíthside-im-
pactairbagsinthefrontdoors.Whenservicingthe
doorwindowsoncarswithfrontside-impactair-
bags,alwaysdisconnectthenegative()battery
cable.See721AirbagSystem(SRS)forcautions
andproceduresrelatingtotheairbagsystem.
CAUTION-
"Inmodelswithside-impactairbags,adjustingthe
frontwindowrequiresthatthebatterycablebe
reconnectedwiththeside-impactairbagdiscon-
nected.ThiswillsetafaultcodeintheSRScon-
trolmodule,turnontheSRSwarninglight,and
disabletheSRSsystemuntilthefaultmemoryis
clearedusingspecialSRStestequipment.
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
1.Raisedoorwindowtotopofitstravel.
DOORWINDOWS 512-3
3.Removefrontdoorpanelandvaporbarrierasde-
scribedin411Doors.
4.Removeairbagunitfromdoor.See721AirbagSys-
tem(SRS).
NOTE-
Insomemodelscoveredinthismanual,itisnotessen-
tialtoremovetheside-impactairbagtoaccessinterna¡
doorcomponents.However,theprocedureisrecom-
mendedforsafetyreasons.
5.Loosenregulatorstopatwindowregulatorsupport.
SeeFig.4.
Fig.4.

Wíndowregulatorstop(arrow).
0013075
6.Ifglassisnotsquarelypositionedinwindowframe,
loosensupportarmboltandrepositionarmasneces-
sary.Tightenbolt.SeeFig.5.
2.Oncarswithside-impactairbags,disconnectnegative
(-)cablefrombattery.

Fig.5.

Adjustwindowtoitsframebylooseningbolt(arrow)andre-
positioningsupportarmupordown.
WINDOW SERVICE,4-DOORMODELS

512-4

DOORWINDOWS
7.Pushregulatorstoptightlyagainstwindowregulator

4.Lowerdoorwindowabout12in.(300mm).Remove
sectorandtightennut.

windowliftingarmretainingclipfromwindowslide.Re-
oCheckfortight,evenfitattopofwindowframe.

fertoFig.2.
"Ifnecessary,temporarilyreconnectnegative(-)cable
tobatteryandraisewindowsoitispressinguniformly

WARNING-
againsttoprubbersea¡beforefinaltightening.

Oncethewindowislowered,dísconnectharness
connectorfrompowerwindowmotortopreventac-
8.Reinitializefrontwindowmotorsasdescribedearlier.

cidentaloperationofthewindow.
TighteningTorques
"Regulatorstoptowindowregulator....9Nm(7ft-Ib)
"Windowregulatorbrackettodoor.....9Nm(7ft-Ib)
Reardoorwindow,removingand
installing(4-doormodels)
1.Removereardoorpanelandvaporbarrier.See411

7.Removewindowglassfromabove.
Doors.
2.Pul¡outrubberguideatfrontofwindowframe.Remove
threescrewsandpul¡offexteriortrimcover.SeeFig.6.
UJ117U1
Fig.6.

Trimcovermountingscrews(arrows).Toremovecover,slide
upandoffdoor.
3.Liftupandremovewindowinnersealingstrip.Remove
clipsatedgeofwindowchannel.RefertoFig.1.
WINDOWSERVICE,4-DOORMODELS
5.Pryliftingarmoutofslide.RefertoFig.3.
NOTE-
Supportwindowindoorbeforedisconnectinglifting
armfromwindowslide.
6.Removerubberchannelfromdoorframeperimeter.
8.Installationisreverseofremoval.
"Rearwindowadjustmentissimilartofrontwindowad-
justment,givenearlier.
"Reinitializewindowmotorsasdescribedearlier.
Reardoorfixedglass,removingand
installing(4-doormodels)
1.Removewindowfromreardoorasdescribedearlier.
2.Removeupperandlowerboltsatguiderail.Liftuprub-
bersea¡toaccessupperbolt.SeeFig.7.
Fig.7.

Rearguiderailmountingbolts(arrows).

3.Removeguiderailscrewattopandmoverailaside
enoughtoslideglassforwardandoutofdoorframe.
SeeFig.8.
4.Installationisreverseofremoval.
WINDOW SERVICE,
2-DOORMODELS
WARNING-
Whenservicingthedoorwindows,thehamesscon-
nectortothewindowregulatorshouldalwaysbe
disconnectodtopreventpinchingfingersinclosing
window.
2-doormodelsareequippedwiththe"closewithdoorshut"
feature.Inthisrriode,thewindowglassmovesdownslightly
whenthedoorlatchisactivated,thengoesuptightlyagainst
theweather-stripwhenthedoorisfullyclosed.
Frontdoorwindow,removingand
installing(2-doormodels)
WARIWNG-
Some1997anda111998carsarefittedwithside-im-
pactairbagsinthefrontdoors.Whenservicingthe
frontwindowsoncarswithfrontside-impactair-
bags,alwaysdisconnectthenegative(-)battery
cable.See721AirbagSystem(SRS)forcautions
andproceduresrelatingtotheairbagsystem.
DOORWINDOWs 512-5
CAUTION-
"Inmodelswithside-impactairbags,removing
thefrontwindowrequiresfhatthebatterycable
bereconnectedwiththeside-impactairbagdis-
connected.ThiswillsetafaultcodeintheSRS
controlmodule,turnontheSRSwarninglight,
anddisabletheSRSsystemuntilthefaultmem-
oryisclearedusingspecialSRStestequipment.
"Removingthefrontwindowwillupsettheadjust-
mentandalignmentofthewindow.Windowad-
justment,asdescribedlater,mustbecarriedout
afterinstallationtopreventdamagingtheglass.
1.Oncarswithside-impactairbags,disconnectnegative
(-)cablefrombattery.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
Fig.8.

Removeguiderailscrew(A)andmoverailaside.

2.Removeinteriordoorpanelandvaporbarrier.See411
Doors.
3.Whereapplicable,removeside-impactairbagfrom
door.See721AirbagSystem(SRS).
NOTE-
Insomemodelscoveredinthismanual,itisnotessen-
tialtoremovetheside-impactairbagloaccessintemal
doorcomponents.However,theprocedureisrecom-
mendedforsafetyreasons.
4.Pulloffexteriordoormolding.See510ExteriorTrim,
Bumpers.
5.LowerdoorwindowcompletelyIfnecessary,tempo-
rarilyreconnectbatterycable.
6.Liftupandremovewindowinnersealinglip.Removeall
metalretainersundersealinglip.SeeFig.9.
NOTE-
Thefrontwindowregulatormotorsmustbere-initial-

7.Raisewindowtoabout10in.(250mm).Ifnecessary,
izedafterrepairsarecarriedout.Ifthewindowmotors

temporarilyreconnectbatterycable.Removeguide
arenotreinitialized,theprogrammedone-touch

bracketmountingnutsandremovebracket.SeeFig.
up/downandanti-pinchfunctionswillbedisabled.See

10,
Frontdoorwindow,initializing.
8.Lowerwindowabout4'/2in.(110mm).Ifnecessary,tem-
porarilyreconnectbatterycable.Workingthroughbore
holeindoorexterior,removelowerguidebracket
through-boltfromglass.SeeFig.11.
9.Lowerwindowabout2'/2in.(65mm).Ifnecessary,tem-
porarilyreconnectbatterycable.Repeatstep8tore-
moveupperthrough-boltfromguidebracket.
10.Raisewindowtoabout71/2in.(190mm)fromtop.Ifnec-
essary,temporarilyreconnectbatterycable.Remove
windowrearlimitstopbracket.SeeFig.12.
WINDOWSERVICE,2-DOORMODELS

512-6

DOORWINDOWS
0013061
Fig.9.

Liftwindowinnersealinglipfromdoor.Notemetalretainer
(arrow).
0013083
Fig.10.WindowrearguídebracketnutsAtoberemoved.Loosen
nutsBtoallowbracketroomtoswiveloutoftheway.
WINDOWSERVICE,2-DOORMODELS
0013063
Fig.11.Using4mmAllensocket,reachthroughrearborehole(A)in
doortoremovewindowguidebracketboits.(Exteriordoor
moldinghasbeenremoved.)
0013065
Fig.12.Toremoverearwindowlimitstopbracket,removeboltAand
loosenclampingboltB.
11.Lowerwindowabout41/2in.(110mm).Ifnecessary,
temporarilyreconnectbatterycable.Whilesupporting
window,removeretainingclipsfromwindowslidesand
disconnectliftingarmsfromslides.SeeFig.13.

Fig.13.Liftingarmretainingclips(arrows)atwindowslides.
12.Tipwindowsorearofglassisupoutofdoor.Whilesup-
portingwindow,removewindowfrontlimitstopbracket.
SeeFig.14.
0013067
Fig.14.Withwindowglassshownpartiallytippedoutofdoor,remove
boltAandloosenboltBinordertoremovefrontwindowlimit
stopbracket.
13.Takeglassfullyoutofdoor.
14.Installationisreverseofremoval,notingthefollowing:
"Guidefrontofwindowintofrontguiderailandrestit
therewhileinstallingfrontwindowlimitstopbracket.
"Wheninstallingwindowrearguidebracket,tighten
countersunkscrewsinglassfirst(throughoutsideof
door),theninstallguiderailbracket.
"Insertrubbersea¡attopofdoorcorrectlySeeFig.15.
"Usenewmountingboltswhenreinstallingtheside-im-
pactairbagtothedoor(whereapplicable).ResetSRS
warninglightandclearSRSfaultmemoryusingspe-
cialtestequipment.See721AirbagSystem(SRS).
"Adjustwindowasdescribedlater.
"Re-inítializewindowregulatormotorsasdescribed
earlier.
DOORWINDOWS

512-7
Fig.15.Correctinstallationofdoortoprubberseal.
TighteningTorques
"Rearguidebrackettowindow.......6Nm(53in-lb)
"Rearguidebracket
torollerguide.....................9Nm(7ft-Ib)
Frontdoorwindow,adjusting
(2-doormodeis)
The"closewithdoorshut"featureof2-doorcars,aswellas
theframelesswindow,makeswindowadjustmentcritical:
WARNING -
"Some1997andafl19982-doorcarsarefittedwith
side-impactairbagsinthefrontdoors.Whenser-
vicingthedoorwindowsoncarswithfrontside-im-
pactairbags,alwaysdisconnectthenegative(-)
batterycable.See721AirbagSystem(SRS)for
cautionsandproceduresrelatingtotheairbagsys-
tem.
"Adjustingthefrontwindowrequiresthatthebat-
terycablebereconnectedwiththeside-impact
airbagdisconnected.Thiswillsetafaultcodein
theSRScontrolmodule,turnontheSRSwarning
light,anddisabletheSRSsystemuntilthefault
memoryisclearedusingspecialSRStestequip-
ment.
"Thereisriskofwindowglassbreakageifcorrect
adjustmentproceduresarenotused.Ifindoubt,
thisprocedureshouldbelefttoatrainedBMW
technician.
WINDOW SERVICE,2-DOORMODELS

512-8

DOORWINDOWS
NOTE-
Toachieveanaccuratewindowadjustmentin2-door
modelswith"closewithdoorshut"feature,simulatea
closeddoorasfollows:Onearlycars,manuallyturnthe
latchonthedoortotheclosedposition.SeeFig.16.On
latercars,insertawedgeofwoodintothestrikeronthe
bodytoclosethestrikerswitch.Besuretoopenthero-
tarylatch(bypullinguponthedoorhandle)orremove
thewedgebeforeclosingthedoor.
0013066
Fig.16.Tomanuallyclosedoorlatch,pushrotarylatchindirectionof
arrow.
CAUTION-
Donotclosethedoorwiththerotarylatchin
closedposition,orwithawedgeinthestriker.
WINDOW SERVICE,2-DOORMODELS
AWindowinsertiondepthatA-pillar
BB-pillarpreloadgap(measuregapat20mmfromtopofdoor)
CWindowinsertiondepthatroofline/windowparallelism
(makemeasurementat3.5in.and16in.fromB-pillaredge)
Fig.17.2-doorwindowadjustmentpositions.
NOTE-
In"

somemodelscoveredinthismanual,itisnotes-
sentialtoremovetheside-impactairbagtoaccessin-
terna¡doorcomponents.However,theprocedureis
recommendedforsafetyreasons.
"Aftereachadjustmentstep,fullylowerandraisewin-
dowandcheckadjustmentbeforegoingontothenext
step.
"1fpartsofthefrontwindowmechanismwerereplaced,
makesureinitialadjustmentsareinthecenteroftheir
travelrange.Oncetheglassisinstalled,positionglass
totherearguiderailasshowninFig.18.
4.TosetwindowpreloadB(SeeFig.1g.):
0013076
Whenmakingadjustmentstothefrontdoorwindow,see

"Measureup20mm(0.75in.)fromtopofdoorand
Fig.17.

markpositiononglass.
"Closedoorjustuntiltopofglasscontactsseal.
1.Oncarswithside-impactairbags,disconnectnegative

"Measuregapbetweenglass(at20mmmark)andwin-
(-)cablefrombattery.

dowseal.
"Ifadjustmentisnecessary,movebottomofwindow
CAUTION-

guideinorouttocorrect.SeeFig.20.
Priortodisconnectingthebattery,readthebattery

"Iffurtheradjustmentisneeded,movebottomofwin-
disconnectioncautionsgivenatthefrontofthis

dowinoroutbyslidingguidebracket.RefertoFig.18.
manualonpageviii.
2.Removeinteriordoorpanelandvaporbarrier.See411

PreloadGap
Doors.

"B(RefertoFig.1g.)
Coupe.........................8mm(0.32in.)
3.Whereapplicable,

removeside-impactairbagfrom

Convertible.....................3mm(0.12in.)
door.See721AirbagSystem(SRS).

5tud
center
Windowglass
surface
Fig.18.Rearguiderailtorearguidebracketinitialadjustment.Top
shouldbesetat30mm(1.2in.)fromglasstostudcenter;
bottomshouldbesetat34mm(1.3in.)fromglasstostud
center.
PreloadB
Coupe:8mm
Convertible:3mm
0013081
Fig.19.Withtopofglassagainstdoorsea¡(toparrow),measurepre-
loadBat20mm(0.75in.)abovetopofdoor.
DOORWINDOWS

512-9
0013153
Fig.20.Rearguideraillowermountingboltsinbottomofdoor(ar-
rows).
5.TosetinsertiondepthA(RefertoFig.17.):
"Lowerwindowabout10in.toaccesswindowbracket
atrearguide.Ifnecessary,temporarilyreconnectbat-
terycable.
"Loosenguiderailbracketand/orrearguiderailmount-
ingboltsandrepositionwindowlefttoright.SeeFig.
21.orFig.22.
"Fullycloseandalignwindow.Checkthatglassenters
windowsea¡tothespecificationlisted.
"Whenadjustmentiscorrect,tightenloosenedfasten-
ers.
0013079
Fig.21.Loosennutsonrearguidebracket(arrows)andreposition
glassfore/aft.Holesinbracketareelongatedtoallowfor
smallamountsofadjustment.
WINDOWSERVICE,2-DOORMODELS

512-10

DOORWINDOWS
0013078
Fig.22.Movewindowfore/aftatrearguiderailtopmountingbolts(ar-
rows).
InsertionDepth
"A(SeeFig.17.)............1-1.5mm(0.04-0.6in.)
6.TosetInsertiondepthC(RefertoFig.17.):
"Lowerwindowslightly.Loosenstopatwindowregula-
tormotor.SeeFig.23.
Fig.23.Windowregulatorstop(arrow).
WINDOWSERVICE,2-DOORMODELS
0013075
"Raisewindow.Loosenrearboltatregulatorsupport
arm(5mmAllenwrench).SeeFig.24.Alignwindow
paralleltorooflinebymovingsupportarmuporclown.
Tightenarmbolt.
"Lowerwindowandremoverubberplugsatbottomof
door.Ifnecessary,temporarilyreconnectbatteryca-
ble.
"Adjustfrontandrearlimitstopssothatwindowretracts
intowindowsealasspecified.SeeFig.25.
"Raisewindowtocheckadjustment.
"Pushregulatorstopfullyforwardandtightenbolt.
"Closedoorandcheckwindowoperation.
0013077
Fig.24.Use5mmAfensockettoloosenmountingboltatsupport
bracket(arrow)andslidebracketuporclowntoadjustwin-
dowpositionatroofline.(Allenboltheadfacesoutsideof
door.)
CAUTION-
"RecheckpreloadgapB(step4).Excessivepre-
loadcouldcausewindowtoshatter.
"Thefullyclosedwindowmustnotcontacttherain
gutterwhenopeningthedoor(intheeventthe
"closewithdoorshut"featureisfaultyorthebat-
teryisdead).
7.Usenewmountingboltswhenreinstallingtheside-im-
pactairbagtothedoor(whereapplicable).ResetSRS
warninglightandclearSRSfaultmemoryusingspecial
testequipment.See721AirbagSystem(SRS).
8.Replacedoorpanel,rubberdoorplugsandoutside
doormolding.
9.Re-initializewindowregulatormotorsasdescribedear-
lier.

0013080
Fig.25.Reachthroughdoorbottomtoadjustwindowlimitstops.
Rearstopbeingadjusted.
Rearventwindoworventlatch,
replacing(2-doormodeis)
1.RemoveC-pillar(rearroofpillar)trim.SeeFig.26.
0013069
Fig.26.C-pillartrimshownremoved.Peeloffwindowsealingtrímand
thenunclippillartrimpiece.Unpluginteriorlightsocket(ar-
row).
2.RemovewindowlatchscrewsatC-pillar.SeeFig.27.
DOORWINDows

512-11
0013070
Fig.27.RearventlatchscrewsonC-pillarandonwindow(arrows).
3.RemovefrontseatbeltslidinganchortrimatB-pillar
(doorpost),andremoveanchornut.SeeFig.28.
Fig.28.B-pillarseatbeltanchortrim(arrow).
5.Removeseatbeltslidinganchor.SeeFig.29.
úulzoiz
4.PAoffslidinganchoradjustíngknob.Partiallypull
awaydooredgeandventwindowtrimstripsandre-
movetopB-pillarplastictrim.
6.Whilesupportingwindow,removeitsB-pillarmounting
fasteners.SeeFig.30.
7.Installationisreverseofremoval.Keepinmindthefol-
lowing:
"Plasticsealingwashersmustbeinstalledbetween
glassandbodyonforwardglassmountingstuds.
"Reinstallsealingwashersonbothsidesofglassatrear
latchattachment.
WINDOWSERVICE,2-DOORMODELS

512-12

DOORWINDOWS
Fig.30.VentwindowmountingnutsonB-pillar(arrows).
WINDOW REGULATORSERVICE
0013071
Fig.29.SeatbeltslidinganchormountingboltsonB-pillar(arrows).
Notedoorpostandventwindowtrimstripspeeledaway.
TighteningTorques
"Latchtoventwindow(M5screw).....6Nm(53in-lb)
"Seatbeltanchornut..............31Nm(23ft-Ib)
"Seatbeltslidinganchor
mountingbolts..................24Nm(17ft-Ib)
"Ventwindowtobody(M6nut).....6.2Nm(55in-lb)
WINDOWREGULATOR SERVICE
Doorwindowregulatorandmotor,
removingandinstalling
Thisprocedureappliestofrontorreardoorwindows.
1.Removedoorpanelandvaporbarrierasdescribedin
411Doors.
WARNING -
"Some1997andall1998modelyearcarsare
equippedwithfrontside-impactairbagsinthe
frontdoors.Wheneverservicingthedoorsorwin-
dowsoncarswithfrontside-impactairbags,al-
waysdisconnectthenegative(-)batterycable.
See721AirbagSystem(SRS)forcautionsand
proceduresrelatingtotheairbagsystem.
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgívenatthefrontof
thismanualonpagevi¡¡.
2.Removedoorglassasdescribedearlierinthissection.
3.Removeinsidedoorhandle.SeeFig.31.
4.Disconnectwiringconnectortopowerwindowmotor.
5.Removeregulatormountingboltsordrilloutrivets.See
Fig.32.
0013193
0013072

Fig.32.Frontwindowregulatormountingfasteners(arrows).
6.Removeregulatorassemblyfromdoor.

Fig.31.Insidedoorhandle.RemovescrewA,thenunhookfromrod
B.
7.Unboltpowerwindowmotorfromrearofregulator.
NOTE-
Someofthewindowregulatorsaremountedtothe
doorswithrivets.Therivetsmustbedrilledout.During
installation,M6x10boltsandself-lockingnutscanbe
substituted.
8.Installationisreverseofremoval.
0013073
"Adjustdoorwindowasdescribedearlier.
"Re-initializewindowregulatorsasdescribedearlier.
TighteningTorques
"Windowregulatortodoor............9Nm(7ft-Ib)
"Windowmotortoregulator...........5Nm(4ft-Ib)

GENERAL
Thisrepairgroupcoversinteriortrimremovalandinstalla-
tionprocedures.Forremovalandinstallationofinterior
switches,includinginteriorlightingequipment,see612
SwitchesandElectricalAccessories.
Mostoftheinteriortrimandfinishpaneisareclippedor
screwedintoplace.Manyofthetrimretainingclipsarede-
signedtobeusedonlyonce.Whenremovingtrimthatisheld
inplacewithclips,itisagoodidealohavesparesonhandbe-
forebeginningthejob.
CENTERCONSOLE
ThefrontsectioncenterconsolehousestheMulti-Informa-
tionDisplay(MID)module,thefrontashtrayandcigarette
lighter;shifterlever,powerwindowswitchesandthehazard
warningswitch.Therearcenterconsolesectionhousesthe
ashtray(s)andcoverstheemergencybrakecableends.
Centerconsole,removingandinstalling
1.Disconnectnegative(-)cablefrombatteryandcover
terminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removeshifterbootorselectorlevercover.See250
Gearshiftt-inkage.
3.Removerearashtrayretainingscrewstotakeoutash-
tray.Removerearconsoleretainingscrewunderash-
tray.
513InteriorTrim
INTERIORTRIM

513-1
GENERAL............................513-1

DASHBOARD......
...
..............:..513-2
Glovecompartment,removingandinstalling..513-2
CENTERCONSOLE...................513-1

Lowerleftdashpanel,
Centerconsole,removingandinstalling.....513-1

removingandinstalling.................513-2
Dashboard,removingandinstalling.........513-3
4.RemoveMulti-InformationDisplaymodule.See620In-
struments.
5.Removehazardwarningswitchandpowerwindow
switchesbypushingupandoutfrombelow.
6.Removelowerleftdashboardpanelandglovecompart-
mentasdescribedlaterinthisrepairgroup.
7.Removeretainingscrewunderhazardlightswitch.Pull
rearconsolebackandremoveretainingnutatbackof
frontconsole.SeeFig.1.
Fig.1.

Consoleretainingscrew.
8.Takeoutrearconsolefirst,thenfrontconsole.
0013154
CENTERCONSOLE

513-2

INTERIORTRim
DASHBOARD
Dashboardremovalisacomplexoperation,involvingdis-
connectionanddismantlingofanumberofelectricalanddash
structuralcomponents.
TheBMWE36isequippedwithSRSairbagsmountedin
thesteeringwheel,inthedashboard(1994andlater)onthe
passengerside,andinthefrontdoors(1997andlater).Air-
bagsunitsarepyrotechnicdevicesandshouldbetreatedwith
extremecaution.Improperhandlingoftheairbagscould
causeseriousinjury.
WARNING -
"TheBMWSupplementalRestraintSystem(SRS)
iscomplexandspecialprecautionsmustbeob-
servedwhenservicing.Seriousinjurymayresult
ifsystemserviceisattemptedbypersonsunfa-
miliarwiththeBMWSRSanditsapprovedser-
viceprocedures.BMW specifiesthatall
inspectionandserviceshouldbeperformedbyan
authorizedBMWdealer.
"Beforeperforminganyworkinvolvingthesteering
wheelorinteriortriminthevicinityoftheairbags,
disconnectthenegative()batterycable.See
721AirbagSystem(SRS).
"SRScontainsaback-uppowersupplywithinthe
SRScontrolmodule.A10minutedíschargeperi-
odshouldbeallowedafterthebatterycablehas
beendisconnected.
Glovecompartment,
removingandinstalling
1.Openglovecompartmentdoor.
2.Removeglovecompartmentmountingscrews.See
Fig.2.
3.Pullglovecompartmentout,disconnectingelectrical
harnessconnectorsasnecessary.
4.Installationisreverseofremoval.
DASH80ARD
Fig.2.

Glovecompartmentmountingscrews(arrows).
Lowerleftdashpanel,
removingandinstalling
0013107
1.Removelowerdashpanelretainingscrews.SeeFig.3.
0013155
Fig.3.

Lowerleftdashpanelretainingscrews(arrows).
2.Pulllowerdashpanelleftandbacktodisengagefrom
driver'sfootwellretainingclips.
3.Installationisreverseofremoval.

Dashboard,removingandinstalling
1.Disconnectnegative(-)cablefrombatteryandcover
terminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
2.Removecenterconsoleasdescribedearlier.
3.Removeglovecompartmentasdescribedearlier.
4.Removelowerleftdashtrimpieceasdescribedabove.
Removelowerrightdashtrimpanel.SeeFig.4.
Fig.4.

Lowerrightdashtrimpieceretainingscrew(arrow).
WARNING -
Storetheremovedairbagsinasafeplace.Position
theairbagsfacingup.
8.Removeinstrumentcluster.See620Instruments.
5.Removedriverandpassengerairbags.See721Air-
bagSystem(SRS).
6.Removesteeringwheel.See320SteeringandWheel
Alignment.
INTERIORTRIM

513-3
Fig.5.

Driversidekneebolstermountingbolts(arrows).
9.Removeheadlightswitch.Removeturnsignaland
windshieldwiper/washerstalkswitches.See612
SwitchesandElectricalAccessories.
10.RemoveA/Ccontrolheadandmodule.See640Heat-
ingandAirConditioning.
11.Removeradio.See650Radio.
12.RemoveA-pillar(windshieldpillar)trimonleftandright
sides.SeeFig.6.
UU13156
Fig.6.

A-pillar(windshieldpillar)trimremoval.Rightsideshown,left
7.Removedriversidekneebolster.SeeFig.5.

issimilar.
DASHBOARD

513-4

INTERIORTRIM
13.Removereinforcementbarbelowsteeringcolumnand
removesteeringcolumnshearbolts.Lowersteering
onlyslightlyandsupportsteeringcolumn.SeeFig.7.
WARNING -
Lowersteeringcolumnonlyenoughtofacilitatere-
movalofthedashboard.Thesteeringcolumnsup-
portsandswivelspindlescanbedamagedifthe
columnisloweredtoomuch.
14.Removeglovecompartmentsupportframe.SeeFig.8.
0012643
Fig.8.

Glovecompartmentsupportframebolts(arrows).
DASHBOARD
0013157
Fig.9.

Windshielddefrosteroutletbeingliftedoff(arrow).
Fig.7.

Reinforcementbarbolts(arrows).Shear(headless)boltsat
steeringcolumnwillhavetobedrilledoutandreplaceddur-
ingreinstallation.

16.Removemountingboltsonleftandrightendsofdash-
board.SeeFig.10.
Fig.10.Dashboardmountingbolt(arrows).Leftsideshown,rightis
similar.Somemodelsmayhavemayhavetwoboltsoneach
side.
17.Liftinstrumentpaneloffslowly,makingsureallharness
15.Carefullypryoutdefrosteroutlets(leftandrightsides)

connectorsandwiringaredisconnected.
atbaseofwindshield.Removescrewbeloweachout-
let.SeeFig.9.

18.Installationisreverseofremoval.

515CentralLockingandAnti-Theft
GENERAL..............:.............515-1

Luggagecompartmentlockingactuator,
removingandinstalling.................515-6
DOORHANDLESANDLOCKS.........515-1

LOCKINGSYSTEMAND
Frontdoorlock,removingandinstalling.....515-1

ELECTRONICIMMOBILIZATION.......515-7
Frontdoorhandle,removingandinstalling...515-3
Reardoorlock,removingandinstalling.....515-4

CentralLockingSystem(ZVM)............515-7
Reardoorhandle,removingandinstalling...515-5

CentralBodyElectronics(ZKEIV)..........515-8
ElectronicImmobilizationSystem(EWS).....515-8
Doorstriker,replacing...................515-6

EWSIIcontrolmodule,relacin

515-10
LOCKINGACTUATORS................515-6

Ringantenna,replacing.................515-10
DoorLockingActuator..................515-6

EWSIItransmitter/receivermodule,
replacing...........................515-11
GENERAL
Thissectioncoversrepairinformationforthecentrallocking
andtheanti-theftsystems.KeepinmindthatE36carsare

CAUTION-
equippedwithsophisticatedandself-diagnosticelectricalsys-

Priortodisconnectingthebattery,readthebattery
tems.Whenexperiencingmalfunctionsrelatinglothecentral

disconnectioncautionsgivenatthefrontofthis
lockingortheanti-theftsystem,itisrecommendedthatthe

manualonpagevi¡¡.
systembediagnosedusingtheBMWservicetester(DIS).
Thisadvanceddiagnostictoolcanusuallypinpointelectrical

NOTE-
faultsquicklyandsafely.ConsultanauthorizedBMWdealer.
Insomemodelscoveredinthismanual,itisnotessen-
tialtoremovetheside-impactairbagtoaccessintemal
NOTE-

doorcomponents.However,theprocedureisrecom-
Additionalgeneralelectricalinformationcanbefound

mendedforsafelyreasons.
in610ElectricalComponentLocationsandElectri-
calWiringDiagrams.

4.Disconnectharnessconnectorfromwindowmotorto
DOORHANDLES ANDLOCKS
Frontdoorlock,removingandinstalling
1.Removefrontdoorpanelandvaporbarrierasde-
scribedin411Doors.
WARNING -
Some1997andall1998carsarefittedwithside-im-
pactairbagsinthefrontdoors.Whenservicingthe
doorlocksoncarswithfrontside-impactairbags,al-
waysdisconnectthenegative(-)batteryterminal.
See721AirbagSystem(SRS)forcautionsandpro-
ceduresrelatingtotheairbagsystem.
2.Raisedoorwindowcompletely
CENTRAL LOCKINGANDANTI-THEFT

515-1
3.Oncarswithside-impactairbags,disconnectnegative
(-)cablefrombattery,thenremoveairbagmodule.
preventaccidentaloperation.
5.On4-doorcars:Peelbackrubberwindowguidefrom
reasguiderail:Removeguiderailmountingboltatbot-
tom.Unclipanywiringfromguiderailandpullguiderail
downwardandremovefromdoor.SeeFig.1.
NOTE-
Thetopoftheguiderailis"hooked"tothedoorsheet
metal.
6.Removeinsidedoorhandleretainingscrew.Discon-
nectinsidehandlefromlinkageandremove.SeeFig.
2.
7.Cutwiretiesandremovedoorlockelectricalharnesscon-
nector.Removedoorlockmountingscrews.SeeFig.3.
8.Workinginsidedoor,disconnectoutsidedoorhandle
andlockcylinderlinkagefromdoorlock.Removelock
frominsidedoor.SeeFig.4.
DOORHANDLESANDLOCKS

515-2

CENTRAL LOCKINGANDANTI-THEFT
0013117
Fig.1.

4-doorcars:Removelowerretainingboltatbaseofwindow
rearguiderailandpivotrailoutofdoor.
Fig.3.

Frontdoorlockmountingscrews(arrows).
uu11686
0012685
Fig.4.

Pryoutlocklinkage(A)fromplasticretainer.Liftdoorlock
mechanismslightlytoRmovelatchingpinfromlockgate(B).
Doorlockmechanismshownremovedfromdoor.
0013073
Fig.2.

Insidedoorhandleretainingscrew(A)Unhooklinkagefrom
handleatB.

9.Installationisreverseofremoval,notingthefollowing:
DOORHANDLESANDLOCKS
"InstalllockmountingboltswithLoctite0270orequiva-
lentthread-locker.
"Reconnectpowerwindowmotorharnessconnector.
"Usenewmountingboltswhenreinstallingtheside-ím-
pactairbagtothedoor(whereapplicable).
"Securewireharnesseswithwireties.
"Checkfunctionofdoorlockandwindowmechanism
beforereinstallinginnerdoorpanel.
TighteningTorques
"Doorlocktodoor.................9Nm(80in-lb)
"Windowguidetodoor............10Nm(89in-lb)

Frontdoorhandle,removingandinstalling
1.Closedoorwindowcompletely.
2.Removefrontdoorpanelandvaporbarrierasde-
scribedin411Doors.
WARNING -
Some1997andal]1998carsarefittedwithside-im-
pactairbagsinthefrontdoors.Whenservicingthe
doorhandlesoncarswithfrontside-impactairbags,
alwaysdisconnectthenegative(-)batteryterminal.
See721AirbagSystem(SRS)forcautionsandpro-
ceduresrelatíngtotheairbagsystem.
3.Oncarswíthside-impactairbags,disconnectnegative
(-)cablefrombattery,thenremoveairbagmodule.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthís
manualonpagevi¡¡.
NOTE-
Insomemodelscoveredinthismanual,itisnotessen-
tialtoremovetheside-impactairbagtoaccessinternal
doorcomponents.However,theprocedureisrecom-
mendedforsafetyreasons.
4.Removedoorlockasdescribedearlier.
5.Removewindowasdescribedin512DoorWindows.
CAUTION-
Onmodelswithside-impactairbags,removinglin-
stallingthefrontwindowrequiresthatthebattery
cablebereconnectedwíththeside-impactairbag
disconnected.ThiswillsetafaultcodeintheSRS
controlmodule,turnontheSRSwarninglight,
anddisabletheSRSsystemuntilthefaultmemo-
ryisclearedusíngspecialSRStestequipment.
6.Pryoutaccesspluginendofdoor.Usescrewdriver
throughaccessholetoslideexteriortrimlockingplate
intoreleasedposition.SeeFig.5.Removedoorhandle
exteriortrimpiece.
7.Workinginsidedoor,removelockingclipfordoorhan-
dleretainingpinandpushpinout.
8.Workinginsidedoor,disconnectelectricalharnesscon-
nectoratdoorhandle.Twistplasticconnectorbracket
toremovefromdoorhandle.
CENTRALLOCKINGANDANTI-THEFT

515-3
0011681
Fig.5.

Insertscrewdriverintoaccessholeandpushlockingplate
forward(arrow)toreleaseexteriorhandletrim.
uu11682
Fig.6.

Doorhandleretainingpin(A)andlockcollarnut(B).Door
handletrimshownremoved.
10.Removedoorhandlefromdoorbyanglingoutofdoor
cavity.RemoveddoorhandleassemblyisshowninFig.
7.
0012684
Fig.7.

Doorhandleharnessconnector(A);retainingpinIockingclip
9.Workingatdoorexterior,removehandlecollarnut

(B);exteriortrimIockingplate(C).Handleassemblyshownre-
whilesupportinghandle.SeeFig.6.

movedfromdoor.
DOORHANDLESANDLOCKS

515-4

CENTRAL LOCKINGANDANTI-THEFT
11.Installationisreverseofremoval.Keepinmindthefol-

4.Removescrewsmountingbottomofwindowreartrack
lowing:

todoor.SeeFig.9.
"Makesurerubbersealforhandleiscorrectlyposi-
tionedbeforetighteningmountingfasteners.
"Installexteriortrimpieceandthenuseahookedtoolto
pulllockingplateintolockedposition.Makesuredoor
handletrimcontactsbodyevenlybeforelockingtrim
inplace.
"Usenewmountingboltswhenreinstallingtheside-im-
pactairbagtothedoor(whereapplicable).ResetSRS
warninglightandclearSRSfaultmemoryusingspe-
cialtestequipment.See721AirbagSystem(SRS).
"Reconnectal¡harnessconnectors(includingpower
windowmotor)beforeinstallingdoorpanel.
"Securewireharnesseswithwireties.
"Adjustandreinitializewindows.See512DoorWin-
dows.
TighteningTorque
"Collarnuttodoorhandle..........10Nm(89in-lb)
1.Removereardoorpanelandvaporbarrierasdescribed
in411Doors.
2.Removewindowfromreardoorasdescribedin512
DoorWindows.
3.Disconnectandremoveinsidedoorhandle.SeeFig.8.
0013073
Fig.8.

Insidedoorhandleretainingscrew(A)Unhooklinkagefrom
handleatB.
DOORHANDLESANDLOCKS
Fig.9.

Rearwindowtracklowerfasteners(arrows).
Reardoorlock,removingandinstalling

5.Removewindowreartracktopscrewandmovetrack
aside.SeeFig.10.
Fig.10.Rearwindowtracktopscrew(arrow).
6.Removescrewfromlockbuttonlinkagerodretainer.Lift
rodoutofretainingclip.SeeFig.11.
7.Disconnectdoorlockharnessconnector.
8.Removedoorlockscrews.SeeFig.12.
0013085
9.Movelockupslightlytodisengagefromexteriorhandle
linkage.Removelockfrominsidedoor.

0011688
Fig.11.Reardoorlockbuttonlinkagerodretainer(A),rodretaining
clip(B),andharnessconnector(C).
Fig.12.Reardoorlockmountingscrews(arrows).
0011687
10.Installationisreverseofremoval.Keepinmindthefol-
lowing:
"Insta¡¡lockmountingboitswithLoctite©270orequiva-
lentthread-locker.
"Reconnectpowerwindowmotorharnessconnector
beforeinstallingdoorpanel.
"Securewireharnesseswithwireties.
"Adjustwindowasdescribedin512DoorWindows.
TighteningTorque
"Doorlocktodoor.................9Nm(80in-lb)
CENTRALLOCKINGANDANTI-THEFT

515-5
Reardoorhandie,removingandinstalling
1.Removereardoorpanelandvaporbarrierasdescribed
in411Doors.
2.Removewindowfromreardoorasdescribedin512
DoorWindows.
3.Removedoorlockasdescribedearlier.
4.Pryoutaccesspluginendofdoor.Usescrewdriver
throughaccessholetoslideexteriortrimlockingplate
intoreleasedposition.SeeFig.13.Removedoorhan-
dleexteriortrimpiece.
u.]lbbl
Fig.13.Insertscrewdriverintoaccessholeandpushlockingplate
forward(arrow)toreleaseexteriorhandletrim.
5.Removedoorhandlemountingscrewswhilesupport-
inghandle.SeeFig.14.
Fig.14.Reardoorhandlemountingscrews(arrows).
0011684
DOORHANDLESANDLOCKS

515-6

CENTRALLOCKINGANDANTI-THEFT
6.Removedoorhandleassemblyfrominsidedoor.
7.Installationisreverseofremoval.Keepinmindthefol-
lowing:
"Makesurerubbersealforhandleiscorrectlyposi-
tionedbeforetighteningmountingfasteners.
"Installexteriortrimpieceandthenuseahookedtoolto
pulllockingplateintolockedposition.Makesuredoor
handletrimcontactsbodyevenlybeforelockingtrim
inplace.
"Reconnectallharnessconnectors(includingpower
windowmotor)beforeinstallingdoorpanel.
"Securewireharnesseswithwireties.
"Adjustwindowasdescribedin512DoorWindows.
TighteningTorque
"Reardoorhandlemountingscrews..10Nm(89in-lb)
NOTE
Ifthestrikerbackupplatefaflsintothebodycavlty,it
canberetrievedafterremovingtheinsidetrimfromthe
B-pillar(door-postpillar).
TighteningTorque
"Strikerplatetobodypillar..........28Nm(20ft-lb)
LOCKINGACTUATORS
DoorLockingActuator
Thefrontdoorlockmechanismandactuatorareshownin
Fig.15.Thereardoorlockandactuatoraresimilar.Thelock
mustfirstberemoved,asdescribedearlier,toreplacetheac-
tuator.
ifdefective.
LOCKINGACTUATORS
Connectionsto
doorhandle
®
o
_

Attaching
pin
0
O~ Lock
mechanism
0012082
Fig.15.Frontdoorlockmechanismandrelatedparts.Rearlock
mechanismissimilar.
Doorstriker,replacing

Luggagecompartmentlockingactuator,
removingandinstalling
Thedoorstrikercontainsanelectricalcontactswitch.Ifthe
switchisfaulty,thestrikermustbereplaced.Toremovethe

1.Raisetrunklid.Removetoolkitandtrunklidtrimpanel.
striker,removethemountingbolts.Disconnecttheharness

SeeFig.16.
connectorfromthestriker.
0013162
Fig.16.Trunklidtrimandtoolkitretainíngscrewsandclips(arrows).
2.Disconnectactuatingrodfromlock.SeeFig.17.
3.lJnplugtwowíringconnectorsfromactuator.SeeFig.
18.
NOTE-
"lfjustoneofthecentrallockingdrivesdoesnotoper-

NOTE-
ate,thelockinglinkagecouldbefrozenorstiffenough

Theactuatorisadjustable.Matchmarktheattaching
topreventactuatonofthedrive.Tryremovethefinte-

screwsbeforeremoval.
riordoorpanelandlubricatingthelockinglinkageas
thefirststep.

4.Removeactuatorattachingscrews.Pullactuatorback-
"Theactuatorisnotserviceableandmustbereplaced

wardsfrombehindmetalshieldtoremove.
5.installationisreverseofremoval.Alignactuatorscrews
withmatchmarksduringinstallation.

002262

Inthissystem,threemicroswitchesareoperatedviathedoor
lockcylinderateachfrontdoor.Turningthekeyapproximately
Fig.17.Pufloffluggagecompartmentlockactuatingrodinthedirec-

45°(position1)operatesthedoorlockingmicroswitch.Tuming
tionofarrow.

thekeyapproximately90°(position2)actuatesthedoublelocking
microswitch.Tumingthekeyapproximately45°intheoppositedi-
rectionthroughposition0actuatestheunlockingmicroswitchand
deactivatesthealarmsystem(position3).SeeFig.19.
Fig.18.Luggagecompartmentactuatorwireconnectorsandattach-
ingscrews(arrows).
LOCKINGSYSTEMAND
ELECTRONICIMMOBILIZATION
Thecentrallockingsystemuseselectricallockactuatorsat
eachdoorandatthetrunklid.Thelockingsystemcanbeac-
tuatedbyeitherfrontdoorlockorbytheluggagecompartment
lock.Onsome1994andlatercars,anadditionalremotecon-
trolkeypadcanalsobeusedtoactivatethelockandanti-theft
systems.
Whenthekeyistunedtothelockposition,amicro-switch
signalsacentralcontrolmoduletolockalldoors,luggage
compartment,gastankflapand,inlaterconvertibles,the
gloveboxlid.Whereapplicable,thisalsoarmstheanti-theft
system.
CENTRALLOCKINGANDANTI-THEFT

515-7
NOTE-
Thecentrallockingsystemrespondstoaccidentsvía
animpact(inertia)switch.Whenthisfunctionísactivat-
ed,thedoorsareautomaticallyunlockedandthehaz-
ardwarninglightsandinteriorlightsareturnedon.The
impactswitchesaremountedintheleftandrightfoot-
wellsbehindthespeakergrilles.
CentralLockingSystem(ZVM)
Differentversionsofthecentrallockingcontrolhavebeen
usedintheE36cars.Inearlyproductioncars(modelyears
1992and1993),thelockingsystemiscontrolledthroughthe
centrallockingmodule.ThissystemisreferredtoasZVM.
Fig.19.ZVMdoorlockcylinderpositíons.
CAUTION-
Donotengagedoublelockingpositionwithpas-
sengersinthecarunlessthemasterkeyisavail-
able.Thedoorcannotbeopenedfromoutsideor
insidewithoutthemasterkey.
NOTE-
Incaseofadischargedbattery,thecarcanstillbe
lockedorunlockedusingthekey.
0011762
LOCKINGSYSTEMANDELECTRONICIMMOBILIZATION

515-8

CENTRALLOCKINGANDANTI-THEFT
CentralBodyElectronics(ZKEIV)

ElectronicImmobilizationSystem(EWS)
Beginningwithvehiclesproduced9193(modelyear1994),

Theelectronicanti-theftsystemknownasEWSwasfirstin-
thecentrallockingsystemwasintegratedwithsunroofand

troducedinJanuary1994.Theearlyversionofthesystem
windowclosureintotheCentralBodyElectronics(ZKEIV)

usesastartinginhibitionmoduletointerrupttheignition,the
(generationfour)system.Thecontrolmoduleforthissystem

fuelinjectionandthestartermotor.Thissystemisactivated
ísmountedinfrontoftheglovecompartment.

anddeactivatedbythecentrallockíngsystem.Thecontrol
moduleforthesystemisinstalledundertheleftsideofthe
Inthissystemtwomicroswítchesareoperatedviathedoor

dashboard.
lockcylinderatbothfrontdoors.Turningthekeyapproximate-
ly45°(position1)operatesthedoorlockingmicroswitchand

StartingwithmodeisbuiltsinceJanuary1995,E36cars
activatesthealarmsystem.Holdingthekeyinthatposition

comeequippedwithasophisticatedcodedelectronicimmobi
alsoclosesanyopenwindowsandthesunroof.

lizationsystemcalledEWSII.Foraschematicofthesystem,
refertoFig.21.
Turningthekeyapproximately45°intheoppositedirection
throughposition0actuatestheunlockingmicroswitchandde-
activatesthealarmsystem(position2).SeeFig.20.
NOTE-
TheEWS11systemisalsosometimesreferredtoasthe
DriveawayProtectionSystemortheelectronicimmobi-
lizationsystem.
OnEWSIIequippedcars,theignitionkeyisembeddedwith
acomputerchipandpermanentlyencoded.Aprimarycodeis
programmedintothekeyandfintothevehicleitself.Asecond-
arycodeischangedeverytimethevehicleisstarted.Ifthekey
codeandEWSIIcontrolmodulecodedonotmatch,theen-
ginemanagementcontrolmoduleandthestarteraredis-
abled.EWSIIignitionkeyscannotbeduplicated.
Thesystemisdesignedtohaveuptotenkeysandonlyan
authorizedBMWdealercanprovidereplacementkeys.
j
NOTE-
0011762a

ftispossibletodamagetheelectroniccircuítryinthe
Fig.20.ZKEIVdoorlockcylinderpositions.

key,renderingifunusable.Inthatcase,anewkey
shouldbepurchasedandinitializedbyanauthorized
BMWdealer.
LOCKINGSYSTEMANDELECTRONIC IMM081LIZATION

CLUTCH
SWITCH
Fig.21.EWSIIsystem.
TRANSMITTER/
RECEIVER
`IMODULE
HALL
y
EFFECT
TD
CENTRALLOCKINGANDANTI-THEFT

515-9
DME
DIAGNOSIS
"D
`mol
111
IIIIIIIII
.r
LOCKINGSYSTEMANDELECTRONIC IMMOBILIZATION

515-10

CENTRALLOCKINGANDANTI-THEFT
EWSIIcontrolmodule,replacing
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevüf.
2.Removeglovecompartmentasdescribedin513Inte-
riorTrim.
3.RemoveEWSIIcontrolmoduleharnessconnector.
Pullmoduleoutofbracket.SeeFig.22.
NOTE-
TheEWS11moduleshouldbeidentifiedwithEWS11
markings.
4.Installationisreverseofremoval.
Ringantenna,replacing

4.Cutoffwiretiesholdingwiringharnesstosteeringcol-
umn.
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removelowersteeringcolumncover.SeeFig.23.
Transmitter/
receiver Ring
r
module antenna
Fig.22.LocationofEWSIIcomponents.
LOCKINGSYSTEMANDELECTRONICIMMOBILIZATION
Fig.23.Steeringcolumncoverretainingscrew(arrow).
5.Gentlypryoffringantennafromignitionswitch.
7.Installationisreverseofremoval.
0012543
3.Removelowerleftdashtrimpanelasdescribedin513
InteriorTrim.
6.UnplugringantennaharnessfromEWSIItransmit-
ter/receivermoduleasdescribedbelow.

EWSIItransmitterlreceivermodule,
replacing
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removelowerleftdashtrimpanelandkneebolsteras
describedin513InteriorTrim.
3.Unclipauxiliaryrelaypanelundersteeringcolumnand
lowerittoaccessrelaysandharnessconnectors.See
Fig.24.
Fig.24.Loweringtheleftsideauxiliaryrelaypanel.
CENTRALLOCKINGANDANTI-THEFT

515-11
0013164
4.Disconnectharnessconnectorfromtransmitter/receiv-
ermodule.Unclipmodulefrompanel.SeeFig.25.
5.Installationisreverseofremoval.
0 A
0013035
Fig.25.PositionofEWSIItransmitter/receivermodule(A)onleftside
auxiliaryrelaypanel.
LOCKINGSYSTEMANDELECTRONIC IMMOBILIZATION

GENERAL
Thisrepairgroupcoversremovalandinstallationofthe
frontandrearseats.
FRONTSEATS
ThefrontseatsinstalledinE36carscomeineithermanual
orelectricallypoweredversions.Cloth,vinylandleatherver-
sionsareoffered.M3sportseatshaveextrabolstersonthe
sidesofthesean-back,athighsupportbolster,andextracon-
trolsforseaninclination.
Seatremovalandinstallationissimilarforallversions.Seat
disassemblydiffersindetailsamongthemanymodelsof
seats.
Frontseat,removingandinstalling
1.Moveseattofui¡forwardpositionandraiseitasfaras
possible.Removetwomountingboltsatrearofsean
rails.SeeFig.1.
2.Moveseattofui¡rearposition,keepingitraised.
3.Disconnectnegative(-)cablefrombattery.

Fig.1.

Frontseatrearmountingbolts(arrows).
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
520Seats
SEATS520-1
GENERAL............................520-1

Rearseatcushionandbackrest,
removingandinstalling
FRONTSEATS........................520-1

(fixedseatbackmodels)................520-5
Frontseat,removingandinstalling........
'
520-1

Rearseatcushionandbackrest,
ManualFrontSeatAssembly.............520-3

removingandinstalling
fold-downseanbackmodels(

)............520-5
PowerFronfSeatAssembly.............;520-4

Rearseatbackrestsidesection,
REARSEATS.........................520-5

removingandinstalling
(fold-downseatbackmodels)............520-6
4.Removeplasticcapsfromfrontmountingnuts,and
thenremovemountingnuts.SeeFig.2.
WARNING -
Deactivatefrontseatbeltlocktensionersbefore
proceedingtonextstep.See720SeatBelts.
NOTE-
Useablankettoprotectdoorsillfromscuffingbysean
railduringseatremoval.
FRONTSEATS

520-2

SEATS
Fig.2.

Frontseatfrontmountingnut(arrow).
FRONTSEATS
0013166
5.On2-doorcars:unhookseatbeltfromguideonseat
back.
8.Removeseatfromcar.
Fig.3.

Seatbeltmountingbolt(arrow).
0013216
9.Installationisreverseofremoval.Keepthefollowingin
mind:
6.Tiltseatbacktoaccessandunplugelectricalharness

"Usewiretiesorequivalentmeanstokeepseathar
connectors.Cutoruntwistwiretiesasnecessary.

nesswiringfrombeingexposedtofraying.
"Reactivatefrontseatbeltlocks.
7.On4-doorcars:Unboltseatbeltfromseatframe.See

"Startallseatmountingboits.
Fig.3.

"Tightenseatmountingfastenersinthíssequence:in-
nerfront;outerfront;innerrear,outerrear.
TighteningTorque
"Frontseattofloor

...............55Nm(41ft-Ib)

ManualFrontSeatAssembly
Thenon-powerseatinE36carsisshowndisassembledin
Fig.4.Componentreplacementispossibleoncetheseathas
beenremovedfromthevehicleasdescribedearlier.
Fig.4.

Constructionofnon-powerfrontseat.
SEATS520-3
1.Backrestpadding

4.Seatadjustmentcontrois

7.Seatframe
2.Backrestframe

5.Seatadjustmentcables

8.Seatcushion
3.

Backrestreleaselever(two-door)

6.

Seattiltcontrol(M3only)

9.

Kneebolster(M3only)
FRONTSEATS

520-4SEATS
PowerFrontSeatAssembly
ThepowerseatinE36carsisshowndisassembledinFig.
5.Component,actuatoranddrivecablereplacementispossi-
bleoncetheseathasbeenremovedfromthevehicleasde-
scribedearlier.
FRONTSEATS
Fig.5.

Constructionofpowerfrontseat.
1.

Backrestframe

6.

Lumbarsupport(to9/94)

11.Seattrack
2.

Seatframe

7.

Verticaladjustment(rear)

12.Seattiltmotor
3.

Backrestreleaselever(two-door)

8.

Backrestadjustmentgearbox

13.Tiltmotorgearbox
4.Backrestreleaselevercable

9.Backrestadjustmentmotor

14.Forward/backwarddriveshafts
5.Lumbarsupport(from9/94)

10.Wiringharness

15.Forward/backwardmotor

REARSEATS
Rearseatcushionandbackrest,
removingandinstalling
(fixedseatbackmodeis)
1.Pullfrontofbottomcushionupandoutofclips.
NOTE-
Removerearheadrests,ifequipped.
2.Folddowncenterarmrestandremovebeltsfrombe-
hindarmrest.
3.Slideseatbackupoffholders.Thenslidetosidelo
clearseatbelts.SeeFig.6.
Rearseatcushionandbackrest,
removingandinstalling
(foid-downseatbackmodeis)
1.Pullfrontofbottomcushionupandoutofclips.
NOTE-
Removerearheadrests,ifequipped.
Fig.6.Toremoverearseat,removebottomcushion.Removebelts
(A)behindcenterarmrest.Slideseatbackupoffholders,
thenforward.
SEATS520-5
2.Removebottomseatbeltanchorbelts.SeeFig.7.
NOTE-
Besuretonoterelativepositionsofmetalbelt-endan-
chorsinordertoreassemblecorrectly.
00131b!
Fig.7.

Rearseatbeltanchorboltunderrearseatcushion(arrow).
3.Tiltbackrestsforwardandunclipplasticcover.SeeFig.
8.
t;
Fig.8.

Rearseatbackmountingcoverplateatbaseofseatback.
REARSEATS

520-6SEATS
4.Pushspring-loadedlockbackandunclipseatback.
SeeFig.9.
Fig.9.

Pushspring-loadedclipback(arrow).
UU13117
5.Installationisreverseofremoval.Makesurebackrest
locksattopseatbeltconnection.
REARSEATS
Rearseatbackrestsidesection,
removingandinstalling
(foid-downseatbackmodeis)
1.Pullfrontofcushionupandoutofclips.
2.Folddownrearseatbackrest.
3.Liftbackrestsidesectionupandout.SeeFig.10.
4.Installationisreverseofremoval.
0013175
Fig.10.Removebackrestsidesectionbyliftingout(A)andup(B).
1#=am

GENERAL............................540-1

Sunroofpanel,emergencyclosing..........540-2
Sunroofpanel,adjusting.................540-2
SUDE-TILTSUNROOF.................540-2

Sunroofmotor,removingandinstalling......540-3
GENERAL

NOTE-
"Besuretocheckthedrainsinthefrontcomersofthe
Theelectrically-operatedslide-tiltsunroofiscontrolledbya

sunroofcarrierifwaterlsenteringthecarthroughthe
setofcablesthatmovethesunroofpanelalongguiderails

headliner.
whenthemotorisoperated.Thesunroofcanbeadjusted

.Removalandrepairofthesunroofandothercompo-
withoutremovingitfromthecar.Replacementofthesunroof

nentsinsidetheroofcavityisbeyondthescopeotthis
linerorcomponentssuchasthecableassemblyrequirethat

manual.
thesunroofpanelberemoved.
Thecomponentsoftheslide-tiltsunroofareshowninFig.1.
Fig.1.

Slide-tiltsunroofassembly.
540Sunroof
SUNROOF 540-1
1.Sunroofpanel

5.Cable

9.Lever
2.Winddeflector

6.Motor

10.Sea¡
3.Frame

7.L]ner

11.Centerrail
4.Drain

8.Lever

12.Sea]
GENERAL

540-2SUNROOF
SLIDE-TILTSUNROOF
Sunroofpanel,emergencyclosing
1.Removeaccesspanelfrombelowsunroofmotor.See
Fig.2.
Fig.2.

Sunroofmotoraccesscoverbeingpriedoff.
0011816
2.Inserthexkeyintodriveinsunroofmotorandturnhex
keytoGlosepanel.SeeFig.3.
SLIDE-TILTSUNROOF
0~i18r7
Fig.3.

UsehexkeytomanuallyGlosesunroof.Turnhexkeytomah-
uallyGlosesunroof.
NOTE-
Thehexkeyformanually(emergency)closingthesun-
roofcanbefoundinthetoolkitlocatedintheluggage
compartment.
Sunroofpanel,adjusting
Thesunroofpanelshouldbeadjustedwheneverthetopof
theclosedsunroofbecomesmisalignedwiththeroofofthe
car,ifitdoesnotGlosesquarely,iftherearewindnoisesat
speed,iftherearewaterleaks,orifthesunroofhasbeenre-
moved.
1.Opensunroofslightly.Rearofsunroofshouldbe2to3
mmbelowsurfaceofroof.
2.Slidesunrooflinerslowlyandcarefullybackintoroof
cavityasfaraspossible.SeeFig.4.
Fig.4.

Slidesunrooflinerbackintoroofcavity.
3.Shutsunrooffully.
CAUTION-
Donotopensunroofwithlinerinthisposition.
Damagetosunroofmechanismcouldresult.

4.Rearadjustment:Loosenrearadjustingwedgesand
pushinoroutuntilrearofsunroofisalignedcorrectly
withroof-top.SeeFig.5.
0013103
Fig.5.

Adjustrearofsunroofbylooseningnuts1and3.Pushadjust-
íngwedges2inorouttoachievecorrectheight.
NOTE-
"Pushsunroofforwardbeforeretighteningwedgefas-
teners.
0013170
Fig.6.

Adjustfrontofsunroofbylooseningscrew(arrow).Pushsun-
roofupordowntoachievecorrectheight.
SUNROOF 540-3
NOTE-
UseLoctite®270oranequivalentthreadsealingcom-
poundwhenreinstallingtheretainingscrews.Alterna-
tively,installnewscrews.
6.Opensunroofslightly.Rearofsunroofshouldbe2to3
mmbelowsurfaceofroof.
7.Slidesunrooflinerslowlyandcarefullyforwardoutof
roofcavityasfaraspossible.
SunroofHeightAdjustmentSpecifications
"Rear..............flush/1mmhigherthanrooftop
"Front...............flush/lmmlowerthanrooftop
TighteningTorque
"Frontorrearadjustingfasteners......6Nm(53in-lb)
Sunroofmotor,removingandinstalling
"UseLoctite®270oranequivalentthreadsealingcom-
poundwhenreinstallingtheretainingfasteners.Alter-

Thesunroofshouldbeintheclosedposítionbeforeremov-
natively,installnewfasteners.

ingorinstallingthesunroofmotor.Ifnecessary,manually
5.Frontadjustment:Loosenretainingscrews,thenpush

closethesunroofpanelasdescribedunderSunroofpanel,
frontofsunroofpanelupordownuntilitisalignedcor-
emergencyciosing.
rectlywithroof-top.Retightenscrews.SeeFig.6.

1.Withignitionswitchoff,Rmoveaccesspanelfrombe-
lowsunroofmotor.RefertoFig.2.
2.Removesunroofmotormountingscrews.SeeFig.7.
0011825
Fig.7.

Sunroofmotormountingscrews(AandB).ScrewatAis
longerthanscrewsatB.
SLIDE-TILTSUNROOF

540-4SUNROOF
3.Disconnectharnessconnectorfrommotorandremove
motor.
4.Installationisreverseofremoval.Besurethemotoris
inthe"closed"positionbeforeinstallingittothesunroof
carrier.SeeFig.8.
SLIDE-TILTSUNROOF
0011813
Fig.8.

Sunroofmotorin"closed"position.Hole(arrow)inlargegear
alignswithshaftsonbothgears(tomid-1994).
NOTE-
Oncarsmanufacturedfrommid-1994,thesunroofmo-
torgearassemblyisencasedandcannotbeseen.Be-
foreinstallingthemotorintheroof,connectelectrical
harnessconnector,operateswitchtorearuntilmotor
stops,thentofrontuntilmotorstops.Theninstallmotor
inroof.
TighteningTorque
"Sunroofmotortomotorcarrier.....2.8Nm(25in-lb)

GENERAL............................541-1

VisorLatchPlate.......................541-4
VisorLatch............................541-4
MANUALCONVERTIBLETOP..........541-1

VisorLatchMotor...
............
........541-5
VisorLatchPlate.......................541-1

Convertibletopandframe,replacing........541-5
VisorLatch...........................541-1

Convertibletopdrivemotor,replacing

......541-7
ConvertibleTopLidReleaseMechanism....541-2

ConvertibleTopEmergencyOperation......541-7
Convertibletopandframe,replacing.......541-2

ConvertibleTopLid.....................541-9
POWERCONVERTIBLE TOP...........541-2

ROLLOVER PROTECTIONSYSTEM....541-9
FrontLatchingMechanism...............541-4
GENERAL
Theconvertibletopcomesinthreeversions:amanuallyop-
eratedtop,asemi-automaticpowertopandafullyautomatic
powertop.
NOTE-
Theconvertibletopcontrolmodule(CVM)islocated
behindtheleftrearsidetrimpanel.Forthelocationof
otherconvertibletopelectriccomponentssee610
ElectricalComponentLocations.
Therearwindowintheconvertiblemodelsismadeofa
strong,flexiblevínylwhichisavailableseparately.Replace-
mentoftherearwindowisnotcoveredinthismanual.
Theleftandrightvisorlatchplatescanbeaccessedbyre-
movingthetrimandmoldingsaroundthesidesandtopofthe
windshield.Eachlatchissecuredtothetopofthewindshield
usingthreebolts.Latchpositionisadjustedasfollows:
541ConvertibleTop
CONVERTIBLETOP

541-1
"Loosenbolts
"Latchtop
"Aligntop
"Retightenbolts.SeeFig.1.
BMWhasdesignedaspecialbatterytrayfortheconvertible
which,inconjunctionwiththemassofthebatteryinthelug-
gagecompartment,servestodampenconvertiblebodyflex
ingandvibration.

Fig.1.

Visorlatchplateisheldtotopofwindshieldwiththreebolts
(arrows).
CAUTION-
TheE36convertiblerequiresaspecialbattery

VisorLatch
whichisdesignedforconstantvibration.Abattery
notdesignedforthiswillfa¡¡muchearlier.

Checkforeaseofreleaseandlockingofconvertibletop
frontlatches.Heightofalatchcanbechangedbyusingthe
adjustingscrew.Tochangelatchtension,itisnecessarytore-
MANUAL CONVERTIBLE TOP

movethetrimonthefrontbowofthetop.Theball-jointpull-rod
lengthcanthenbeadjusted.Lubricatelatchifnecessary.See
VisorLatchPlate

Fig.2.
MANUAL CONVERTIBLE TOP

541-2

CONVERTIBLETOP
Fig.2.

Manuallyoperatedfrontlatch.Loosenmountingnuts(A)and
locknut(B),thenadjustlatchheightwithhex-bolt(C).(Fully
automaticfrontlatchheightadjusterissimilar.)Latchtension
ísadjustedatrodball-jointend(D).
ConvertibleTopLidReleaseMechanism
Theconvertiblelidreleasehandleissituatedinthetrim
panelbehindthedriver'sseat.Toremovethehandle,pullits
plasticinsertforwardandremovethetriminsert.Thehandleis
mountedwithasinglescrew.
Abowdencableisroutedfromthehandletotheleftlidlatch.
Anothercableisroutedfromthelefttotherightlatchinsidethe
luggagecompartment.Itisaccessedbypullingdownthetrim
liningoffthefrontwallofthecompartment.
Convertibletopandframe,replacing
1.Openconvertibletoppartially.Openconvertibletoplid.

J
I~I~KX
Openbackwindows.

_
v
2.Removefastenersincompartmentsbehinddoorposts
andliftoutcompletetop.Countnumberofshimson
horizontalmountingbolts.SeeFig.3.
3.Installationisreverseofremoval.BesuretoreplaceU-
shapedshimsonhorizontalmountingbolts.SeeFig.4.
Fig.4.

Horizontalpositioningbolt(A)andU-shapedadjustingshims
4.Toadjustpositionandfitoftop,removeoraddU-

(B)forconvertibletop.Oneoftwomainmountingnuts(ar
shapedshimsuntiltopisproperlyaligned.Tightennuts

rows)alsovisible.
andscrews.
POWERCONVERTIBLETOP
Thesemi-automatictop,installedin1996convertibles,
mustfirstbemanuallyreleasedfromthevisorlatchplatesand
pushedbackpastthe"tensionpoint,"wheréupon,theauto-
maticretractingmotorandlinkagetakeoverandpullitintothe
storagecompartmentbehindthebackseat.
POWERCONVERTIBLETOP
Fig.3.

Mountingnuts(A)forconvertibletop(twooneachside).There
isalsoahorizontalboltwithspacersoneachside(B).
0012754
Thefullyautomatictop,standardon1997andlaterconvert-
ibles,allowscompleteoperationofthetop,fromfullyopento
fullyclosed,withthepushofatoggleswitchontheconsole.
Thetopswitchincorporatesa"topunlatched"warningLED.
Aschematicrepresentationofthefullyautomaticconvert-
ibletopisshowninFig.5.

KL30
CONVERTIBLE
BATTERY
(ONTOPMOTOR)
UP
DOWN
S2
-I(ONTOPMOTOR)
(INTOPSTORAGEWELL)
S4
E36
AUTOMATIC
CONVERTIBLE
S5
(ONTRUNKLOCK)ITOPCONTROL
MODULE
ILHSIDETOP
LATCHDRIVE)
1
M-4míA7--Offi-
Íl
ít~~
ENSOR
HARDTOPLOCKSIGNAL
O
1~~11:iq
SIGNAL
TOPMOTOR
POSITIONSIGNAL
Fig.5.

Semi-automaticandfullyautomaticconvertibletopsystem.Mainad-
ditionalcomponentsinfullyautomatictopshowninsidedashedlines.
CONVERTIBLETOP

541-3
TOPLID
MOTOR
EMTOP
n
~ llí9.1
-----------
I
I

I
I FRONT I
M LATCH I
1

MOTOR'I
I

1
I
L--------- J
X
POWERCONVERTIBLETOP

541-4

CONVERTIBLETOP
Foldingroof
Frontlatches
Convertible
topframe
i
Lowermountingpata
Horizontal
positioning~~-
bolt
Manual
front
8e
latch

1
handle
~

O
Visorlatchplata
Fig.6.

MechanicalcomponentsofE36convertibletop.Manual,semi-automatic,andfullyautomatictopshavesimilarmechanicalconstruction.
NOTE-
Theelectroniccircuitsusedtocontrolconvertibletop
operationarecomplex.Diagnosisoftheconvertibletop
andtheRolloverProtectionSystemarebeyondthe
scopeofthisbook.YourauthorizedBMWdealerhas
theproperdiagnosticequipmentandtoolstocarryout
thesetasks.
FrontLatchingMechanism
Aclose,tightfitbetweenthefrontbowoftheconvertible
roofandthetopofthewindshieldiscriticalforpreventing
moistureandwindnoisefromintrudingintothepassenger
compartment.
VisorLatchPlate
Theleftandrightvisorlatchplatescanbeaccessedbyre-
movingthetrimandmoldingsaroundthesidesandtopofthe
windshield.Eachlatchisattachedtothetopofthewindshield
usingthreebolts.Latchpositionisadjustedasfollows:
"Loosenbolts
Latchtop
"Aligntop
"Retightenbolts.SeeFig.7.
POWERCONVERTIBLETOP
4
a
0012756
VisorLatch
0012768
Fig.7.

Visorlatchplateisheldtotopofwindshieldwiththreebolts
(arrows).
Thesemi-automaticandthefullyautomatictopfrontlatches
areofsimilardesign.Fortheautomaticlatchingmechanism
anadditionalmotorhasbeeninstalledinthefrontbowofthe
convertibletop.Thisreleasesthetopfromthevisorlatch
platesandpulísitbackfarenoughforthemainretracting
mechanismtocompletethejob.
Thelatchesandthemotorcanbeaccessedbyremoving
thefrontcovertrimfromtheconvertibletop.

Theleftlatchinthefullyautomaticversionhastwomi-
croswitches(S7andS8)whichsignalopen,closedand
latchedstates.SeeFig.8.
Thelengthofthedeadcenterpointrodiscritica¡locorrect
openingandlatchingoftheconvertibletop.SeeFig.9.
DeadCenterPointRod
"DimensionA........205.5f1mm(8.09t0.04in)
VisorLatchMotor
Thefullyautomaticconvertibletopislatchedandunlatched
byoneelectricmotorinstalledinthefrontroofbow.Tore-
place,removefrontcovertrimfromtheroof.Removeelectri-
calharnessconnectorsfrommotor,andremovemounting
screws.Slidethemotorofftheoutputshaftstotheleftand
rightlatches.
Duringreinstallation,theoutputshaftsmustbetumeduntil
theS8microswitchintheleftlatchistripped.
Convertibletopandframe,replacing
1.Openconvertibletoppartially.Openconvertibletoplid.

Fig.9.

Presetlengthofdeadcenterpointrod.
Openbackwindows.
2.Fullyautomaticpowerconvertibletop:Removefront
covertrimfromtop.Disconnectelectricalharnesscon-
nectorsfromfrontlatchmotor.Disconnectconnectors
fromS7andS8microswitchesatleftlatch.
Motors
M1Convertibletop
M2Convertibletoplid
M3Frontlatch(fullyautomatictop)
Microswitches
S1&S2Inconvertibletopmotor
S3Inconvertibletopstoragecompartment
S4Intoplinkage(semi-automaticonly)
S5Inluggagecompartmentlatch
S6Inrightconvertibletoplidlatch
S7&S8Inleftconv.toplatch(fullyautomatic)
Fig.8.

Locationofautomaticandsemi-automaticconvertiblelatchmechanisms,motorsandmicroswitches.
CONVERTIBLE TOP

541-5
POWER CONVERTIBLE TOP

541-6

CONVERTIBLETOP
3.Removeheadliner,startingfromfrontandworking

7.Removefastenersinbottomofstoragecompartments
backward.Notearrangementandlacingoftensioning

behinddoorpostsandliftoutcompletetop.Notenum
cablesoitcanbereinstalledinitsoriginalconfigura-

berofshimsonhorizontalmountingbolt.SeeFig.12.
tion.SeeFig.10.
0012748
Fig.10.Headlinertensioningcableandsomeofitsretainingeyelets
(arrows).
4.DisconnectelectricalharnessconnectorfromS4mi-
croswitchinmiddlelinkageofconvertibletop.
5.Disconnectelectricmotorlinkagerodsinconvertible
topstoragecompartmentbehindleftrearseat.SeeFig.
Vizib1
Fig.11.Convertibletoplinkagerods(arrows)incompartmentbehind
leftrearseat.
POWERCONVERTIBLETOP
8.Installationisreverseofremoval.BesuretoreplaceU-
shapedshimsonhorizontalmountingbolts.SeeFig.
13.
0012754
Fig.13.Horizontalpositioningbolt(A)andU-shapedadjustingshims
(B)forconvertibletop.Oneoftwomainmountingnuts(ar-
rows)alsovisible.
6.Pullelectricalharnessthroughtodisengagefromtop.

9.Toadjustpositionandfitoftop,RmoveoraddU-
shapedshimsuntiltopisproperlyaligned.Tightennuts
andscrews.

Convertibletopdrivemotor,replacing

5.Workinginconvertibletopstoragecompartmentbe-
hinddriver'sseat,removeconvertibletoplinkagerods
1.Openconvertibletoppartially,stoppingwhenconvert-

fromtopofmotor.RefertoFig.11.
ibletoplidisfullyupen.Removelid.
2.Releaseluggagecompartmentlock-outbypressingon
microswitchinrightconvertibletoplidlatch.SeeFig.
14.
0012745
Fig.14.Rightsideconvertibletoplidlatch.Arrowpointstolocation
ofluggagecompartmentlock-outmicroswitch.
3.Openluggagecompartment.Removetrimandinner
liningfromleftsideofcompartment.
4.Disconnectelectricalharnessconnectorsattopmotor.
Releaseemergencyreleasecablefromlever.Pushle-
veruptoreleasemotor.SeeFig.15.
uu12759
Fig.15.Convertibletopmotor(A)andreleaselever(B)inluggage
compartment.
CONVERTIBLE TOP

541-7
6.Removefourfastenersholdingmotortobodyandre-
movemotorthroughluggagecompartment.SeeFig.
16.
0012761
Fig.16.Convertibletopmotormountingscrews(arrows).Gasket(A)
mustberenewedwhenmotorisreplaced.
7.Installationisreverseofremoval.Keepthefollowingin
mind:
"Replacesealinggasketbetweentopofmotorand
body.
"SecuremotormountingscrewswithLocktite®270or
equivalent.
TighteningTorque
"Convertibletopmotortobody
mountingscrews.................10Nm(7.5ft-Ib)
ConvertibleTopEmergencyOperation
Amalfunctionintheelectricalsystemoranotherfaultinthe
convertibletopmechanismcancausetheautomaticorsemi-
automatictoptobestuckinopen,shut,orintermediateposi-
tion.Thefollowinggeneralproceduresaresuggestedinorder
toclosethetopinanemergencysituation.Resettingproce-
duresforconvertibletopsynchronizationafteremergencyclo-
surearebeyondthescopeofthismanual.
MainMotor.Toreleasethetoplinkagefromthemotor,lift
theleftcomeroftherearseattoaccessemergencyrelease
handle.SeeFig.17.
POWERCONVERTIBLETOP

541-8

CONVERTIBLETOP
CAUTION-
Incaseoffailureoftheautomaticorsemi-auto-
maticconvertibletopfunction,onlyusetheemer-
gencyproceduretoclosethetop,nevertoopenit.
AnauthorizedBMWdealershouldthenbecon-
sulted.
0012764
Fig.17.Convertibletopmotoremergencyreleasehandleunderrear
seat.Pullindirectionofarrowtoreleasetop.
Itisthenpossibletopushthetopmanuallytoanearclosed
position.Inthecaseofthesemi-automatictop,simplyattach
andlockthefrontlatches.
FrontLatches.Oncethefullyautomaticconvertibletop
hasbeenreleasedfromthemotorandmanuallypushedto
near-closure,emergencylatchíngofthetopispossiblebyus-
ingtheS-shapedhexkeyprovidedintheemergencytoolkit.
First,removetheplasticcoveroverthelatchmotorinthe
frontbowoftheconvertibletop.SeeFig.18.
Next,usethehexkeyfromtoolboxtocrankthefrontlatch-
esshut.SeeFig.19.
LuggageCompartment Cover.Amicroswitchintheright
convertibletoplidlatchpreventstheluggagecompartment
frombeingopenedwhilethelidisup.Thislockoutcanbe
overriddenbypressingonthemicroswitch.RefertoFig.14.
POWERCONVERTIBLETOP
Fig.18.Removeplasticcoverfromcenterofconvertiblerooffront
bowtoaccesslatchingmotordrive.
0012762
Fig.19.Usingemergencyhexkeytomovefrontpartofconvertible
top.
CAUTION-
Theconvertibletoplidandtheluggagecompart-
mentcoverinterferewitheachotherandcannot
beopenatthesametime.Toavoiddamageto
paintedsurfaces,anassistantshouldkeepthelid
downuntiltheluggagecompartmentcovercanbe
closed.

ConvertibleTopLid
ThecomponentsoftheconvertibletoplidareshowninFig.
20.
Fig.20.Componentsoftheconvertibletoplid.
ROLLOVERPROTECTIONSYSTEM
Thelidlatchesarecableoperatedbyadrivemotorlocated
intheleftsideoftheluggagecompartment,behindthetrimlin-
er.Thesamemotorisusedtoraiseandlowerthelidduring
automaticconvertibletopoperation.
Thelatchcablesmustbeadjustedsothatthelidfitssnugly
againstthebodywhenlocked.
Theliddrivemotorcanberemovedandreplacedfromthe
luggagecompartment.
Twospring-locaedcassettesaremountedbehindtherear
seat.Asinglerolloversensor,mountedontheleftcassette,
signalstheconvertibletopmodule(CVM)ofanimminentroll-
over,whereuponthemoduletriggersbothcassetteswithin
3j10thofasecond.SeeFig.21.
Oncethecarsignitionhasbeenswitchedon,therollover
sensorperformsaself-testlasting6seconds.Duringthistime
ayellowwarninglightislitonthedashboard.Ifthewarning
lightfailstogooutafter6seconds,thismeansthatafaulthas
beendetectedinthesystem.ThefaultisstoredintheCM
Faultscanberetrievedanddiagnosedbyspecialdiagnostic
equipment.
NOTE-
DiagnosisoftheconvertibletopandtheRolloverPro-
tectionSystemarebeyondthescopeofthisbook.Your
authorizedBMWdealerhastheproperdiagnostic
equipmentandtoolstocarryoutthesetasks.
CONVERTIBLETOP

541-9
Fig.21.Constructionoftherolloverprotectioncassette.
Afterdeployment,thedetentpawlinarolloverprotection
cassettecanberetractedusingthespecialtoolinthetoolkit,
fittedtothescrewdriverhandle.Therearseatheadrestneeds
toberaisedforthisprocedure.
WARNING -
Ensurethattheareaaboveandadjacenttotheroll-
overbarsremainsclearandunobstructedatall
times.
CAUTION-
"Itisnotpossibletoclosetheconvertibletopwith
therolloverbarsextended.
"Ifahardtopismounted,besuretoinstallthepro-
tectiverolloverbarcoversprovidedwiththehard-
toptopreventdamaglngtherearwindowincase
ofdeployment.
0012744
ROLLOVERPROTECTIONSYSTEM

600ElectricalSystem-General
GENERAL............................600-1
VoltageandPolarity....................600-1
Ming,FusesandRelays................600-1
ElectricalSystemSafetyPrecautions.......600-1
ElectricalTestEquipment................600-2
WIRINGDIAGRAMS...................600-2
MingCodesandAbbreviations...........600-2
ELECTRICALTROUBLESHOOTING .....600-3
VoltageandVoltageDrops...............600-4
GENERAL

ElectricalSystemSafetyPrecautions
Abriefdescriptionoftheprincipalpartsoftheelectricalsys-
temispresentedhere.Alsocoveredherearebasicelectrical
systemtroubleshootingtips.
VoltageandPolarity
Thevehicleelectricalsystemisa12-voltdirectcurrent(DC)
negative-groundsystem.Avoltageregulatorcontrolssystem
voltageatapproximatelythe12-voltratingofthebattery.Al¡
circuitsaregroundedbydirectorindirectconnectiontothe
negative(-)terminalofthebattery.Anumberofgroundcon-
nectionsthroughoutthecarconnectthewiringharnessto
chassisground.Thesecircuitsarecompletedbythebattery
cableorgroundstrapbetweenthebodyandthebatterynega-
tive(-)terminal.
Wiring,FusesandRelays
Nearlyallpartsofthewiringharnessconnecttocompo-
nentsoftheelectricalsystemwithkeyed,push-onconnectors
thatlockintoplace.Notableexceptionsaretheheavybattery
cablesandthestarterwiring.Thewiringiscolor-codedforcir-
cuitidentification.
Withtheexceptionofthebatterychargingsystem,most
electricalpowerisroutedfromtheignitionswitchorthebat-
terythroughthemainfuse/relaypanel,locatedin¡heleftrear
comeroftheenginecompartment.Fusesarecolorcodedto
indicatecurrentcapacities.
Therelaysandcontrolunits/modulesaremountedinvari-
ousplacesthroughoutthevehicle.See610ElectricalCom-
ponentLocations.
ELECTRICALSYSTEM-GENERAL 600-1
Voltage,measuring.....................600-4
Voltagedrop,testing....................600-4
Continuity,checking.....................600-5
ShortCircuits..........................600-5
Shortcircuit,testingwithohmmete'r.........600-6
Shortcircuit,testingwithvoitmeter.........600-6
TABLES
a.TerminalandCircuitNumbers.................600-3
Pleasereadthefollowingwarningsandcautionsbeforedo-
inganyworkonyourelectricalsystem.
WARNING -
"Thecarscoveredbythismanualareequipped
withaSupplementalRestraintSystem(SRS)that
automaticallydeploysoneormoreairbags.Each
airbagunithousesanexplosivepowerfulcharge.
AnyworkinvolvingtheSRSsystemshouldonly
beperformedbyanauthorizedBMWdealer.
Makingrepairswithouttheproperknowledgeand
specialtestequipmentmaycauseseriousper-
sonalinjury.See721AirbagSystem(SRS).
"Theignitionsystemofthecaroperatesatlethal
voltages.Peoplewithpacemakersorweakhearts
shouldnotexposethemselvestotheignitionsys-
tem.Extracautionmustbetakenwhenworking
ontheignitionsystemorwhenservicingtheen-
ginewhileitisrunningorthekeyison.See120
IgnitionSystemforadditionalignitionsystem
warningsandcautions.
"Beforeoperatingthestarterwithoutstartingthe
engine(aswhenmakingacompressfontest),dis-
abletheignitionsystemasdescribedin120Igni-
tionSystem.
"Keephands,clothingandotherobjectsclearof
theelectricradiatorcoollngfanwhenworkingon
awarmengine.Thefanmaystartatanytíme,
evenwhentheignitionisswitchedoff.
GENERAL

600-2

ELECTRICALSYSTEM-GENERAL
CAUTION-
"Alwaysturnofftheengineanddisconnectthe
negative()cablefromthebatterybeforeremov-
inganyelectricalcomponents.Disconnectingthe
batterymayerasefaultcode(s)storedincontrol
modulememory.Checkforfaultcodesusingspe-
cialBMWdiagnosticequipment.
"Priortodisconnectingthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
"Connectanddisconnectignitionsystemwires,
multipleconnectors,andignitiontestequipment
leadsonlywhiletheignitionisoff.
"Donotdisconnectthebatterywithenginerun-
ning.
"Donotquick-chargethebattery(forbooststart-
ing)forlongerthanoneminute,anddonotex-
ceed16.5voltsatthebatterywiththeboosting
cablesattached.Waitatfeastoneminutebefore
boostingthebatteryasecondtime.
"Donotuseatestfampthathasanormalincan-
descentbulbtotestcircuitscontafningelectronic
components.Thehighelectricalconsumptionof
thesetestlampsmaydamagethecomponents.
"Donotuseananalogmeter.Useonfyadigital
multimeter.
"Manyofthesolid-statemodulesarestaticsensi-
tive.Staticdischargewillpermanentlydamage
them.Alwayshandlethemodulesusingproper
staticpreventionequipmentandtechniques.
"Toavoiddamagingharnessconnectorsorrelay
panelsockets,usejumperwireswithflat-blade
connectorsthatarethesamesizeastheconnec-
tororrelayterminals.
"Alwaysswitchadigitalmultimetertotheappropri-
atefunctionandrangebeforemakingtestcon-
nections.
"Donottrytostarttheengineofacarwhichhas
beenheatedabove176°F(80°C),(forexample,
inapaintdryingbooth).Allowittocooltonormal
temperature.
"Disconnectthebatterybeforedolnganyelectric
weldingonthecar.
"Donotwashtheenginewhileitisrunnfng,orany-
timetheignitionisswitchedon.
WIRINGDIAGRAMS
ElectricalTestEquipment
Manyoftheelectricaltestsdescribedinthismanualcallfor
measuringvoltage,currentorresistanceusingadigitalmulti-
meter(DMM).Digitalmetersarepreferredforprecisemea-
surementsandforelectronicsworkbecausetheyare
generallymoreaccuratethananalogmeters.Thenumerical
displayisalsolesslikelytobemisread,sincethereisnonee-
dlepositiontobemisinterpretedbyreadingatanangle.
AnLEDtestlightisasafe,inexpensivetoolthatcanbeused
toperformmanysimpleelectricalteststhatwouldotherwise
requireadigitalmultimeter.TheLEDindicateswhenvoltage
ispresentbetweenanytwotest-pointsinacircuit.
CAUTION-
"Choosetestequipmentcarefully.Useadigital
multimeterwithatleadt10megaohminputim-
pedance,oranLEDtestlight.Ananalogmeter
(swing-need1e)oratestlightwithanormalincan-
descentbulbmaydrawenoughcurrenttodam-
agesensitiveelectroniccomponents.
"Anohmmetermustnotbeusedtomeasureresis-
tanceonsolidstatecomponentssuchascontrol
unitsortimedelayrelays.
"Alwaysdisconnectthebatterybeforemakingre-
sístance(ohm)measurementsonthecircuit.
WIRINGDIAGRAMS
ThewiringdiagramsshowninElectricalWiringDiagrams
havebeenspeciallydesignedtoenablequickandefficientdi-
agnosisandtroubleshootingofelectricalmalfunctions.
WiringCodesandAbbreviations
Alotofinformationisincludedineachwiringdiagramifyou
knowhowtoreadthem.Wirecolorsinthediagramsareab-
breviated.Combinedcolorcodesindicateamulti-colored
wire.ForexamplethecodeBLU/REDindicatesaBluewire
withaRedstripe.
Manyelectricalcomponents,connectors,fuses,and
groundlocationsareidentifiedusingauniquenumber.Each
oftherenumberscorrespondstoaparticularpartinthecircuit
commonlyfoundinElectricalWiringDiagrams.

NOTE-
Sometimesthecolorofeninstalledwiremaybediffer-
entthantheoneonthewiringdiagram.Don'tbecon-
cerned.Justbesureloconfirmthatthewireconnects
lotheproperterminals.
Wirecolorcodes
"BLU...................................Blue
"BRN....:.............................Brown
"YEL..................................Yellow
"GRN..................................creen
"GRY...................................Gray
"ORG.................................Orange
"RED...................................Red
"BLK..................................Black
"VIO...................................Violet
"WHT...................:..............White
Tablea.TerminalandCircuitNumbers
Number

1Circuítdescription
1

jLowvoltageswitchedterminalofcoi¡
4

1Highvoltagecentertermina¡ofcoi¡
+x

Originatesatignitionswitch.Suppliespower
whentheignitionswitchisinthePARK,RUN,or
STARTposition
15

Originatesatignitionswitch.Suppliespower
whenignitionswitchisinRUNorSTART
position
30

Batterypositive(+)voltage.Suppliespower
wheneverbatteryisconnected.(Notdependent
onignitionswitchposition,unfused)
31

1Ground,batterynegative(-)terminal
50

Suppliespowerfrombatterytostartersolenoid
whenignitionswitchisinSTARTpositiononly
+54

Originatesatignitionswitch.Suppliespower
whenignitionswitchisintheRUNpositiononly
85

1Groundside(-)ofrelaycoil
86

1Power-inside(+)ofrelaycoil
87

1Relayactuatedcontact
D

Alternatorwarninglightandfieldenergizing
circuit
ELECTRICAL SYSTEM-GENERAL 600-3
Additionalabbreviationsshowninthewiringdiagramsare
givenbelow.
Abbreviations
"ABS...........................antilockbrakes
"A/C...........................airconditioning
"AST/ASC+T...................al¡seasontraction
"CONV.............................convertible
"DME....................digitalmotorelectronics
"ECM

..................electroniccontrolmodule
"EWS/EWSII...........codeddriveawayprotection
"SRS.........supplementalrestraintsystem-airbag
"TCM................transmissioncontrolmodule
"ZKE(94-98models)........centralbodyelectronics
"ZVM(92-93models)...............centrallocking
ELECTRICAL TROUBLESHOOTING
Mostterminalsareidentifiedbynumbersonthecompo-
nentsandharnessconnectors.Theterminalnumbersforma-

Fourthingsarerequiredforcurrenttoflowinanyelectrical
jorelectricalconnectionsareshowninthediagrams.Though

circuit:avoltagesource,wiresorconnectionstotransportthe
manyterminalnumbersappearonlyonce,severa¡othernum-

voltage,aloadordevicethatusestheelectricity,andacon-
bersappearinnumerousplacesthroughouttheelectricalsys-

nectiontoground.Mostproblemscanbefoundusingadigital
temandidentifycertaintypesofcircuits.Someofthemost

multimeter(volt/ohm/ampmeter)tocheckforvoltagesupply,
commoncircuitnumbersarelistedbelowinTablea.

forbreaksinthewiring(infiniteresistance/nocontinuity),orfor
apathtogroundthatcompletesthecircuit.
Electriccurrentislogicalinitsflow,alwaysmovingfromthe
voltagesourcetowardground.Electricalfaultscanusuallybe
locatedthroughaprocessofelimination.Whentroubleshoot-
ingacomplexcircuit,separatethecircuitintosmallerparts.
Thegeneraltestsoutlinedbelowmaybehelpfulinfinding
electricalproblems.Theinformationismosthelpfulwhen
usedwiththewiringdiagrams.
Besuretoanalyzetheproblem.Usethewiringdiagramsto
determinethemostlikelycause.Getanunderstandingofhow
thecircuitworksbyfollowingthecircuitfromgroundbackto
thepowersource.
Whenmakingtestconnectionsatconnectorsandcompo-
nents,usecaretoavoidspreadingordamagingtheconnec-
torsorterminals.Sometestsmayrequirejumperwiresto
bypasscomponentsorconnectionsinthewiringharness.
Whenconnectingjumperwires,usebladeconnectorsatthe
wireendsthatmatchthesizeoftheterminalbeingtested.The
smallinterna¡contactsareeasilyspreadapart,andthiscan
causeintermittentorfaultyconnectionsthatcanleadtomore
problems.
ELECTRICAL TROUBLESHOOTING

600-4

ELECTRICALSYSTEM-GENERAL
VoltageandVoltageDrops
Thewires,connectors,andswitchesthatcarrycurrentare
designedwithverylowresistancesothatcurrentflowswitha
minimumlossofvoltage.Avoltagedropiscausedbyhigher
thannormalresistanceinacircuit.Thisadditionalresistance
actuallydecreasesorstopstheflowofcurrent.Avoltagedrop
canbenoticedbyproblemsrangingfromdimheadlightsto
sluggishwipers.Somecommonsourcesofvoltagedropsare
corrodedordirtyswitches,dirtyorcorrodedconnectionsor
contacts,andlooseorcorrodedgroundwiresandgroundcon-
nections.
Avoltagedroptestisagoodtesttomakeifcurrentisflowing
throughthecircuit,butthecircuitisnotoperatingcorrectly.A
voltagedroptestwillhelptopinpointacorrodedgroundstrap
orafaultyswitch.Normally,thereshouldbelessthan1volt
dropacrossmostwiresorclosedswitches.Avoltagedrop
acrossaconnectororshortcableshouldnotexceed0.5volts.
Voltage,measuring
1.Connectdigitalmultimeternegativeleadtoareliable
groundpointoncar.
NOTE-
Thenegative(-)batteryterminalisalwaysagood
groundpoint.
2.Connectdigitalmultimeterpositiveleadtopointincir-
cuityouwishtomeasure.SeeFig.1.Ifareadingisob-
tained,currentisflowingthroughcircuit.
NOTE-
Thevoltagereadingshouldnotdeviatemorethan1volt
fromthevoltageatthebattery.Ifthevoltagedropis
morethanthis,checkforacorrodedconnectororcose
groundwire.
ELECTRICAL TROLIBLESHOOTING
fromBattery
Fig.1.

Digitalmultimeterbeingusedtotestvoltage.
Novoltager_l
-1
Load
L J
Switch
NOTE-
Themaximumvoltagedropinanautomotivecircuit,as
recommendedbytheSocietyofAutomotiveEngineers
(SAE),isasfollows:0voltsforsmallvireconnections;
0.1Voltsforhighcurrentconnections;0.2voltsforhigh
currentcables;and0.3voltsforswitchorsolenoidcon-
tacts.Onlongerwiresorcables,thedropmaybeslight-
lyhigher.Inanycase,avoltagedropofmorethan1.0
voltusuallyindicatesaproblem.
0013238
NOTE-
"Avoltagedroptestisgenerallymoreaccuratethana

Voltagedrop,testing
simpleresistancecheckbecausetheresistancesin-
volvedareoftentoosmalltomeasurewithmostohm-

Voltagedropcanonlybecheckedwhencurrentisrunning
meters.Forexample,aresistanceassmallas0.02

throughthecircuit,suchasbyoperatingthestartermotoror
ohmswouldresultsina3voltdropinatypical150

turningontheheadlights.Adigitalmultimetershouldbeused
ampstartercircuit.(150ampsx0.02ohms=3volts).

loensureaccuratereadings.
"Keepinmindthatvoltagewiththekeyonandvoltage
withtheenginerunningarenotthesame.Withtheig-

1.Connectdigitalmultimeterpositiveleadtopositive(+)
nitiononandtheengineoff(batteryvoltage),voltage

batteryterminalorapositivepowersupplycloselobat
shouldbeapproximately12.6volts.Withtheengine

terysource.
running(chargingvoltage),voltageshouldbeapprox-
imately14.0volts.Measurevoltageatthebatterywith

2.Connectdigitalmultimeternegativeleadtootherendof
theignitiononandthenwiththeenginerunningtoget

cableorswitchbeingtested.SeeFig.2.
exactmeasurements.
3.Withpoweronandcircuitworking,metershowsvolt-
agedrop(differencebetweentwopoints).Thisvalue
shouldnotexceed1volt.

Continuity,checking
ShortCircuits
fromBattery
CAUTION-
Useonlyahighqualitydigitalohmmeterhaving
highinputimpedancewhencheckingelectronic
componente.Theinternalpowersourceusedin
mostanalog(swing-need1e)meterscandamage
solidstatecomponents.
0013239
Fig.2.

Digitalmultimeterbeingusedtocheckforvoltagedrop
acrossaswitch.
Thecontinuitytestcanbeusedtocheckacircuitorswitch.
Becausemostautomotivecircuitsaredesignedtohavelittle
ornoresistance,acircuitorpartofacircuitcanbeeasily
checkedforfaultsusinganohmmeter.Anopencircuitoracir-
cuitwithhighresistancewillnotallowcurrenttoflow.Acírcuit
withlittleornoresistanceallowscurrenttofloweasily.
Whencheckingcontinuity,theignitionshouldbeoff.Oncir-
cuitsthatarepoweredatalltimes,thebatteryshouldbedis-
connected.Usingtheappropriatewiringdiagram,acircuitcan
beeasilytestedforfaultyconnections,wires,switches,relays,
andenginesensorsbycheckingforcontinuity.Foracontinu-
itycheckonabrakelightswitch,seeFig.3..
Ashortcircuitisexactlywhatthenarreimplies.Thecircuit
takesashorterpaththanitwasdesignedtotake.Themost
commonshortthatcausesproblemsisashorttoground
wheretheinsulationonapositive(+)wirewearsawayandthe
metalwireisexposed.Whenthewirerubsagainstametal
partofthecarorothergroundsource,thecircuitisshortedto
ground.Iftheexposedwireislive(positivebatteryvoltage),a
Pusewillblowandthecircuitmaypossiblybedamaged.
ELECTRICALSYSTEM-GENERAL 600-5
Brakelightswitch
Brakepedalinrestposition
Q
Brakepedaldepressed
Brakelightswitch
Fig.3.

Brakelightswitchbeingtestedforcontinuity.Withbrakeped-
alinrestposition(switchopen)thereisnocontinuity(infinite
ohms).Withpedaldepressed(switchclosed)thereiscontinu-
ity(zeroohms).
Shortstogroundcanbelocatedwithadigitalmultimeter.
Shortcircuitsareoftendifficulttolocateandmayvaryinna-
ture.Shortcircuitscanbefoundusingalogicalapproach
basedonthecurrentpath.
CAUTION-
"Oncircuitsprotectedwithhighratingfuses(25
ampandgreater),thewiresorcircuitcompo-
nentsmaybedamagedbeforethefuseblows.
Alwayscheckfordamagebeforereplacingfuses
ofthisrating.
"Whenreplacingblownfuses,useonlyfuseshav-
ingthecorrectrating.Alwaysconfirmthecorrect
fuseratingprintedonthefuselrelaypanelcover
DC
ELECTRICAL TROUBLESHOOTING

00-6

ELECTRICALSYSTEM-GENERAL
Shortcircuit,testingwithohmmeter

Shortcircuit,testingwithvoltmeter
1.Removeblownfusefromcircuitanddisconnectcables

1.Removeblownfusefromcircuit.
frombattery.
2.Disconnectharnessconnectorfromcircuifsloador
2.Disconnectharnessconnectorfromcircuit'sloador

consumer.
consumer.
3.Usinganohmmeter,connectonetestleadtoloadside
offuseterminal(terminalleadingtocircuit)andtheoth-
ertestleadtoground.SeeFig.4.
Loaddisconnected
fromBattery
LO
nI

~

Shotrouit
vu.u
toearthth
Switch
Load
0013241
Fig.4.

Digitalmultimeterbeingusedasanohmmetertofindshort
circuit.
4.lfthereiscontinuitytoground,thereisashortto
ground.
ELECTRICALTROUBLESHOOTING
NOTE-
Mostfusespowermorethanoneconsumer.Besureaff
consumersaredisconnectedwhencheckingforashort
circuit.
3.Usingavoltmeter,connecttestleadsacrossfusetermi-
nals.SeeFig.5.Makesurepowerispresentíncircuit.
lfnecessaryturnkeyon.
~2.U
fromBattery
Loaddisconnected
Short-circuit
toearth
I

Fusebox
0013240
5.Ifthereisnocontinuity,workfromwireharnesshearest

Fig.5.

Digitalmultimeterbeingusedasavoltmetertofindshortcir
tofuse/relaypanelandmoveorwigglewireswhileob-

cuit.
servingmeter.Continuetomovedownharnessuntil
meterdisplaysareading.Thisisthelocationofshortto

4.lfvoltageispresentatvoltmeter,thereisashortto
ground.

ground.
Visuallyinspectthewireharnessatthispointforanyfaults.

5.lfvoltageisnotpresent,workfromwireharnessnear-
Ifnofaultsarevisible,carefullysliceopentheharnesscover

esttofuse/relaypanelandmoveorwigglewireswhile
orthewireinsulationforfurtherinspection.Repairanyfaults

observingmeter.Continuetomovedownharnessuntil
found.

meterdisplaysareading.Thisisthelocationofshortto
ground.
6.Visuallyinspectwireharnessatthispointforanyfaults.
lfnofaultsarevisible,carefullysliceopenharnesscov-
erorwireinsulationforfurtherinspection.Repairany
faultsfound.

610ElectricalComponentLocations
GENERAL............................610-1

FOSEPOSITIONTABLES.............610-19
FUSEANDRELAYPOSITIONS.........610-1
FusePositions........................610-1
RelayPositions........................610-2
AuxiliaryRelayPanel...................610-2
SplicePanel,Left......................610-2
SplicePanel,Right.....................610-3
COMPONENT LOCATIONS.............610-3
ComponentLocationTable...............610-9
GENERAL

FUSEANDRELAYPOSITIONS
Thisrepairgroupcoversfuse,relay,andcontrolmodulelo-

Thefrontpowerdistributionbox,anauxiliaryrelaypanel,
cationinformation.Electricalequipmentandaccessoriesin-

andtwoauxiliarysplicepanelscontainmostofthefusesand
stalledvariesdependingonmodelandmodelyear.Always

relaysinE36vehicles.Refertothecomponentlocationlater
confirmthattheproperelectricalcomponenthasbeenidenti-

inthissection,aswellasthetablesattheendofthisrepair
fiedbyusingtheelectricalwiringdiagrams.

groupforelectricalcomponentlocation.
WARNING -
Oncarsequippedwithairbags,specialprecautions
applytoanyelectricalsystemtestingorrepair.Air-
bagunitsareexplosivedevicesandmustbehan-
dledwithextremecare.Beforestartinganyworkon
anairbagequippedcar,refertothewamingsand
cautionsin721AirbagSystem(SRS).
CAUTION-
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
"Relayandfusepositionsaresubjecttochange
andmayvaryfromcartocar.Ifquestionsarise,
anauthorizedBMWdealeristhebestsourcefor
themostaccurateandup-to-dateinformation.
"Agoodwaytoverifyarelaypositionistocom-
parethewiringcolorsattherelaysockettothe
colorsindicatedonthewiringdiagramslocatedat
therearofthismanual.
"Alwaysswitchtheignitionoffanddisconnectthe
negative(-)batterycablebeforeremovingany
electricalcomponents.
"Connectanddisconnectignitionsystemwires,
multipleconnectors,andignitiontestequipment
leadsonlywhiletheignitionisswitchedoff.
"Onlyuseadigitalmultimeterforelectricaltests.
ELECTRICALCOMPONENTLOCATIONS

610-1
TABLES
a.E36ComponentLocations..................610-10
b.1992E36FusePositions...................610-20
c.1993E36FusePositions...................610-22
d.1994E36FusePositions

...................610-24
e.1995E36FusePositions...................610-26
f.

1996E36FusePositions

...................610-28
g.1997-1998E36FusePositions...............610-30
FusePositions
CAUTION-
"Replacefuseswiththoseofthesamerating.In-
stallingafusewithhigherratingcanleadtocir-
cuitfailureandmayalsostartafire.
"Relay/fusepositionsvarybymodelandequip-
ment.
Fusesnumber1through46aremountedinthefrontpower
distributionbox.SeeFig.1.
Fuses31-46
~Illlllllllll
°-Ilmmlmomlmoi
Fuses1-20
(a1:1E El
~
~O!7
L~~n
4~ i
Fuses21-30
Fig.1.

Fusepositions1-46infrontpowerdistributionbox.
0013034
FUSEANDRELAYPOSITIONS

610-2

ELECTRICALCOMPONENT LOCATIONS
Fusesnumber47and50aremountedontheleftsidesplice
panel.ReferloFig.5.
Fuse48ismountedontheauxiliaryrelaypanel.Referto
Fig.3.
Fuse49ismountedintherightsideoftheluggagecompart-
mentbehindthetrimcover.
RelayPositions
Mountedintheleft-handrearcomeroftheenginecompart-
ment,thepowerdistributionboxcontains46(usesand15re-
laypositions.SeeFig.2.
Fuses31-46
-Era&QTMM~
Fig.2.

E36frontpowerdistributionbox.
FUSEANDRELAYPOSITIONS
Fuses1-20
13
EL1
5
]
mmmmmmmmmm
Fuses21-30--

0013034)
1.Fuelpumprelay

9.

Heater/A/CBlowerrelay
2.System(main)relay

10.

Reardefoggerrelay
3.Oxygensensorheaterre-

11.ABSsystemrelay
lay

12.ABSpumprelay
4.

Hornrelay

13.

Highspeedradiatorfanre-
5.

Taillight/foglightrelay

]ay
6.Lowbeamrelay

14.A/Ccompressorrelay
7.

Highbeamrelay

15.

Lowspeedradiatorfanre-
8.

Emergencyflasherrelay

¡ay
AuxiliaryRelayPanel
Theauxiliaryrelaypanelcontainsfiverelaypositions.Inlat-
ermodeisanadditionalfuseholder(Fuse48)andtheEWSII
(anti-theft)transmitter/receivermodulearelocatedonthis
panel.SeeFig.3.
Thepanelislocatednexttothesteeringcolumnunderthe
driver'ssidedashboard.Toaccessthispanel,removethe
pwerdashpanelondriver'sside.See513InteriorTrim.
Thenremovethedriver'ssidekneebolster.Lowertherelay
panelbygentlyreleasingtheplasticretainers.SeeFig.4.
Duringinstallation,besuretheretainertabsareengagedin
therelaypanel.
SplicePanel,Left
3
¡ni
Fig.3.Auxiliaryrelaypanelunderleftsideofdash.
Fuse48)
0013035
1.

Comfortrelay(whereap-

4.

Notused
plicable)

5.

Notused
2.Crashcontrolmodule

6.

EWSIItransmitter/receiv-
3.

Parkventilationrelay

ermodule(fromJan.1995)
0013164
Fig.4.

Auxiliaryrelaypanelunderleftsideofdashboard(arrow).
Theleftsplicepanelcontainsfourrelaypositionsandanad-
ditionalfuseholder(Fuses47and50).
Toaccesstheleftsideelectricalsplicepanel,removethe
leftsidedashpanelandkneebolster,asdescribedearlier.
Thepanelislocatedaboveandlotheleftoftheclutchpedal.
SeeFig.5.

Fig.5.

Splicepanelunderleftsideofdash.
SplicePanel,Right
ir1!1,111lí~lll
.
'
ELECTRICALCOMPONENTLOCATIONS

610-3
0013091
1.

Unloaderrelay

4.

Starterimmobilization
2.

Wiperrelay

relay(1994only)
3.Wipermotorrelay

F47&F50Fuses47and50
Therightsplicepanelcontainsthreerelaypositions.Itislo-
catedundertherightsideofthedashboard.
Toaccessthepanel,removetheglovecompartmentasde-
scribedin513InteriorTrim.SeeFig.6.
Fig.6.

Splicepanelunderrightsideofdash(arrow).Glovecompart-
mentandrightsideventsshownremoved.
COMPONENT LOCATIONS
Onthefollowingpagesareillustrationsandphotosshowing
thelocationofmajorelectricalcomponentsinE36vehicles.
NOTE-
-Everycomponentisnotinstalledineverycar.
"Duetochangesinproduction,componentlocations
mayvaryfromwhatisillustrated.ConsultyourBMW
dealerforthelatestinformation.
"Thegear-position/neutralsafetyswitchísalsosome-
timesreferredtoastheautomatictransmissionrange
switch.
"TheEWS11systemisalsosometimesreferredtoas
theDriveawayProtectionSystemortheelectronicim-
mobilizationsystem.
"All-SeasonTraction(AST)isalsosometimesreferred
toasASCorASC+T.
COMPONENT LOCATIONS

610-4

ELECTRICAL COMPONENT LOCATIONS
--JL
Windshield
washertank
&pump
Fig.7.

E36enginecompartmentlayout.M42enginecompartment
shown.
-,x
0013204
Fig.8.Controlmodulesunderrightsideofdash.Glovecompart-
menthasbeenremoved.Formoduleidentification,seeFig.
9.
COMPONENT LOCATIONS
RSP'I

4
ABS

Mainengine

Power
hydraulic harness distribution
controlunit

connectorI

box
oe
1.SRS(Airbag)controlmodule(through1993)
2.ABS/ASC+Tcontrolmodule(asapplicable)
3.Centrallockingmodule(through1993)
4.Anti-theftalarmmoduleor
ZKEIVcontrolmodule(from1994)
5.Rearwindowblowerrelay(convertiblemodels)
6.Hornrelay
7.Wiper/washermodule
8.Rearpowerwindowrelay(four-doormodels)
9.Luggagecompartmentlidlockrelay(convertible)
10.Cruisecontrolmodule
EWSIIcontrolmodule(fromJan.1995)
RSP:Rightsplicepanel
0013215
Fig.9.

Identificationofcontrolmodulesunderrightsideofdash.
Moduleutilízationvariesbyyearandmodel

1.Heatervalves
2.ABSpedaltravelsensor
3.ABSpump
Fig.10.Leftrearofenginecompartment.
4.Mainengineharnesscon-
nector
5.Powerdistributionbox
ELECTRICALCOMPONENTLOCATIONS610-5
0013202
0013226
Fig.11.M42engineidiespeedcontrolvalve(arrow)beneathintake
manifold
0012421
Fig.12.M44engineintakeairtemperature(¡Al)sensorinairfilter
housing
Fig.13.M50/S50USengineintakeairtemperature(IAT)sensor(1)
andthrottlepositionsensor(2).
301180
0012724
Fig.14.M52/S52USengineintakeairtemperature(IAT)sensorinbot-
tomofintakemanifold(throttlehousingshownremoved).
COMPONENT LOCATIONS

610-6

ELECTRICALCOMPONENTLOCATIONS
Fig.15.M44engineharnessconnectorsatairintake
0011644
Fig.16.A/Crechargingports(arrows),rightrearofenginecompart-
ment
COMPONENT LOCATIONS
0012427
811004
Fig.17.Six-cylinderignitioncoilintopofcylinderhead(M52engine).
Fig.18.Coolingfandualswitchinradiator(arrow).
0013203

Fig.19.M44enginecoolanttemperature(ECT)sensor(arrow).

Fig.22.Headlightgroundatleftfrontofenginecompartment(arrow).
0012704
Fig.20.M52enginecoolanttemperature(ECT)sensor(A)islocated
beneathtopenginecover(B)andcrankcaseventhose(C).
uu12700
Fig.21.M52throttlepositionsensor(A),idlespeedcontrolvalve(B),
andsecondaryairpump(C).
ELECTRICALCOMPONENTLOCATIONS

610-7
00119s4

0013131
uvijijo
Fig.23.Maingroundatrightstruttower(A).Bisnegativejumpercon-
nection.
COMPONENT LOCATIONS

610-$

ELECTRICALCOMPONENTLOCATIONS
Fig.24.Brakepedalswitches.
Fig.25.Driversideairbagconnector(arrow).
COMPONENT LOCATIONS
0011751
Fig.26.Passengersideairbagconnector(arrow)behindglovecom-
partment.
Fig.27.Antennadiversitymodule(arrow)inleftC-pillar.
Fig.28.Rightsideoffueltankunderrearseatcushion.
0013108
0013010
0013142

Fig.29.Transmissiongear-position/neutralsafetyswitchundercenter
console.Squeezeconnectortabs(arrows)todisengagehar-
nessconnector
ELECTRICALCOMPONENTLOCATIONS

610-9
6263
Fig.30.Back-uplightswitch(arrow)ontransmission.(Switchmaybe
foundonrightorleftsideoftransmission,dependingonap-
plication.)
Fig.31.ASSwheelspeedsensor(arrow)infrontsteeringarm.
ComponentLocationTable
Tableaisacross-referencedlistingofelectricalcompo-
nentsinE36vehiclesbeginningonpage10.Inadditiontolo-
cationdescriptions,wherepossiblethereisareferencetoa
figureshowingthecomponent.
NOTE-
-Everycomponentisnotinstalledineverycar.
"Duetochangesinproduction,componentlocations
mayvary.ConsultyourBMWdealerforthelatestin-
formation.
"Thefigurenumbersareallwithinthissection.Many
otherelectricalcomponentsareillustratedthroughout
thisbook.Consultthemainindex
"Thegear-position/neutralsafetyswitchisaleosome-
timesreferredtoastheautomatictransmissionrange
switch.
"TheEWS11systemisalsosometimesreferredtoas
theDriveawayProtectionSystemortheelectronicim-
mobilizationsystem.
"All-SeasonTraction(AST)isalsosometímesreferred
toasASCorASC+T.
0012117
COMPONENT LOCATIONS

610-10

ELECTRICALCOMPONENTLOCATIONS
Component

ModelYear

Location

Referto
ABSHydraulicControlUnit

1992-1998

Leftrearenginecompartmentundermastercylinder

Fig.7.
Fig.10.
ABSHydraulicControlUnitRelay

1992-1998

Powerdistributionbox

Fig.2.
ABSPedalTravelSensor

1992-1998

Onbrakeboosterbesidemastercylinder

Fig.10.
ABSRelay

1992-1998

Powerdistributionbox

Fig.2.
ABS/AST(Traction)ControlModule

1992-1998

Behindglovecompartment

Fig.8.
Fig.9.
ABSSpeedSensor,LeftFront

1992-1998

Leftfrontsteeringarm

Fig.31.
Wheel
ABSSpeedSensor,LeftRear

1992-1998

Leftreartrailingarm
Wheel
ABSSpeedSensor,RightFront

11992-1998

Rightfrontsteeringarm
Wheel
ABSSpeedSensor,RightRear

1992-1998

ILeftreartrailingarm
Wheel
1
A/CCompressor

11992-1998

(Rightlowerfrontofengine
A/CCompressorControlRelay

11992-1998
1992-1998
1992-1998
A/CControlModule
A/CEvaporatorTemperature
Sensor
A/CPressureSwitch

1992-1998

Rightfrontofenginecompartment
A/CProgramSwitch

1992-1998

Centerofdashbelowradio
A/CRechargingPorts

1992-1998

Rightrearenginecompartment

Fig.16.
AirFlowSensor

1992-1998

Betweenthrottlehousing&filterhousing

Fig.7.
AirbagContactSlipRing

1992-1998

Rearofsteeringwheel
Airbag,Driver

1992-1998

Incenterofsteeringwheel

Fig.25.
Airbag,Passenger

1994-1998

Rightfrontofdashaboveglovecompartment

Fig.26.
Airbag,Side-Impact

1997-1998

Behindright/leftfrontdoorpanel
AirbagControlModule(Basic)

1992-1993

Behindglovecompartment

Fig.8.
Fig.9.
AirbagControlModule(ZAE)

1994-1998

Oncentertunnelunderrearseatcushion
AirbagCrashSensor,Airbag

1992-1993

OnrighUleftfrontstruttower
AirbagCrashSensor,Right/Left

1997-1998

Right/leftdoorsi¡¡behindfrontseat
SideImpact
Alternator(Generator)

1992-1998

Leftlowerfrontofengine
AmplifierHi-fi

1992-1998

Leftfrontsideofluggagecompartment
AntennaAmplifierAM/FM

1992-1998

InupperleftsideC-pillar

Fig.27.
COMPONENT LOCATIONS
Table a.E36 Component Locations
Powerdistributionbox

Fig.2.
Behindcenterconsole
Leftsideofheaterbox
Continued

Table a.E36 Component Locations
Component

ModelYear

Location

Referto
Anti-theftControlModule

1992-1998

Behindglovecompartment

Fig.8.
Fig.9.
Anti-theftHorn

11992-1998

1Rightrearenginecompartment
Anti-slip(Traction)ControlModule

1994-1998

Powerdistributionbox

Fig.8.
(AST/ASC+T)

Fig.9.
Anti-slip(Traction)ControlSwitch

1994-1998

Incenterconsole
AutomaticClimate(A/C)Control

1992-1998

Behindcenterconsole
Module
AutomaticTransmissionRange

1992-1998

~Nexttogearshiftleverincenterconsole

Fig.29.
Switch(GearPosition/Neutral
SafetySwitch)
AuxiliaryCoolingFanDualSwitch

1992-1998

Rightsideradiator

1

Fig.18.
AuxiliaryCoolingFanMotor

1992-1998

Behindfrontgrill
AuxiliaryFuseBox(LeftSplice

1992-1998

IBehindleftfrontfootwellkick-panel
Panel)
AuxiliaryRelayPanel

11992-1998

1Leftsideofdashundersteeringcolumn
AuxiliaryFuseBoxInTrunk

1

1997-1998

1Rightsideoftrunkbehindtrimpanel
AuADSry
ThrottlePositionMotor

11994-1998

Frontofenginecompartment
B+JumpStartJunctionPoint

1992-1998

Rightrearofenginecompartment

Fig.7.
Back-UpLightSwitch(Manual)

1992-1998

Rightorleftsidetopoftransmission

Fig.30.
BodyElectronicsControlModule

1994-1998

Behindglovecompartment

Fig.8.
(ZKEIV)

Fig.9.
BrakeFluidLevelSensor

1992-1998

Topofbrakefluidreservoiratmastercylinder

Fig.15.
BrakeLightSwitch

11992-1998

1Onbrakepedalsupportbracket
BrakePadSensor,LeftFront

11992-1998

1Leftfrontbrakecaliper
BrakePadSensor,RightRear

1992-1998

Rightrearbrakecaliper
CamshaftActuator(VANOS)

1993-1998

Frontofcylinderhead
CamshaftPositionSensor(Cylinder

1992-1998

Frontofengine
Identification)
CarbonCanisterValve(TLEV)

11997-1998

1Insparewheelwellintrunk
ELECTRICALCOMPONENTLOCATIONS

610-11
Fig.5.
Fig.4.
Fig.24.
Fig.7.
CentralLockingModule(ZVM)

11992-1993

1Behindglovecompartment

I

Fig.8.
Fig.9.
CheckControlModule(ifapplicable)11992-1998

1Belowleftsideofdash
ChildProtectionWindowControl

1992-1998

Centerconsole
(console)
ChimeModule

1992-1998

Belowleftsideofdashinleftdashtrimpanel
Clock(Multi-Function)

1993-1998

Centerconsole
ClutchPedalSwitch

1992-1998

Onclutchpedalsupportbracket
Continued
COMPONENT LOCATIONS

610-12

ELECTRICALCOMPONENTLOCATIONS
Tablea.E36ComponentLocations
Component

ModelYear

Location

Referto
Combination(Stalk)Switch

1993-1998

Leftsidesteeringcolumn(turnsignals/high-lowbeanswitch)
ConvertibleTopActuatingSwitch

1994-1998

Centerconsole
ConvertibleTopControlModule

1994-1998

InlowerleftC-pillarbehindtrimpanel
ConvertibleTopEndPositionSwitch

1994-1998

Inconvertibletoplinkage
ConvertibleTopMotor

1994-1998

Inleftsideoftrunkbehindtrimpanel
ConvertibleTopPosition

1994-1998

Inconvertibletoplinkage
Microswitch
ConvertibleTopStorageLidLock

1994-1998

Inconvertibletopcompartmentleftside
Motor
ConvertibleTopStorageLid

1994-1998

Inrightsideconvertibletopstoragelidlatch
Microswitch
ConvertibleTopStorageLidMotor

1994-1998

Inleftsideoftrunkbehindtrimpanel
CoolantLeve¡Sensor(ifapplicable)

1992-1998

Boltedonradiator,leftside
CoolantTemperatureSensor

1992-1998

Leftfrontofengine/cylinderhead

Fig.19.
Fig.20.
CoolingFanDualSwitch

1992-1998

Rightsideradiator

Fig.18.
CoolingFanMotor

1992-1998

Behindfrontgrill
CrankshaftPosition/RPMSensor

1992-1995

Atfrontcrankshaftpulley
CrankshaftPosition/RPMSensor

1996-1998

Leftrearofcrankcase
CrashSensor,Airbag

1992-1993

Onright/leftfrontstruttower
CrashControlModule

1992

Auxiliaryrelaypanel
CrashControlModule

1993-1998

Driver'ssidefootwell
CrashSensor,Right/LeftSide

1997-1998

Right/leftdoorsillbehindfrontseat
ImpactAirbag
CruiseControlActuator

1992-1998

Leftfrontofenginecompartment

Fig.7.
CruiseControlModule

1992-1998

Behindglovecompartment

Fig.8.
Fig.9.
DataLinkConnector

1992-1998

Rightsideofengine

Fig.7.
DigitalMotorElectronics(DME)

1992-1998

Rightrearenginecompartment,behindbulkheadpanel

Fig.7.
ControlModule
DoorLockHeater

1993-1994

Leftfrontdoorhandle
DoorHandleSwitch

1994-1998

leftfrontdoor
Drive-awayProtection(EWSII)

1/1995-1998

Behindglovecompartment

Fig.8.
Module

Fig.9.
DualCoolantTemperatureSensor

1997-1998

Belowintakemanifold

Fig.19.
COMPONENT LOCATIONS
Fig.20.
ElectronicImmobilizerControl

(1/1995-1998~Behindglovecompartment

Fig.8.
Module(EWSII)

Fig.9.
Continued

Tablea.E36Component Locations
Component

ModelYear

Location

Referto
EngineCompartmentLightSwitch

1993-1996

Overrightheadlightassembly

Fig.7.
EngineControlModule(ECM)

1992-1998

Rightrearenginecompartment,behindbulkheadpanel

Fig.7.
EngineControlModule(System)

1992-1998

IPowerdistributionbox

Fig.2.
Relay
EngineCoolantLeve¡Sensor

11992-1998

1Leftfrontofenginecompartment,radiatorcoolantreservoir
EngineCoolantTemperature

1992-1998

ILeftfrontofengineunderintakemanifold

I

Fig.19.
Sensor

Fig.20.
EvaporativeEmissionValve

1992-1998

LeftsidestrutPowerarea
EvaporatorTemperatureSensor

1992-1998

Leftsideofheaterbox
EWSIIControlModule

1/1995-1998

Behindglovecompartment

Fig.8.
Fig.9.
EWSIIRingAntenna

11/1995-19981Atignitioncylinder
EWSIITransmitterModule

1/1995-1998

Rightsideofsteeringcolumninauxiliaryrelaypanel

Fig.3.
ExhaustGasFlapValve

1996-1998

Leftrearmufflerarea
FlasherRelay

1992-1998

Powerdistributionbox

Fig.2.
FoglightRelay

1

1992-1998

1Powerdistributionbox

1

Fig.2.
FreshAirFlapActuator

1

1992

1Rightsideofheaterbox
FreshAirFlapActuator

11993-1995

1Belowrightsideheaterbox
FreshAirFlapActuator

11996-1998

Belowleftsideheaterbox
FuelInjectors

1992-1998

Topleftsideofengine
FuelLeve¡Sensor,Left

11992-1998

/Underleftsideofrearseatinfueltank
FuelLeve¡Sensor,Right

1

1992-1998

1Underrightsideofrearseatinfueltank

1

Fig.28.
FuelPump

1

1992-1998

1

Underrightsideofrearseatinfueltank

1

Fig.28.
FuelPumpRelay

1

1992-1998

1Powerdistributionbox

1

Fig.2.
FuelPump/StartIdentificationRelay

1994-1996

Powerdistributionbox
FuelTankPressureSensor

11997-1998

1Rightrearwheelwellbehindtrimliner
ELECTRICALCOMPONENTLOCATIONS

610-13
FuseandRelay

x(Power

11992-1998

ILeftsideofenginecompartment

I

Fig.2.
DistributionBox

Fig.7
Fig.10.
GasFillerLockMotor

1992-1998

Rightsideofluggagecompartment
GearPosition/NeutralSafetySwitch

1992-1998

Nexttogearshiftleverincenterconsole

Fig.29.
(AutomaticTransmissionRange
Switch)
GloveCompartmentLockMotor

1994-1998

Behindglovecompartment
Grounds
G100

1995-1998

Frontofleftfrontfender(headlights)

Fig.22.
G101

1992-1998

Frontofrightfrontfender
Continued
COMPONENT LOCATIONS

610-14

ELECTRICALCOMPONENTLOCATIONS
Component

ModelYear

Location

Referto
G102

1992-1998

Leftfrontstruttower
G103

1992-1998

Rightfrontstruttower
G110

1992-1998

Leftfrontofengine
G111

1992-1998

Nearbattery
G117

1992-1998

Rightrearofengine
G119

1992-1998

Rightfrontofengine
G123

1992-1998

Rightsideofsafetywall
G200

1992-1998

Leftkickpanel
G201

1992-1998

RightsideofI/P
G202

1992-1998

LeftsideofI/P
G203

1992-1998

Rightkickpanel
G230

1992-1998

Rightkickpanel
G301

1992-1998

Belowrightfrontseat
G302

1992-1998

Belowcenterconsole
G303

1992-1998

Belowrightrearseat
G310

1992-1998

Behindrightrearseat
G312

1992-1998

Behindleftrearseat
G313

1992-1998

Rightsideofrearshelf
G314

1992-1998

Leftsideofrearshelf
G400

1992-1998

Leftfrontsideoftrunk
G404

1992-1998

Leftrearsideoftrunk
CamshaftPositionSensor

1992-1998

Frontofengine

Fig.7.
HardTop,Connector1

1994-1998

Inconvertibletopcompartmentleftside
HardTop,ConnectorII

1994-1998

Inconvertibletopcompartmentleftside
HazardFlasherRelay

1992-1998

Powerdistributionbox

Fig.2.
HeadlightHighBeamRelay

1998

Lefthandsideofdashbehindinstrumentcluster
HeadlightHighBeamRelay

1992-1997

Powerdistributionbox
HeadlightLowBeamRelay

1992-1998

Powerdistributionbox
HeatExchangerTemperature

1993-1998

Centerconsole
Sensors(leftandright)
HeaterBlowerMotor

1992-1998

Behindfreshaircowl
HeaterBlowerMotorRelay

1992-1998

Powerdistributionbox

Fig.2.
HeatRearRecirculationFlap

1997-1998

Rightsideofheaterbox
Actuator
COMPONENTLOCATIONS
Tablea.E36ComponentLocations
Continued

Component

ModelYear

Location

Referto
HeaterRecirculationFlapActuator

1992-1998

Belowleftdashrightsideofsteeringcolumn
HeaterBlowerMotorResistorPack

1992-1998

Behindcenterofdashboard
HeaterRegulatorFlapActuator

1997-1998

Rightsideofheaterbox
HeaterValveAssembly

1992-1998

Leftrearenginecompartment
HeatingNentilationRelayBox

1992-1993

Belowleftsideofdash
HeatingNentilationRelay

1994-1998

Leftfrontfootwell
HighSpeedCoolingFanRelay

1992-1998

Powerdistributionbox

Fig.2.
Homs,Right/Left

1993-1998

Frontofenginecompartment
HornRelay

1992-1998

Powerdistributionbox

Fig.2.
HornRelay(Alpine)

1994-1998

Behindglovecompartment

Fig.8.
BoardComputer/Anti-Theft

Fig.9.
IdleSpeedControlValve

1992-1995

Toprearofenginebehindintakemanifold(M42engine)

Fig.11.
IdleSpeedControlValve

1992-1995

Topleftsideofengine(M50engine)
IdleSpeedControlValve

1993-1996

Belowintakemanifold(M50/S50USengine)
IdleSpeedControlValve

1996-1998

Onthrottlehousing(M44engine)

Fig.15.
IdleSpeedControlValve

1997-1998

Leftfrontofenginebelowintakemanifold(M52/S52USengine)
IgnitionCoils

1992-1998

Rightofengineunderplasticcover(four-cylinder)

Fig.7.
IgnitionCofs

1992-1998

Topofengineundercover(six-cylinder)

Fig.17.
IgnitionSwitch

1992-1998

Rightsídeofsteeringcolumn
IntakeAirResonanceChangeover

1992-1998

Leftrearofenginecompartment
Valve(DISA)
IntakeAirTemperatureSensor

1992-1995

Inmassairflowsensor(M42engine)
IntakeAirTemperatureSensor

1996-1998

Intopofairfilterhousing(M44engine)

Fig.12.
IntakeAirTemperatureSensor

1992-1998

ILeftsídeofengineinintakemanifold(six-cylinder)

-

-

I

Fig.13.
Fig.14.
Kick-DownSwitch(A/T)

11992-1998

1Leftfootwell
MixingActuators

11992-1998

1Heaterbox
ELECTRICAL COMPONENT LOCATIONS

610-15
Table a.E36 Component Locations
KnockSensors

11992-1998

1Leftsideofengineblock
LeftFrontPowerWindowMotor

11992-1998

/Leftfrontdoor
LeftFrontWindowMonitoringSwitch11997-1998

1Leftfrontdoortrimpanel
LeftFrontWindowRetractionSwitch11992-1993

1Leftfrontdoorhandlelockassembly
LeftSplicePanel

11992-1998

1Underleftsideofdashatkick-panel

1

Fig.5.
MainFuseandRelayBox(Power

1992-1998

ILeftsideofenginecompartment

Fig.2.
DistributionBox)
1

I
MassAirFlowSensor

1992-1998

ILeftsideofengine,intakeairduct

Fig.7.1

I
Fig.15.
Continued
COMPONENT LOCATIONS

610-16

ELECTRICALCOMPONENTLOCATIONS
Component

ModelYear

Location

Referto
MixingSwitch

1992-1994

Centerconsole
Multi-FunctionClock

1992-1998

Centerconsole
Multi-informationDisplay(MDI)

1992-1998

Centerconsole
NormalSpeedCoolingFanRelay

1992-1998

Powerdistributionbox

Fig.2.
NeutralSafetySwitch(Automatic

1992-1998

Nexttogearshiftleverincenterconsole

Fig.29.
TransmissionRangeSwitch)
OilPressureSwitch

1992-1998

Leftfrontofenginebelowintakemanifoldatoilfilterhousing
On-BoardComputer

1992-1998

Centerconsole
On-BoardComputerHornRelay

1992-1998

Behindglovecompartment

Fig.8.
Fig.9.
On-BoardComputerTemperature

11992-1998

IRightfrontofenginecompartment
Sensor
OutsideTemperatureSensor

1992-1997

Inrightfrontbrakecoolingduct
OutsideTemperatureSensor

1998

Rightrearofenginecompartmentbehindfreshaircowl
OxygenSensorHeaterRelay

1992-1998

Powerdistributionbox

Fig.2.
OxygenSensor(s)

1992-1998

Onexhaustpipeahead/behindcatalyticconverter(M42/M44engine)
OxygenSensor(x2)

1992-1995

Onexhaustpipeaheadofcatalyticconverter(M50/S50USengine)
OxygenSensors(x4)

1996-1998

Onexhaustmanifold/exhaustpípebehindcatalyticconverter
(M52/S52USengine)
ParkingBrakeSwitch

11992-1998

IOnrearofparkingbrakelever
PowerDistributionBox

11992-1998

IRearleftofenginecompartment

I

Fig.2.
Fig.7.
Fig.10.
RadioMicroswitch

1992-1996

Centerconsolebehindradio
RadioReceíver

11997-1998

1Rightrearluggagecompartment
RelayAndFuseBox(Power

1992-1998

ILeftsideofenginecompartment

I

Fig.2.
DistributionBox)

Fig.7.
Fig.10.
RearWindowBlower

1994-1998

Behindrearseat(convertible)
RearWindowBlowerMicroswitch

1994-1994

Atconvertibletoplinkage
RearWindowBlowerMicroswitch

1995-1998

Behindrearseat(convertible)
RearWindowBlowerRelay

11994-1998

Behindglovecompartment

Fig.8.
Fig.9.
Fig.2.
Fig.30.
Fig.8.
RearWindowDefoggerRelay
Reversing(Back-up)LightSwitch
SplicePanel,Right
RolloverProtectionActuator

11994-1998
COMPONENT LOCATIONS
Table a.E36 Component Locations
1992-1998
1992-1998
1992-1998
Powerdistributionbox
Rightorleftsidetopoftransmission
Behindglovecompartment
Behindrearseat(convertible)
Fig.9.
Continued

Tablea.E36Component Locations
Component

ModelYear

Location

Referto
RolloverSensor

1994-1998

InlowerleftC-pillarbehindtrimpanel(Convertible)
SeatBeltSwitch

1992-1998

Infrontseatbeltbuckle
SeatCushionTiltMotor

1992-1998

Underfrontseat
SeatHeater

1993-1998

Underfrontseat
SeatHeightMotorFront

1992-1998

Underfrontseat
SeatMovementMotor

1992-1998

Underfrontseat
SeatbackHeater

1993-1998

Inupperfrontseatback
SeatbackReclinerMotor

1993-1998

Underfrontseat
SeatOccupancyDetector

1994-1998

Underrightfrontseat
SecondaryAirPump(4-cyl.)

19971/2-1998

Leftenginecompartment,belowpowerdistributionbox(M44engine)
SecondaryAirPump(6-cyl.)

1996-1998

Frontofenginecompartment(M52/S52USengine)
SecondaryAirPumpRelay

1996-1998

Powerdistributionbox

Fig.2.
SecondaryAirPumpValve

1996-1998

Rightsideofengine
SideImpactAirBagRight/Left

1997-1998

Behindright/leftdoortrimpanel
SídeImpactAirbagCrashSensor,

1997-1998

Right/leftdoorsi¡¡behindfrontseat
Right/Left
ShiftInterlock

1992-1998

Centerconsolebesideshiftselector
SlipControlModule(ABS/AST)

1992-1998

Behindglovecompartment

Fig.8.
Fig.9.
SplicePanel,LeftSide

1992-1998

Behindfootwellspeakergrill

Fig.5.
SplicePanel,RightSide

1992-1998

Behindglovecompartment

Fig.6.
Starter

1992-1998

Leftrearofengine
StarterImmobilizationRelay

1994-1998

Inleftsplicepanelbehindfootwellspeakergrill
StarterRelay

1992-1993

Belowleftsideofdash
StarterRelay

1994-1998

Behindleftfootwellspeakergrill
SunroofControlAssembly

1992-1998

Inroofcenterpanel
SupplementalRestraintSystem

11992-1993

IBehindglovecompartment

I

Fig.8.
(Airbag)ControlModule

Fig.9.
SupplementalRestraintSystem

1994-1998

1Undercenterofrearseat
(AirbagZAE)ControlModule
Switch,PowerWindow

11992-1998

1Centerconsole
TelephoneEjectBox

11994-1996

1Centerconsole
ELECTRICALCOMPONENTLOCATIONS

610-17
TelephoneTransceiver

1992-1992

Inluggagecompartment
ThrottleFlapHeater

1994-1996

Leftsideofengine
ThrottlePositionSensor

1992-1998

ILeftsideofengineinthrottlehousing

I

Fig.7.
Fig.15.
Fig.21.
Continued
COMPONENT LOCATIONS

610-18

ELECTRICAL COMPONENT LOCATIONS
Tablea.E36ComponentLocations
Component

ModelYear

Location

Referto
TransmissionControlModule

1992-1998

Rightrearenginecompartmentbehíndpanel

Fig.7.
TransmissionRangeSwitch(Gear

1992-1998

Nexttogearshiftleverincenterconsole

Fig.29.
Position/NeutralSafetySwitch)
TransmissionValveUnít

1992-1993

Intransmissionoilpan
TransmissionValveUnit

1994-1998

Onleftsideoftransmission
TrunkLidMicroswitch

1994-1998

Intrunklid
TrunkLidRelay

1994-1998

Behindglovecompartment(convertible)

Fig.8.
Fig.9.
TrunkLightSwitch

1992-1998

Leftundersideoftrunklid
TrunkLockMotor

1992-1998

Rearofluggagecompartment
UnloaderRelay

1992-1998

Inleftsplicepanelbehindfootwellspeakergrille

Fig.5.
VariableCamshaftControlModule

1994-1996

IRearrightsideofenginecompartment
(VANOS)
VariableCamshaftControl(VANOS)

1993-1998

Frontofcylinderhead
Veh¡cleSpeedSensor

1992-1998

Onfinaldrive
VolumeAirFlowSensor(M42

1992-1995

Leftsideofenginecompartment

Fig.7.
Engine)
WasherFluidLeve¡Sensor

1992-1998

Rightfrontofenginecompartment
WasherPump

1992-1998

Rightsideofenginecompartmentonwindshieldwasherreservoir

Fig.7.
WiperMotor

1992-1998

Rearenginecompartment
WiperMotorRelay

1992-1998

Inleftsplicepanelbehindfootwellspeakergrill

Fig.5.
WiperRelay

1992-1998

(Behindglovecompartment

I

Fig.8./Fig.
9.
Wiper/WasherModule

1992-1993

Leftsideoffootwellunderfootrest
(early)
Wiper/WasherModule

1993(late)-

Behindglovecompartment

Fig.8.
1998

1

Fig.9.
ZAEAirbagControlModule

1
1994-1998

1Oncentertunnelunderrearseatcushion
ZKEIVControlModule

1994-1998

IBehindglovecompartment

Fig.8.I

Fig.9.
COMPONENT LOCATIONS

FUSEPOSITIONTABLES
TablebthroughTableglistfusepositionsinthepowerdis-
tributionboxand,whereapplicable,intheauxiliaryrelaypan-
el,theleftsidesplicepanelandtheluggagecompartment.
Refertothebeginningofthisrepairgroupforlocationsof
thesepanels.
ELECTRICALCOMPONENTLOCATIONS

610-19
FUSEPOSITIONTABLES

610-20

ELECTRICALCOMPONENTLOCATIONS
Fuses31-46
o_
~oomooommmo~
8I

15AIHorn
Fuses21-30
Fuses1-20
Fusepositions1-46infrontpowerdistributionbox
Tableb.1992E36FusePositions
Fuse

1Rating

1ProtectedCircuit
1

1

30A1Powersunroof(seealsofuse13)
2I

INotused
31

30A1Headlightwasher
(aEl1:1El
41

15A1Heatedseats(seealsofuse23)
51

30A1Powerseats(seealsofuse40)
61

20A1Rearwindowdefogger(seealsofuse23)
7

5A~Anti-theftsystem(Alpine)(seealsofuse43)
Centrallocking(ZVMII)(seealsofuse35,
43)
9(

20A1Soundsystem(seealsofuse44)
101

30A1ABS(seealsofuse21,27,38,46)
11

7.5A

Crashcontrolmodule(seealsofuse12,25,
29,34)
Headlights/foglights(seealsofuse12,15,
22,23,25,29,30)
On-BoardComputer(seealsofuse12,23,
27,31,33,37,45,46)
12

7.5A

Crashcontrolmodule(seealsofuse11,25,
29,34)
Headlights/foglights(seealsofuse11,15,
22,23,25,29,30)
On-BoardComputer(seealsofuse11,23,
27,31,33,37,45,46)
13

5A

Powersunroof(seealsofuse1)
Powerwindows(seealsofuse14)
14
j

30A1Powerwindows(seealsofuse13)
15

5A

Headlights/foglights(seealsofuse11,12,
22,23,25,29,30)
16

5A~Enginecontrolmodule(seealsofuse28)
HeatingandA/C(IHKRE36)(seealsofuse
20,23,31,37,39,41)
17I

INotused
FUSEPOSITIONTABLES
0013034
Tableb.1992E36FusePositions
Fuse

Rating

ProtectedCircult
181

15A1Fuelpump
19j

15A1Parkventilation(seealsofuse20)
20

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,23,31,37,39,41)
Parkventilation(seealsofuse19)
21

1

5A{ABS(seealsofuse10,27,38,46)
22

5A

Headlights/foglights(seealsofuse11,12,
15,23,25,29,30)
Instrumentillumination(seealsofuse25,33,
37)
Park/taillights(seealsofuse33,37)
23

5A

Multi-functionclock(seealsofuse27,31,45,
46)
Headlights/foglights(seealsofuse11,12,
15,22,25,29,30)
Heatedseats(seealsofuse4)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,31,37,39,41)
Instrumentcluster(seealsofuse27,31,46)
On-BoardComputer(seealsofuse11,12,
27,31,33,37,45,46)
Rearwindowdefogger(seealsofuse6)
Turnsignals/hazardlights(seealsofuse34)
24I

10AI

Powermirrors
25

5A

Crashcontrolmodule(seealsofuse11,12,
29,34)
Headlights/foglights(seealsofuse11,12,
15,22,23,29,30)
Instrumentillumination(seealsofuse22,33,
37)
26

15A~Back-uplights
Electronictransmissioncontrol(A4S310R)
(seealsofuse28,46)
27

5A

ABS(seealsofuse10,21,38,46)
Multi-functionclock(seealsofuse23,31,45,
46)
Instrumentcluster(seealsofuse23,31,46)
On-BoardComputer(seealsofuse11,12,
23,31,33,37,45,46)
28

5A

Cruisecontrol(seealsofuse46)
Enginecontrolmodule(seealsofuse16)
Startingsystem
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,46)
29

7.5A

Crashcontrolmodule(seealsofuse11,12,
25,34)
Headlights/foglights(seealsofuse11,12,
15,22,23,25,30)
30

7.5A

Headlights/foglights(seealsofuse11,12,
15,22,23,25)
31

5A

Multi-functionclock(seealsofuse23,27,45,
46)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,37,39,41)
Instrumentcluster(seealsofuse23,27,46)
On-BoardComputer(seealsofuse11,12,
23,27,33,37,45,46)

Tableb.1992E36FusePositions

Tableb.1992E36FusePositions
Fuse

Rating

ProtectedCircuit
32

30A

Glovecompartmentlight/cassette
compartmenVashtraylight/charging
socket/cigarlighter(seealsofuse33,37,
44)
33

10A

Cellulartelephone(seealsofuse43)
Glovecompartmentlight/cassette
compartment/ashtrayIighUcharging
sockeUcigarlighter(seealsofuse32,37,
44)
Interiorlights(alsoseefuse43)
Licenseplate/luggagecompartmentlights
(seealsofuse37)
Instrumentíllumination(seealsofuse22,25,
37)
On-BoardComputer(seealsofuse11,12,
23,27,31,37,45,46)
Park/taillights(seealsofuse22,37)
34

15A~Crashcontrolmodule(seealsofuse11,12,
25,29)
Turnsignals/hazardlights(seealsofuse23)
351

25AjCentrallocking(ZVMII)(seealsofuse7,43)
361

30A1Wiper/washer(seealsofuse37,44,45)
37

10A

GlovecompartmentIighUcassette
compartmenVashtraylight/charging
socket/cigarlighter(seealsofuse32,33,
44)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,39,41)
Instrumentillumination(seealsofuse22,25,
33)
Licenseplate/luggagecompartmentlights
(seealsofuse33)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,45,46)
Park/taillights(seealsofuse22,33)
Wiper/washer(seealsofuse36,44,45)
381

30A1ABS(seealsofuse10,21,27,46)
39

7.5A

HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,41)
401

30A1Powerseats(seealsofuse5)
41

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,39)
Radiatorauxiliaryfan
42I

7.5AINotused
43

5A

Anti-theftsystem(Alpine)(seealsofuse7)
Cellulartelephone(seealsofuse33)
Centrallocking(ZVMII)(seealsofuse7,35)
Interiorlights(alsoseefuse33)
44

15A

Glovecompartmentlight/cassette
compartmenVashtraylight/charging
sockeUcigarlighter(seealsofuse32,33,
37)
Soundsystem(seealsofuse9)
Wiper/washer(seealsofuse36,37,45)
45

7.5A

Multi-functionclock(seealsofuse23,27,31,
46)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,37,46)
Wiper/washer(seealsofuse36,37,44)
ELECTRICALCOMPONENTLOCATIONS

610-21
Fuse

Rating

ProtectedCircuít
46

15A

ABS(seealsofuse10,21,27,38)
Brakelights
Multi-functionclock(seealsofuse23,27,31,
45)
Cruisecontrol(seealsofuse28)
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,28)
Instrumentcluster(seealsofuse23,27,31)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,37,45)
WARNING -
Fusedesignationsandlocationsaresubjectto
change,andmayvaryfromcartocar,dependingon
options.Ifquestionsarise,pleaserememberthatan
authorizedBMWdealeristhebestsourceforthe
mostaccurateandup-to-dateinformation.
FOSEPOSITIONTABLES

610-22

ELECTRICALCOMPONENT LOCATIONS
Fuses31-46
Ylililll
milililil
Fuses21-30
Fusepositions1-46infrontPowerdistributionbox
Tablec.1993E36FusePositions
fuse

1Rating

jProtectedCircuit
1I

30AIPowersunroof
2I

INotused
Fuses1-20
31

30A1Headlightwasher
41

15A1Heatedseats(seealsofuse23)
51

30A1Powerseats(seealsofuse40)
0013034
61

20A1Rearwindowdefogger(seealsofuse23)
5A1Centrallocking(ZVM)(seealsofuse35,43)
8

15A

Anti-theft(Alpine)(seealsofuse43)
Horn
91

20A1Soundsystem(seealsofuse44)
10

1

30A1ABS(seealsofuse21,27,38,46)
11

7.5A

Headlights/foglights(seealsofuse12,15,
23,25,29,30)
On-BoardComputer(seealsofuse12,23,
27,31,33,37,45,46)
12

7.5A

Headlights/foglights(seealsofuse11,15,
23,25,29,30)
On-BoardComputer(seealsofuse11,23,
27,31,33,37,45,46)
13I

5AINotused
141

30A1Powerwindows(seealsofuse33)
15

5A

Headlights/foglights(seealsofuse11,12,
23,25,29,30)
16

5A~Enginecontrolmodule(seealsofuse28)
HeatingandA/C(IHKRE36)(seealsofuse
20,23,31,37,39,41)
17I

INotused
181

15A1Fuelpump
19I

15AINotused
20

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,23,31,37,39,41)
Parkventilation
FUSEPOSITIONTABLES
Tablec.1993E36FusePositions
fuse

Rating

ProtectedCircuit
21

1

5A1

ABS(seealsofuse10,27,38,46)
22

5A~Instrumentillumination(seealsoPuse25,33,
37)
Park/taillights(seealsofuse33,37)
23

5A

Multi-functionclock(seealsofuse27,31,45,
46)
Headlights/foglights(seealsofuse11,12,
15,25,29,30)
Heatedseats(seealsofuse4)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,31,37,39,41)
Instrumentcluster(seealsofuse27,31,46)
On-BoardComputer(seealsofuse11,12,
27,31,33,37,45,46)
Rearwindowdefogger(seealsofuse6)
Turnsignals/hazardlights(seealsofuse34)
24I

10AIPowermirrors
25

5A

Headlights/foglights(seealsofuse11,12,
15,23,29,30)
Instrumentillumination(seealsofuse22,33,
37)
26

10A~Back-uplights
Electronictransmissioncontrol(A4S310R)
(seealsofuse28,46)
27

5A

ABS(seealsofuse10,21,38,46)
Multi4unctionclock(seealsofuse23,31,45,
46)
Instrumentcluster(seealsofuse23,31,46)
On-BoardComputer(seealsofuse11,12,
23,31,33,37,45,46)
28

5A

Cruisecontrol(seealsofuse46)
Enginecontrolmodule(seealsofuse16)
Startingsystem
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,46)
29

7.5A

Headlights/foglights(seealsofuse11,12,
15,23,25,30)
30

7.5A

Headlights/foglights(seealsofuse11,12,
15,23,25)
31

5A

Multi-functionclock(seealsofuse23,27,45,
46)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,37,39,41)
Instrumentcluster(seealsofuse23,27,46)
On-BoardComputer(seealsofuse11,12,
23,27,33,37,45,46)
32

30A

Glovecomparimentlight/cassette
compartment/ashtraylight/charging
socket/cigarlighter(seealsofuse33,37,
44)

Tablec.1993E36FusePositions

Tablec.1993E36FusePositions
fuse

1Rating

1ProtectedCircuit
33

10A

Cellulartelephone(seealsofuse43)
GlovecompartmentIighUcassette
compartment/ashtraylight/charging
socket/cigarlighter(seealsofuse32,37,
44)
Interiorlights(alsoseefuse43)
Licenseplate/luggagecompartmentlights
(seealsofuse37)
Instrumentillumination(seealsofuse22,25,
37)
On-BoardComputer(seealsofuse11,12,
23,27,31,37,45,46)
Park/taillights(seealsofuse22,37)
Powerwindows(seealsofuse14)
34

15A

Crashcontrolmodule
Turnsignals/hazardlights(seealsofuse23)
35

1

25A1

Centrallocking(ZVMII)(seealsofuse7,43)
361

30A1Wiper/washer(seealsofuse37,44,45)
37

10A

Glovecompartmentlight/cassette
compartmenUashtrayIighUcharging
socket/cigarlighter(seealsofuse32,33,
44)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,39,41)
Instrumentillumination(seealsofuse22,25,
33)
Licenseplate/luggagecompartmentlights
(seealsofuse33)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,45,46)
Park/taillights(seealsofuse22,33)
Wiper/washer(seealsofuse36,44,45)
381

30A1ABS(seealsofuse10,21,27,46)
39

7.5A

HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,41)
401

30A1Powerseats(seealsofuse5)
41

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,39)
Radiatorauxiliaryfan
421

7.5A1Airbag(SRS)(seealsofuse43)
43

5A

Anti-theftsystem(Alpíne)(seealsofuse8)
Airbag(SRS)(seealsofuse42)
Cellulartelephone(seealsofuse33)
Centrallocking(ZVMII)(seealsofuse7,35)
Interiorlights(alsoseefuse33)
44

15A

GlovecompartmentIighUcassette
compartment/ashtrayIighUcharging
sockeUcigarlighter(seealsofuse32,33,
37)
Soundsystem(seealsofuse9)
Wiper/washer(seealsofuse36,37,45)
45

7.5A

Multi-functionclock(seealsofuse23,27,31,
46)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,37,46)
Wiper/washer(seealsofuse36,37,44)
ELECTRICALCOMPONENTLOCATIONS

610-23
fuse

Rating

ProtectedCircuit
46

15A

ABS(seealsofuse10,21,27,38)
Brakelights
Multi-functionclock(seealsofuse23,27,31,
45)
Cruisecontrol(seealsofuse28)
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,28)
Instrumentcluster(seealsofuse23,27,31)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,37,45)
WARNING -
Fusedesignationsandlocationsaresubjectto
change,andmayvaryfromcartocar,dependingon
options.Ifquestionsarise,pleaserememberthatan
authorizedBMWdealeristhebestsourceforthe
mostaccurateandup-to-dateinformation.
FOSEPOSITIONTABLES

610-24

ELECTRICALCOMPONENTLOCATIONS
Fuses31-46
v
------------
Fuses21-30
Fuses1-20
Fusepositions1-46infrontpowerdistributionbox
Tabled.1994E36FusePositions
fuse

Rating

ProtectedCircuit
1

30A

Powersunroof
2

15A

Notused
3

30A

Headlightwasher(alsoseefuse37)
4

15A

Heatedseats(seealsofuse23)
5

30A

Powerseats(seealsofuse40)
6

20A

Rearwindowdefogger/blower(seealsofuse
23)
7

$A

Centralbodyelectronics(ZKEIV)
(convertibleonly)(seealsofuse33,43)
Centrallocking(seealsofuse35,43)
Convertibleroof(seealsofuse35,43)
Rol¡-overprotection(seealsofuse35,42,
43)
8I

15AIHorn
9(

20A1Soundsystem(seealsofuse44)
10I

30A

ABS(seealsofuse21,38,46)
AST(seealsofuse21,38)
11

7.5A

Headlights/foglights(seealsofuse12,15,
23,25,29,30)
On-BoardComputer(seealsofuse12,23,
27,31,33,37,45,46)
12

7.5A

Headlights/foglights(seealsofuse11,15,
23,25,29,30)
On-BoardComputer(seealsofuse11,23,
27,31,33,37,45,46)
13I

5AINotused
141

30A1Frontpowerwindows
0013034
15

15A

Headlights/foglights(seealsofuse11,12,
23,25,29,30)
FOSEPOSITIONTABLES
Tabled.1994E36FusePositions
fuse

1Rating

1ProtectedCircuit
16

5A~Enginecontrolmodule(seealsofuse28)
HeatingandA/C(IHKRE36)(seealsofuse
20,23,31,37,39,41)
17I

10AINotused
181

15A1Fuelpump
191

30A1Rearpowerwindows
20

30A

Blowermotor
HeatingandA/C(IHKRE36)(seealsofuse
16,23,31,37,39,41)
Parkventilation
21

5A

ABS(seealsofuse10,38,46)
AST(seealsofuse10,38)
22

5A

Instrumentillumination(seealsofuse25,37)
Park/taillights(seealsofuse33,37)
23

5A

Headlights/foglights(seealsofuse11,12,
15,25,29,30)
Heatedseats(seealsofuse4)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,31,37,39,41)
Instrumentcluster(seealsofuse27,31,46)
On-BoardComputer(seealsofuse11,12,
27,31,33,37,45,46)
Rearwindowdefogger/blower(seealsofuse
6)
Turnsignais/hazardlights(seealsofuse34)
24I

10AIPowermirrors
25

5A~

Headlights/foglights(seealsofuse11,12,
15,23,29,30)
Instrumentillumination(seealsofuse22,37)
26

10A~Back-uplights
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,46)
27

5A~Instrumentcluster(seealsofuse23,31,46)
On-BoardComputer(seealsofuse11,12,
23,31,33,37,45,46)
28

5A

Cruisecontrol(seealsofuse46)
Enginecontrolmodule(seealsofuse16)
Startingsystem
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,46)
29

7.5A

Headlights/foglights(seealsofuse11,12,
15,23,25,30)
30

7.5A

Headlights/foglights(seealsofuse11,12,
15,23,25)
31

5A

Multi-functionclock
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,37,39,41)
Instrumentcluster(seealsofuse23,27,46)
On-BoardComputer(seealsofuse11,12,
23,27,33,37,45,46)
321

30A1Cigarlighterlashtraylights

ELECTRICALCOMPONENTLOCATIONS610-25
Tabled.1994E36FusePositions

Tabled.1994E36FusePositions
fuse

1Rating1ProtectedCircuit
33

10A

Centralbodyelectronics(ZKEIV)(seealso
Puse7,43)
Chargingsocket
Interiorlights(alsoseefuse43)
Licenseplatelluggagecompartmentlights
(seealsofuse37)
On-BoardComputer(seealsofuse11,12,
23,27,31,37,45,46)
Park/taillights(seealsofuse22,37)
Telephone(seealsofuse43)
34

15A

Crashcontrolmodule
Turnsignals/hazardlights(seealsofuse23)
35

25A~Centrallocking(seealsofuse7,43)
Convertibleroof(seealsofuse7,43)
Roll-overprotection(seealsofuse7,42,43)
36j

30A1Wiper/washer(seealsofuse37,44,45)
37

10A

Cassettecompartmentlight
Enginecompartmentlight
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,39,41)
Instrumentillumínation(seealsofuse22,25)
Licenseplate/luggagecompartmentlights
(seealsofuse33)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,45,46)
Park/taillights(seealsofuse22,33)
Wiper/washer(seealsofuse36,44,45)
38

30A

ABS(seealsofuse10,21,46)
AST(seealsofuse10,21)
39

7.5A

HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,41)
401

30A1Powerseats(seealsofuse5)
41

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,39)
Radiatorauxiliaryfan
42

7.5A

Airbag(SRS)(seealsofuse43)
Roll-overprotection(seealsofuse7,35,43)
43

5A

Anti-theftsystem(Alpine)
Airbag(SRS)(seealsofuse42)
Centralbodyelectronics(ZKEIV)(seealso
fuse7,33)
Centrallocking(seealsofuse7,35)
Convertibleroof(seealsofuse7,35)
Interiorlights(alsoseefuse33)
Rol¡-overprotection(seealsofuse7,35,42)
Telephone(seealsofuse33)
44

15A~Glovecompartmentlight
Soundsystem(seealsofuse9)
Wiper/washer(seealsofuse36,37,45)
45

7.5A~On-BoardComputer(seealsofuse11,12,
23,27,31,33,37,46)
Wiper/washer(seealsofuse36,37,44)
fuse

1Rating

1ProtectedCircuit
46

15A

ABS(seealsofuse10,21,38)
Brakelights
Multi-functionclock(seealsofuse23,27,31,
45)
Cruisecontrol(seealsofuse28)
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,28)
Instrumentcluster(seealsofuse23,27,31)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,37,45)
WARNING -
Fusedesignationsandlocationsaresubjectto
changeandmayvaryfromcartocar,dependingon
options.Ifquestionsarise,pleaserememberthatan
authorizedBMWdealeristhebestsourceforthe
mostaccurateandup-to-dateinformation.
FOSEPOSITIONTABLES

610-26

ELECTRICALCOMPONENTLOCATIONS
Fuses31-46
v.
-------------
Fuses21-30
Fuses1-20
Fusepositions1-46infrontpowerdistributionbox
Tablee.1995E36FusePositions
fuse

Rating

ProtectedCircuit
1

30A

Powersunroof
2

15A

Notused
3

30A

Headlightwasher(alsoseefuse37)
4

15A

Heatedseats(seealsofuse23)
5

30A

Powerseats(seealsofuse40)
6

20A

Rearwindowdefogger/blower(seealsofuse
23)
7

5A

Centralbodyelectronics(ZKEIV)
(convertibleonly)(seealsofuse14,31,33,
35,43)
Centrallocking(seealsofuse26,28,35)
Convertibleroof(seealsofuse27,35,42,
43)
Interiorlights(alsoseefuse33,43)
Roll-overprotection(seealsofuse35,42,
43)
8I

15AIHorn
91

20A1Soundsystem(seealsofuse33,44)
0013034
10

30A

ABS(seealsofuse21,23,27,38,46,47)
AST(seealsofuse21,26,27,38,46)
11

7.5A

Headlights/foglights(seealsofuse12,15,
17,23,25,29,30)
On-BoardComputer(seealsofuse12,23,
27,31,33,37,45,46)
12

7.5A

Headlights/foglights(seealsofuse11,15,
17,23,25,29,30)
On-BoardComputer(seealsofuse11,23,
27,31,33,37,45,46)
13I

5AINotused
14

30A~Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,31,33,35,43)
FrontpowerWindows
15

15A

Headlights/foglights(seealsofuse11,12,
17,23,25,29,30)
FOSEPOSITIONTABLES
Tablee.1995E36FusePositions
fuse

1Rating

1ProtectedCircuit
16

5A~Enginecontrolmodule(seealsofuse28,39)
HeatingandA/C(IHKRE36)(seealsofuse
20,23,31,37,39,41)
17

10A

Headlights/foglights(seealsofuse11,12,
15,23,25,29,30)
181

15A1Fuelpump
191

30A1RearpowerWindows
20

30A

Blowermotor
HeatingandA/C(IHKRE36)(seealsofuse
16,23,31,37,39,41)
Parkventilation
21

5A

ABS(seealsofuse10,23,27,38,46,47)
AST(seealsofuse10,26,27,38,46)
22

5A~

Instrumentillumination(seealsofuse25,33,
37)
Park/taillights(seealsofuse33,37)
23

5A

ABS(seealsofuse10,21,27,38,46)
Headlights/foglights(seealsofuse11,12,
15,17,25,29,30)
Heatedseats(seealsofuse4)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,31,37,39,41)
Instrumentcluster(seealsofuse27,31,46)
Multi-functionclock(seealsofuse26,27,31,
45,46)
On-BoardComputer(seealsofuse11,12,
27,31,33,37,45,46)
On-BoardDisplay(seealsofuse26,27,31,
45,46)
Rearwindowdefogger/blower(seealsofuse
6)
Turnsignals/hazardlights(seealsofuse34)
24I

10AI

Powermirrors
25

5A

Headlights/foglights(seealsofuse11,12,
15,17,23,29,30)
Instrumentillumination(seealsofuse22,33,
37)
26

10A

AST(seealsofuse10,21,27,38,46)
Back-uplights
Centrallocking(seealsofuse7,28,35)
Electronictransmissioncontrol(A4S
310R/Z)(seealsotuse28,46)
Multi-functionclock(seealsofuse23,27,31,
45,46)
On-BoardDisplay(seealsofuse23,27,31,
45,46)
Startingsystem(seealsofuse28)
27

5A

ABS(seealsofuse10,21,23,38,46,47)
AST(seealsofuse10,21,26,38,46)
Convertibleroof(seealsofuse7,35,42,43)
Instrumentcluster(seealsofuse23,31,46)
Multi-functionclock(seealsofuse23,26,31,
45,46)
On-BoardComputer(seealsofuse11,12,
23,26,31,33,37,45,46)
On-BoardDisplay(seealsofuse23,31,45,
46)

Tablee.1995E36FusePositions

Tablee.1995E36FusePositions
fuse

IRating

1ProtectedCircuit
28

5A

Centrallocking(seealsofuse7,26,35)
Cruisecontrol(seealsofuse46)
Enginecontrolmodule(seealsofuse16,39)
Electronictransmissioncontrol(A4S
310R/Z)(seealsofuse26,46)
Startingsystem(seealsofuse26)
29

7.5A

Headlights/foglights(seealsofuse11,12,
15,17,23,25,30)
30

7.5A

Headlights/foglights(seealsofuse11,12,
15,17,23,25,29)
31

5A

Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,33,35,43)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,37,39,41)
Instrumentcluster(seealsofuse23,27,46)
Multi-functionclock(seealsofuse23,26,27,
45,46)
On-BoardComputer(seealsofuse11,12,
23,26,27,33,37,45,46)
On-BoardDisplay(seealsofuse23,27,45,
46)
321

30A1Cigarlighter/ashtraylights
33

10A

Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,31,35,43)
Chargingsocket
Doorlockheating
Instrumentillumination(seealsofuse22,25,
37)
Interiorlights(alsoseefuse7,43)
Licenseplate/luggagecompartmentlights
(seealsofuse37)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,37,45,46)
Park/taillights(seealsofuse22,37)
Soundsystem(seealsofuse9,44)
Telephone(seealsofuse43)
34

15A

Crashcontrolmodule
Turnsignals/hazardlights(seealsofuse23)
35

25A

Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,31,33,43)
Centrallocking(seealsofuse7,26,28)
Convertibleroof(seealsofuse7,27,42,43)
Rol¡-overprotection(seealsofuse7,42,43)
361

30A1Wiper/washer(seealsofuse37,44,45)
37

10A

Cassettecompartmentlight
Enginecompartmentlight
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,39,41)
Instrumentillumination(seealsofuse22,25,
33)
Licenseplate/luggagecompartmentlights
(seealsofuse33)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,45,46)
Park/taillights(seealsofuse22,33)
Wiper/washer(Canadaonly)(seealsofuse
36,44,45)
38

30A

ABS(seealsofuse10,21,23,27,46,47)
AST(seealsofuse10,21,26,27,46)
ELECTRICALCOMPONENTLOCATIONS

610-27
fuse

Rating

ProtectedCircuit
39

7.5A~Enginecontrolmodule(seealsofuse16,28)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,41)
401

30A1

Powerseats(seealsofuse5)
41

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,39)
Radiatorauxiliaryfan
42

7.5A~Airbag(SRS)(seealsofuse43)
Convertibleroof(seealsofuse7,27,35,43)
Rol¡-overprotection(seealsofuse7,35,43)
43

5A

Anti-theftsystem(Alpine)(seealsofuse47)
Airbag(SRS)(seealsofuse42)
Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,31,33,35)
Centrallocking(seealsofuse7,35)
Convertibleroof(seealsofuse7,27,35,42)
Interiorlights(alsoseefuse7,33)
Roll-overprotection(seealsofuse7,35,42)
Telephone(seealsofuse33)
44

15A~Glovecompartmentlight
Soundsystem(seealsofuse9,33)
Wiper/washer(seealsofuse36,37,45)
45

7.5A

Multi-functionclock(seealsofuse23,26,27,
31,46)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,37,46)
On-BoardDisplay(seealsofuse23,27,31,
46)
Wiper/washer(Canadaonly)(seealsofuse
36,37,44)
46

15A

ABS(seealsofuse10,21,23,27,38,47)
AST(seealsofuse10,21,26,27,38)
Brakelights
Cruisecontrol(seealsofuse28)
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,28)
Instrumentcluster(seealsofuse23,27,31)
Multi-functionclock(seealsofuse23,26,27,
31,45)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,37,45)
On-BoardDisplay(seealsofuse23,27,31,
45)
47

15A

ABS(seealsofuse10,21,23,27,38,46)
Anti-theftsystem(Alpine)(seealsofuse43)
48

40A

Notused
WARNING -
"Fusedesignationsandlocationsaresubjectto
change,andmayvaryfromcartocar,depending
onoptions.lfquestionsarise,pleaseremember
thatanauthorizedBMWdealeristhebestsource
forthemostaccurateandup-to-dateinformation.
"Tolocatefuses47-48,refertoFuseandRelay
Positionsinthisrepairgroup.
FOSEPOSITIONTABLES

610-28

ELECTRICALCOMPONENTLOCATIONS
Fuses31-46
kLírcoo)]LE
7aMaz
Fuses21-30
Fusepositions1-46infrontpowerdistributionbox
Tablef.1996E36FusePositions
fuse

Rating

ProtectedCircuit
1

30A

Powersunroof(seealsofuse13)
2

15A

Notused
3

30A

Headlightwasher(alsoseefuse37)
4

15A

Heatedseats(seealsofuse23)
5

30A

Powerseats(seealsofuse40)
6

20A

Rearwindowdefogger/blower(seealsofuse
23)
7

5A

Centralbodyelectronics(ZKEIV)
(convertibleonly)(seealsofuse14,33,35,
43)
Centrallocking(seealsofuse26,28,35)
Convertibleroof(seealsofuse27,35,42,
43)
Interiorlights(alsoseefuse33,43)
Rol¡-ovenprotection(seealsofuse35,42,
43)
8I

15AIHorn
91

20A1Soundsystem(seealsofuse44)
10

30A

ABS(seealsofuse21,23,27,38,46,47)
AST(seealsofuse21,26,27,38,46)
11

7.5A

Headlights/foglights(seealsofuse12,15,
17,23,25,29,30)
On-BoardComputer(seealsofuse12,23,
27,31,33,37,45,46)
12

7.5A

Headlights/foglights(seealsofuse11,15,
17,23,25,29,30)
On-BoardComputer(seealsofuse11,23,
27,31,33,37,45,46)
131

5A1Powersunroof(seealsofuse1)
14

30A~Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,33,35,43)
Frontpowerwindows
15

15A

Headlights/foglights(seealsofuse11,12,
17,23,25,29,30)
FUSEPOSITIONTABLES
Fuses1-20
0013034
Tablef.1996E36FusePositions
fuse

1Rating

1ProtectedCircult
16

5A~Enginecontrolmodule(seealsofuse28,39)
HeatingandA/C(IHKRE36)(seealsofuse
20,23,31,37,39,41,48)
17

10A

Headlights/foglights(seealsofuse11,12,
15,23,25,29,30)
181

15A1Fuelpump
191

30A1Rearpowerwindows
20

30A

Blowermotor
HeatingandA/C(IHKRE36)(seealsofuse
16,23,31,37,39,41,48)
Parkventilatíon
21

5A

ABS(seealsofuse10,23,27,38,46,47)
AST(seealsofuse10,26,27,38,46)
22

5A

Instrumentillumínation(seealsofuse25,33,
37)
23

5A

ABS(seealsofuse10,21,27,38,46)
Headlights/foglights(seealsofuse11,12,
15,17,25,29,30)
Heatedseats(seealsofuse4)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,31,37,39,41,48)
Instrumentcluster(seealsofuse27,31,46)
Multi-functionclock(seealsofuse26,27,31,
45,46)
On-BoardComputen(seealsofuse11,12,
27,31,33,37,45,46)
On-BoardDisplay(seealsofuse26,27,31,
45,46)
Rearwindowdefogger/blower(seealsofuse6)
Turnsignals/hazardlights(seealsofuse34)
24I

10AIPowermirrors
25

5A

Headlights/foglights(seealsofuse11,12,
15,17,23,29,30)
Instrumentillumination(seealsofuse22,33,
37)
26

10A

Airbag(SRS)(seealsofuse43)
AST(seealsofuse10,21,27,38,46)
Back-uplights
Centrallocking(seealsofuse7,28,35)
Electronictransmissioncontrol(A4S
310R/Z)(seealsofuse28,46)
Multi-functionclock(seealsofuse23,27,31,
45,46)
On-BoardDisplay(seealsofuse23,27,31,
45,46)
Startingsystem(seealsofuse28).
27

5A

ABS(seealsofuse10,21,23,38,46,47)
AST(seealsofuse10,21,26,38,46)
Convertibleroof(seealsofuse7,35,42,43)
Instrumentcluster(seealsofuse23,31,46)
Multi-functionclock(seealsofuse23,26,31,
45,46)
On-BoardComputer(seealsofuse11,12,
23,26,31,33,37,45,46)
On-BoardDisplay(seealsofuse23,31,45,
46)

Tablef.1996E36FusePositions

Tablef.1996E36FusePositions
fuse

Rating

ProtectedCircuit
28

5A

Centrallocking(seealsofuse7,26,35)
Cruisecontrol(seealsofuse46)
Enginecontrolmodule(seealsofuse16,39)
Electronictransmissioncontrol(A4S
310R/Z)(seealsofuse26,46)
Driveawayprotection(EWSII)(seealsofuse
31,46)
Startingsystem(seealsofuse26)
29

7.5A

Headlights/foglights(seealsofuse11,12,
15,17,23,25,30)
30

7.5A

Headlights/foglights(seealsofuse11,12,
15,17,23,25,29)
31

5A

Driveawayprotection(EWSII)(seealsofuse
28,46)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,37,39,41,48)
Instrumentcluster(seealsofuse23,27,46)
Multi-functionclock(seealsofuse23,26,27,
45,46)
On-BoardComputer(seealsofuse11,12,
23,26,27,33,37,45,46)
On-BoardDisplay(seealsofuse23,27,45,
46),
321

30A1Cigarlighter/ashtraylights
33

10A

Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,35,43)
Chargingsocket
Enginecompartmentlight(alsoseefuse37)
Instrumenfillumination(seealsofuse22,25,
37)
Interiorlights(alsoseefuse7,43)
Licenseplate/luggagecompartmentlights
(seealsofuse37)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,37,45,46)
Park/taillights(seealsofuse37)
Telephone(seealsofuse43)
34

15A

Crashcontrolmodule
Turnsignals/hazardlights(seealsofuse23)
35

25A

Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,33,43)
Centrallocking(seealsofuse7,26,28)
Convertibleroof(seealsofuse7,27,42,43)
Roll-overprotection(seealsofuse7,42,43)
361

30A1Wiper/washer(seealsofuse44,45)
37

10A

Cassettecompartmentlight
Enginecompartmentlight(alsoseefuse33)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,39,41,48)
Instrumentillumination(seealsofuse22,25,
33)
Licenseplate/luggagecompartmentlights
(seealsofuse33)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,45,46)
Park/taillights(seealsofuse33)
38

30A

ABS(seealsofuse10,21,23,27,46,47)
AST(seealsofuse10,21,26,27,46)
ELECTRICALCOMPONENTLOCATIONS

610-29
fuse

1Rating

1ProtectedCircuit
39

7.5A~Enginecontrolmodule(seealsofuse16,28)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,41,48)
401

30A1Powerseats(seealsofuse5)
41

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,39,48)
Radiatorauxiliaryfan
42

7.5A~Airbag(SRS)(seealsofuse26,43)
Convertibleroof(seealsofuse7,27,35,43)
Rol¡-overprotection(seealsofuse7,35,43)
43

5A

Anti-theftsystem(Alpine)(seealsofuse47)
Airbag(SRS)(seealsofuse26,42)
Centralbodyelectronics(ZKEIV)(seealso
fuse7,14,33,35)
Centrallocking(seealsofuse7,35)
Convertibleroof(seealsofuse7,27,35,42)
Interiorlights(alsoseefuse7,33)
Rol¡-overprotection(seealsofuse7,35,42)
Telephone(seealsofuse33)
44

15A~Glovecompartmentlight
Soundsystem(seealsofuse9)
Wiper/washer(seealsofuse36,37,45)
45

7.5A

Multi-functionclock(seealsofuse23,26,27,
31,46)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,37,46)
On-BoardDisplay(seealsofuse23,27,31,
46)
Wiper/washer(seealsofuse36,44)
46

15A

ABS(seealsofuse10,21,23,27,38,47)
AST(seealsofuse10,21,26,27,38)
Brakelights
Cruisecontrol(seealsofuse28)
Driveawayprotection(EWSII)(seealsofuse
28,31)
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,28)
Instrumentcluster(seealsofuse23,27,31)
Multi-functionclock(seealsofuse23,26,27,
31,45)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,37,45)
On-BoardDisplay(seealsofuse23,27,31,
45)
47

15A

ABS(seealsofuse10,21,23,27,38,46)
Anti-theft(Alpine)(seealsofuse43)
48

40A

HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,37,39,41)
WARNING -
"Fusedesfgnationsandlocationsaresubjectto
changeandmayvaryfromcartocaldepending
onoptions.Ifquestionsarise,pleaseremember
thatanauthorizedBMWdealeristhebestsource
forthemostaccurateandup-to-dateinformation.
"Tolocatefuses47-48,refertoFusePositionsin
thisrepairgroup.
FOSEPOSITIONTABLES

610-30

ELECTRICALCOMPONENTLOCATIONS
Fuses31-46
v
--------------
15AIHorn
Fuses21-30
Fuses1-20
Fusepositions1-46infrontpowerdistributionbox
Tableg.1997-1998E36FusePositions
fuse

Rating

ProtectedCircuit
1

I

30AI

Powersunroof
41

15A1Heatedseats(seealsofuse23)
51

30A1Powerseats(seealsofuse40)
10

30A

ABS(seealsofuse21,27,38,46)
AST(seealsofuse21,27,38,46)
13I

5AINotused
FUSEPOSITIONTABLES
0013034
2I

5A

EnginecontrolsDMEM5.2(seealsofuses
16,18,39,46)
30A

Wiper/washermodule(seealsofuse36,37,
44)
20A~Rearwindowdefogger/blower(seealsofuse
23,43)
Antenna(seealsofuse23)
5A~Centrallocking(seealsofuse28,31,35,45)
Convertibleroof(seealsofuse24,27,42,
43,49)
91

20A1Soundsystem(seealsofuse33,43,44)
11

7.5A

Headlights/foglights(seealsofuse12,15,
23,25,29,30)
On-BoardComputer(seealsofuse12,23,
26,27,31,33,37,45,46)
12

7.5A

Headlights/foglights(seealsofuse11,15,
23,25,29,30)
On-BoardComputer(seealsofuse11,23,
26,27,31,33,37,45,46)
14I

30A~Centralbodyelectronics(ZKEIV)(seealso
fuse33,35,43)
Powerwindows(seealsofuse19)
15

15A

Headlights/foglights(seealsofuse11,12,
23,25,29,30)
Tableg.1997-1998E36FusePositions
fuse

1Rating

1ProtectedCircuit
16

5A

EngínecontrolDMEM5.2(seealsofuse2,
18,39,46)
EnginecontrolDMEMS41.1(seealsofuse
18,39,46,50)
HeatingandA/C(IHKRE36)(seealsofuse
20,23,31,39,41,48)
17I

10A1Notused
18

15A

EnginecontrolDMEM5.2(seealsofuse2,
16,39,46)
EnginecontrolMS41.1(seealsofuse16,39,
46,50)
191

30AjPowerwindows(seealsofuse14
20

30A

Blowermotor
HeatingandA/C(IHKRE36)(seealsofuse
16,23,31,37,39,48)
Parkventilation
21

5A

ABS(seealsofuse10,27,38,46)
AST(seealsofuse10,27,38,46)
22

5A

Instrumentillumination(seealsofuse25,33,
37)
23

5A

Antenna(seealsofuse6)
Headlights/foglights(seealsofuse11,12,
15,25,29,30)
Heatedseats(seealsofuse4)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,31,39,41,48)
Instrumentcluster(seealsofuse27,31,45,
46)
Multi-functionclock(seealsofuse26,27,31,
45,46)
On-BoardComputer(seealsofuse11,12,
27,31,33,37,45,46)
On-BoardDisplay(seealsofuse26,27,31,
45,46)
Rearwindowdefogger/blower(seealsofuse
6,43)
Turnsignals/hazardlights(seealsofuse34)
24

10A~Convertibleroof(seealsofuse7,27,42,43,
49)
Powermirrors
25

5A

Headlights/foglights(seealsofuse11,12,
15,23,29,30)
Instrumentillumination(seealsofuse22,33,
37)
26

10A

Back-uplights
Electronictransmissioncontrol(A4S
310R/Z)(seealsofuse28,46)
Electronictransmissioncontrol(A5S310Z)
(seealsofuses28,46)
Multi-functionclock(seealsofuse23,27,31,
45,46)
On-BoardComputer(seealsofuse11,12,
23,27,31,33,37,45,46)

Tableg.1997-1998E36FusePositions

Tableg.1997-1998E36FusePositions
fuse

1Rating

1ProtectedCircuit
27

5A

Airbag(SRS)(seealsofuse42)
ABS(seealsofuse10,21,38,46)
AST(seealsofuse10,21,38,46)
Convertibleroof(seealsofuses7,24,42,
43,49)
Instrumentcluster(seealsofuse23,31,45,
46)
Multi-functionclock(seealsofuse23,26,31,
45,46)
On-BoardComputer(seealsofuse11,12,
23,26,31,33,37,45,46)
On-BoardDisplay(seealsofuse23,27,31,
45,46)
28

5A

Centrallocking(seealsofuse7,31,35,45)
Cruisecontrol(seealsofuse46)
Electronictransmissioncontrol(A4S
310R/Z)(seealsofuse26,46)
Electronictransmissioncontrol(A5S310Z)
(seealso(uses26,46)
Driveawayprotection(EWSII)(seealsofuse
31,45)
Startingsystem(seealsofuse31,45)
29

7.5A

Headlights/foglights(seealsofuse11,12,
15,23,25,30)
30

7.5A

Headlights/foglights(seealsofuse11,12,
15,17,23,25,29)
31

5A

Centrallocking(seealsofuse7,28,35,45)
Driveawayprotection(EWSII)(seealsofuse
28,45)
HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,39,41,48)
Instrumentcluster(seealsofuse23,27,45,
46)
Multi-functionclock(seealsofuse23,26,27,
45,46)
On-BoardComputer(seealsofuse11,12,
23,26,27,33,37,45,46)
On-BoardDisplay(seealsofuse23,26,27,
31,45,46)
Startingsystem(seealsofuses28,45)
32

30A

Cassettecompartment(seealsofuses33,
37,44)
Chargingsocket(seealsofuses33,37,44)
Cigarlighter/ashtraylights(seealsofuses
33,37,44)
Glovecompartmentlight(seealsofuses33,
37,44)
ELECTRICALCOMPONENTLOCATIONS

610-31
fuse

1Rating

1ProtectedCircuit
33

10A

Ashtraylight(seealsofuses32,37,44)
Cassettecompartment(seealsofuses32,
37,44)
Cellularphone(seealsofuse43)
Centralbodyelectronics(ZKEIV)(seealso
fuse14,35,43)
Chargingsocket(seealsofuses32,37,44)
Cigarlighter(seealsofuses32,37,44)
Instrumentillumination(seealsofuse22,25,
37)
Interior¡ights(seealsofuse43)
Glovecompartmentlight(seealsofuse32,
37,44)
Licenseplate/luggagecompartmentlights
(seealsofuse37)
Luggagecompartmentlight(seealsofuse
37)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,37,45,46)
Park/taillights(seealsofuse37)
Soundsystem(seealsofuses9,43,44)
34

15A

Crashcontrolmodule
Turnsignals/hazardlights(seealsofuse23)
35

25A~Centralbodyelectronics(ZKEIV)(seealso
fuse14,33,43)
Centrallocking(seealsofuse7,28,31,45)
36

30A

Headlightwashers(seealsofuses3,37)
Wiper/washer(seealsofuse3,37,44)
37

10A

Ashtraylight(seealso(uses32,33,44)
Cassettecompartmentlight(seealsofuses
32,33,44)
Chargingsocket(seealsofuses32,33,44)
Cigarlighter(seealsofuses32,33,44)
Glovecompartmentlight(seealsofuses32,
33,44)
Licenseplate/luggagecompartmentlights
(seealsofuse33)
Instrumentillumination(seealsofuses22,
25,33)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,45,46)
Park/taillights(seealsofuse33)
Wiperwashermodule(seealsofuses3,36,
44)
38

30A

ABS(seealsofuse10,21,27,46)
AST(seealsofuse10,21,27,46)
39

7.5A

EnginecontrolDMEM5.2(seealsofuse
16,18,46)
EnginecontrolDMEMS41.1(seealsofuses
16,18,46,50)
HeatingandA/C(IHKRE36)(seealsofuse
12,20,23,31,41,48)
40

30A

Powerseats(seealsofuse5)
41

30A~HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,39,48)
Radiatorauxiliaryfan
42

7.5A

Airbag(SRS)(seealsofuse27)
Convertibleroof(seealsofuse7,24,27,43,
49)
Rol¡-overprotection(seealsofuse43)
FOSEPOSITIONTABLES

610-32

ELECTRICALCOMPONENTLOCATIONS
Table g.1997-1998 E36 Fuse Positions
fuse

Rating

ProtectedCircult
43

5A

Anti-theftsystem(Alpine)(seealsofuse47)
Cellularphone(seealsofuse33)
Centralbodyelectronics(ZKEIV)(seealso
fuse14,33,35)
Convertibleroof(seealsofuse7,24,27,42,
49)
Interiorlights(alsoseefuse33)
Rearwindowdefogger/blower(seealsofuse
6,23)
Roll-overprotection(seealsofuse42)
Soundsystem(seealsofuses9,33,44)
44

15A

Ashtraylight(seealsofuses32,33,37)
Cassettecompartmentlight(seealsofuses
32,33,37)
Chargingsocket(seealsofuses32,33,37)
Cigarlighter(seealsofuses32,33,37)
Glovecompartmentlight(seealsofuses32,
33,37)
Soundsystem(seealsofuse9,33,43)
Wiper/washer(seealsofuse3,36,37)
45

7.5A

Centrallocking(seealsofuses7,28,31,35)
Drive-awayprotection(EWSII)(seealso
fuse28,29,31)
Instrumentcluster(seealsofuses23,27,31,
46)
Multi-functionclock(seealsofuse23,26,27,
31,46)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,37,46)
On-BoardDisplay(seealsofuse23,27,31,
46)
Startingsystem(seealsofuses28,31)
46

15A

ABS(seealsofuse10,21,27,38)
AST(seealsofuse10,21,27,38)
Brakelights
Cruisecontrol(seealsofuse28)
Electronictransmissioncontrol(A4S310R)
(seealsofuse26,28)
Electronictransmissioncontrol(A5S310Z)
(seealsofuse26,28)
EnginecontrolDMEM5.2(seealsofuses2,
16,18,39)
EnginecontrolDMEMS41.1(seealsofuses
16,18,39,50)
Instrumentcluster(seealsofuse23,27,31,
45)
Multi4unctionclock(seealsofuse23,26,27,
31,45)
On-BoardComputer(seealsofuse11,12,
23,26,27,31,33,37,45)
47
1

15A1Anti-theftsystem(seealsofuse43)
48

40A

HeatingandA/C(IHKRE36)(seealsofuse
16,20,23,31,39,41)
49

20A

Convertibleroof(seealsofuses7,24,27,
42,43)
50

5A

EnginecontrolDMEMS41.1(seealsofuses
16,18,39,46)
FUSEPOSITIONTABLES
WARNING-
"Fusedesignationsandlocationsaresubjectto
changeandmayvaryfromcartocar,depending
onoptions.Ifquestionsarise,pleaseremember
thatanauthorizedBMWdealeristhebestsource
forthemostaccurateandup-to-dateinformation.
"Tolocatefuses47-50,refertoFusePositionsin
thisrepairgroup.

611WipersandWashers
GENERAL............................611-1

Windshieldwipermotor,
removingandinstalling.................611-8
WIPERBLADES......................611-1
WiperBladeCleaningProblems...........611-1
Wiperblades,replacing.................611-1
Wiperbladeinserts,replacing.............611-2
Wiperarms,removingandinstalling........611-2
WINDSHIELDWIPERASSEMBLY.......611-3
Windshieldwiperassembly,removing
andinstalling(4-doormodels)...........611-3
Windshieldwiperassembly,removing
andinstalling(2-doormodels)...........611-5
GENERAL
Thisrepairgroupcoverswindshieldwiperandwashersys-
temrepairinformation.Pleasenotethatsomeproceduresare
differentfor2-and4-doormodels.
Thewindshieldwiper/washerstalkswitchassemblyiscov-
eredin612SwitchesandElectricalAccessories.Electrical

NOTE-
wiringdiagramsandrelaysforthewiper/washersystemare

BMwhasavailableaspecialtoollgauge(BMWspecial
coveredinElectricalWiringDiagrams.

toolno.009210)toaligntheangleofthewiperarmto
thewindshieldglass.
WIPERBLADES
CAUTION-
Neverturnonthewiperbladeswhilethehoodis
open.Damagetothewipersystemandhoodmay
occur.Toensuresafetyduringwiperbiadesystem
procedures,removethewindshieldwiperfuse.
See610ElectricalComponentLocations.
WiperBladeCleaningProblems
Commoncleaningproblemswiththewipersincludestreak-
ingorsheeting,waterdropsafterwiping,andbladechatter.
Streakingisusuallycausedwhenwiperbladesarecoated
withroadfilmorcarwashwax.Cleanthebladesusingsoapy
water.Ifcleaningdoesnotcuretheproblem,theblades
shouldbereplaced.BMWrecommendsreplacingthewiper
bladestwiceayear,beforeandafterthecoldseason.
WIPERSANDWASHERS

611-1
WINDSHIELDCLEANINGSYSTEM......611-9
Windshieldspraynozzle,
removingandinstalling.................611-9
Washerfluidreservoir,replacing..........611-9
Windshieldwasher
fluidpump,replacing...................611-9
Washerfluidlevelsensor,replacing
(modelswithcheckcontrol)............611-10
Wiperbladechattermaybecausedbydirtyorwornblades,
orbywiperarmsthatareoutofalignment.Cleantheblades
andwindshieldasdescribedabove.Adjustthewiperarmso
thatthereisevenpressurealongtheblade,andsothatthe
bladeatrestisperpendiculartothewindshield.Ifproblems
persist,thebladesandwiperarmsshouldbereplaced.
Thewiperbladescanberenewedinoneoftwoways:either
byreplacingthecompletebladeorbyreplacingjusttherubber
insert.
Insertreplacementisthemosteconomicalmethod,al-
thoughovertimethewiperbladeitselfwillbecomeworn.One
ruleofthumbwouldbetoreplacejusttheinsertseverysecond
time.
Wiperblades,replacing
1.Pivotwiperarmoffwindshield.
2.Positionwiperbladeapproximatelyperpendicularto
wiperarm.
3.Removewiperbladefromwiperarmbydepressingre-
tainingtabandslidingbladeoutofarm.SeeFig.1.
Dropsthatremainbehindafterwipingareusuallycausedby

NOTE-
oil,roadfilm,ordieselexhaustresidueontheglass.Usean

Somewiperbladeversionsmayhavetworetaining
alcoholorammoniasolutionoranon-abrasivecleaner(such

tabs.
asBon-Ami

tocleanthewindshield.
GENERAL

611-2

WIPERSANDWASHERS
5.Slidenewinsertthroughwiperbladeguides.Lockin-
sertmplaceatendgudes.
.,\

--

--

,

1
Wiperarms,removingandinstalling
Fig.1.

Windshieldwiperbiaderetainingtab.Pressinontab(arrow)
toreleasebfadefromarm.
4.Installationisreverseofremoval.Instanwiperbladeto
wiperarmuntilretainingtabcanbeheardtoclickinto
position.
Wiperbiadeinserts,replacing
1.Removewiperbladeasdescribedearlier.
2.Unhookendofwiperbladeinsertfromwiperarm
guides.SeeFig.2.
0011784
Fig.2.

Unhookwiperbiadeinsertfromwiperarmguide.Ifnecessary,
guideslightlyusingneed1enosepliers.
3.Pulloldinsertfromwiperarmguides,notinginstallation
position.
4.Removemetalsupportstripsfromoldinsertandinstan
intoslotsinnewinsert,notinginstallationdirectionof
cutoutsinsupportstrips.
GENERAL
NOTE-
Thenotchedcutoutsintheretainingstripsshoulden-
gagethemoldednotchesintheinserts.
NOTE-
On2-doormodelsitmaybenecessarytoraisethe
hoodtotheserviceposition.See410Fenders,Engine
Hood.
CAUTION-
"Usefendercovertoprotectwindshield.
"Removewindshieldwiperfusetopreventacci-
dents.
1.Withenginehoodinclosedposition,removebothwiper
blades.
2.Openhood.Removecapcoveringwiperarmretaining
nutsbyinsertinganarrowscrewdriverbiadeinslotbe-
lowcapandpryingupward.
NOTE-
Markingpositionofwiperarmonshaftwillaidinstalla-
tion.
3.Usinga13mmsocket,removewiperarmretainingnut
andremovewiperarm.SeeFig.3.
Fig.3.

Wiperarmretainingnut.(arrow).
,
NOTE-
ftmaybenecessarytogentlyrockwiperarmbackand
forthtoloosenarmfromshaft.

4.Installationisreverseofremoval.Recheckwiperarm
tighteningtorqueafterwaiting15minutes.
TighteningTorque
"Wiperarmtowipershaft..........25Nm(18ft-Ib)
WINDSHIELDWIPERASSEMBLY
Thewindshieldwiperassembly(linkageandmotor)isre-
movedasasingleunit.Oncetheassemblyisremoved,the
wipermotorandotherlinkagepartscanberepairedorre-
placed.Foranillustrationofwiperassemblycomponents,see
Fig.4.
Hexnut
I
J
Wipermotor
Fig.4.

Windshieldwipermotorassemblyandrelatedparts.
WIPERSANDWASHERS

611-3
Windshieldwiperassembly,
removingandinstalling
(4-doormodeis)
1.Disconnectnegative(-)cablefrombattery.
NOTE-
Thewiperarmsshouldbeintheparkedpositionbefore
removingthewiperassembly.Toavoiddamagingthe
wiperarmsandpivots,donotmanuallyslideorforce
thewiperarmsacrossthewindshield.
CAUTION-
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
0013030
WINDSHIELD WIPERASSEMBLY

611-4

WIPERSANDWASHERS
2.Removewiperarmsasdescribedearlier.
3.Placeenginehoodinserviceposition.See410Fend-
ers,EngineHood.
4.Unclipenginebulkheadplenumgrilleatbaseofwind-
shieldandpulíitawayfromrubbergasket.SeeFig.5.
Fig.5.

Detachgrillclips(arrows)andpullupward.
0012527
5.Removewiringharnessretainingclipfrombulkheadin
rearofenginebay.Removescrewsretainingwiring
harnessprotectivecover.SeeFig.6.
0012529
Fig.6.

Enginebulkheadwiringharnesscoverscrews(arrows).
WINDSHIELD WIPERASSEMBLY
Fig.7.

Rightsideplenumretainingscrews(arrows).
7.Ondriver'ssideofairplenum,pushasidewiringhar-
nessandremovescrewretainingplenum.Pullplenum
upandremovefromenginecompartment.SeeFig.8.
001¿534
Fig.8.

RemovescrewatAandpullplenumhousingupward.
8.On6-cylindermodels:Removeplastictopenginecov-
ers.See110EngineRemovalandInstallation.
NOTE-
Coverínsideedgesofcowlpanelsheetmetalwiththick
tapetopreventdamageduringwiperassemblyremov-
al.
9.Removelargenutandwasheratbaseofwiperarm
shaftscowipanel.SeeFig.9.
10.Removewiperassemblysupport.SeeFig.10.
6.Onpassengersideofairplenum,pushasidewiring

11.Separateharnessatbulkheadconnector.SeeFig.11.
harnessandremovetwoscrewsretainingplenum
housing.SeeFig.7.

12.Wrapprotectivetapearoundwipershaftondriver's
sidetopreventdamagingpaintedmetalduringremov-
al.

Fig.9.

Wipershaftnutatcowl(arrow).
Fig.10.Wiperassemblysupportbolts(arrows).
0012533
0012535
Fig.11.Wiperassemblyelectricalconnector(arrow).
0012536
13.Pushwiperarmshaftdownintocowlareaandmaneu-
verwiperassemblyoutofcowl.
WIPERSANDWASHERS

611-5
14.Installationisreverseofremoval,notingthefollowing:
"Installallfastenersfinger-tightfirst.
"Onceinstalled,wipermotorshouldfirstberunto
parkedpositionandswitchedoff.
"Next,instafwiperarmsbutnotblades.
"Closehoodandfitwiperblades.
"Checkallelectricalharnessfittingsandsealinggrom-
metsforcorrectreinstallation.Replaceanywireties
cutoffduringremoval.
TighteningTorques
"Wipershaftnutatcowl.............12Nm(9ft-Ib)
"Wipersupporttowiperassembly
ortobody......................10Nm(89in-lb)
"Wiperarmtowipershaft..........25Nm(18ft-lb)
Windshieldwiperassembly,removingand
installing(2-doormodeis)
NOTE-
Thewiperarmsshouldbeintheparkedpositionbefore
removingthewiperassembly.Toavoiddamagingthe
wiperarmsandpivots,donotmanuallysiddeorforce
thewiperarmacrossthewindshield.
1.Disconnectnegative(-)cablefrombattery.
CAUTION-
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
"Usefendercovertoprotectwindshield.
2.Removewiperarmsasdescribedearlier.
3.Placeenginehoodinserviceposition.See410Fend-
ers,EngineHood.
4.Removetrimretainersatleftandrightsideandremove
airplenumgrill.SeeFig.12.
5.Removescrewsretainingwiringharnessprotective
cover.SeeFig.13.
6.Onpassengersideofairplenum,pushasidewiring
harnessandremovetwoscrewsretainingplenum
housing.SeeFig.14.
WINDSHIELD WIPERASSEMBLY

611-6

WIPERSANDWASHERS
Fig.12.Leftsideairplenumgrilltrimretainers(arrows).
uu12529
Fig.13.Enginebulkheadwiringharnesscoverscrews(arrows).
WINDSHIELDWIPERASSEMBLY
Fig.15.RemovescrewatAandpullplenumupward.
0012635
Fig.14.Rightsideplenumretainingscrews(blackarrows).Note
positiveleadstomain(+)connector(whitearrow).
7.Ondriver'ssideofairplenum,pushasidewiringhar-
nessandremovescrewretainingpienum.Pullplenum
upandremovefromenginebay.SeeFig.15.
8.Onpassengersideofenginecompartmentbulkhead,
removeenginecontrolmodule(ECM)compartment
cover.SeeFig.16.
9.Disconnectharnessconnector(s)fromECMandauto-
matictransmissioncontrolmodule(ifapplicable).Care-
fullypullharnessandwireloomasfarforwardas
possible.Ifnecessary,disconnectpositiveleadsat
main(+)connector.
10.Removewiperassemblymountingfasteners.SeeFig.
17.

0012531
Fig.16.Enginecontrolunit(ECM)compartmentcoverscrews(ar-
rows).
WIPERSANDWASHERS

611-7
Fig.18.Wiperassemblyelectricalplug(arrow).
uu1zbs6
13.Coverinsideedgesofcowipanelsheetmetalwiththick
tapetopreventdamagingitduringwiperassemblyre-
moval.
14.Wrapprotectivetapearoundwipershaftondriverside
topreventdamagingsheetmetalduringremoval.
15.Pushwiperarmshaftdownintocowiareaandmaneu-
verwiperassemblyoutofcowi.
16.Installationisreverseofremoval,keepinginmind:
"Installallfastenersfingertightfirst.
"TorquetopfastenersinsequenceindicatedinFig.17.
Thentightenwiperassemblysupportboltsinsideair
plenum.
"Wiretiewiperharnesslowiperassemblysupportin-
sideplenum.
"Onceinstalled;wipermotorshouldfirstberunto
parkedpositionandswitchedoff.
"Next,insta¡¡wiperarmsbutnotblades.
"Closehoodandfitwiperblades:
"Checkallelectricalharnessfittingsandsealinggrom-
metsforcorrectreinstallation.Replaceal]wiretiescut
duringremoval.
CAUTION-
ThegasketsandsealinggrommetsattheECM
compartmentcover(passengersideofbulkhead)
mustbeinstalledcorrectlytokeepmoistureoutof
critica¡electricalcomponente.
Fig.17.Wiperassemblymountingfasteners(arrows).

TighteningTorques
"Wipershaftnutatcowi.............12Nm(9ft-Ib)
11.Removewiperassemblysupport.RefertoFig.10.

"Wiper
supporttowiperassembly
ortobody......................10Nm(89in-lb)
12.Separateharnessatbulkheadconnector.SeeFig.18.

-Wiper
armtowipershaft..........25Nm(18ft-Ib)
WINDSHIELDWIPERASSEMBLY

611-8

WIPERSANDWASHERS
Windshieldwipermotor,removingandin-
stalling
1.Disconnectnegative(-)cablefrombattery.

8.Installwiperarmcrankinstraightlinewithlinkage.See
Fig.20.
CAUTION-
"Priortodisconnectiogthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpagevi¡¡.
"Usetendercovertoprotectwindshield.
2.Removewiperassemblyasdescribedearlier.
3.Removenutonwipermotorlinkagecrankandremove
linkagecrankfrommotor.SeeFig.19.
0012539
Fig.19.Wiperlinkagecranknut(arrow)andwipermotormounting
bolts(A).
4.Unscrewthreemotortoassemblymountingboltsand
removemotor.RefertoFig.19.
5.Insta¡¡newmotortowiperassembly.Donotinsta¡¡
crank.
6.Connectmotortoelectricalharness.Ifnecessary,re-
connectbatterytemporarily.
WINDSHIELDWIPERASSEMBLY
7.Operatemotor,thenturnoffswitch.Motorwillstopin
"park"position.
NOTE-
Wheninstallingwipercrankontowipermotor,brace
crankwithadriftpinthroughtheholeoncrankintohole
onwiperassembly.
Fig.20.Alignwipercrankwithlinkage,asillustrated.
9.Remainderofinstallationisreverseofremoval.
0012538
TighteningTorques
"Wipermotorto
wiperassembly(usenewbolts).....10Nm(89in-lb)
"Wipermotorcrankto
wipermotor(M8nut).............27Nm(20ft-Ib)

WINDSHIELDCLEANINGSYSTEM

Washerfluidreservoir,replacing
1.Openhoodandsiphonoutwasherfluidreservoir.
Thewindshieldcleaningsystemincludesthespraynozzles
intheenginehood,thewasherfluidpump,andthewasherflu-
idreservoirinthefrontpassengersideoftheenginecompart-
ment.
Thewindshieldspraynozzlescanbeaimedbyusingasew-
ingneed1eorasimilardiameterstiffpieceofwire.
Windshieldspraynozzle,
removingandinstalling
1.Openhoodandremovehoodinsulatingpadretaining
clipsuntilbottomofnozzlecanbefullyaccessed.See
410Fenders,EngineHood.
2.Carefullydisconnecthosefromnozzle.Disconnecthar-
nessconnectorsfornozzleheater.
3.Pushnozzleoutofhood.SeeFig.21.
Fig.21.Firstpushnozzleforwardthenupwardfromunderneath
hood.
4.Installationisreverseofremoval,notingthefollowing:
"Checkthatcolorsofharnessandnozzleconnector
match.
"Checkandadjustnozzlesbeforedriving.
WIPERSANDWASHERS

611-9
2.Removewindshieldwasherpumpandhoseasde-
scribedlater.
3.Removewindshieldwasherfluidlevelsensorasde-
scribedlater.
4.Removelargeplasticwasherreservoirretaineratfend-
er.
5.Removereservoir.
6.Installationisreverseofremoval,notingthefollowing:
"Oninstallationcheckthatwasherfluidhoseisnot
kinked.
"Replacehoseclamp.
Windshieldwasherfluidpump,replacing
Thewindshieldwasherfluidpumpísmountedinthewasher
fluidreservoir.
1.Openhoodandsiphonoutwasherfluidreservoir.
2.Depressretainingtabsonelectricalconnectorandun-
plugharnessconnectorfrompump.
3.Loosenhoseclampandremovewasherfluidlinefrom
washerpump.
4.PApumpoutoftank.SeeFig.22.
Fig.22.Pullwindshieldwasherpumpuptoremove(arrow).
5.Installationisreverseofremoval.Checkpumptotank
sealinggrommetfordamageandcorrectfit.Replace
hoseclamp.Checkthatwasherfluidhoseisfreeof
kinks.
WINDSHIELDCLEANINGSYSTEM

611-10

WIPERSANDWASHERS
Washerfluidleve¡sensor,replacing
(modeiswithcheckcontrol)
Thewasherfluidlevelsensorismountedinthefluidreser-
voir,nearthebottomofthecontainer.
NOTE-
Checkwireleadsatsensorforworninsulationandcor-
rosion.Checkelectricalcontactsinharnessconnector
forcorrosion.
1.Openhoodandsiphonoutwasherfluidreservoir.
2.Liftharnessconnectorretainingleverandunplughar-
nessconnectortowasherfluidlevelsensor.SeeFig.
23.
3.Pul¡fluidleve¡sensoroutfromrubbergrommet.
4.Installnewsensorintoreservoir.Checksealinggrom-
metforcorrectfit.Replaceifdamaged.
WINDSHIELD CLEANING SYSTEM

612SwitchesandElectricalAccessories
GENERAL............................612-1

Headlightswitch,replacing

...............612-5
Foglightswitch,replacing.................612-5
INTERIORSWITCHES.................612-1

Hazardwarningswitch,replacing..........612-5
Turnsignalswitchandwiperswitch,

Powerwindowswitch,replacing...........612-5
replacing...........................612-1

Outsidemirrorswitch,replacing............612-6
IgnitionSwitchAssembly................612-3
Ignitionelectricalswitch,replacing.........612-3

INTERIORLIGHTS.....................612-6
Ignitionlockcylinder,replacing............612-4

Domelight,rearmaplights,trunklight,
HeadlightandFoglightSwitchAssembly....612-5

replacingbulbs.......................612-7
GENERAL

Turnsignalswitchandwiperswitch,
replacing
Thissectioncoversreplacementofinteriorswitchesand
accessories.

Theproceduresforremovingtheturnsignalstalkswitch
andthewipersystemstalkswitcharesimilar.
Whenworkingonelectricalswitches,alwaysdisconnect
thenegative(-)cablefromthebatteryandinsulatethecable
endtopreventaccidentalre-connection.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
WARNING -
Thecarscoveredbythismanualareequippedwith
aSupplementalRestraintSystem(SRS)thatauto-'
maticallydeploysoneormoreairbags.Eachairbag
unithousesanexplosivepowerfulcharge.Any
workinvolvingtheSRSsystemshouldonlybeper-
formedbyanauthorizedBMWdealer.Makingre-
pairswithouttheproperknowledgeandspecialtest
equipmentmaycauseseriouspersonalinjury.See
721AirbagSystem(SRS)
3.Withfrontwheelspointedstraightahead,removesteer-
"Testingandreplacementinformationfortheoilores-

¡ngwheel.See320SteeringandWheelAlignment.
sureswitchiscoveredin119LubricationSystem.
NOTE-
"WirfngdiagramscanbefoundinElectricalWiring
Diagrams.
"Fuse,relayandelectricalcomponentlocationscanbe
foundin610ElectricalComponentLocations.
"Replacementinformationforthetransmissiongear
position/neutralsafetyswitchiscoveredin250Gear-
shiftUnkage.
INTERIORSWITCHES
NOTE-
Topreventmarringinteriortrim,wrapthetipsofscrew-
driversandplierswithtapebeforepryingoutswitches
orelectricalaccessories.
SWITCHES ANDELECTRICAL ACCESSORIES

612-1
1.Disconnectnegative(-)cablefrombatteryandcover
terminalwithinsulatingmaterial.
2.Removeairbagunitfromsteeringwheel.See721Air-
bagSystem(SRS).Storeairbagunitinasafeplace
w¡thpadfacingup.
NOTE-
Tohelowithreassembly,marksteeringwheelandcol-
umnbeforedisassembly.
4.Removetrimpanelfromlowerleftsideofinstrument
panel.See513InteriorTrim.
INTERIORSWITCHES

612-2

SWITCHES ANDELECTRICAL ACCESSORIES
5.Removelowersteeringcolumncoverfromsteeringcol-
umn.SeeFig.1.
uu12543
Fig.1.

Lowersteeringcolumncoverretainingscrew(arrow).
6.Removestalkswitchholderretainingscrew.SeeFig.2.
Fig.2.

Stalkswitchholderretainingscrew(arrow).
0012555
7.Depressretainingtabstoreleasestalkswitchholder.
Pushstalkswitchholderdownwardsandoffsteering
column.SeeFig.3.
8.Depresscatchesonstalkswitchandreleaseswitch
fromcolumnaSeeFig.4.
9.Cutwíretiesretainingharnesstosteeringcolumn.Dis-
connectswitchelectricalconnectorlocatedatbottomof
steeringshaft.
10.Installationisreverseofremoval,notingthefollowing:
"Placeturnsignalindicatorincenterpositionbeforein-
stalling.
"Ensurethatselfcancellingcamsonturnsignalswitch
arenotdamagedduringinstallation.
INTERIORSWITCHES
WARNING-
Oncetheairbagunitisinstalledandallotherser-
viceprocedureshavebeencompleted,starttheen-
gineandcheckthattheSRSwarninglightgoesout.
Ifthewarninglightstayson,theSRSsystemwillnot
functionasdesigned.Havethesystemdiagnosed
andrepairedbyanauthorizedBMWdealer.
0012545
Fig.3.

Depressretainingtabs(arrows)andpushholderdown-
wards.
0012556
Fig.4.

Depressupperandlowercatchessimultaneouslyandunplug
harnessconnector.
TighteningTorques
"Steeringwheeltosteering
columnspindle(Bolt).............63Nm(46ft-lb)

IgnitionSwitchASsembly

3.Removescrewretaininglowersteeringcolumncover
andremovecover.RefertoFig.1.

,
Thecomponentsoftheignitionswitchassemblyareshown
inFig.5.Theignitionelectricalswitchandtheignitionlockcyl-
indercanberemovedwiththeignitionswitchassemblyat-
tachedtothesteeringcolumn.
ignitionelectricalswitch,replacing
1.Disconnectnegative(-)cablefrombatteryandcover
terminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
2.Removetrimpanelfromlowerleftsideofinstrument
panel.See513InteriorTrim.
F~"
Fig.5.

Ignitionswitchassembly.
SWITCHES ANDELECTRICAL ACCESSORIES

612-3
4.Cleanawaycoloredsealerfromignitionswitchset
screwsandremoveslottedsetscrewsonbothsidesof
switch.SeeFig.6.
5.Releasetabsandremoveswitchafterseparatingelec-
tricalharnessconnector.
6.Installationisreverseofremoval,notingthefollowing:
3

EWSIIringantenna(Jan.1995andlatermodels)
"Beforematingignitionelectricalswitchtoignitionlock,
checkthatswitchisincorrectpositionrelativetoigni-
tionlock.
"Sealsetscrewsusingpaintorlacquer.
0012241
INTERIORSWITCHES

612-4

SWITCHESANDELECTRICALACCESSORIES
Fig.6.

Ignitionswitchsetscrews(arrows).
Ignitionlockcylinder,replacing
NOTE-
OncarswithEWS11(productiondate1/95andlater),
theringantennasurroundingtheignitionswitchmust
beremoved.See515CentralLockingandAnti-theft.
1.Insertmasterkeyfintolockcylinderandturn60°to"ra-
dio"position.SeeFig.7.
Fig.7.

Turnignitionswitch60°to"radio"position(arrow).
2.Insertathinpieceofstiffwireintoopeninginlockcylin-
derandpulllockcylinderout.SeeFig.8.
NOTE-
Onearlycars(uptoproductiondate1ol95),turnlock
cylinderback12°torelease.
INTERIORSWITCHES
0012555
0011807
0011808
Fig.8.

Withignitionkeyin"radio"position,insertstiffwireintolock
openingtoreleasecylinder.
HeadlightandFoglightSwitchAssembly
Theheadlightandfoglightswitchesareretainedintheleft
dashboardinsert.Thisalsocontainsthedriver'ssidefacelev-
e¡airvents.Toserviceeitherswitch,removeinsertbyremov-
ingasinglescrew.SeeFig.9.
NOTE-
Accesstoelectricalhamessconnectorsbehinddash
insertmaybeeasieriflowerleftdashtrimanddriver
sidekneebolsterareremoved.See513InteriorTrim.
Fig.9.

Removeretaíningscrewtopulloutleftdashinsert(arrow).

Headlightswitch,replacing
1.Removeleftsidedashinsertanddisconnectharness
connectortoheadlightswitch.SeeFig.10.
3.Removenutmountingswitchtodashinsert.SeeFig.
11.
Fig.11.Headlightswitchmountingnut(arrow).
4.Pullswitchoutfromhousing.
SWITCHES ANDELECTRICAL ACCESSORIES

612-5
0012558
5.Installationisreverseofremoval.Alignnewswitchto
dashinsert.SeeFig.12.
TighteningTorque
"Headlightswitchretainingnut.......2Nm(18in-lb)
Foglightswitch,replacing
0012559
Fig.10.Removingheadlightswitchelectricalharnessconnector

1.Removeleftsidedashinsert,asdescribedearlier,and
(arrow).

removefoglightswitchharnessconnector.
2.PAoffheadlightswitchknob.Wrappingadhesivetape
aroundknobfacilitatesremoval.

springtabstogether.
0012560
Fig.12.Fitgrooveonheadlightswitchintoswitchbezelondashinsert
(arrows).
2.Slidefoglightswitchoutofdashinsertbysqúeezing
3.Installationisreverseofremoval.
Hazardwarningswitch,replacing
1.Unclipshiftbootandliftupfromshiftleverconsole.
Carefullyremoveinsulationpad.See250Gearshift
Linkage.
2.Workingunderneathcenterconsole,pushhazard
warningswitchupandoutofconsolewithyourfingers.
3.Disconnectharnessconnectorfromswitch.
4.Installationisreverseofremoval.
Powerwindowswitch,replacing
1.Unclipshiftbootandliftupfromshiftleverconsole.
Carefullyremoveinsulationpad.See250Gearshift
Linkage.
2.Workingunderneathcenterconsole,pushwindow
switchupoutofconsolewithyourfingers.SeeFig.13.
3.Disconnectharnessconnectorfromswitch.
4.Installationisreverseofremoval.
INTERIORSWITCHES

612-6

SWITCHES ANDELECTRICAL ACCESSORIES
Fig.13.Removingwindowswitchfromconsole.
Outsidemirrorswitch,replacing
0012561
1.Carefullyprymirrorswitchfromarmrest.SeeFig.14.
Fig.14.Pryoutsidemirrorswitchfromdoorarmrest.
2.Disconnectharnessconnectorfromswitch.
3.Installationisreverseofremoval.
INTERIORLIGHTS
0013168
INTERIORLIGHTS
Domelight,rearmaplights,trunklight,
replacingbulbs
1.Prydomelightoutfromleftside.SeeFig.14.
Fig.15.Domelightassemblybeingremoved.
2.Releaselockingbladeandswingbackreflector.Spread
apartcontactbladestoreplacebuib.
3.Pryrearmaplightoutwithsmallscrewdriver,remove
reflectorandreplacebulb.SeeFig.16.
Fig.16.Rearinteriorlightassemblyshownremoved.
0011855

4.Usescrewdrivertocarefullypryofftrunklightlensand
replacebulb.SeeFig.17.
Fig.17.Trunklightlensbeingremoved.
InteriorLightBulbWattages
"Domelight...........................10watts
"Rearmaplight.........................5watts
"Trunklight............................10watts
SWITCHESANDELECTRICALACCESSORIES

612-7
uulio56
INTERIORLIGHTS

INSTRUMENTCLUSTER...............620-1
Instrumentcluster,seif-testing............620-1
Instrumentcluster,removingandinstalling...620-1
Instrumentclusterbulbs,replacing.........620-2
GENERAL
Thisrepairgroupcoversremovalandinstallationofthein-
strumentclusterandtheMulti-informationDisplay(MID)mod-
ule.Bulbreplacementinformationfortheseunitsisalso
includedhere.
NOTE-
Aquickcheckofthetemperaturegaugeanditselectri-
calcircuitisgivenin170RadiatorandCoolingSys-
tem.Usethisproceduretodiagnoseafaulty
temperaturegauge
INSTRUMENTCLUSTER
Whenservicingtheinstrumentcluster,alwaysdisconnect
thenegative(-)cablefromthebatteryandinsulatethecable
endtopreventaccidentalre-connection.
Instrumentcluster,seif-testing
Severa¡differentversionsofthebasicinstrumentcluster
havebeenfittedinE36cars.Itispossibletoperformaninstru-
mentclustertestanddisplaysystemtestinformation.
Someoftheinformationdisplayedbytheinstrumentcluster
duringseif-testingisusedforinterna¡BMWorganizationpur-
poses,suchasmatchingthecorrectinstrumentclustercom-
ponentsduringpartsreplacement.Otherfunctionstestthe
variousinstrumentmodules.Self-testisalsousedtorecode
theinstrumentclusterafterremoval.
Inlaterproductionvehicles(1996andlater)thetestresults
canbedownioaded,viathediagnosticplug,byanauthorized
BMWdealertechnician.
1.Turnignitionto"radio"position.
2.Pressandholdresetbuttonontrip-odometeruntiltrip-
odometerdisplayshowsnumericalcodes.
620Instruments
4.Turnoffignition.
Instrumentcluster,
removingandinstalling
INSTRUMENTS 620-1
GENERAL............................620-1

Odometercodingplug,replacing...........620-2
Vehiclespeedsender,replacing...........620-3
MULTI-INFORMATION DISPLAY(MID)...620-4
Multi-InformationDisplay,
removingandinstalling.................620-4
3.Witheachsubsequentpressofthebutton,adifferent
functionistested.Somefunctionswillactivateneed1e
gauges.
1.Disconnectnegative(-)cablefrombatteryandcover
terminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
2.Removeairbagunitfromsteeringwheel.See721Air-
bagSystem(SRS).Storeunitinasafeplace.
WARNING -
Theairbagisanexplosivedevfceandshouldbe
treatedwithextremecaution.Improperhandlingof
theairbagcouldcauseseriousinjuryordeath.
Storetheairbagwiththehornpadfacingup.If
storedfacingdown,accidentaldeploymentcould
propelitvfolentlyintotheair,causinginjury.
3.Withfrontwheelspointedstraightahead,removesteer-
ingwheel.See320SteeringandWheelAlignment.
4.Removeinstrumentclusterretainingscrews.SeeFig.
1.
5.Placeatoweloversteeringcolumn.Carefullytilttopof
clusteroutofdashpanel.Unlockanddisconnecthar-
nessconnectorsfrombackofcluster.SeeFig.2.
INSTRUMENTCLUSTER

620-2INSTRUMENTS
Fig.1.

Instrumentclusterretainingscrews(arrows).
INSTRUMENT CLUSTER
0012562
Fig.3.

Turnbulbbase45°indirectionshown(arrow).
l
v

wrv
9

10

11

12

13

14

15

16

)7

18

19

20
y
21
1.Temperaturewarning

12.Brakefluidwarning
oo13n6

2.Rightturnsignal

13.Brakepadwearwarning
3.Instrumentlighting

14.ABSwarning
Fig.2.

Instrumentclusterconnectorlockinglever(arrow).

4.Oilpressurewarning

15.Seatbeltwarning
5.Highbeam

16.ASTwarning
6.Batterycharginglamp

17.Checkcontrol
6.Installationisreverseofremoval,notingthefollowing:

7.Leftturnsignal

18.Checkengine
"Instrumentclusterharnessconnectorlockinglevers

8.Lowfuelwarning

19.LCDlighting
mustbein
up
positionbeforeinstallingconnector.

9.Airbagwarning

20.Rearfoglight(notused)
10.Catalyticconverterwarning

21.Frontfoglights
"Installairbagtosteeringwheelasdescribedin721

11.Emergencybrake
AirbagSystem(SRS).

0012563
"Reconnectnegative(-)cabletobatterylast,onceal¡

Fig.4.

Bulbdesignationchart.
harnessconnectorshavebeenreconnected.
"RecodeclusterasdescribedinInstrumentcluster,

CAUTION-
seif-testing.

Notewattageofbulb.Excessivewattagecould
meltclusterhousing.Replacedefectivebulbswith
Instrumentclusterbulbs,replacing

reptacementbulbsofthesamewattage.
1.Removeinstrumentclusterasdescribedabove.

Odometercodingplug,replacing
2.Removefaultybulbbyturningbulbbase45°inits
mountandremovefromhousing.SeeFig.3.

Thecodingplugmaintainsarecordofthevehiclemileage.
Thebackoftheinstrumentclusteranditsbulblocationsare

1.Recordvehiclemileage.
showninFig.4.
2.Removeinstrumentclusterasdescribedearlier.

3.Breakopenplasticretainerinbackofinstrumentclus-
terandremovecodingplug.SeeFig.5.
5.Resetvehiclemileage.
1ILO
NOTE-
ConsultanauthorizedBMWdealerservicedepartment
aboutresettingvehiclemileageusingthespecialBMW
Servicetester.
Vehiclespeedsender,replacing
0
0013029
Fig.5.

Removecodingplugretainerwithascrewdriver(arrow).
4.Installcodingplugandnewretainer.Reinstallinstru-
mentcluster.
Thevehiclespeedsendersuppliesanelectronicpulsed
speedsignaltothespeedometer.Thesenderismountedbe-
neaththerearofthecar,onthedifferentialcoverplate.
1.Locatevehiclespeedsenderelectricalconnectorat
backofdifferential.Depressretainingleversoncon-
nectorandremove.SeeFig.6.
INSTRUMENTS 620-3
0013180
Fig.6.

Vehiclespeedsenderharnessconnector(A)andsender(B).
2.Removevehiclespeedsenderretainingscrewsandre-
movesenderfromdifferentialcover.
3.Oninstallation,replaceO-ringandcoatwithoil(90W).
SeeFig.7.
0011755
NOTE-

'
Ifthespeedometerismalfunctioning,checkthevehicle

Fig.7,

O-ringcorrectlyinstalledonvehiclespeedsender,
speedsensorhamessconnectoronthereardifferen-
tial.Waterdamage,frayedwiresandcorrosionofthe
connectorcontactsareoftenthecauseofspeedometer

4.Insta¡¡senderintodifferentialandtightenmounting
malfunction.

boltsevenlyinstagesuntilthesenderisfirmlyseated.
TighteningTorque
"Vehiclespeedsender
todifferentialcover.........6.6-8.4Nm(53-74in-lb)
INSTRUMENTCLUSTER

620-4INSTRUMENTS
MULTI-INFORMATION DISPLAY(MID)
Severa¡differentversionsoftheMulti-InformationDisplay,
havebeeninstalledinE36cars.Thetop-of-the-linemodelis
calledtheOh-BoardComputer.SeeFig.8.
Ambienttemperature/ciock
Checkcontrol/clock
0013028
Fig.8.

DifferentversionsofMulti-InformationDisplay(MID)installed
inE36cars.
Multi-InformationDisplay,
removingandinstalling
TheMulti-InformationDisplay(MID)isilluminatedbybulbs.
Itmustberemovedtoreplacethebulbs.Bulbreplacementis
includedinthisprocedure.
1.Removedashboardparcelshelf.ReachunderMID
moduleandpushoutward.SeeFig.9.
2.SlideharnessretainingleverforwardtoreleaseMID
fromwiringharness.SeeFig.10.
3.ToRmoveafaultybulb,useanarrowscrewdriverto
turnbulbbase45°counterclockwíse.SeeFig.11.
MULTI-INFORMATIONDISPLAY(MID)
111
Fig.9.

RemovingtheMulti-InformationDisplay(MID)module.
0012564
Fig.10.MIDwiringharnessreleaselever(arrows).
Fig.11.Turnbulbbase45°counterclockwise.
4.Installationisreverseofremoval.
0012566

FRONTLIGHTING.....................630-1
Headlightbuib,replacing................630-1
Headlightassembly,
removingandinstalling................630-2
Foglightassembly,removingandinstalling..630-3
Frontturnsignalassembly,
removingandinstalling................630-4
GENERAL
Theheadlightandfoglightassembliesusehalogenbulbs.
Toensurethelongevityofhalogenbulbs,thebulbglass
shouldnotbehandied.Dirtandskinoílsmaycauseabulbto
failprematurely.Ifnecessarywipebulbusingacleancloth
dampenedwithrubbingalcohol.
NOTE-
Useonlyoriginalequipmentreplacementbulbs.Non-
originalequipmentbulbsmaycausefalsefailureread-
ingsonthecheckcontroldisplay(whereapplicable).
WARNING -
INhenworkingonelectricalsystems,removethe
fuseprotectingthecircuitunderrepair.See610
ElectricalComponentLocations.
FRONTLIGHTING
Headlightbulb,replacing
1.Openenginehood.
2.Workinginbackofheadlightassembly,grasprearof
bulbsocket(harnessconnector)andturncounterclock-
wise90°.Pullbulboutofheadlightassembly.SeeFig.1.
3.Disconnectharnessconnectorfrombulb.
CAUTION-
Donottouchhalogenbubswithyourbarehands.
Ifnecessarywipebulbusingacleanclothdamp-
enedwithrubbingalcohol.
630ExteriorLighting
EXTERIORLIGHTING

630-1
GENERAL............................630-1

SideMarkerLights......................630-4
REARLIGHTING......................630-4
TaillightBulbs.........................630-4
Taillightassembly,removingandinstalling...630-5
CenterBrakeLight......................630-5
Centerbrakelighthousing,replacing
(4-doorandcoupemodels)..............630-5
Licenseplatelight,removingandinstalling

..630-6
0012567
Fig.1.

Toreleasebulbfromheadlightassembly,rotatesocketcoun-
terclockwisetodisengageretainingtabs(arrows).Rightside
bulbisshowninunlockedposition.NotethatbottomtabAis
widerthanothertwo.
4.Installationisreverseofremoval.Aligntabsonbulb
basetocutoutsonrearoflensassembly.Securebulb
byrotatingclockwise90°.
BulbApplications
"Lowbeamheadlightbulb.................H9006
"Highbeamheadlightbulb................H9005
FRONTLIGHTING

630-2

EXTERIORLIGHTING
Headlightassembly,
removingandinstalling
CAUTION-
Followingheadlightassemblyworkheadlight
beamaimmustbeadjustedusingspecialequip-
ment.
1.Leftside:Removeairfilterhousing,airintakeduct,and
airmassmeter.See100Engine-General.
2.Disconnectharnessconnectorsfromheadlightbulbs.
3.Removefrontturnsignal.SeeFrontturnsignalas-
sembly,removingandinstallinglaterinthisrepair
group.
4.Removeradiatorcover.SeeFig.2.
5.Usingawrench,braceadjustingnutattopcenterof
headlight.Removethreescrewsattopofassembly.
SeeFig.3.
Fig.3.

Braceheadlightadjustingnutasshownandremovetop
screws(arrows).
FRONTLIGHTING
0012568
0012569
6.Removetwoscrewsonbottomofassembly.SeeFig.
4.
0012567a
Fig.4.

Headlightbottomretainingscrews(arrows).Screwsmount
inthreadedexpandingrivetswhichactasheadlightheight
adjusters.
7.Removeheadlightassemblyfromfront.
8.Oninstallation,tightenlowerscrewsfirstwhileholding
expandingrivetswithawrench.Thereshouldbea2.5
mmgapbetweenbottomoflensandfrontpanel.Use
adjustingnuttoraiseorlowerheadlightunit.SeeFig.5.
0012681
Fig.5.

MeasuregapA(2.5mm)betweenbottomofheadlightas-
semblyandfrontpanel.
9.Clearancebetweenhoodandheadlightcovershould
be1.5mm.Adjustbyturningupperheadlightadjustinq
nuts,thentightendowncenterscrew.SeeFig.6.

4
Foglightassembly,
removingandinstalling
1.Foglightlensreleasecatch
2.Foglightlensrearprotectivecap
3.Foglightbulb
4.Foglightlens
Fig.7.

Foglightassembly(removed).
0012682
Fig.6.

MeasuregapB(1.5mm)betweenfrontofhoodandheadlight
cover.Notehorizontalheadlightadjustingnut(1)andretaining
screw(2).
Thefollowingprocedurecoversfoglightlensandfoglight
buibreplacement.FoglightcomponentsareshowninFig.7.
0012683
EXTERIORLIGHTING

630-3
1.Insertascrewdriverinupperairductinletoffrontlower
valenceanddisengagefoglightlenscatchmechanism.
Swinglightoutwardandgentlydisengagehingedend.
SeeFig.8.
Fig.8.

Insertscrewdriverinupperairductinlet.
uu¡¿biu
2.Removerearprotectioncapanddisengagesteelwire
foglightbulbclamp.
3.Removebulbfromrearoffoglightassembly.Discon-
nectelectricalharnessfromfoglightbulb.
CAUTION-
Donottouchhalogenbulbswithyourbarehands.
Ifnecessarywipebuibusingacleanclothdamp-
enedwithrubbingalcohol.
4.Installationisreverseofremoval.Checkelectricalcon-
nectorforcorrosion.Spraywithcontactcleaner,ifnec-
essary.
BulbApplication(USAModels):
"Foglightbulb

........................Hl(55w)
FRONTLIGHTING

630-4

EXTERIORLIGHTING
Frontturnsignalassembly,

SideMarkerLights
removingandinstalling
SidemarkerlightsonlatermodelE36carsaresnappedinto
Theprocedurebelowalsoincludesturnsignalbulbreplace-

thefrontfenders.Toservice,carefullyprytheassemblyoutof
ment.

thefender,thendetachtheelectricalharnessconnectorand
bulbsocket.
1.Workinginsideenginecompartment,useascrewdriver
topressturnsignalassemblyretainingclipawayfrom
retainingtabonheadlightassemblyframe.Pushturn

REARLIGHTING
signalforward.SeeFig.9.
Fig.9.

Pressonclip(arrow).Lightslidesstraightout.
REARLIGHTING
0012571
2.Depresstabsonbulbsocketandremovefromturnsig-
nalassembly.SeeFig.10.
0012572
Fig.10.Depresslockingtabs(arrows)toremovebulbandsocket
fromturnsignalhousing.
TaillightBulbs
Toaccesstaillightbulbs,seeFig.11.Thelocationofthe
rearbulbsareshowninFig.12.Turnbulbsocket1/4turntore-
move.
Fig.11.Toremovetaillightbulbcover,turnretainer(arrow)1/aturn
counterclockwise.
Fig.12.Taillightbulbidentification.
0012574

Taillightassembly,
removingandinstalling
1.Opentrunklid.Removecoverfromrearoftaillight.Re-
fertoFig.11.
2.Depresslockingtabsonelectricalharnessconvector
anddisconnectfromrearoftaillightlensassembly.Re-
movefourtaillightassemblyretainingnuts.SeeFig.13.
0012574
Fig.13.Taillightmountingnuts(arrows)andharnessconnector(A).
3.Installationisreverseofremoval.
CenterBrakeLight
Onconvertiblemodels,itisnecessarytoopentrunklidand
removeinnertailgatetrimadjacenttolicenseplatelightas-
sembly.Thenremovetheelectricalconnectorsandfourcen-
terbrakelightretainingnuts.Pushcenterbrakelightout.
Replacebulbsifnecessary.
On4-doorandcoupemodels,opentrunklid.Workingdi-
rectlyundercenterbrakelight,turnbulbsocketcounterclock-
wise1/4turnandremovefromcenterbrakelightassembly.
Replacebulbifnecessary.SeeFig.14.
EXTERIORLIGHTING

630-5
0012575
Fig.14.Turncenterbrakelightsocketcounterclockwiseandremove
bulb.
Centerbrakelighthousing,replacing
(4-doorandcoupemodels)
1.Removerearwindowparcelshelf.See513Interior
Trim.
2.Depresstabsoncenterbrakelightelectricalconnector
anddisconnect.
3.Removeretainingscrewsandremovesocket.
4.Replacebulb.
REARLIGHTING

630-6

EXTERIORLIGHTING
Licenseplatelight,
removingandinstalling
1.Withtrunklidraised,removelícenseplatelighttrim
panelscrews.SeeFig.15.
0012576
Fig.15.Removescrews(arrows)andremovelicenseplatelighttrim
panel.
2.Usingaflattippedscrewdriver,prygentlyonrightside
oflicenseplatelightassembly.SeeFig.16.
3.Liftlicenseplatelightassemblyfromsheetmetal.Re-
leaseharnessconnectorlockingtabsandseparate
harnessfromlicenseplatelightelectricalconnector.
REARLIGHTING
Fig.16.Insertscrewdriver(arrow).
NOTE-
Inspectbulbcontactspringsfordamageandcorrosión.
Reptacesocketassemblyifnecessary.
4.Installatíonisreverseofremoval.
0012577

GENERAL
E36carsareequippedwithintegratedautomaticheating
andairconditioningsystems.Manyoftheproceduresgivenin
thisrepairgrouprequirethattheA/Crefrigerantchargebe
evacuatedusingspecializedequipment.SeeA/CSystem
WarningsandCautionslaterinthisrepairgroup.
HEATERANDCONTROLS
Blowermotor,removingandinstalling
NOTE-
On6-cylindercars,theplastictopenginecoverandfuel
railcovermustberemoved.Thefuelinjectorhamessre-
tainingscrewsmustberemovedandtheharnessset
aside.Theenginecontrolmodule(ECM)covermustbe
removed,thecontrolunitconnectorsunpluggedandthe
harnesspulledoutoftheway.See130FuelInjection.
1.Disconnectnegative(-)cablefrombattery.
2.Openhood.Unclipenginebulkheadplenumgrilleat
baseofwindshíeldandremovegrille.SeeFig.1.
HEATINGANDAIRCONDITIONING

640-1
640HeatingandAirConditioning
GENERAL ............................640-1

HeaterandA/Cairdistributionmotor,
replacing(rotary-knob)................640-10
HEATERANDCONTROLS .............640-1

RearWindowDefogger...

.............640-10
Blowermotor,removingandinstalling......640-1

RearWindowBlower(convertiblemodels)..640-10
Blowermotorresistorpack,replacing

......640-3

AIRCONDITIONING ..................640-11
Heatervalve,replacing..................640-3
Heaterbox,removingandinstalling........640-4

A/CSystemWarningsandCautions......:640-11
Heatercore,replacing.......:...........640-6

A/Ccompressor,replacing..::.::........640-12
Heatercoretemperaturesensor,replacing..640-7

A/CCompressorClutch.......:.........640-13
HeaterandA/CControlHead.............640-7

A/Ccondenser,replacing................640-14
HeaterandA/Ccontrolhead,removing

A/Creceiver/drier,replacing.............640-15
andinstalling(rotary-knob).............640-7

A/Cexpansionvalve,
HeaterandA/Ccontrolhead,removing

removingandinstalling................640-16
andinstalling(digital-display)............640-8

A/Cevaporator,removingandinstalling....640-17
HeaterandA/Ccontrolmodule,removing

A/Cevaporatortemperaturesensor,
andinstalling(rotary-knob).............640-8

replacing...........................640-17
HeaterandA/Ccontrolmodule,removing

A/Cmicrofilter,replacing................640-18
andinstalling(digital-display)............640-8
Sensorfanforinteriortemperature,

TABLES
replacing...........................640-9

a.BlowerMotorTestValues....................640-3
HeaterandA/CAirDistributionMotors......640-9

b.HeaterCoreTemperatureSensorTestValues....640-7
c.EvaporativeTemperatureSensorTestValues...640-17
d.A/CSystemFluidCapacities(total)............640-18
0012527
Fig.1.Detachgrilleretainingclips(arrows)andpullgrilleupward
andoutofrubbergasket.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
HEATERANDCONTROLS

640-2

HEATINGANDAIRCONDITIONING
3.Removewiringharnessretainingclipatbulkhead.Re-
movescrewsretainingwiringharnesscoverandpull
coverforward.SeeFig.2.
0012529
Fig.2.Mingharnesscoverscrewsatbaseofwindshield(arrows).
4.Onpassengerside,pushasidewiringharnessandre-
movetwoscrewsretainingplenumhousing.SeeFig.3.
Fig.3.

Ríghtsideplenumretainingscrews(arrows).
VU1L535
5.Ondriverside,pushasidewiringharnessandremove
screwretainingplenum.Pullplenumupandremove
fromenginebay.SeeFig.4.
6.Unclipblowermotorhousingcover,disconnectcontrol
cable,andturncenterretainer1/4turntoremovecover.
SeeFig.5.
7.Disconnectelectricalconnectorsfromblowermotor.
8.Removeleftuppersectionofblowerhousingbydetach-
ingspringclipsatedgeofhousing.SeeFig.6.
HEATERANDCONTROLS
Fig.4.

RemovescrewatAandpullairplenumupward.
0012534
0012636
Fig.5.

Blowermotorhousingclips(A);controlcable(B);andcenter
retainer(C).
i[u6,
Fig.6.

Springclips(arrows)ondriversideofblowerhousing.

9.Releaseblowermotorretainingstrapandremoveblow-
ermotorandfansfromcowlopening.
NOTE-
Twistandrotateblowermotorassemblytofacilítatere-
movalfromopening.Iftheblowermotoristoberein-
stafled,usecarenottodamagefanwheelsduring
removal.fftheblowermotorfstobereplaced,cutoff
fanwheelsatcentertoaidinremoval.
10.Installationisreverseofremoval.Wheninstallingare-
placementblowermotor,instanmotorintocowlarea
beforeinstallingfanwheels.Blowermotortestspecifi-
cationsarelistedinTablea.
NOTE-
OnreplacementblowermotorsfromBMW,thefan
wheelscomeunattachedtoaidininstallation.Locate
arrowonblowermotorandinstanfanwheelsatthispo-
sition.Besurecolorcoolngmatches.Retainfanwheels
usingthenewclips.SeeanauthorizedBMWpartsde-
partmentforthelatestpartsinformation.
Tablea.BlowerMotorTestValues
Testingvoltage

13VDC
Operatingvoltage

9-15VDC
Max.currentconsumption(approx.)

12amps
Maximumspeed

3,600-4,000rpm
Axialplay(max.allowable)

1.0mm(0.04in.)
Blowermotorresistorpack,replacing
Theblowerresistorpackisclippedintotheupperleftsideof
theheaterbox.
1.Removelowerleftdashtrimpanel.See513Interior
Trim.
2.Workingunderleft(driver's)sideofdash,unclipand
pulíoutresistorpackfromsideofheaterbox.Remove
harnessconnectorfromresistorpack.SeeFig.7.
3.Installationisreverseofremoval.
Heatervalve,replacing
Thetwo-wayheatervalveislocatedintherearoftheengine
compartmentonthedriverside.Thesolenoidoperatedvalves
controlthecoolantflowthroughthedual-chamberheater
core.
1.Drainenginecoolant.See170RadiatorandCooling
System.
HEATINGANDAIRCONDITIONING

640-3
uuiGO4I
Fig.7.

Blowerfanresistorpack(blackarrow)andresistorpackre-
ceptacle(whitearrow)belowleftsideofdash.
WARNING-
Allowthecoolingsystemtocoolbeforeopeningor
drainingthecoolingsystem.
2.Disconnecthosesandharnessconnectoratheater
valve.SeeFig.8.
001[ó38b
Fig.S.

Hoses(A)andharnessconnector(B)atheatervalve.
3.Carefullypullheatervalveoutofrubbermountingand
pullupandoutofenginecompartment.
4.Installationisreverseofremoval.Usenewhose
clamps.Inspecthosesandreplaceasnecessary.
HEATERANDCONTROLS

640-4

HEATINGANDAIRCONDITIONING
Heaterbox,removingandinstalling
Theheaterbox,locatedunderneaththecenterofthedash-
board,housestheheatercore,theA/Cevaporator,andasso-
ciatedsensorsandactuators.Removaloftheheaterbox
requiresthattheA/Crefrigerantbedischarged.
CAUTION-
"Removingtheheaterboxrequiresevacuating
theAICsystem.DONOTattemptthisprocedure
withoutpropertoolsandtraining.
"Anypersonwhoservicesamotorvehicleaircon-
ditionermust,bylaw,beproperlytrainedandcer-
tified,anduseapprovedrefrigerantrecycling
equipment.TechniciansmustcompleteanEPA-
approvedrecyclingcoursetobecertified
UU12639
Fig.10.Heatercoremountingnutsatleftsideofbulkhead(arrow).
1.Drainenginecoolant.See170RadiatorandCooling

wiperassemblyshownremovedforclarity.
System.
2.Removecompletedashboard.See513InteriorTrim.
3.Removeblowermotorasdescribedearlier.
4.Removenutretainingwaterhoseflangetorearbulk-
head.I'ushflangetooneside.SeeFig.9.
Fig.9.

Nutretainingcoolanthoseflangeatbulkhead(arrow).
NOTE-
Clearanyremainingcoolantfromtheheatercoreby
blowingcompressedairfintothecoolantfeedhose.
HEATERANDCONTROLS
0012638b
6.Cutwiretieholdingwireharnesstoheaterboxanddis-
connectcableharnessconnectorfromheaterbox.See
Fig.11.
0012647
Fig.11.Harnessconnectors(A)andcabletie(B)atheaterbox,under
driversidedash.
7.Followingmanufacturer'sinstructions,connectap-
provedrefrigerantrecovery/recycling/rechargingunitto
A/Csystemanddischargesystem.
8.UnboltA/Crefrigerantlinesflangefromenginebay
bulkhead.SeeFig.12.
9.Onmodelswithrotary-knobA/Ccontrolhead:Discon-
5.Removenutsfromheaterboxretainingbracketonen-

nectwiringharnessconnectorstoA/Ccontrolmodule
ginebulkheadleftside.SeeFig.10.Repeatprocedure

incenterconsoleandremovemodule.SeeFig.13.
forrightsidenuts.

Fig.12.MountingboltforA/Crefrigerantlineflange(arrow).
001Suu7
Fig.13.A/Ccontrolmodule(A)behindcenterconsole.Arrowspoint
toelectricalharnessconnectorstobedisconnected.
CAUTION-
ReplaceheaterandAICflangeO-ringsandtight-
enfastenerstospecifiedtorques.
0012644
HEATINGANDAIRCONDITIONING

640-5
Fig.14.Heatingandventilationductsonleftsideofheaterbox
(arrows).Rightsideductsaresimilar.
Fig.15.Heaterboxretainingbracketincenterconsole(arrow).
0012645
10.Unclipandremoveheatingandventilationductson

TighteningTorques
sidesofheaterbox.SeeFig.14.

"A/Crefrigerantlinesflange
tobulkhead....................3.5Nm(31in-lb)
11.Removeheaterboxretainingbracketoncentertunnel

"Waterhoseflangetobulkhead
andremoveheaterbox.SeeFig.15.

(M6nut)......................3.5Nm(31in-lb)
"Heaterboxretainingbracket
12.Installationisreverseofremoval.Evacuateandre-

totunnel......................4.5Nm(40in-lb)
chargeA/Csystemusingspecializedequipment.Fill
andbleedcoolingsystem.See170Radiatorand
CoolingSystem.
HEATERANDCONTROLS

640-6

HEATINGANDAIRCONDITIONING
Heatercore,replacing
1.Drainengínecoolant.See170RadiatorandCooling
System.
WARNING -
Allowthecoolingsystemtocoolbeforeopeningor
drainíngthecoolingsystem.
2.Removecenterconsole.See513InteriorTrim.
3.RemoveMulti-InformationDisplay(MID)module.See
620Instruments.
4.Removelowerdashpanelandkneebolsterondriver
side.See513InteriorTrim.
Fig.17.Wireharnessretainingclipsandwiretiesatheaterboxcover
5.Workingunderdriversideofdash,removecoolant

(arrows).
flangefromheatercore.SeeFig.16.
0012651
Fig.16.Boltsat3-waycoolantflangeunderdriver'ssideofdash(ar-
rows).
NOTE-
Residualcoolantinheatercorewillspill.Protectthe
carpet.
6.Workingatfrontofdriveshafttunnel,unclipwirehar-
nessesandmovetoonesideinfrontofheaterbox.See
Fig.17.
7.Removeheatercoretemperaturesensorsasdescribed
laterinthisrepairgroup.
8.Removefrontheaterboxcover.SeeFig.18.
9.Onrightsideofheaterbox,unclipheaterairductactu-
atinglever.Removecross-rod(withflaps)fromfrontof
heatercore.SeeFig.19.
HEATERANDCONTROLS
0012662
Fig.18.Screwsretainingfrontheaterboxcover(shownremoved)to
heaterbox(arrows).
0012661
Fig.19.PryheaterflapactuatingleverindirectionA.Pulloffairflap
cross-rodindirectionB.

10.Pul¡heatercoreupandbackward,awayfromheater
box.Ifnecessary,removeleftandrightreinforcing
bracketbolts.SeeFig.20.
CAUTION-
ReplacecoolantflangeO-ringsandtightenfas-
tenerstospecifiedtorques.
TighteningTorques
1.Removecenterconsole.See513Interiortrim.
0012660
Fig.20.PAheatercoreupandtowardbackofcar.Lowermounting
boltsforsteeringcolumnbraceandglovecompartmentsup-
portframemayhavetoberemoved(arrows).
11.Installationisreverseofremoval.Fillandbleedcooling
system.See170RadiatorandCoolingSystem.
"Coolantflangetoheatercore.......3Nm(27in-lb)

HeaterandA/CControlHead
Heatercoretemperaturesensor,replacing
Theautomaticheatingandairconditioningsystemuses
severa¡sensorstocontrolinteriorairtemperature.Usethefol-
lowingprocedureandthedatainTablebtopinpointproblems
withtheheatercoresensors.
2.RemoveMulti-InformationDisplay(MID)module.See
6201nstruments.
HEATINGANDAIRCONDITIONING

640-7
0012648
Fig.21.Removeheatercoretemperaturesensorsindirectionshown
(arrow).
Tableb.HeaterCoreTemperatureSensorTest
Values
Testtemperature

Resistance
4°F(-20°C)

84.39-109.61kohms
14°F(-10°C)

48.58-62.09kohms
32°F(0°C)

28.89-36.40kohms
68°F(20°C)

11.13-13.83kohms
140°F(60°C)

2.19-2.78kohms
212°F(100°C)

0.58-0.77kohms
Twotypesofheaterandaírconditioningcontrolheadsviere
installedinE36cars.Earlymodelshavecontrolheadswith
fourrotaryknobsandaseparatecontrolmodule.Aflexible
shaft,clippedtotherightsideofthecontrolhead,controlsthe
heaterflaps.
LatermodelE36cars,startinginapproximatelymid-1995,
havedigitaldisplaycontrolheadswithbuttons.TheA/Ccon-
trolmoduleisintegratedwiththedigitalcontrolhead.
HeaterandA/Ccontrolhead,
removingandinstalling(rotary-knob)
3.Pul¡temperaturesensorsfromheaterboxanddiscon-

1.RemoveMulti-InformationDisplay(MID)modulefrom
nectharnessconnectors.SeeFig.21.

centerofdash.See620Instruments.
4.Installationisreverseofremoval.

2.Pul¡offouterrotaryknobsfromA/Ccontrolhead.Re-
movetwoscrewsonknobbezels.Removecontrolpan-
elfaceplatebypryingitoffcontrolheadgently.SeeFig.
22.
3.Carefullypushcontrolheadbackintodashanddown-
wardthroughMIDopening.SeeFig.23.
HEATERANDCONTROLS

640-8

HEATINGANDAIRCONDITIONING
0012649
Fig.22.A/Ccontrolheadfaceplatescrewsonrotaryknobversion(ar-
rows).Oncescrewsareremoved,faceplatemustbeun-
clippedfromcontrolhead.
Fig.23.Pushcontrolpaneloutofcenterconsole.
4.Removeharnessconnectors.Unfastenheaterduct
controlflex-shaftonrightsideofcontrolheadby
squeezingretainingtab.PAshaftoutofcouplingin
controlheadandremovehead.
5.Installationisreverseofremoval.
HEATERANDCONTROLS
0012650
HeaterandA/Ccontrolhead,
removingandinstalling(digital-display)
1.RemoveMulti-InformationDisplay(MID)modulefrom
centerofdash.See620Instruments.
2.ReachintodashthroughMIDopeningandpushA/C
controlheadoutwards.
3.Disconnectharnessconnectorandremovecontrol
head.
4.Installationisreverseofremoval
HeaterandA/Ccontrolmodule,
removingandinstalling(rotary-knob)
1.RemoveMulti-InformationDisplay(MID)modulefrom
centerofdash.See620Instruments.
2.Removecenterconsole.See513InteriorTrim.
3.DisconnectwiringharnessconnectorstoA/Ccontrol
moduleincenterconsoleandremovemodule.SeeFig.
24.
0013007
Fig.24.A/Ccontrolmodule(A)incenterconsole.Arrowspointto
electricalharnessconnectorsatA/Cmodule.
HeaterandA/Ccontrolmodule,
removingandinstalling(digital-display)
TheA/Ccontrolmoduleforcarswiththedigitaldisplayis
mountedonthebackofthecontrolhead.SeeFig.25.
1.Removecontrolheadasdescribedearlierandplaceon
ananti-staticmat.

Sensor
fan
Fig.25.DigitaldisplayA/Ccontrolheadcomponents.
2.Unscrewleftandrightscrewsretainingcontrolheadto
controlmodule.Pressretainingclipsandreleasefront
platefromcontrolhead.RemoveA/Ccontrolmodule
fromcontrolheadhousing.
Sensorfanforinteriortemperature,
repiacing
Asmallelectricfan,installedintheA/Ccontrolhead,draws
cabinairpasttheclimatecontroltemperaturesensor.
1.RemoveA/Ccontrolheadasdescribedearlier.
2.Rotary-knobcontrolhead:Disconnectelectricalcon-
nectorfromtopofcontrolheadhousing.Pryopenplas-
tichousingandremovesensorfan.SeeFig.26.
0013181
Fig.26.Sensorfan(A)andharness(B)inbackofA/Ccontrolhead
(rotary-knobcontrolheadshown).
3.Digitaldisplaymodels:Disconnectelectricalharness
connectorfromcontrolheadhousing.Removescrews
holdingsensorfantobottomofcontrolmoduleandre-
move.RefertoFig.25.
4.Installationisreverseofremoval.
HEATINGANDAIRCONDITIONING

640-9
HeaterandA/CAirDistributionMotors
Therecirculation,freshairandothervent-ductflapsare
controlledelectricallyviaaseriesofairdistributionactuating
motors.Carswiththerotary-knobcontrolheadusethreeelec-
tromechanicalmotors,eachheldinplaceviaasmallplastic
clip.SeeFig.27.
Rightsideofheaterboxl
Fig.27.Locationofearlyproductionairdistributionmotors(arrows).
Latersystems(withthedigitaldisplaycontrolhead)usefive
distributionmotors,fourofwhicharedigítallycontrolled.See
Fig.28.
HEATERANDCONTROLS

640-10

HEATINGANDAIRCONDITIONING
i
El Radio
Antenna
Rear

.
,

si,-Leftside

I
d
1.Rearvents
2.Freshair
3.Face-levelvents
4.Recirculation
5.Footwellvents 0013017
Fig.28.Locationoflateproductionairdistributionmotorsinheater
box(showninrear,sideandtopviews).
HeaterandA/Cairdistributionmotor,
replacing(rotary-knob)
1.Toaccessleftsidemotors(dashventmixingorrecircu-
lationflap),removelowerdashpanelandkneebolster
ondriverside.See513InteriorTrim.
2.Toaccessrightsidemotor(freshairflap),removeglove
compartment.See513InteriorTrim.
3.Eachmotorcanberemovedafteritselectricalwiring
harnessconnectorhasbeenremoved.Squeezeplastic
cliptoreleasemotor.SeeFig.29.
Fig.29.A/Cairdistributionmotorplasticretaíningclip(arrow).Re-
leaseclipandtiltmotoroutofhousing.
RearWindowDefogger
0011877
Therearwindowdefoggerswitchisintegratedwiththe
heatingandA/Ccontrolhead.
HEATERANDCONTROLS
Fig.30.Wiringdiagramofrearwindowdefoggerandradioantenna.
RearWindowBlower(ConvertibleModels)
Ablowerfan,fittedintotherearseatback,defogstherear
window.Itwillonlyoperatewiththeenginenunningandthe
topraised.Amicroswitchbehindtherearseatsprovidesthe
signalthatthetopisraised.
Toaccesstheblowerfanmotor,itisnecessarytoremove
fourscrewsfromthecenterseatback.Removethewiringhar-
nessconnectorandmotormountingboits,thenremovemotor
bypullingitdownandforward.SeeFig.31.
ri
Suppressor
filter
1
0013005
Fig.31.Rearwindowblowerincenterofrearseatback(arrow).
Theelectricrearwindowdefoggerisintegratedwiththera-
dioantenna.SeeFig.30.

y

/f

0013014

Toaccesstherearwindowblowerrelay,removetheglove
compariment.SeeFig.32.
Fig.32.Rearwindowblowerrelaylocatedinfrontofglovecompart-
ment(arrow).
AIRCONDITIONING
Thissectioncoversremovalandinstallationofaircondition-
ingrefrigerantcomponents.A/Ctestinganddiagnosis,refrig-
erantdischarge,evacuatíonandrechargearenotcovered
here.
Thesubassembliesandlinesoftheairconditionerarefilled
witheitherrefrigerantR12(1992cars)orR-134a(1993and
latercars).ThemajorcomponentsoftheA/Csystemare
showninFig.33.
A/CSystemWarningsandCautions
WARNING-
"Alwaysbecarefulthatrefrigerantdoesnotcome
incontactwithyourskin.Alwayswearhandand
eyeprotection(glovesandgoggles)whenwork-
ingaroundtheAICsystem.Ifrefrigerantdoes
comeincontactwithyourskinoreyes:
-Donotrubskinoreyes;
-Immediatelyflushskinoreyeswithcoolwater
for15minutes;
-Rushtoadoctororhospital;
-Donotattempttotreatyourself.
"Workinaweflventilatedarea.Avoidbreathingre-
frigerantvapors.Exposuremayirrítateeyes,
nose,andthroat.Switchonexhaustlventilation
systemswhenworkingontherefrigerantsystem.
"DonotexposeanycomponentoftheAICsystem
tohightemperatures(Above80°Cl176°F)or
openflames.Excessiveheatwillcauseapres-
sureincreasewhichcouldburstthesystem.
HEATINGANDAIRCONDITIONING

640-11
0013015
WARNING-
"Keeprefrigerantawayfromopenllames.Poison-
ousgaswillbeproducedifitbums.Donotsmoke
nearrefrigerantgasesforthesamereason.
"TheAICsystemisfilledwithrefrigerantgas
whichisunderpressure.Pressurizedrefrigerant
inthepresenceofoxygenmayformacombusti-
blemixture.Neverintroducecompressedairfinto
anyrefrigerantcontainer(fullorempty),capped
offAICcomponent,orpieceofserviceequip-
ment.
"Refrígerantgasesareheavierthanair,displace
oxygenandmaycausesuffocationinareasof
poorcírculation,forexampleunderacar.Switch
onexhaustlventilationsystemswhenworkingon
therefrigerantsystem.
"Stateandlocalgovernmentsmayhaveadditional
requirementsregardingairconditioningservic-
ing.Alwayscomplywithstateandlocallaws.
"ElectricweldingnearrefrigeranthosescausesR-
134atodecompose.Dischargesystembefore
welding.
CAUTION-
-AsofJanuary1,1992,anypersonwhoservices
amotorvehicleairconditionermust,bylaw,be
properlytrainedandcertified,anduseapproved
refrigerantrecyclingequipment.Technicians
mustcompleteanEPA-approvedrecycling
coursetobecertified.
"Itisrecommendedthatal¡systemrefrigerantAIC
refrigerantbelefttoanauthorizedBMWdealeror
otherqualifiedAICservicefacility.
"Donottopoffapartiallychargedrefrigerantsys-
tem.Dischargesystem,evacuateandthenre-
chargesystem.
"R-134aandR-12refrigerantsandrefrigerantoils
andsystemcomponents,includinghosesand
sealingO-rings,areNOTcompatible.Compo-
nentdamageandlorsystemcontaminationwill
result.
"Themixtureofrefrigerantoil(PAGoil)andrefrig-
erantR-134aattackssomemetalsandalloys(for
example,copper)andbreaksdowncertainhose
materials.Useonlyhosesandlinesthatareiden-
tifiedwithagreenmark(stripe)ortheletteringR-
134a".
"ImmediatelyplugopenconnectionsonAICcom-
ponentstopreventdirtandmoisturecontamina-
tion.
"Donotsteamcleancondensersorevaporators.
Useonlycoldwaterorcompressedair.
AIRCONDITIONING

640-12

HEATINGANDAIRCONDITIONING
A/CCompressor,replacing
1.Followingmanufacturer'sinstructions,connectanap-
provedrefrigerantrecovery/recycling/rechargingunitto
A/Csystemanddischargesystem.
WARNING -
Donotdischarge%hargetheAICsystemwithout
properequipmentandtraining.Damagetothevehi-
cleandpersonalinjurymayresult.
2.Removesplashshieldfromunderengine.
3.MarkA/Cdrivebeltwithdirectionofrotation.Remove
A/Cbelttensionertrimcap.SeeFig.34.
0011988
Fig.34.Toaccesstensionerretainingbolt,removetrimcapfrom
drive-belttensioner.
Fig.33.A/Ccomponents.Arrowsindicatedirectionofrefrigerantflow.
AIRCONDITIONING
4.On4-cylinderengines:LoosenA/Cbelttensionerbolt
undertrimcap,thenremovebeltfromA/Ccompressor.
SeeFig.35.
~=1
A/Ccompressor

A

0013019
Fig.35.4-cylinderengines:LoosenretainingboltAontensionertore-
leasedrive-belttension.Toincreasetension,rotatepulleyin
directionofarrow,thentightenboltA.
5.On6-cylinderengines:ReleasetensiononA/Cbeltby
turningtensionerpulleyclockwíse(againstspringten-
sion).SeeFig.36.
NOTE-
Detailedinstructionsfordrive-beltremovalandinstalla-
tioncanbefoundin020MaintenanceProgram.

Fig.36.6-cylinderenginebeltdiagram:ToremoveA/Cbelt,leverten-
sioner(A)inclockwisedirectionusinglong-handledwrench
orbreaker-bar.
6.Disconnectelectricalharnessconnectorfromcom-
pressor.
7.RemoveA/Cpressurehoseandsuctionhoseflange

10.Beforerecharging,evacuatesystemforatleast30min.
boltsfromcompressor.PlughosesimmediatelySee

Rechargesystemfollowingequipmentmanufacturer's
Fig.37.

instructions.SeeTabled.A/CSystemRefrigerant
Capacities.
0011879
Fig.37.A/Ccompressorpressurehose(A)andsuctionhose(B).(6-
cylinderengineshown.4-cylinderengineissimilar.)
HEATINGANDAIRCONDITIONING

640-13
Fig.38.A/Ccompressormountingboits(arrows).
9.Installationisreverseofremoval.
CAUTION-
"AlwaysreplaceO-ringswhenreconnectingre-
frigerantfines.
"Wheninstalllnganewcompressoralwaysre-
placereceiverldrierunit.
TighteningTorques
"A/Ccompressortoengineblock....22Nm(17ft-Ib)
"A/ClineflangetoA/Ccompressor
5/8in.fine. .....................20Nm(15ft-Ib)
3/4in.fine......................39Nm(29ft-Ib)
7/8in.fine... ...................42Nm(31ft-Ib)
11/16in.fine....................48Nm(35ft-Ib)
A/CCompressorClutch
Thecompressorclutchcanbereplacedwithoutdisturbing
thesealedrefrigerantsystem,althoughclearancesinthesix-
cylindercarsmaybeverytight.Detachthecompressorfrom
thecompressorbrackettogainextraclearance.
8.Removecompressormountingboits.SeeFig.38.Re-

TypicalA/CcompressorandclutchisshowninFig.39.
movecompressorbypullingdownwardfromunder-
neathcar.

Removedriveplateandpulleytoaccessclutchmagnetic
winding.SeeFig.40.
AIRCONDITIONING

640-14

HEATINGANDAIRCONDITIONING
7
Fig.39.A/Ccompressorandclutchcomponents.
800871208
1.Clutchplateretainingbolt

5.A/Ccompressorpulley
2.Clutchplate

6.Clutchretainingcirclip
3.Pulleyretainingcirclip

7.Clutch(magneticwinding)
4.Clutchbearing

8.Compressor
00870082
Fig.40.A/Ccompressordriveplatecanbeheldstationarywithstrap
tooltoallowremovalofretainingbolt.
NOTE-
BMWsareequippedwithcompressorsfromvarious
manufacturers.Specialtoolsmayberequiredtore-
movedriveplateorpulley.
AIRCONDITIONING
TighteningTorque
"Compressorclutchbolt
tocompressorshaft..............20Nm(15ft-Ib)
A/Ccondenser,replacing
1.Followingmanufacturer'sinstructions,connectanap-
provedrefrigerantrecovery/recycling/rechargingunitto
A/Csystemanddischargesystem.
WARNING -
DonotdischargelchargetheAICsystemwithout
properequipmentandtraining.Damagetothevehi-
cleandpersonalinjurymayresult.
2.Removefrontbumperandradiatorgrilles.See510Ex-
teriorTrim,Bumpers.
3.Removeauxiliaryelectricradiatorfan.See170Cool-
ingSystem.
4.DetachA/Clinesfromlowerrightcornerofcondenser.
Pluglinesimmediately.SeeFig.41.
Fig.41.A/Cflangeboltsatcondenser(arrows).
5.Removecondensermountingboltsfromfrontradiator
support.SeeFig.42.
6.Liftupcondensertodisengagefromlowermountsand
removefrombelow.
7.Installationisreverseofremoval.
CAUTION-
"AlwaysreplaceO-ringswhenreconnectingre-
frigerantfines.
"Wheninstallinganewcondenseralwaysreplace
receiverldrierunit.

Fig.42.UpperA/Ccondensermountingbolts(arrows).
8.Beforerecharging,evacuatesystemforatleast30min.
Rechargesystemfollowingequipmentmanufacturer's
instructions.SeeTabled.A/CSystemRefrigerant
Capacities.
A/Creceiver/drier,replacing
TheA/Creceiver/drierismountedinthefrontrightcorneeof
theenginecompartmentbehindtheheadlightassembly.
CAUTION-
Thereceiver/driermustbereplacedwhen
-ThereisdirtintheAICsystem
-Thecompressorhasseizedorhasbeenre-
placedforanyreason
-Thecondenserorevaporatorarereplacedfor
anyreason
-TheAICsystemisleakingandthereisnomore
refrigerant
-TheAICsystemwasopenfor24hoursormore.
1.Followingmanufacturer'sinstructions,connectanap-
provedrefrigerantrecovery/recycling/rechargingunitto
A/Csystemanddischargesystem.
2.Removerightheadlightassembly.See630Exterior
Lighting.
CAUTION-
3.DisconnectA/Celectricalharnessconnectors.SeeFig.

AlwaysreplaceO-ringswhenreconnectingrefrig-
43.

erantlines.
4.Removerefrigerantpressurelinesfromreceiver/drier.
Pluglinesimmediately.
5.Removereceiver/driermountingbolts.
0013182
6.Removeunderbodysplashshieldonpassengerside.
SeeFig.44.
7.Removepassengersidebrakecoolingduct.Discon-
nectoutsidetemperaturesensorharness,ifapplicable.
HEATINGANDAIRCONDITIONING

640-15
0012669
Fig.43.A/Creceiver/drierelectricalharnessconnectors(A),pressure
lineretainingbolts(B),andmountingbolts(C).
0012668
Fig.44.Passengersidesplashshieldretainingscrews(arrows).
8.Pushreceiver/drierdownandremovefromunderneath
car.Makesurethatreceiver/drierisclearofanyelectri-
calharnesses.
9.Installationisreverseofremoval.
10.Beforerecharging,evacuatesystemforatleast30min.
Rechargesystemfollowingequipmentmanufacturer's
instructions.SeeTabled.A/CSystemRefrigerant
Capacities.
AIRCONDITIONING

640-16

HEATINGANDAIRCONDITIONING
A/Cexpansionvalve,
removingandinstalling
Fig.45.Controlmodulecarrierretainingscrews(arrows).
1.Followingmanufacturersinstructions,connectanap-
provedrefrigerantrecovery/recycling/rechargingunitto
A/Csystemanddischargesystem.
WARNING -
Donotdischarge%hargetheWCsystemwithout
properequipmentandtraining.Damagetothevehi-
cleandpersonalinjurymayresult.
2.Removeglovecompartmentandglovecompartment
supportframe.See513InteriorTrim.
3.Removerightsidefootwellvents.
4.Removerightsidecontrolmodulecarrierscrewsandtilt
carrierdown.SeeFig.46.
5.Removeexpansionvalvecover.SeeFig.46.
Fig.46.Fourscrewsretainexpansionvalvecover(arrows).
AIRCONDITIONING
0012666
0012663
6.RemoveA/Crefrigerantlinefiangebolt(s)fromexpan-
sionvalve.Pluglinesimmediately.SeeFig.47.
NOTE-
Ifnecessary,removeairplenumgrillefromrearofen-
ginecompartmentasdescribedearlierinBlowermo-
tor,removingandinstalling.Removewiringhamess
coverscrewsandthenremoverightsideplenum
screws.Reachingfintotheplenumchamber,remove
AICfineflangebolttoallowexpansionvalveroomfor
removal.
Fig.47.Refrigerantlinefiangemountingboltatexpansionvalve
(arrow).
7.Removescrewsfromtopofexpansionvalveandre-
moveexpansionvalvefromevaporator.SeeFig.48.
Fig.48.Expansionvalvemountingscrews(A).
0011667

CAUTION-
AlwaysreplaceO-ringswhenreconnectingrefrig-
erantfines.
9.Beforerecharging,evacuatesystemforatleast30min.
Rechargesystemfollowingequipmentmanufacturer's
instructions.SeeTabled.A/CSystemRefrigerant
Capacities.
A/Cevaporator,removingandinstalling
1.Followingmanufacturer'sinstructions,connectanap-
provedrefrigerantrecovery/recycling/rechargingunitto
A/Csystemanddischargesystem.
2.Removecompleteheaterboxasdescribedearlier.
3.Removeexpansionvalveasdescribedearlier.
4.Unfastenevaporatorsensorelectricalharnessconnec-
torandpulioutsensorfromieftsideofheaterbox.See
Fig.50.
Fig.49.Pulloutevaporatorsensorfromhousingindirectionofarrow.
5.Removerearheaterboxcover.
6.Removeclipsretaininglowerevaporatorhousingcover.
Tiltoutheatercore,thenpullevaporatoroutofhousing.
7.Installationisreverseofremoval.
CAUTION-
AlwaysreptaceO-ringswhenreconnectingrefrtg-
erantfines.
8.Beforerecharging,evacuatesystemforatleast30min.
Rechargesystemfollowingequipmentmanufacturer's
instructions.SeeTabled.A/CSystemRefrigerant
Capacities.
HEATINGANDAIRCONDITIONING

640-17
8.Installationisreverseofremoval.

A/Cevaporatortemperaturesensor,
replacing
ou12b46
Theevaporatortemperaturesensorismountedintheleft
(driver)sideoftheheaterboxbehindthecenterconsole.
1.Removelowerdashpanelandkneeboisterondriver
side.See513InteriorTrim.
2.Removeleftfootwellventilationductbyremovingre-
tainingrivetinbottomofduct.Pullitdownandaway
fromheaterbox.SeeFig.50.
Fig.50.Leftfootwellventilatíonduct(arrow).
0o1300ba
3.Disconnectsensorelectricalconnectorfromheater
box.Pullsensorstraightoutofheaterbox.RefertoFig.
49.
4.Installationisreverseofremoval.Tablec.listsevapo-
ratortemperaturesensortestvalues.
Tablec.EvaporatorTemperatureSensor
TestValues
Testtemp.

Resistance
23°F(-5°C)

11.4-11.9kohms
32°F(0°C)

8.8-9.2kohms
41°F(5°C)

6.8-7.2kohms
50°F(10°C)

5.3-5.6kohms
59°F(15°C)

4.2-4.5kohms
68°F(20°C)

3.3-3.6kohms
77°F(25°C)

2.6-2.9kohms
86°F(30°C)

2.1-2.3kohms
95°F(35°C)

1.7-1.9kohms
AIRCONDITIONING

640-18

HEATINGANDAIRCONDITIONING
A/Cmicrofilter,replacing
1.Removeglovecompartment.See513InteriorTrim.
2.Removerightfootwellventilationduct.SeeFig.51.
0012664
Fig.51.Unfastenretainingrivetsfromrightventilationduct(arrows).
3.Removerightsidecontrolmodulecarrierscrewsandtilt
carrierdown.SeeFig.52.
Fig.52.Controlmodulecarrierretainingscrews(arrows).
0012666
4.RotateA/Cmicrofilterhousingreleaseknobabout45°
counterclockwiseandremovefilterhousingcover.See
Fig.53.
5.Removemicrofilterwhilemovingmoduleharnesses
outoftheway.
6.Installationisreverseofremoval.
AIRCONDITIONING
Fig.53.A/Cmicrofiltercoverreleaseknob(arrow)onpassengerside
ofheaterbox.
Tabled.A/CSystemFluidCapacities(total)
Fluid

IQuantity
R-12refrigerant

1200gt25g
(2.65Ibsa0.05lbs.)
R-134arefrigerant

1000g±25g
(2.20Ibs.t0.05lbs.)
PAGoilSP-10

1200mlf20ml
(R12system) (6.8oz.±0.7oz.)
Nippondeso120miRefrigerantoil
(R134asystem)

ISeikoSeiki150m1

GENERAL............................650-1

Rearspeaker,removingandinstalling......650-5
Doorpanelspeaker,
AUDIOSYSTEM.......................650-1

removingandinstalling.................650-5
Radioconnector........................650-6
RADIOANDSPEAKERSERVICE.......650-2
Radio,removingandinstalling............650-2
Leftfootwellspeaker,
removingandinstalling................650-3
Rightfootwellspeaker,
removingandinstalling................650-4
GENERAL

AUDIOSYSTEM
ThissectioncoverstheBMWfactory-installedsoundsys-

TheBMWE36isequippedwithathreebandradio/cassette
tem,includingradioandspeakerremoval,radioconnectors

playerunitmountedinthemiddleofthecenterconsole.Inad
andterminaldesignations.

dítiontoAMandFMbands,theradiowillreceivebroadcasts
fromtheNationalWeatherService.
Theantennaisincorporatedintotherearwindowdefogger.
650Radio
Fig.1.

Radioamplifier(premiumpackage)inluggagecompartment
behindleftpanel.
RADIO 650-1
TABLE
a.RadioConnectorTerminalDesignation..........650-6
ThecassettedeckisequippedwiththeDo1byTMCnoisere-
ductionsystem,forimprovedtapeperformancewithreduced
backgroundtapenoise.
A6-speakeraudiosystemwasstandardintheearlyyears
ofthemodelline.Manyadditionalfeatureshavebeenin-
stalledasoptionalorstandardequipmentduringthevehicle
productionrun.
"A200-wattpoweramplifierwithcustom-contoured
equalizationandtenspeakeroutput.SeeFig.1.
"Amulti-disccompactdiscchanger,forwhichthevehicle
andtheradioareprewired.SeeFig.2.
Fig.2.

Optionalmulti-disccompactdiscchangeranddisccartridge.
AUDIOSYSTEM

650-2RADIO
"A320-wattHarmon-Kardontenspeakersystem,including

RADIOANDSPEAKERSERVICE
aseparatehighpowermulti-channelaudioamplifierand
twosub-woofers.Inthissystem,thebassandvolumeout-
putsfromtheselectedaudiosourceautomaticallycom-

Radio,removingandinstalling
pensateforvehiclespeed,makingconstantvolume
adjustmentsunnecessary.Anadditionalfeatureofthis

CAUTION-
soundsystemistheabilitytoswitchfromnormalleft-right

"Beforebeginningworkontheradioorsound
stereointoSpatialEnhancementMode,whichproducesa

system,verifythattheradioisanoriginalequip-
fuller,roundersound.SeeFig.3.

mentBMWradioandthatthewiringharnesshas
notbeenmodified.
TheE36radioisalsoequippedwithabuilt-inanti-theftsys-
tem.lfpowerisremovedfromtheradiocircuitrybyremoving
theradioelectricalconnectors,orbydisconnectingthebat-
tery,theradioisrenderedinoperative.Theradioisnotperma-
nentlydamaged,andproperoperationcanberestoredby
enteringtheradioanti-theftcode.
Fig.3.Tenspeakersoundsystem.
RADIOANDSPEAKERSERVICE
"Servicingofaftermarketsoundequipmentshould
bereferredtoanauthorizedagentoftheequip-
ment'smanufacturer.
"Donotremoveradioordisconnectthebattery
withoutfirstobtainingtheanti-theftcode.
1.Carefullypryopensmallsquarecoversatleftandright
sidesofradio.

2.Usingspecialhexkey,turnradiomountingscrews
counterclockwisetoloosen.SeeFig.4.
0011845
Fig.4.

UsespecialhexkeyorTorxdrivertoloosen/tightenradio
mountingscrews.
3.Pul¡radiooutofinstrumentpanelopening.
4.Removeconnector(s)fromrearofradio.SeeFig.5.
Fig.5.

Radioconnectorbeingremoved.
5.Installationisreverseofremoval.
0011846
Leftfootweilspeaker,
removingandinstalling
Fig.6.

Hoodreleaseleverretainingscrew(arrow).
RADIO650-3
1.Removescrewfromcenterofhoodlatchreleaselever.
Removelever.SeeFig.6.
0012578
2.Rotateplastictrimpanelretainer1/4turn.Pul¡offdoor
sea¡fromedgeofspeakercoverandpullspeakertrim
panelbacktowardrearofcar.SeeFig.7.
0012579
Fig.7.

Rotateplasticretainer(blackarrow)andremovepanelindi-
rectionshown(whitearrows).
RADIOANDSPEAKERSERVICE

650-4RADIO
3.Removespeakerbyremovingmountingscrews.See
Fig.8.
Fig.8.

Speakermountingscrews(arrows).
0012580
4.Disconnectharnessconnector(s)fromspeaker.See
Fig.9.
001,58
Fig.9.

Disconnectspeakerelectricalconnector(s)indirectionshown
(arrows).
5.Installationisreverseofremoval.
Rightfootwellspeaker,
removingandinstalling
1.Removeglovecompartmentlowertrim.SeeFig.10.
2.Rotatespeakercoverplasticretainer1/aturn.Remove
doorsea¡atedgeofspeakercover.SeeFig.11.
3.Pul¡speakertrimpanelawayfrombodyandthenpul¡
panelbacktowardrearofcar.
RADIOANDSPEAKERSERVICE
0012582
Fig.10.Removelowerglovecompartmenttrimpanelretainingscrew
(blackarrow).Pulltrimindirectionshown(whitearrows).
0012583
Fig.11.Speakercoverretainer(blackarrow).Pulltrimindirection
shown(whitearrow).
4.Removespeakerbyremovingmountingscrews.Dis-
connectharnessconnector(s)fromspeaker.
5.Installationisreverseofremoval.

Rearspeaker,removingandinstalling

Doorpanelspeaker,
removingandinstalling
NOTE-
Rearspeakersinconvertiblemodelsareinstalledun-
dertherearsidepanels.Forrearsidepanelremoval
procedure,see411Doors.
1.Workingatrearparcelshelf,pryspeakercoverbyinner
edgeandremove.SeeFig.12.
0011632
Fig.12.Pryupinneredgeofspeakercoveroffrearparcelshelf.
2.Removemountingscrewsanddepressspeakerretain-
ingclip.SeeFig.13.Lowerspeakerintotrunk.
Fig.13.Removescrews(A)anddepressclip(B).
4.Installationisreverseofremoval.
0011633
3.Disconnectspeakerconnectorandremovespeaker
frombox.
RAM 650-5
1.Oncarswithside-impactairbags,disconnectnegative
(-)cablefrombattery.
CAUTION-
Priortodisconnecttogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
2.Removeinnerdoorpanel.See411Doors.
WARNING-
Some1997andall1998modelyearcarsare
equippedwithfrontside-impactairbagsinthefront
doors.Whenservicingthedoorswithfrontside-im-
pactairbags,alwaysdisconnectthenegative()
batteryterminal.See721AirbagSystem(SRS)for
cautionsandproceduresrelatingtotheairbagsys-
tem.
3.Onbackofdoorpanel,removenutontopofspeaker
retainingbracketandremovebracketfrombehind
speaker.SeeFig.14.
Fig.14.Speakerretainingnut(arrow).
4.Disconnectspeakerconnectorfromharnessconnector
andremoveloudspeakerforwardthroughdoorpanel.
5.Installationisreverseofremoval.Installside-impact
airbagusingnewscrews.See721AirbagSystem
(SRS).
RADIOANDSPEAKERSERVICE

650-6RADIO
RadioConnector

Tablea.RadioConnectorTerminalDesignation
Tablealistsradioconnectorterminaldesignations.Thepin
numbersareidentifiedinFig.15.
2010
304050
609070080110
120130140
150160170
Fig.15.Radioconnector.SeeTablea.
RADIOANDSPEAKERSERVICE
Terminals1-17
C1)Connector
0011850
Connector
Signal
Terminal
1

1Speaker,leftfront+
2

1

Speaker,rightfront+
3

1Speaker,leftrear+
4

1Telephonemutefeature(whereapplicable)
5

1Positive(terminalR)
6

1Frontspeaker,left
7

1I-busconnection(diagnostics)
8

Speaker,leftfront
9

1Constantpositive,Terminal30
10

Speedometersignalforspeed-sensitive
volumecontrol(whereapplicable)
11

1

Speaker,rightfront
12

1Speaker,leftrear
13

1Illumination(terminal58G)
14

Speaker,rightrear
15

1Ground(terminal31)
16

Automaticantennaorwindowantenna
amplifierorpremiumsoundsystemamplifier
17

Notassigned
!'~_T-

GENERAL............................720-1

REARSEATBELTASSEMBLY..........720-4
Rearseatbelt,removingandinstalling
FRONTSEATBELTASSEMBLY........720-2

(fixedseatbackmodels)................720-4
AutomaticFrontSeatBeltLockTensioners..720-2

Rearseatbelt,removingandinstalling
Mechanicalspringtensioner,disarming.....720-2

(fold-downseatbackmodels)............720-5
Frontseatbeltreel,removingandinstalling..720-3

Centerrearlap-belt,removingandinstalling..720-5
GENERAL
AllE36modelsareequippedwith3-pointshoulderbeltsat

tractandtensiontheseatbeltby55mm(approximately2
fourseatingpositions.On4-doormodels,thereisanaddition-

inches)intheeventofanaccident.
allapbeltinthecenteroftherearseat.
Theseatbeltreelshouldlockwhendrivingquicklythrough
Automaticseatbelttensionersareintegratedintothefront

curves,duringseverebrakingorincaseofacollision.Theau-
seatbeltlocks.Throughthe1996modelyearcars,amechan-

tomaticreeldoesnotrequireanyservicingandshouldnever
¡calspringtensionerisused.SeeFig.1.On1997andlater

beopened.Beltsthatdonotretractand/orlockproperly
cars,apyrotechnic(explosivecharge)tensionerisused.Au-

shouldbereplacedpromptly.
tomaticseatbelttensionersaredesignedtoautomaticallyre-
1.Seatbeltlockboft
2.Seatbeltlockwithmechanicalspringtensioner
3.Seatbeltanchorbar(two-doormodels)
4.Seatbeltanchorbolt
5.Seatbeltreelbolt
6.Seatbeltreel
7.B-pillarguidenut
8.B-pillarslidingguide
9.Convertibleseatbeltreel
10.ConvertibleB-pillarguide
Fig.1.

Frontseatbeltcomponents.
720SeatBelts
SEATBELTS

720-1
GENERAL

720-2

SEATBELTS
WARNING -
"Formaximumprotectionfrominjury,seatbelts
shouldbereplacedasaset(includingallhard-
ware),iftheyaresubjecttooccupantloadingina
collision.
"Seatbeltsshouldnotbemodifiedorrepaired.
Theseatbeltanchoragepointsshouldnotbe
changedormodified.
"Donotbleachordyeseatbeltwebbing.Webbing
thatisseverelyfadedorre-dyedwillnotmeetthe
strengthrequirementsofacollisionandmustbe
replaced.
"Seatbeltsshouldbeperiodicallyinspectedfor
webbingdefectssuchascutsorpulledthreads.
FRONTSEATBELTASSEMBLY
AutomaticFrontSeatBelt
LockTensioners
Theprocedurefordisablingthemechanicalspringtension-
erusedonearlycarsiscoveredbelow.Oncarswiththepyro-
technic(explosivedevice)tensioners,theorangeharness
connectorshouldberemovedfromthetensioneranytimethe
seatisremoved.
WARNING -
Boththemechanicalandthepyrotechnictensioners
arepowerfuldevícesandshouldbehandledwith
extremecare.
Mechanicalspringtensioner,disarming
1.Removefrontseat.See520Seats.
2.Disarmtensioner-electricallyadjustableseats:
"Workingatsideofseat,turnactivating/deactivating
screwclockwiseuntildisplaychangesfromgreento
red.SeeFig.2.
"Beforereinstallingseat,turnscrewuntildisplaychang-
esbacktogreen.
NOTE-
Greenisarmed.Redisdisarmed.
3.Disarmtensioner-manuallyadjustableseats:
"Cutwíretienexttotabonbowdencable.SeeFig.3.
"Turnandlifttabtodisengagecablehousingfromseat
bracket.
"Disconnectcableendfromseatlever.
"Whenreinstalling,correctlyengagetabendofcable
intoseatbracketandfasteninpositionusingnewwíre
tie.
FRONTSEATBELTASSEMBLY
0012737
Fig.2.

Electricallyadjustablefrontseat.Turnscrew(A)todisarmme-
chanicaltensioner.DisplayBtucosfromgreentored.
F19.3.Manuallyadjustablefrontseat.Turnandlifttab(arrow)todis-

Frontseatbeltreel,
removingandinstalling
1.On4-doormodels:Removeseatbeltanchorboltfrom
frontseat.RefertoFig.1.
2.On2-doormodels:Removeseatbeltanchorbarfrom
rearofdoorsill.SeeFig.4.
Fig.4.

Two-doorseatbeltanchorbar(arrow).
3.On4-doorandcoupemodels:Removeplastictrimcov-
erfromB-pillar(reardoorjambpillar)slidingseatbelt
guide.Removenutandguideloop.SeeFig.5.
4.On4-doormodels:Startingatuppercorners,peelrub-
berdoorsealsawayfromB-pillartrim.Removetrim
fromB-pillar.
5.On2-doormodels:Removereassidepanel.See411
Doors.
Fig.5.

B-pillarseatbeltguidenuttrim(arrow).
SEATBELTS

720-3
movereelandseatbelt.
9.Installationisreverseofremoval.
0012672
ou12a74
Fig.6.

B-pillartrimremovedtoshowseatbeltcross-bracketbolts
(arrows).
8.Disconnectharnessconnectorfromreelassembly.Re-
TighteningTorque
6.RemovetwoboltsholdingcrossbrackettoB-pillar.See

"Frontseatbelttoseat
Fig.6.

(usethreadlockingcompound).....47Nm(35ft-Ib)
"Frontseatbeltguideloop
7.RemoveseatbeltreelmountingboltatbaseofB-pillar.

toB-pillarslidinganchor

..........31Nm(23ft-Ib)
"FrontseatbeltreeltoB-pillar.......48Nm(36ft-Ib)
FRONTSEATBELTASSEMBLY

720-4

SEATBELTS
REARSEATBELTASSEMBLY
On4-doorE36models,therearetwo3-pointshoulderbelts
andacenterlapbeltinback.On2-doormodels,thereisno
centerrearlap-belt.
Inmodelswiththestationaryrearseatback,theshoulder
beltreelsareboltedtothemiddleoftheparcelshelf.Inmodeis
withfold-downrearseatback,theshoulderbeltreelsareat-
tachedtothefoldingseatback.
TherearseatbeltassembliesareshowninFig.7.
Fig.7.

Detafsofrearseatbeltassembly.
Seats.
REARSEATBELTASSEMBLY
1.Removerearseatcushionandbackrest.See520
2.Removeplastictrimcoverovershoulderbeltreelsfrom
rearwindowshelf.SeeFig.8.
3.Removerearwindowshelf.SeeFig.9.
4.Unboltandremoveshoulderbeltreels.
NOTE-
Theshoulderbeltanchorbeltsalsoholdthecenterlap-
beltinplace(whereapplicable).Besuretonoterelative
positionsofmetalbelt-endanchorsinordertoreas-
semblecorrectly.
bodynexttoreardoorframe.
8.Installationisreverseofremoval.
5.Removeshoulderbeltanchorboltfrombeneathrear
seat.

WARNING -
Alignmenttabsonseatbeltreelsmustberein-
stalledintheiroriginalpositions
Fig.8.

Removerearshoulderbeltreeltrimcoverfromrearwindow
shelf.Unclipplastic,thenslideoffshoulderbeltsasshownby
arrows.
Rearseatbelt,removingandinstalling

Fig.9.Removerearwindowshelf.Speakergrillesandthirdbrake
(fixedseatbackmodeis)

lightsocketwillhavetoberemoved.Thefrontoftheshelflifts
offitsclips(blackarrows)beforetheshelfslidesforward.
6.On4-doormodels:Unboltshoulderbeltlockboltfrom
7.On2-doormodels:Removerearsidepanelasde-
scribedin411Doors.Unboltshoulderbeltlockbolt
frombodynexttoquarterpanel.
TighteningTorques
"Rearseatbeltreelbolt,anchorbolt,
orlockbolttobody...............48Nm(36ft-Ib)

Rearseatbelt,removingandinstalling
(foid-downseatbackmodeis)
1.Removerearseatcushion.See520Seats.
2.Removeshoulderbeltanchorboltfrombeneathrear
seat.
NOTE-
Theshoulderbeltanchorboltsalsoholdthecenterlap-
beltinplace(whereapplicable).Besuretonoterelative
positionsofmetalbelt-endanchorsinordertoreas-
semblecorrectly.
3.On4-doormodels:Unboltshoulderbeltlockboltfrom
bodynexttoreardoorframe.
4.On2-doormodels:Removerearsidepanelasde-
scribedin411Doors.Unboltshoulderbeltlockbolt
frombodynexttoquarterpanel.
5.Unlockandflipdownfoldingrearseatbackrest.Re-
movetrimplugfrombackofcushion(luggagecompart-
mentside).
6.Removeseatbeltreelboltandwasher.SeeFig.10.
Fig.10.Rearseatbeltreelbolt(arrow).
0012676
7.Gentlypryoffplastictrimattopofbackrestandpullout
seatbeltreelfromseat.
NOTE-
Theseatbeltreelisheldsnuglybythebackrestcush-
ion.Moderateforcewillbeneededtopulíítout.
8.Installationisreverseofremoval.
TighteningTorques
"Rearseatbeltreelbolt,anchorbolt,
orlockbolttobody...............48Nm(36ft-Ib)
Centerrearlap-belt,
removingandinstalling
1.Removerearseatcushion.See520Seats.
2.Removeshoulderbeltanchorboltsfrombeneathrear
seat.
3.Installationisreverseofremoval.
SEATBELTS

720-5
NOTE-
Theshoulderbeltanchorboltsalsoholdthecenterlap-
beltinplace.Besuretonoterelativepositionsofmetal
belt-endanchorsinordertoreassemblecorrectly.
WARNING -
Alignmenttabsonseatbeltreelsmustberein-
stalledintheiroriginalpositions.
TighteningTorques
"Lap-beltreelboltorlockbolttobody.48Nm(36ft-Ib)
REARSEATBELTASSEMBLY

721AirbagSystem(SRS)
AirbagSystems........................721-1
AIRBAG SENSORS ANDELECTRONICS 721-2
SRSWarningLightandFaultDisplay.......721-2
Airbagcontactring,replacing.............721-3
Airbagcrashsensor,replacing............721-4
ZAEcontrolmodule,replacing............721-5
GENERAL
Thisrepairgroupcoversonlyremovalandinstallationofair-
bagcomponents.Airbagsystemrepairandfaultdiagnosisis
notcoveredhere.Diagnostics,componenttesting,andairbag
systemrepairshouldbecarriedoutbytrainedBMWservice
technicians.
NOTE-
SpecialtestequipmentisrequiredtoretrieveSRSfault
codes,diagnosesystemfaults,andresetltumoffthe
SRSindicatorlight.TheSRSindicatorlightwillremain
onuntilanyproblemhasbeencorrectedandthefault
memoryhasbeencleared.
WhenservicingcarsequippedwithSRS,theprecautions
onthispagemustbeobservedtopreventpersonalinjury.
AirbagSystems
TheairbagsysteminstalledonE36carsthroughthe1993
modelyearconsistedofasingleairbaginthesteeringwheel.
Thissystemcanbeidentifiedbytheorangecrashsensorslo-
catedonthefrontwheelwellsandtheabsenceofapassenger
sideairbag.
TheZAEairbagsystem,startinginmodelyear1994(pro-
ductiondate9/93andlater),providesbothadriversideanda
passengersideairbag.OnZAEvehicles,thecrashsensors
areintegratedintotheairbagcontrolmodule,locatedunder
thecenteroftherearseat.TheZAEcontrolmoduletriggers
deploymentoftheairbagsWhenitsensosthevehicledeceler-
atingatarateequivalenttoahead-oncollisionofatleast13
mph(18km/h).
Insome19974-doormodelsandall1998models,side-impact
airbagswereinstalledinthefrontdoors.Theairbagunitsare
mountedbehindthedoortrimpanels.Cautionmustbeused
whenworkingonvehiclesystemsintheproximityofairbags,
suchasthesteeringcolumn,thedashboard,orthedoors.
AIRBAGSYSTEM(SRS)

721-1
GENERAL ............................721-1

Frontside-impactairbagcrashsensor,
removingandinstalling.................721-5
AIRBAGS

.............................721-5
Driversideairbag,removingandinstalling...721-5
Passengersideairbag,
removingandinstalling.................721-6
Frontside-impactairbag,
removingandinstalling.................721-7
WARNING-
"Airbag(s)areinflatedbyanexplosivedevice.
Handledimproperlyorwithoutadequatesafe-
guards,theSystemcanbeverydangerous.Spe-
cialprecautionsmustbeobservedpriortoany
workatornearthedriversideairbag,thepassen-
gersideairbag(whereapplicable)ortheside-im-
pactairbags(whereapplicable).
"Theairbagisavehiclesafetysystem.Seriousin-
jurymayresultifSystemserviceisattemptedby
personsunfamiliarwiththeBMWSRSanditsap-
provedserviceprocedures.BMWadvisesthatall
inspectionandservicebeperformedbyanautho-
rizedBMWdealer.
"Alwaysdisconnectthebatteryandcovertheneg-
ative()batteryterminalwithaninsulatorbefore
startingdiagnostic,troubleshootingorservice
worknotassociatedwithSRS,andbeforedoing
anyweldingonthecar.
"Ifanairbaghasbeenactivatedduetoanacci-
dent,BMWspecifiesthatSRScomponentsbe
replaced.Formoreinformationonpost-collision
SRSservice,seeanauthorizedBMWdealer.
"Donotallowtheairbagunittocomeincontact
withcleaningsolutionsorgrease.Neversubject
anairbagunittotemperaturesaboye212°F
(100°C).Whenreconnectingthebattery,noper-
sonshouldbeinsidethevehicle.
"Alwaysplaceanairbagunitthathasbeenre-
movedfromitspackagingwiththepaddedside
facingupward.Donotleaveanairbagunltunat-
tended.
"!ftheairbagunitorairbagcontrolmodulehas
beendroppedfromaheightof!12meter(1Y2ft.)or
more,theairbagunitshouldnotbeinstalled.
AírbagsystemcomponentsareshowninFig.1.
GENERAL

721-2

AIRBAGSYSTEM(SRS)
Fig.1.

Airbagsystemcomponents.
AIRBAGSENSORSANDELECTRONICS
CAUTION-
"Ifanairbagisactivated,thefollowingcompo-
nentsmustbereplaced:
Airbagwithcontactring;
-Pyrotechnicseatbelttensioners(iffitted);
-SRSControlmodule;
-Impactsensors;
Allairbagswhichdidnotdeploy.
"ConsultyourBMWdealerforpartsandservice
information.
TheE36airbagsystemconsistsofthefollowingcompo-
nents:crashsensors(inearlycars,through1993),anelec-
troniccontrol/monitoringmodule(withintegratedcrash
sensorinZAEsystems),anindicatorlightintheinstrument
panel,andinflatableairbagsequippedwithgasgeneratorsin
thesteeringwheelandinthepassengersideoftheinstrument
panel(ZAEsystems).
Some1997andal¡1998carsalsohaveside-impactairbags
inthefrontdoors.
AIRBAGSENSORS ANDELECTRONICS
1.Crashsensors(through1993)

wheel
2.

SRScontrolmoduleinfrontof

5.

Side-impactairbags(1997/98)
glovecompartment(through

6.ZAEcontrolmoduleunderrear
1993)

seat(from1994)
3.

Passengersideairbagunitin

7.Side-impactairbagcrashsensors
dashboard(ZAEsystem)

indoorsilis(1997/98)
4.

Driversideairbagunitinsteering

8.

Kneebolsters
Inadditiontotheairbags,thevehiclesareequippedwíth
kneebolstersforextraprotection.
SRSWarningLightandFaultDisplay
Theairbagsystemutilizesaself-diagnosticcontrolmodule
todetectandstoresystemfaults.Ifafaultisdetected,the
SRSindicatorintheinstrumentclustercomesonandstays
on.
Whentheignitionkeyistumedon,theindicatorlightwillillu-
minateforapproximately4-6seconds.Theilluminatedlight
indicatestheself-testoftheelectroniccontrol/monitoring
module,theignítorsandcrash-sensorcircuits,andthesystem
wiring.Theairbagsystemshouldbeinspectedbyanautho-
rizedBMWdealeriftheindicatorlightdoesnotcomeon,ifit
doesnotgooutinapproximately4-6secondsafterswitching
ontheignition,orifthelightcomesonduringdriving.Ifthe
systemhasdetectedafault,thelightwillcomeonandstayon.

1.Disconnectnegative(-)cablefrombatteryandcover
negativeterminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpageviii.
2.Removedriversideairbagfromsteeringwheel.See
Driversideairbag,removingandinstallinginthis
repairgroup.
3.Withwheelsfacingstraightaheadandsteeringwheel
centered,removesteeringwheel.See320Steering
andWheelAlignment.
4.Removecontactringcover(flatplasticringcontaining
warningtext)fromsteeringwheel,ífapplicable.
5.Disconnectgroundwire,ifapplicable
6.Liftoutplasticlockfromsteeringwheel,ifapplicable.
SeeFig.2.
0011903
Fig.2.

Airbagcontactringlock(arrow).Pryoutlockandremove
spríngfrombehindlock.Someairbagsteeringwheelsarenot
equippedwithcontactringlock.
WARNING -
"Thecontactringlockholdsthecontactringinthe
centeredposition.Oncethelockisremoved,the
contactringisfreetorotate.Donotallowthecon-
tactringtorotateoncethelockisremoved.
"Ifthecontactringisaccidentallyrotatedoutof
center,turntheringeitherfullyclockwiseorcoun-
terclockwise,thenturnintheoppositedirection3
completerevolutionsuntilthealignmentarrow
canbeseenthroughthelockopening.
AIRBAGSYSTEM(SRS)

721-3
Airbagcontactring,replacing

7.Removemountingnutsorscrewsfromcontactring.
SeeFig.3.Disconnectwirelead(s)andremovecontact
Theairbagcontactringismountedtotherearofthesteer-

ringfromrearofsteeringwheel.
ingwheelandismadeupofawireribbonthatcofsandun-
coilsasthesteeringwheelistumed.Thecontactringassures
continuouselectricalcontacttothedriversideairbagunit.
Fig.3.

Airbagcontactringmountingfasteners(arrows).
8.Installationisreverseofremoval,notingthefollowing:
"Coathornslipring(electricalcontactring)withCRC®
copperpastebeforeinstallingsteeringwheel.
"Pressonlowerlockuntilitísfullyengaged.
"Wheninstallingcontactringlock,makesurelock
springengagespinsonlockandlockcover.
"Specialinstructionsapplywheninstallingairbag
equippedsteeringwheel.See320Steeringand
WheelAlignment.
Earlycars(through1993):
"Routewiringleadforhornthroughsquareopeningin
steeringwheel.
"WheninstallinganewcontactringfromBMW,remove
lockingscrewafterinstallingthecontactringtosteer-
ingwheel.SeeFig.4.
"Lockcontactringmountingfastenersinplaceusing
lacquerpaintorvarnish.
0011904
Fig.4.

Airbagcontactringlockingscrew(arrow),asinstalledonnew
replacementpartfromBMW(earlyproductioncars).
AIRBAGSENSORS ANDELECTRONICS

721-4

AIRBAGSYSTEM(SRS)
CAUTION-
Anewcontactringisheldincenterpositionwitha
screw.Thislockingdevicemustberemovedafter
contactringisinstalledonsteeringwheel.See
Fig.4.
Latercars(1994on):
"Connectgroundleadatcontactring.
"WheninstallinganewcontactringfromBMW,remove
lockingpinafterinstallingcontactringtosteeringwheel.
SeeFig.5.
Airbagcrashsensor,replacing
Fig.5.

Airbagcontactringlockingpin(arrows),asinstalledonnew
replacementpartfromBMW(laterproductioncars).Contact
ringmountíngscrewsshownatA.
CAUTION-
Anewcontactringisheldincenterpositionwitha
screworpin.Thislockingdevicemustberemoved
aftercontactringisinstalledonsteeringwheel.
SeeFig.5.
Theairbagsystemincarsproducedthrough1993usestwo
crashsensorsmountedintheenginecompartmentontheleft
andrightwheelarches.Thesensorsareidentifiedbytheiror-
angecolor.
WARNING -
Ifenairbagisdeployed,bothsensorsmustbere-
placed.
1.Disconnectnegative(-)cablefrombatteryandcover
negativeterminalwithinsulatingmaterial.
CAUTION-
Priortodisconnectiogthebattery,readthebattery
disconnectioncautíonsgivenatthefrontofthls
manualonpageviii.
AIRBAGSENSORSANDELECTRONICS
2.Removelowersteeringcolumntrimmountingscrew
andremovelowertrim.SeeFig.6.
Fig.6.

Lowersteeringcolumnretainingscrew(arrow).
3.RemoveorangeSRSconnectorfromitsholderand
carefullyseparateconnector.SeeFig.7.
Fig.7.

OrangeSRSconnectorbelowsteeringcolumn(arrow).
4.Workinginenginecompartment,removeanti-tamper
Torxscrewsfromcrashsensor.Removesensorand
disconnectharnessconnector.SeeFig.8.
5.Installationisreverseofremoval.Makesurearrowon
sensorfacesforwardwheninstallingsensor.
WARNING -
Oncetheairbagunitisinstalledandallotherser-
viceprocedureshavebeencompleted,starttheen-
gineandcheckthattheSRSwarninglightgoesout.
Ifthewarninglightstayson,theSRSsystemwillnot
functionasdesigned.Havethesystemdiagnosed
andrepairedbyenauthorizedBMWdealer.
0012543
0011891

Fig.8.

Airbagcrashsensormountingscrews(arrows)onearlycars.
NoteTorxscrewswithanti-tamperpininscrew-head.
ZAEcontrolmodule,replacing
NOTE-
SomeversionsofearlyZAEcontrolmodulesareno
longeravailablefromBMW.Whenreplacingcontrol
modulesoncarsbuiltbetweenSeptember1993and
June1994,consultaBMWpartsdepartmentforthelat-
estinformationonretrofittingthelatermodule.
3.RemoveorangeSRSconnectorfromitsholderand
carefullyseparateconnector.RefertoFig.7.
1.Disconnectnegative(-)cablefrombatteryandcover
negativeterminalwithinsulatingmaterial.

4.Workingbehindsteeringwheel,completelyloosenTorx
screws(T30)whileholdingairbaginplace.SeeFig.9.
2.Liftrearseatcushion.Unplugharnessconnectorsand

Supportairbagunittopreventitfromfallingout.
removeZAEairbagcontrolmodule,whichisboltedto
topofdriveshafttunnel.
3.Installationisreverseofremoval.
Frontside-impactairbagcrashsensor,
removingandinstalling
1.Disconnectnegative(-)cablefrombatteryandcover
negativeterminalwithinsulatingmaterial.
2.Removefrontseat.See520Seats.
3.Convertible:removerearseat
4.Removeplasticdoorsilltrim.
5.Foldupcarpetinbackoffrontseat.
6.Pulloffconnectorfromcrashsensor,whichislocated
underrugnexttodoorsi¡¡.
7.Removesensorbyremovingscrews.Notedirectionar-
rowbeforeremovingsensor.
8.Installationisreverseofremoval,notingdirectionarrow
onsensor.
AIRBAGS
AIRBAGSYSTEM (SRS)

721-5
Driversideairbag,
removingandinstalling
1.Disconnectnegative(-)cablefrombatteryandcover
negativeterminalwithinsulatingmaterial.
WARNING -
OncarswithZAEsystem:Iftheairbagsystemhas
detectedafault(SRSindicatorilluminated),await-
ingperiodofatleasttenminutesmustbeobserved
beforeremovingtheairbagfromthesteeringwheel.
Thiswillallowthesystemcapacitortodischarge,re-
ducingthepossibilityofatriggerpulsebeinggener-
atedtotheairbag.
CAUTION-
Priortodisconnectingthebattery,readthebattery
disconnectioncautionsgivenatthefrontofthis
manualonpagevi¡¡.
2.Removelowersteeringcolumntrimmountingscrew
andremovelowertrim.RefertoFig.6.
Fig.9.

Driversideairbagunitmountingscrews(arrows).
0011893
AIRBAGS

721-6

AIRBAGSYSTEM(SRS)
5.Carefullyliftairbagunitoffsteeringwheelanddiscon-

6.Installationisreverseofremoval.Tightenrightside
nectorangeharnessconnectorfromrearofairbagunit.

screwonairbagfirst(asviewedfromdriver'sseat),
SeeFig.10.

thenleftsidescrew.
NOTE-

NOTE-
Insomemodels,theairbagelectricalconnectiontothe

Ifthereisnoelectricalharnessconnectorbetweenthe
steeringwheelisviaapluginbackoftheairbagunit.

airbagandthesteeringwheel,besuretofitthepush
Thereisnowireharnesstodisconnect.

inelectricalpluginbackoftheairbagfintotheproperre-
ceptacleinthesteeringwheel.
Fig.10.Driversideairbagunitharnessconnector(arrow).
AIRBAGS
WARNING -
"Storetheremovedairbagunitwiththehornpad
facingup.Ifstoredfacingdown,accidentalde-
ploymentcouldpropelitviolentlyintotheair,
causinginjury.
"Onceanairbagisremoved,thecarmustnotbe
driven.
"Donotconnectthebatterywiththeairbagdis-
connected.Afaultcodewillbestored,settingoff
theSRSwarninglight.Specialtoolsareneeded
toresetthefaultmemory.
"Specialinstructionsapplywheninstallinganair-
bagequippedsteeringwheel.See320Steering
andWheelAlignment.
"Oncetheairbagunitisinstallndandallotherser-
viceprocedureshavebeencompleted,startthe
engíneandcheckthattheSRSwarninglight
goesout.Ifthewarninglightstayson,theSRS
systemwillnotfunctionasdesigned.Havethe
systemdiagnosedandrepairedbyanauthorized
BMWdealer.
0013184
TighteningTorque
"Airbagunittosteeringwheel........8Nm(71in-lb)
Passengersideairbag,
removingandinstalling
1.Disconnectnegative(-)cablefrombatteryandcover
negativeterminalwithinsulatingmaterial.
2.Removeglovecompartment.See513InteriorTrim.
3.Liftcoverfromtopofpassengersideairbagondash-
board.SeeFig.11.
0013108
Fig.11.Afterremovingglovecompartment,liftoutpassengersideair-
bagcover.Noteairbagmountingbolts(A)andairbagelectri-
calconnector(B).
4.Removepassengersideairbagmountingbolts.Dis-
connectelectricalharnessconnectorfromrearofair-
bagunitandremoveairbag.
5.Installationisreverseofremoval.Makesurewiringhar-
nessisnotpínchedwheninstallingairbagunitindash-
board.

Frontside-impactairbag,
removingandinstalling
1.Disconnectnegative(-)cablefrombatteryandcover
negativeterminalwithinsulatingmaterial.
CAUTION-

"Storetheremovedairbagunitwiththesoftpad
Priortodisconnectiogthebattery,readthebattery

facingup.ffstoredfacíngdown,accidentalde-
disconnectioncautionsgivenatthefrontofthis

ploymentcouldpropelitviolentlyintotheair,
manualonpageviii.

causinginjury.
2.Removeinsidedoorpanelasdescribedin411Doors.
Removevaporshield.
3.Disconnectelectricalharnessconnectorfromdoor-
mountedairbagunit.SeeFig.12.
WARNING-
Theplugconnectorinsidethedoorisnotmarkedin
orange,unlikeotherSRSconnectorsinthecar.
Fig.12.Frontside-impactairbag(innerdoorpanelremoved).Ais
electricalharnessconnector.
AIRBAGSYSTEM (SRS)

721-7
CAUTION-
"Theelectricalharnessconnectoroftheside-im-
pactairbagunitmaybeeitheronthesideofthe
unítorinthebackWhenremovingandinstalling
theunit,payattentiontotheroutingofthehar-
nesstoavoidkinksorbreaksinthewire.
4.Removemountingscrewsandremoveairbagfrom
door.
5.Installationisreverseofremoval.
WARNING-
Theside-impactairbagmountingscrewsmustal-
waysbereplacedanytimetheyareremoved.Use
newscrewswithfactory-appliedlockingsealer.
TighteningTorque
"Side-impactairbagtodoor

.......8.5Nm(75in-lb)
AIRBAGS

GENERAL
Thissectioncontainswiringdiagramsfor1992through
1998BMW3Seriesmodels.
WARNING -
Oncarsequippedwithairbags,specialprecautions
applytoanyelectricaltestingorrepair.Theairbag
unitisanexplosivedeviceandmustbehandled
withextermecare.Beforestartinganyworkonan
airbagequippedcar,refertothewarningsandcau-
tionsin720Seatbeltsand721AirbagSystems
(SRS).
NOTE-
The"

gearposition/neutralsafetyswitchisalsosome-
timesreferredtoastheautomatictransmissionrange
switch.
"TheEWS11systemisalsosometimesreferredtoas
theDriveawayProtectionSystemortheelectronicim-
mobilizationsystem.
ELECTRICALWIRINGDIAGRAMS

ELE-1
ElectricalWiringDiagrams
GENERAL ............................ELE-1

Horns

............................ELE-153
InstrumentPanel....................ELE-165
ELECTRICAL WIRINGDIAGRAMS ......ELE-2

InteriorLights/Illumination.............ELE-211
ABS

............................ELE-117

LumbarControl.....................ELE-247
ABS/AST...........................ELE-120

On-BoardComputer..................ELE-173
Airbag(SupplementalRestraintSystem)..ELE-140

ParkVentilation.....................ELE-139
AirConditioningandHeating...........ELE-129

PowerDistribution.....................ELE-2
Anti-Theft(Alpine)....................ELE-144

PowerDoorLocks...................ELE-226
Anti-Theft(EWSII)...................ELE-150

PowerMirrors.......................ELE-241
BodyComputerModule...............ELE-176

PowerSeats........................ELE-243
ChargingSystem

.....................ELE-67

PowerSunroof......................ELE-248
ConvertibleTop......................ELE-253

PowerWindows.....................ELE-231
CruiseControl.......................ELE-112

Radio/Cassette/CD/Speakers..........ELE-255
DataLinkConnector...................ELE-86

RearWindowDefogger...............ELE-160
EngineCooling.......................ELE-94

ShiftInterlock.......................ELE-110
EngineManagement...................ELE-70

Starting.............................ELE-63
ExteriorLights.......................ELE-194

TransmissionElectronics...............ELE-96
GroundDistribution....................ELE-35

WarningSystem:Chimes.............ELE-178
Headlights/Foglights..................ELE-180

Wiper/Washer......................ELE-155
HeatedSeats.......................ELE-245
ELECTRICAL COMPONENT LOCATIONS
Relayandfusepositions,groundlocations....................................seeRepairGroup610
CAUTION-
Alwaysswitchtheignitionoffanddisconnectthe
negative(-)batterycablebeforeremovingany
electricalcomponents.
"Priortodisconnectingthebattery,readthebat-
terydisconnectioncautionsgivenatthefrontof
thismanualonpageviii.
"Connectanddisconnectignitionsystemwires,
multipleconnectorsandignitiontestequipment
leadsonlywhileignitionisswitchedoff.
-Alwaysswitchatestmetertotheappropiatefunc-
tionandrangebeforemakingtestconnections.
"All-SeasonTraction(AST)isalsoreferredtoasASC
orASC+T.
GENERAL

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104370
FUSE
LINK
80A
BATTERY
FUSE
LINK
BOA
4
26
- AUXILIARY
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FUSE

IFUSEBOX
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2CA
27X19564
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RED
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51X10016
61X10816
I-1

I-1
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CONVERTIBLE
TOPCONTROL
MODULE
ELECTRICALWIRINGDIAGRAMS ELE-19
PowerDistribution
1998Except318ti(1of5)
FUEL
PUMP
161X111010
FUEL
PUMP
15~X1DD16
- FRONTPOWER
I

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IDISTRIBUTION
BOX
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21

STARTER GENERATOR
UNLOAD-
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CONTROL CONTROL CONTROL

RELAY
-

MODULE MODULE MODULE
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RELAY
BtJUMPSTART
JUNCTIONPOINT
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1998Except318ti(2of5)
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WIPER/

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UNLOADER

HIGHSPEED

COMPRESSOR

HIGHSPEED
FRONTS-7
FRONTSEAT
FRONTSEAT WASHER

DEFOGGER RELAY

RELAY CONTROL

RELAY
CONTROL

LUMBAR

CONTROL

MODULE

RELAY

(323,328,M3)

RELAY

(318)
SWITCH SWITCH SWITCH
---------f_-------------_-___--------------_----
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CHECKCONTROL

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CONTROL

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MODULE

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MODULE(ZKEIV)

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104371

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IMPACT IMPACT

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MODULE
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CONTROLMODULE MIRRORLIGHT REAR

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____________________
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ELECTRICAL
WIRING DIAGRAMS
ELE-21
Power Distribution
1998 Except
318ti (3 of 5)
2B
NOTUSED
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MODULE

CLUSTER
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MODULE MODULE
SWITCH
---
--
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TOFUSEF45

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CRUISE CRUISE
CONTROL CONTROL
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GRNIBLU
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104373
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X7002B
Power
Distribution
1998
Except318ti(4of5)
"_-__--_----."----+
ROLLOVER
MIRRORJET
LIGHT
DAYTIME
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SWITCH
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MODULE
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PowerDistribution
1995-96318ti(2of5)
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ELE-54ELECTRICALWIRINGDIAGRAMS
HEADLIGHT/

RIGHT

RIGHT

LEFT LEFT

LEFT
FOGLIGHT

HIGH RIGHT ANTI-

DOUBLE

RIGHT FRONT AUXILIARY LEFT LOW HIGH

LEFT FRONT
WASHER WASHER BEAM PARK THEFT

TEMPERATURE PRESSURE FOG

TURN

FAN

PARK BEAM BEAM

LEFT

FOG

TURN RIGHT
PUMP PUMP LIGHT LIGHT HORN

SWITCH SWITCH LIGHT LIGHT MOTOR LIGHT LIGHT LIGHT HORN LIGHT LIGHT HORN
I

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I

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1--,

1-7

1-7

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84317
ENGINE
CAMSHAFT
TRANSMISSION CONTROL

POSITION
CONTROL MODULE

_(SENSOR
MODULE
(EGS)

(DME)

~_

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I

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2I
I

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I I I C POSITION
(SENSOR
rv

Q.1
___JSHIELD
DATA
LINK
CONNECTOR
Ground Distribution
1995-96 318ti (1 of 3)
HEATED CRANKSHAFT IGNITION
OXYGEN POSITION

COIL2
I, (SENSOR LI (SENSOR

(SHIELD
SHIELD
SHIELD
RIGHT

LEFT
FRONT

LEFT
RIGHT

BRAKE

HIGH LOW

FRONT WIPER(
AUXILIARY

WASHER WASHER

FLUID

BEAM BEAM

AUXILIARY WASHER HAZARD
CHIME TURN UNLOADER JET JET WIPER
LEVEL WIPER LIGHT LIGHT BLOWER TURN MODULE FLASHER
MODULE

LIGHT

RELAY

HEATER

HEATER

MOTOR

SWITCH

RELAY

RELAY

RELAY

RELAY

LIGHT

(LOW11)

RELAY
I--,

F-
I

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I--,

I--,

I--,

F-I

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CRANKSHAFT
POSITION
(SENSOR
_SHIELD
G100
1 II,,
(1995)
BRN BRN
1G202
CYLINDER1

CYLINDER2

CYLINDER3

CYLINDER4
IGNITION IGNITION IGNITION IGNITION
COIL COIL COIL co,L
1

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ENSOR

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ASS
WIPER( LIGHT LIGHT
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MODULE

SPEED MOTOR HYDRAULIC HI-FI

RADIO

RADIO
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(
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ASS

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RIGHT

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DRIVER'S PASSENGER'S DRIVER'S
FRONT DRIVER'S MIRROR DOOR DOOR ELECTRONICS MAP

SUNROOF SPATIAL WASHER MAKEUP MAKEUP SEAT
ASSSLIP

SPEED SIDE CONTROL LOCK HANDLE CONTROL READING INERTIA CONTROL SOUND INTERVAL MIRROR MIRROR BELT
CO.TPOLMOOULE SENSOR MIRROR SWITCH HEATER SWITCH MODULE ASSEMBLY SWITCH ASSEMBLY (1996) MODULE SWITCH SWITCH SWITCH
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GroundDistribution
1995-96318ti(2of3)
BE.
PASSENGER'S

WIPER/

CRUISE

BODY
SEAT PASSENGER'S PASSENGER'S

CRASH

WASHER

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ELECTRONICS
CONTROL SEAT SEATBACK

CRUIBECONTROL CONTROL MODULE COMPUTER ACTUATOR CONTROL CLUTCH
SWITCH

HEATER

HEATER

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MODULE

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BLOWER SWITCH CONTROL ULATION CONTROL TEMPERATURE WHEEL

LIGHT THEFT

HAZARD CLEANING HOOD INDICATOR
MOTOR ILLUM SWITCH MOTOR MODULE SENSOR SWITCH SWITCH HORN

SWITCH MODULE SWITCH LIGHT
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DRIVER'S PASSENGER'S
DRIVER'S PASSENGER'S RESTRAINT
REAR
FRONT TAPE CIGAR FRONT

POWER POWER SEAT
SEAT SYSTEM
ASHTRAY ASHTRAY PLAYER LIGHTER CIGAR TELEPHONE PROGRAM

WINDOW WINDOW HEATER HEATER CONTROL
LIGHT
LIGHT LIGHT LIGHT LIGHTER EJECTBOX SWITCH

SWITCH SWITCH SWITCH SWITCH
MODULE
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-1
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7
G3021
W/ONBOARD
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ELE-56 ELECTRICALWIRINGDIAGRAMS
ANTI-

PASSENGER'S
SEAT THEFT

SEAT
OCCUPANCY CONTROL

BELT
DETECTOR MODULE

SWITCH
84320
RIGHT
DRIVER'S

DRIVER'S

REAR

DRIVER'SSEAT

DRIVER'S

LEFT

RIGHT

CENTRAL

LEFT

RIGHT
DOOR SEAT-

DRIVER'S
BRAKE

LUMBAR

SEAT

TRUNK TRUNK LOCKING LICENSE LICENSE TRUNK
JAMB

BACK

FUEL

SEAT

PAD

SUPORT

CONTROL TELEPHONE

LIGHT

LIGHT

SWITCH PLATE PLATE LIGHT SUPPRESSION
SWITCH HEATER PUMP
HEATER SENSOR MOTOR/VALVE SWITCH TRANSCEIVER ASSEMBLY ASSEMBLY (1995) LIGHT LIGHT SWITCH FILTER
F-1--,1-7I_-IF- F -,

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1
G404
1
G103
(1998)
GroundDistribution
1995-96318ti(3of3)
ZG404
CRANKSHAFT
HALL
ENGINE
TRANSMISSION

POSITION

EFFECT

CONTROL

HOTFILM

CYLINDER 1

CYLINDER2

CYLINDER3

CYLINDER4
ENGINECONTROL

CONTROL

SENSOR

CAMSHAFT

MODULE

AIRMASS

IGNITION

IGNITION

IGNITION

IGNITION
MODULE(DME)

MODULE(EGS)

-j
SHIELD

SENSOR
,~

(DME) METER COIL COIL COIL COIL
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CRANKSHAFT I
COIL

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I I I I I I ,
SHIELDL

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mYY~Y

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Y

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1G131
(1996)

GroundDistribution
1997318ti(1of3)
HEADLIGHT/ RIGHT RIGHT

RIGHT

LEFT LEFT

LEFT
89159
FOGLIGHT LOW HIGH RIGHT ANTI- DOUBLE

RIGHT FRONT AUXILIARY LEFT LOW HIGH

LEFT FRONT
WASHER

BEAM

BEAM

PARK

THEFT TEMPERATURE PRESSURE FOG

TURN

FAN

PARK

BEAM

BEAM

LEFT

FOG

TURN

RIGHT
PUMP LIGHT LIGHT LIGHT HORN SWITCH SWITCH
LIGHT LIGHT MOTOR LIGHT LIGHT LIGHT HORN LIGHT LIGHT HORN
I-i

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SHIELD
HALL
TRANSMISSION

EFFECT

HOTFILM

CYLINDER1

CYLINDER2

CYLINDERS

CYLINDER/
ENGINECONTROL

CONTROL

CAMSHAFT UNLOADER AIRMASS IGNITION IGNITION IGNITION IGNITION
MODULE(DME)

CRANKSHAFT
MODULE(EGS)

SENSOR RELAY METER COIL
COIL COIL COIL
II

POSITION

r

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ELECTRICALWIRINGDIAGRAMS ELE-57
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1
G103
1
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(1908)
RIGHT

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BRAKE STARTER HIGH LOW

FRONT WIPER/
AUXILIARY

BRAKE

WASHER WASHER

FLUID IMMOBILI- BEAM BEAM

AUXILIARY WASHER HAZARD
CHIME TURN UNLOADER LIGHT INSTRUMENT

JET

JET WIPER LEVEL ZATION LIGHT LIGHT BLOWER TURN MODULE FLASHER
MODULE LIGHT RELAY SWITCH CLUSTER

HEATER HEATER MOTOR SWITCH SWITCH RELAY RELAY. RELAY LIGHT (LOW11) RELAY
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189160
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1997318ti(2of3)
WIPER/

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CRASH WASHER ON-BOARD CONTROL ELECTRONICS
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MODULE

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MAKEUP PASSENGER'S MAKEUP
ABSSIIP

SIDE

CONTROL WINDOW HANDLE

CONTROL

READING FOOTWELL FOOTWELL CONTROL INTERVAL MIRROR

WINDOW

MIRROR
CONTROL MODULE

MIRROR

SWITCH

MOTOR

SWITCH

MODULE

ASSEMBLY

LIGHT

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PEAR CONTROL
BLOWER SWITCH CONTROL ULATION CONTROL TEMPERATURE

WHEEL

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HAZARD H000 INDICATOR

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MOTOR ILLUM SWITCH MOTOR MODULE SENSOR SWITCH SWITCH

SWITCH SWITCH LIGHT

MOTOR SWITCH ILLUMINATION
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SUPPLEMENTAL
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POWER POWER SEAT SEAT

SYSTEM
WASHER WASHER PLAYER LIGHTER CIGAR TELEPHONE
ABC
PROGRAM
I

WINDOW WINDOW HEATER NEATER

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SWITCH

MODULE

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LIGHTER

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SWITCH

SWITCH

SWITCH

SWITCH

SWITCH

SWITCH

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CENTER TRUNK TRUNK CENTRAL LICENSE LICENSE TRUNK
JAMB

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CD

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LIGHT SUPPRESSION REAR
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ANTI-

PASSENGER'S PASSENGER'S DRIVER'S

DRIVER'S

ASS

LEFT

RIGHT
SEAT

THEFT

SIDE

SEAT

SEAT

SIDE

ABS

SLIP

PUMP

FRONT

FRONT

ASS
OCCUPANCY
CONTROL

IMPACT I BELT

BELT

IMPACT

HYDRAULIC CONTROL

MOTOR

SPEED

SPEED

CONTROL
DETECTOR MODULE SENSOR SWITCH SWITCH SENSOR

UNIT MODULE RELAY SENSOR SENSOR MODULE
F-,

I

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F-I

F-I
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Y =1 -T -T Y =f
ELECTRICAL WIRING DIAGRAMS ELE-59
Ground Distribution
1997 318ti (3 of 3)
I
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F-, F-, F-,
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ELE-60 ELECTRICALWIRINGDIAGRAMS
HEADLIGHT/
FOGLIGHT

ANTI- DOUBLE

AUXILIARY
WASHER

RIGHT

RIGHT

THEFT TEMPERATURE PRESSURE

RIGHT

FAN

LEFT

LEFT

LEFT

LEFT

RIGHT
PUMP
LOW HIGH RIGHT
HORN SWITCH SWITCH
RIGHT FRONT
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GENERATOR
122
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ELE-70ELECTRICALWIRINGDIAGRAMS
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87273
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EngineManagement
19921.8L(1of2)
HOTAT
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87274
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ELECTRICALWIRINGDIAGRAMS ELE-71
EngineManagement
19921 .8L (2of2)
INTEGRATED CLIMATE
HEATEDOXYGEN CRANKSHAFT CAMSHAFT

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ENGINECONTROL
MODULE (OME)
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THROTTLE
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ELE-72ELECTRICALWIRINGDIAGRAMS
87275
I

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11 12
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EngineManagement
19922.5L(1of2)
FUELINJECTIONVALVES
11 71 11 11 21 1-
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871 851
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CYL
1-6
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I

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SENSOR RPMSENSOR
1S)X199]9
ELECTRICALWIRINGDIAGRAMS ELE-73
EngineManagement
19922.511-(2of2)
86

v30v87I
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TRANSMISSIONS
SYSTEM
----------
---------

---------------
TRANSMISSIONTRANSMISSION
TRANSMISSION CONTROL

AUTOMATIC TRANSMISSION
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RANGESWITCH
HOTINRUN
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FUSE
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DISTRIBUTION
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SYSTEM

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PRESSURE SWITCH
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FLOWSENSOR

ELE-74 ELECTRICALWIRINGDIAGRAMS
87277
IGNITIONSWITCH
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BATTERY
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71
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EngineManagement
1993-951.8L(1of2)
FRONTPOWERD_IS_TRI_BU_TIO_NBOX

_ ______
I

ENGINECONTROLMODULERELAY

FUELPUMPRELAY
-~I

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CVL1

DVL2

CVL3

CYL4

A/TRANGE

TRANSMISSIONCONTROLMODULE
(EGS)
SWITCH

87278
GR
FUEL
PUMP
FRONTPOWERDISTRIBUTION BOX
----------------
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OXYGENSENSORRELAY

I

HEATEDOXYOEN
IRUNAND

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GIN/VIO

I

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74
7

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16
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68
87
2Y
GRN
EngineManagement
1993-951.8L(2of2)
a
ELECTRICALWIRINGDIAGRAMS ELE-75
I

ELK
,ICRANKSENS
YEL
67i
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28
,
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SHEILOGROUND
_____SRN
36
I
;
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199531811
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I,
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RESONANCE

SPEEDR

PRESSURE

CVLl-2

CYL3-4

ENGINECOOLANT
VALVE VALVE CHANGEOVER

SWITCH KNOCK KNOCK
TEMPERATURE
VALVE
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(19953
1BlI
811

SENSOR

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81
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SYSTEM
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ONLY)
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GR

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ENGMECONTROL
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8,
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ELE-76 ELECTRICALWIRINGDIAGRAMS
187279
SOLID
STATE
SOLENOIOVALVE
(RUNNINGLOSSES)
(1995ONLY)

CYLl

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30-7
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RT

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GRNIGRN 1
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OFF -I
IGNITIONSWITCH
EngineManagement
1993-952.51(1of2)
FUELINJECTIONVALVES
STARTING
SYSTEM
1995
ONLYr~I~~
f
IGNITION
COILS
FRONTPOWERDISTRIBUTION BO%
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1995
ONLY
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1995
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RED/WHT
RED/WHT
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MODULE
RELAY
BtJUNCTIONPOINT
CYL
1-fi
FUEL
PUMP
RELAY
GRNIVIO
BPN/GRN
RED
RED
WIEGS
RED/WHT
SPLICE
----------------
RED/WHT
WHT/
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IL
6-1--l

--IJJ --ljJ tlJil
T-

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CYL4

CYL5

CVLfi

6119

IDLESPEED

EMISSION ACTUATOR

SLIPCONTOLMODULE
CONTROLVALVE
VALVE
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87200
ml
1
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RED
RED
SPLI_E--
FRONTPOWERDISTRIBUTION BOX
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OXYGENSENSORRELAY
I
~ RED/WHT
RED/WHT
/I\ RED/WHT
W/OEGS
EngineManagement
1993-952.5L(2of2)
ELECTRICALWIRINGDIAGRAMS ELE-77
HEATEDOXVGEN
CRANKSHAFT
CYL1-3 CYL4-6
SENSOR POSITION( KNOCK KNOCK
-

RPMSENSOR

SENSOR

SENSOR
W/E..

I

I

I

INSTRUMENT
WHT/BLK
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I/

BLKK/B~SVBITEM

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64
I
B
IAICSWITCH
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VALVEPOS
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H

IR%DDATA
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I
WHT/VEL
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INTAKEAIR

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TEMPERATURE
POSITION
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SENSOR
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BRNIORG 26
ISHEILDGROUND
BLK40
I02SSIGGND
VEL

13,
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W/EGS

ANTI-THEFT

GRNORBLKlV10

66

I
DRIVE-AWAY
SIG
1

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!

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______ ___------------
TRANSMISSION_ CONTROL

AUTOMATICTRANSMISSION

G117
MODULE(EGS)

RANGESWITCH
ENGINECOOLANT

HGTINRUN
TEMPERATURE
TEA'
IA
SENSOR r
,FROOWNERT
TEA'
EP
IPD
(DISTRIBUTION
L-J
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141
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BRN/RED
78

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INTKAIRTEMP
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BLK
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A/CPRESSSIG
HALLEFFECT
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ELE-78ELECTRICALWIRINGDIAGRAMS
I
ACTIVATEVALVE I
IACTIVATEVALVEI
31
BR~NIVEI
I
ACTIVATEVALVEI
32
BRN/WHT
I
ACTIVATEVALVEI
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BLK/BLU
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CANLOWI
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1
G117
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I

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88547
UELINJECTIONVALVES
CYL4

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(19970NLY)
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HOTINACC,RUN
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DISTRIBUTION
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BDX
X10016
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W/ASC,
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199831871 W/ABS
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1998
31811
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II II II II I______ I I_______________
6119

CYL1

CYL2

CYL3

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SLIFCONTROL

TRANSMISSION CONTROL MODULE
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f-W/EGS

GRN/VIO
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INRUNANDSTART

HOTFILMAIR

HALLEFFECT

CRANKSHAFT

ELCTRONIC
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88648
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EngineManagement
1996-971.91-(2of2)
EVAPORATIVE
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EMISSION
CONTROL
VALVE
VALVE
ELECTRICALWIRINGDIAGRAMS ELE-79
EXCEPT
1997
318ti
INSTRUMENT
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EXCEPT
31811
INTAKEAIR

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88893
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FRONTPOWERDISTRIBUTION BOX
FUELINJECTIONVALVES

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HOTINRUN
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OXYGEN OXYGEN OXYGEN CAMSHAFT

DUALTEMPERATURE
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VALVE
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SENSOR
68894
(1997
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ELECTRICALWIRINGDIAGRAMS ELE-81
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1996-97 2.81L(2of2)
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1993-94325i,325iC&3251s
INDIC
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ELECTRICAL WIRING DIAGRAMS ELE--101
TransmissionElectronics
1995 318ti
HOTINRUN HOTINRUN
&START &START
r FUSE
I
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L3r- 0-__
2
I

16
FRONTPOWER
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MODULE
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(TEMPOMAT)

ELE-102 ELECTRICALWIRINGDIAGRAMS
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TransmissionElectronics
1996-97ExceptM3(1of2)
HOTATALL
TIMES
HOTINRUN HOTINRUN HOT(NACCY,RUN
_________ _~Ba

85TART

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6START
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ELECTRONIC CRUISECONTROL

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MODULE
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89171
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CRUISECONTROL
MODULE
(TEMPOMAT)
TransmissionElectronics
1996-97ExceptM3(2of2)
GRN/BLU
(1997)
1B
WHT/GRN
(1996)
WHT/VIO/YEL (1997)
20WHT/VIO (19961
ELECTRICALWIRINGDIAGRAMS ELE-103
7
WHT/VIC

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COMPRESSOR ENGINE
CONTROL CONTROL
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(3181,6318ti)
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11YELIGRN
TransmissionElectronics
1998ExceptM3(1of2)
HOTATALL HOTINRUN HOTINRON HOTINACCV,RUN
TIMES &START &START

&START
7
I

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TransmissionElectronics
1998ExceptM3(2of2)
DATALINK
CONNECTOR
COMPUTER ~~
WHT/GRN
DATALINES
W~
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31077
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TransmissionElectronics
1995-97M3(1of2)
HOTATALL
TIMES
HOTINRUN HOTINRUN

HOTINACCV,RUN
.JUNCTION
I

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RED
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1995&1998
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1995k1998
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1995-97M3(2of2)
196LATEPROD
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Transmission Electronics
1998M3(1of2)
HOTATALL
HOTINRUN
HOTINRUN

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Transmission Electronics
1998M3(2of2)
ELECTRICAL WIRINGDIAGRAMS ELE-109
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1998
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ELE-112 ELECTRICALWIRINGDIAGRAMS
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1992-93
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CHECKCONTROL
MODULE
""TRANS
ISSIONCONTROL
MODULE
YEL/VIO
CRUISE
CONTROLACTUATOR

63528
CRUISECONTROL
MODULE
1 YEL/VIO
2 BLK/GRN
11 BLK/BLU
28 VIO/YEL
CruiseControl
1994&1995EarlyProductionExcept318ti
HOTINRUNANDSTART HOTINACCY,RUNANDSTART
FUSE

FUSE
,FRONTPOWER
I F26

F46
IDISTRIBUTIONBOX
L-A6 -J
GRNJ

viol
GRY

YEL
23
24 BLU/BLK
IAUTOMATIC
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~1
RANGE
.
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3
I
O
ELECTRICALWIRINGDIAGRAMS ELE-113
BRAKE

BRAKE
LIGHT

F

ILIGHT
SWITCH

I

ISWITCH
1S
16 BLKIWHT
17 BRN/ORG
18 BLU/RED
15 BLK/BRN
20 BLU/WHT
21 BLU/GRY
22 BLU/GRN
I

IVEHICLEI
1

I
SPEEDI
G203

ISENSOR
IN
STRUMENTCLUSTER
VIO/YEL
W/OCCM

[

W/0CM
CRUISE
CONTROL
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12
3
WlEGS W/OEGS
1
14
YELIWHT
BLU/RED
EXTERIORLIGHTS
SYSTEM
CLUTCH
SWITCH
CRUISECONTROL
ACTUATOR

ELE-114 ELECTRICAL WIRING DIAGRAMS
Besafi
1 YELIVIO
BRN/ORG
2

(ORBLU/BRN
BLK/GRN
6 BRN/BLK
CruiseControl
1995LateProduction&1996-97Except318ti
HOTINRUNANDSTART

HOTINACCY,RUNANDSTART
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FUSE
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3
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16 YEL/WHT
15 BLU/BRN
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19
26 BLUIBLK
LI-A____________I-B! J
22
23 RED/BRN
20 BLU/WHT
25
28 V10/YEL
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LLI

BRN/GRG
MODULE
G203
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17 WHT/VIO

COMPUTER
DATALINES
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I

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I
TRANSMISSION
CONTROL
MODULE
CRUISECONTROL
ACTUATOR

82783
22
23
RED/BRN
23
BLUIWHT
28
VIO/YEL
HOTINRUNANDSTART

HOT
INACC,RUNANDSTART
1D
BLK/WHT
11
BLK/BLU
111~1~~~~
1111~1~~
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COMP
LINES
18
BLU/GRN
1997
19

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20
BLU/BLK
21
BRNIORG
CRUISE

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SPEED SPEED I

0203
CONTROLMODULE
CONTROLS

INPUT

SENSOR-
SYSTEM

---
----
ELECTRICALWIRINGDIAGRAMS ELE-115
CruiseControl
1995-97318ti
W/EGS WIOEGS
INSTRUMENT
IENGINE VEHICLE (
CLUSTER
CLUTCH
SWITCH
WHT/VIO
UTERDATA
Q
CRUISE
CONTROL
SWITCH
CRUISE
CONTROLACTUATOR

ELE-116 ELECTRICALWIRINGDIAGRAMS
22
CRUISECONTROL
MODULE
104520
1 YELNIO
BRNIORG
2

(ORBLUIBRN
BLK/GRN
6 BRNIBLK
17 WHTNIO
COMPUTER
i

1'DATALINES
SYSTEM
18 BLU/GRN
20 BLU/BLK
21
BRNIORG
23 REDIBRN
24 BLUIWHT
25
26 VIOIYEL
BLKI
WHT
HOTINRUN

HOTINACCY,
ANDSTAR_T

RUNANDSTART
USE FUSE
FRONTPOWER
F28

F46

I
DISTRIBUTION BOX
6A
_-_________________
Z15A_I
viol

V'O'
YEL

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CONTROL Viol~

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YEL

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3
I
BLKII
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2,L 20
TACH ENGINE I
I
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I
INSTRUMENTCLUSTER
Viol
YEL
CruiseControl
1998
I

D

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T

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NORMAL
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ml
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1

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7
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70 BLKM'HT~
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1

1

1

1

1

1

1

1

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13 BRNIOPG
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16
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G2011G203
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328,M3)
MODULE
YEL/BRN
67.11

I
TRANSMISSION
CONTROL
CRUISE ONTROL
ACTUATOR

98445
SLIPCONTROL MODULE
(ABS)
ELECTRICAL WIRINGDIAGRAMS ELE-117
ABS
1992-94w/oTractionControl
HOTINACCY .

HOTAT

HOTINRUN

HOTAT

HOTINRUN
RUNAN
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D~START

ALLTIMES

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ALLTIMES

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52
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53

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19

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FRSPDSENSGROUNO
29 NCA
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19BLUIGRY
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41BLU/BLK
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SEN.
SIGNAL

47

YEL
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41

YEL
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RLSPEED SENSSIGNAL
1
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TXDDIALDATALINK
RRSPDSENSGROUND
WHTIYEL
WHTIVIO
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WHT/VEL 15,
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CONNECTOR
BLUIBLK BLU/GRY
ABSBRAKEPEDAL
TRAVELSENSOR
L 3-'4-------------- .L3-A------- .---------- -A--- -0A-------__-- -'A
2

20

14
GRN/BLU/I

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I

GRNI
VEL BLU

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GRN/BLU/I

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VEL BLU YEL
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31

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l
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20

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n

l
RIGHTFRONT
38
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BRN/GRN

BRNIGRN

1

II
INLETVALVE
II
LEFTFRONT
LFNTOUTLETVLVCTRL
2
BRN/RED

BRN/RED 9

OUTLETVALVE
II
RIGHTFRONT
RFNTOUTLET VLVCTRL

21

BRNIGRN/VEL

BRNIGRN/VEL

9

OUTLETVALVE
REARAXLE
REARAXLEOUTVLVCTRL

36

BRN/WHT

BRN/WHT 10

II
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54

BRN/BLU

BRN/BLU11
REARAXLE INLETVLVCTRL
REARAXLE
VOLTMON,HYDRAULICS

3

RED/BRN/VEL

RED/BRN/YEL12

IIINLETVALVE
I-G203
FLSPOSENSGROUND1
30
NCA

NCA
SRED
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NCA
YEL
VIO
CALNA
ABS

I
WARNI
IND I
I
INSTRUMENT CLUSTER
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I

SENSOR
RIGHT
NCA

I
FRONT
ABS
SPE
BEN
LEFT
REAR
ABS
SPEED
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88574
HOTINACCV,

HOTAT

HOTINRUN

HOTAT

HOTINRUN
RUNAN...~~~OCCCSTART

ALLT...777ICCCMES ANDSTART

ALLTIMES

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..
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F27E
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ORSRTBU
ONBOX
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VIGII
VEL
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8

23
ABSPUMP

INSTRUMENT
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ICLUSTER
I
I
ND
(

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ASS
IND
!_ ___
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VIO/I
VEL
ABS/AST
1995-97318ti&19973181,3181C&318isw/TractionControl
BRAKELIGHT
r SWITCH
IT
1
EXTERIOR
LIGHTS
SYSTEM
BLU/RED
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/
DATALINKCONNECTOR 2D~ "
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9

WHT/
GROUND )19
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VEL
CANHIGH
17

1
CANLOWI

1A

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G203
ENGINE
CONTROLS
SYSTEM
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GRN

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VEL
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GRNI
GRN/
FLU/1

GRN/U/
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2
1G203
ABC
SWITCH
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I'G202
TXDDIAG

B

WHTIVIO

IILEFTFRONT
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BRN/RED 2

SO-NOIDVALVE
BRAKELIGHTSWITCH
e RED/GRN
VOLTSUPPLY,
FUSE3'
29 RED/GRN

1
VOLTSUPPLV,FUSE

R
VOLTSUPPLV,F

DVALVE
38j
13

GRN/BLU/VEL

BRN/GRN

3

IISOLENO
USE21
14BLU/VIO
ABC
SWITCH
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ABSPUMPMOTORRELAY
ABSSIGNAL

27

RED/BLU

I

BRN/GRN/VEL

4
j
ABSPUMPMOTORRELAY

1

RED/GRN/VEL
ASSSIGNALINSTRCLUSTER
,
42

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j
GROUND
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ABSHYDRAULIC UNI

7

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28

RED/BLUIYEL

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18
38 BRN/WHT/YEL
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II
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36 BRN/RED

RIGHTREAR
j
RIGNTFRONTINLETVALVE

39

BRN/GRN

BRN/BLK/VEL
25
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SOLENOIDVALVE
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37

BRN/GRN/VEL
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33

BRNIWHT

II
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32 BRN/BLU

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SOLENOIDVALVE
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35 BRN/BLK/YEL
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i
34

BRN/GRN/VEL

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31 BRN/BLUIYEL

BRNIBLU/VEL 1
87

VALVE
SEPERATORVALVE j
25 BRN

(318L3181C
.3101s)
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2

VEL/BLK

31811

ABSHYDRAULIC UNIT
4 YEL (3181,3181C,3181s)
318U
RRSPEEDSENSORABS

23

VEL/BRN
23 VELIBRN (3181,3181C,3181s)
31611
RFSPOSENSGNO
4 YEL
2 VEL/BLK (
3
3181.3181C.3181s)
18U
RFSPEEDSENSORABS

25

BRN
LRSPDSENSGND
3 BLU
LRSPEEDSENSORABS

24

BRN
LFSPDSENSGND
5 BRN/RED
SPEEDSENSORS
)
26

BRN
LF

AB
G202

I

I

pI

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G202
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ZI2I

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2I

Z

ZZ

Z
RED/GRN/YEL
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BRN/WHT/VEL 1
RED/BLU 17
I
IFRONT
SEE30R
IIISEN90R

IFONT

FEAR
SENSOR

SENSOP
M11
JII
LEFTFRONT
SOLENOIOVALVE
II
RIGHTFRONT
SOLENOIDVALVE
IILITFEAR
SOLENOIDVALVE
Dii
SII
SLEOLFTE
RE
NOARIOVALVE

ELE-120ELECTRICALWIRINGDIAGRAMS
ABS/AST
1994-953251,325iC&325is,1996-973281,3281C&328is,1995-97M3
w/TractionControl(1of2)
VIO/YEL
SLIP
CONTROLMODULE(ADS)
88685
HOTINACCY,

HOTAT

HOTINRUN

HOTAT
RUNANDSTART

ALLTIMES

ANDSTART ALLTIMES
I

--
USE
--------------

USE
---------------------------S
EL I/F

/F0

DISTRIBUTION BOX
I
F46

US

U
32
VIOI
VEL
LREARSOLVLVSIGI
SENSGND
I~
LFSPEEDSENSSIGNALSIGNAL
SENSGND
SENSGNO
=5=___--_--___--Till .-___-_-__-_--______-___- _.J'SA-_-

30A_I
11NCA
10 NCA
BRN/BLK/VEL
NCA
REDORYEL
RFSPEEDSENSSIGNAL
YELEL
RRSPEEDSENSSIGNAL
)
45

GRN
SIGNALABSTRAVELSENSI)
14BLU/LUG
O
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SENSGNDI
2~9 CA
TXDSIG j
7
WHTIVIO
RXOSIG j
8
WHT/VEL
LRSPEEOSENSSIGNAL
j
46

W-
ASSTRAVELSENSSIG

!
31

BLU/BLK
GROUND
1
BRN
GROUND,MODULE j
3
BRN
GROUND
j19
BRN
1
G203
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DATALINK
W-1-1-l61
CONNECTOR
199432510NLY
BLUI BLU/
BILK

GRY
ABSBRAKEPEDAL
TRAVELSENSOR
20
GRNIBLU/

RED/ GRY/BLK/
~VEL BLU YEL
41

2I

9
6

B 5
BRN/I REDIBLGI
BLK

VEL
m
ABSPUMPMTRRLY
%
52 BRWGRV

j
G202

GRV/BLKIYEL
BATTERYVOLT
2
RED/BLU/YEL

RED/BLU/YEL
BATTERYVOLT
16 RED/BLU/YEL

RED/BLUIVEL
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33 REOIBLUIYEL

RED/BLU/YEL
LREARSOLVLVSIG
12 RRN/BLU

BRNIBLU.
RED/GRN/YEL
SIGNAL
4
WHTIGRN

WNT/GRN
8
EML-SIGNAL
5WHTIRED/VEL

WIT/REDVEL
9
-S INFLUENCE

6

WHT/GRN/VEL

WHT'GRN/YEL

10
18 SRN/-T

BRNIWHT
LPEASSOLVLVSIG

11
ADSSTEPMOTOR

20

BLKISRN/VEL

BLK/BRNIYEL

12
ADSSTEPMOTOR

21

BLK/GRN/VEL

8LK/GRN/YEL

13
ABSLPCTRL
34 GRV/BLK/VEL
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35 GRN/BLU/VEL
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SOLVLV
36 BRNIBLU/VEL

BRN/BLU/YEL
14
ABSPWRPROTECT RLY

13

BRN/BLK
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49

BLU

BLU

16
RTFNTSOLVLVSIG
37 BRNIGRNIYEL

BRNIGRNIYEL
16
LREARSOLVLVSIG

3D

BRN/GRV/VEL

BRN/GRV/VEL

17
LFNTSOLVLVSIG
40 FNIWHTIYEL

BRN/WHT/VEL
18
SPDSIG
41 BLK

BLK
19
42HT/RED

WHT/RED
ASCTHROTFLAPPOT

20
ASCTHROTFLAPPOT
43 WHTIBLU

WHT/BLU
21
ABCLPCTRL

44

BLUISRN

8'URN

22
FITFNTSOLVLVBIG

22

BRN/GRN

BRN/G
/B
RN

23
ASCTHROTFLAPPOT
23WHT/BRN

WHTIGRN
24
PUMPMTRSENSSHIELD
50 NCA

NCA
25
IDLESPDSIG
25 WNTIGRY
WHT/GRV
pfi
THROTFLAPPOSTH
26 WHTIGRY/VEL

WHT/GRV/YEL
27
ASCSWSIG
27 BLU/VIO

BLU/VIO
28
LFNTSOLVLVSIG
54BRN/RED

BRN/RED
29
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51
RED/BLU
U-1-U-1-
NCA
RED
OR
iEL~
ABSRELAY
NCA
NCA
NCA- NCA
YEL NOA
GRN/BLUIVEL
BRN/BLK/VEL
LEFT
FRONT
ABS
SPEED
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SENSOR
RIGHT
FRONT
ABS
SPEED
SENSOR
RIGHT
REAR
ASS
SPEED
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88567
2 GRY/BLK/YEL
3
RED/BLU/YEL
4
REDIBLUIYEL
5
RED/BLUIYEL
B BRNIBLU
7 RED/GRN/YEL
S WHTIGRN
9
WHT/RED/YEL
1S
WHT/GRNIYEL
11
BRN/WHT
12
BLKIBRN/YEL
13
BLK/GRN/YEL
ABS/AST
1994-953251,32511C&3251s,1996-973281,328iC&328is,1995-97M3
w/TractionControl(2of2)
GRN/BLU/VEL
AUXILIARYTHROTTLE
POSITIONMOTOR
M
BRN/BLU/YEL
15
BLU
18
BRN/GRNIYEL
17
BRNIGRYIYEL
18
BRN/WHT/YEL
19
BLK
20
WHT/RED
21
WHT/BLU
22
BLU/BRN
23
BRNIGRN
24
-T/13F.
25
NCA
2B
WHT/GRY
27
WHT/GRNIYEL
28
BLU/VIO
2B BRN/RED
30
BRNIBLK/YEL
ENGINECONTROL
MODULE(OME)
AU%'LIARYTHROTTLE
POSITIONSENSOR
19(1996-97328'.M3)
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I

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5RI1011
I
TRANSMISSION
CONTROLMODULE(EGS)
BLKIGRN/YEL
IELK/BRN/YEL
1
WHT/RED
2WHT/BLU
3WHT/BRN
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WHTIGRYIYEL WHT/GRY/YEL
11(ORBRNIORG)
I
(ORBRN/ORG)
MIMMEME
MEMOa~
iim1111
ELECTRICALWIRINGDIAGRAMS ELE-121
HOTINRUNANDSTART
r

FUSE
,FRONT POWER
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F27

IDISTRIBUTION BOX
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14
GRN/
VIO
BLU/VIO 6
INTERIORLIGHTS GRO=C
SYSTEM
G203+
RED/GRN/YEL
G202-Ip
SPIN. S
T-T

BLU22
(

NCA
21
RED/BLU/YEL 5
BRN/WHT/YEL
SRN/RED
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BRN/WNT 19
BRN/BLU18
BRN/BLK/YEL 2
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i
47BL
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162
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PUMPMOTOR
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ELE-122ELECTRICALWIRINGDIAGRAMS
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HOTATALLTIMES

HOTINRUNANDSTART
SLIP
CONTROL
MODULE
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89149
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5
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37 B~
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340RNIGRY/YEL
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25 BRN
FUSE

FUSE

USE

FUSE

FUSE
FRONTPOWER
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P10------------------
121----

F2-J
DISTRIBUTIONBOX
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I
GASHVENTMIXFLAPHZS
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DASHVENTMIXFLAP
IDASHVENTMIXFLAP I
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INTEGRATED CLIMATE
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BRN/RED1
MIXINGACTUATOR
VEL/RED1
OR
PI14THEATEXCHANGER
TEMPERATURESENSOR
BRNIORG
2
BLU1
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ALLTIMES

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INTEGRATED CLIMATE
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IN
a
AirConditioning &Heating
1993-95Except318ti(1of2)
CONTROLPANEL
ELECTRICALWIRINGDIAGRAMS ELE-131
EXCEPT
119953181
19953181
BLKINil

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ELK/
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15,I

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CAMSHAFT
CONTROL
MODULE
G203
INTERIOR
LIGHTS
SYSTEM

ELE-132ELECTRICALWIRINGDIAGRAMS
2REDIGRN
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BLKIGRY
4
BLKIBLU
5
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YEL/GRN
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74494
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AirConditioning&Heating
1993-95Except318ti(2of2)
J.-~~
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CONTROLRELAY
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GRN5
GRN6
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1994-95
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BLOWERRELAY
AUTOMATIC CLIMATE
CONTROLMODULE
HOTATALL HOTATALL HOTATALL HOTATALL HOTINRUN
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ANDSTART

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1996-97Except318ti
23

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Ni
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EQUIPPED
PARKVENTILATION
VEL

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AirConditioning&Heating
1998Except318ti
HOTATALL HOTATALL HOTINRUN HOTATALL HOTINRUN HOTATALL

HOTATALL
=M~S TIMES -=Tf~R- TES 6S=ART TyMES

TIMES
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RECIRCULATION

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1995318ti
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LIGHTS
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ELE-136 ELECTRICALWIRINGDIAGRAMS
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NCA ,1YEL
101447
BLK/WHT/YEL 14r
BRN/

(VENT I
NCA

1YEL

L---J
ON-BOARDCOMPUTER
BLOWERMOTOR

ELE-140 ELECTRICALWIRINGDIAGRAMS
Airbag(Supplemental RestraintSystem)
88996
_HO_T_ATALLTIMES
IGNITION
SWITCH
!STARTSTART
OFF
NCA

1
Ru1~T-ACC_(
7WHT1110
AI,

I
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22
T%D ~ "~~ DATALINK
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12
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2
YE-
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3
WHT
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RED 1RED
110
YEL

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I

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J
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12
XZ83

Xanz
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GKF
12BLU/VIO/YEL

3
SUPPLEMENTAL
RESTRAINTSVSTEM
CONTROLMODULE
DRIVER'SSEAT
8900D

BELTSWITCH
NC
20
DATALINK
CONNECTOR
BLU/BL
BLUIG
X782
BLU/VIO/VEL
18RN BRN
"-# G203
HOTATALLTIMES
(IGNITION
START

OFF
SWITCH
I
I

I
I RUN ACC
__I
POWER
V15
IOJ
DISTRIBUTION
XLB
INSTRUMENT
CLUSTER
C
RIGHT
FRONT
IMPACT
SENSOR
DRIVER'S
AIRBAG
GAS
GENERATOR
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AIRBAGGAS
GENERATOR
14
~SEATBELT
WARNINGLAMP
XIZICONTROL
INSTRUMENT
CLUSTER
LEFT
FRONT
IMPACT
SENSOR
11992-93
EarlyProduction
1993
LateProduction

ELECTRICAL WIRING DIAGRAMS ELE-141
Airbag(SupplementalRestraintSystem)
_HO_TA_TALL_TIMES
I

IGNITION
VIO

VIO

ISTART

OFF
!SWITCH
23
__ 25 ___

I

!
~`

(FRONT

RUN ACC
SUPPLEMENTAL

I

FUSE ~1FUSE
PDYdER
RESTRAINTS

!

F42

[F43
(DISTRIBUTION

VIOI
SYSTEMCONTROL

7.5A

75q

!BOX
(
MODULE

-----
24Y 26Y

VIO!
15
5VIO/GRN

INSTRUMENT
R

>3I

I gIRBAG CLUSTER
I INDICATOR/
31E

g

dI'

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G3
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03
I

5;
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14

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O
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3
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15
13
BLUIBLK
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ABBF+
14
1~BLU/GRYORS
LU/BRN
ABBF-,
ABF-
1JVEL/SRN
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WHT/VIO
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SEATBELTSWITCH
NCA BRN
NCA BLU
CONTACT-GS
G203(2-DOOR)

SOCCEATPANCY1 N"BRN 1

"U
G303(4-DOOR)

3

2

DETECTOR
G404(318TI)
WHTIFED
m00
(7
G404~G203(X
318T1)(31871)8TI)

11994-96
PASSENGER'S
AIRSAGGAS
GENERATOR
WHT/VIO 20
DATALINK
CONNECTOR
BLU/VIO/YEL
ORBLU/REO/

BLU/VIO/VEL

----- I
12
WHT

3

2ORBLUIPEO/W HT

14ISEATBELT

I
GKF

-{

i

(WARNINGLAMP
X17(CONTROL

I
1BRN SRN

I-

J
INSTRUMENT
G201
G404

CLUSTER
(1994) (1995-1996)
CA~~
m01
DRIVER'S
SEATBELTSWITCH
24BRNIBLK

BRN/BLK 7I

-,CODELECTRONICS
CS

_-ICONTROLMOOULE
1995LATEPRODUCTION AND1996

ELE-142 ELECTRICALWIRINGDIAGRAMS
89015
GKBF
TXD
ABF"
ABF-
GKF
ABBF,
ABBF-1)
CS
SUPPLEMENTAL
RESTRAINT
SYSTEM
CONTROL
MODULE
BBRN
31EI~

+G303
9WHT/VIO
BRN
LU
Airbag(SupplementalRestraintSystem)
1997
PASSENGER'S
SEATBELTSWITCH
WHT/VIO
/BLK

BRNI~~ I
NCA
15WHT/RED
SBE
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VEL

.9

YEL

18

VEL

NCA
20
WHT/BLUORBLK/BLU
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)

IA
IRIBAGGAS
2

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GENERATOR
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NCA

CA
CONTACT RINGS
12BLUIGRN/VEL

3
~1....

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1
BLU/VIO/VEL
DRIVER'S
SEATBELTSWITCH
BRN
22~
DATA
LINK
CONNECTOR
BLU/BRN

BLU/BR
HOTINRUN

VIO'
23
ORSTPRT
1a

2a
vIo
23

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INSTRUMENT,
6
IF
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BRN
I
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al"G2O3
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+
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I
WARN,
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I
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INSTRU
T
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I
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2
VIOT
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3

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G203
RIGHTSIDE
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GENERATOR
LEFTSIDE
AIRBAGGAS
GENERATOR
.RN/.L.

.RN/BL
VIO/GRNI

VIOIGRN
DETECTOR

SENSOR

SENSOR
SEAT
D

R
"
S
(EX.318T1)3
(3

I
-_
I BODYELECTRONICS
CONTROLMODULE

SUPPLEMENTAL
RESTRAINT
SYSTEM
CONTROLMODULE
108623
8LU'8=K5V~10/GRN
8BLU/RED/WHT

BLU/RED/WHT
3
F
4VIO/GRN
"VIO/GRN
(318ti)G201
~r
BRN/ORG .BRN/=ERG3
G20~3
(318,323,328,M3)

PASSENGER'S
SEATBELTSWITCH
D
WHT/VIO
Airbag(SupplementalRestraintSystem)
1998
CONTACTPINGS
2BLU/GRN/VEL

BLU/GRNIVEL
3

YEL2B~UI=101
(31811)G201INBRNIORG "BRN/OR

~ qV
G20~
s
3
(318,323,328,M3)

DRIVER'SSEAT
BELTSWITCH
BLU/BLK

BLU/8
WH71VI
DATALINK
CONNECTOR
'BLU/BRN

BLU/BRN
5
WHT/RED
1BLU

_,

BLU

__

BLU
.RN / BRN ';/ B'
VEL ._

VEL

.. YEL .. NC
//BRN

/

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20
WHTIBLU
,21
WHT/YEL
34
BRN/BL={I

CONTROL
BODY

MODULEOO
DYELECTRONICS
E
I
1 EI-/-N YEL/BRN
2YELIRED YELIFED
3BLU/RED BLU/RED
q/BLU/BFN BLU/BRN
DRIVER'SSIDE
PYROTECHNICAL
BELTTENSIONER
PASSENGER'S SIDE
PYROTECHNICAL
BELTTENSIONER
ELECTRICALWIRINGDIAGRAMS ELE-143
HOTINRUN

HOTINACC,RUN
ORSTART

ORSTART
r

1FRONTPOWER
FUSE

USE

DISTRIBUTION BOX
-I52
12
---
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__-J
14TXID017

24YX19018
vio
23l.Xlb
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AIRBAG SEATBELT I
INDICATOR INDICATOR I
'x35.
14y
X1~
BLUII BLU/VIO/
BLK

YEL
DRIVER'S
AIRBAGGAS
GENERATOR
PASSENGER'S
AIRBAGGAS
GENERATOR
LEFTSIDE
AIRBAGGAS
GENERATOR
RIGHTSIDE
AIRBAGGAS
GENERATOR
vio/
GRN
ViolI

violI

viol
GRN

GRN

GRN
2
SEAT

I
DRIVER'S

PASSENGER'S
OCCUPANCY

SIDE

SIDE
DETECTOR

IMPACT

IMPACT
3Y

1`('
SENSOR
1Y

3Y
SENSOR
WHTI
REDI

ORGI

BLUI

ORGI

ORGI

WYEL
BRNI
ORG
IL
G201 G203
(318ti)

(318,323,
328,M3)

ELE-144 ELECTRICALWIRINGDIAGRAMS
89002
F7CONTROL
MODULE
tALPINE)
LED
fl
LOW-NOISE
MICROPHONE
CA
ANTENNA
NCA

51
RED(GRVIVELI
VIO

3~2
VIO/WHT
BRN

53
3BRN/ORG
(

NCA

NCA(<BRNBRNIGR
BLK

"NCA

NCA 5EBRNIBLU
~NCA~ NCA
,36
BRN/BLK
RED

I
"'
I
'
I
7
BIKIB
NCA

e

BLUI}

GRN/EL
LU/YEL

WHT/RE
LU/GRN

DIYEL
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11
BRNIW T

"B=N
NCA

X13025'
VVVV=O
BB=K
NN=A
NCA
ELK
VIO ..VIO
BRN/WHT
Anti-Theft
1992-933181&3251
AlpineSystem
HOTATALLTIMES HOTINACCV.RUNANDSTART
I

FUSE

--------
-

FRONT
POWER
RU

FU
DISTRIBUTION
BO%
16X14415

26X10018
REDIGRYIYELI

VIO/WHTI
RED/GRY/YEL/

VIO/WHT
TRUNK
LIGHT
SWITCH
T TEPIOR
LIGHTSSYS
BRN/BLK
G203
LK/GRN~I --
I
"-ar

II

I__
BRNIGRY/VEL

4

I

ILFDROPEN
I
BRN/BLUIYEL 2
~ IRFDROPEN I
BRN/BLK/

I

BRN/GRVIYEL
2

2
RIGHT
REAR
DOOR
CONTACT
BRN/GRY/YEL 23I--_
LFDROPEN
EllI
WHTIREDIYEL 2
2
4I
ANTI-THEFT
BLUIPED/YEL

5

1ANTI-THEFT
BRN/OR01

BRN/

BR
NT
1

B
oil
NB
::I
G
I
SW
VER'S
DDOTOHAN.
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IRIJ

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BPNIREDIYEL
CENTRAL
2

LOCKING
MODULE
DRIVER'S
DOORHANDLE
SWITCH
(WITHCOLOIWET
PACKAGE)
1
BRN
BRN'
1
G203
BLKIBLU
BRN/BL2K
f'
/

BRN/BLU/YE.L1

BLK/BL21 HORN RELAY
~ONTACT R ~SWITCH MBR'S (ALPINE) C

INE)
INSTRUMENT
CLUSTER
CRASH
CONTROL
MODULE
X13412I
BRN/BLK

27I
X134 1
IREARDROPEN
I
ON-BOARD
COMPUTER

89003
ANTI-THEFT
CONTROL
MODULE
(ALPINE)
LOW-NOISE
MICROPHONE
ANTENNA
_VIO
_BILK
_NCA
NCA
Anti-Theft
1992-93318is&325is
AlpineSystem
HOTA_TA_LLTIMES____HOTINACCV,RUNAN_DSTART
FUSE

FUSE

1FRONT POWERWER
DISTRIBUTION
I

FS

F43

IBOX
L-S----------- 5A___J
Is
I
XIOOIS

2sIxjoD+B
RED/GRV/VEL

VIO/WHT
I

I
"

BRN/GRV/VEL
23I

I
LFDROPEN -I
xLZI ____
RED/GRY/VELI

VIO/WHTI

INSTRUMENT
CLUSTER
NCA

IRED/GRV/VEL

I
VIO

~2VIO/WHT
S
BRN

~
3BRN/ORG

SPUN
+
3203
~-~

I'

I_
GA
1

INCA

BPN/GRV/VEL

SRN/GRV/YEL

6
IL
-
FO
-
RO
-
PE
_
N I
BLK/f

II
;HT.NCA

N
CA

15

BRN/BLU/YEL

.
B
R
N/BLUIVEL

2
(
,I
RFDROPEN
NCA

NCA
B
(NOTUSED)

BRN/BLU/VEL

II
-

7, BLK/BLU

BRN/GRV/VEL
7
I
NCA

SBLU/GRN/VEL

II
BLU/VEL

9WHTIRED/VEL

WHT/RED/YEL 24II
ANTI-TH
BLUIGRN

IOBLU/RED/YEL

EFT
BLU/RED/VEL 25I
BLU

IIBRN/WHT

.

BRN/WHT

IANTI-THEFT
INTERIOR
NCA

5
72BRN/RED/VEL

"

LIGHTSSYS

BRN/RED/YEL

S
xI3D25

I

X13012

ILFDRHNDL
BLK/BLU
2
BRNI BRNI
1 1
3203 G203
ELECTRICALWIRINGDIAGRAMS ELE-145
BRN/WHT
TRUNK
LIGHT
SWITCH
I
IBOARD
I IOMPUTER
I (HORN
RELAY
ANTI-THEFT
HORN
(ALPINE)
BRNIBLUIYELI
2
PASSENGER'S
WINDOW
RETRACTION
DOORHANDLE
CONTACT
BRN/RED/VzLI

BRN/BLUIY2LI

BRN/GRV/VELI BRN
BL BLK

DRIVER'S

PASSENGER'S

DRIVER'S
ITCH
HANDLE

SWROH
MB

SWITCH
MB
(WITH
COLD/WET

~'
VIO~

VIO

BRINt
PACKAGE)

BRINt

BRIM
BRN/RLU/YEL
2.
BLK/GRN/YEL

2
il

I
BPN/GRV/YEL
ORIVER'S
WINDOW
DETRACTION
DOORHANDLE
CONTACT
CRASH
CONTROL
MODULE
CENTRAL
LOCKING
MODULE
BPN/BLU/ EL..L(I

----

I
PASSENGER'SSIDE
POWERWINDOW MODULE
DRIVER'SSIDE
POWERWINDOW
MODULE

ELE-146ELECTRICALWIRINGDIAGRAMS
ANTI-THEFT
CONTROL
MODULE
(ALPINE)
83413
ANTENNA
VIO

12V~0/WHT
BRN

~~

BRNBRN/ORG
4
NCA

BRN/GY/YEL
NCA

B
BR~

NIBLUIVEL
NCA

660R -
NCA

86
BLU
BLUIYEL

B
WHD/1=EL
BLU/GRN

10
BLU
B
LU

1
11
BRNL /WHT
N
CA

12
BR17~V=L
X13923
VIO
BRN/WHT
0=K
NCA
NCA
BLK BLK
Anti-Theft
1994EarlyProduction
AlpineSystem
TRUNK
LIGHT
SWITCH
EXTERIOR
LIGHTSSVS
HOTINACCY,RUNANDSTART
rfi
-IFRONTPOWER
E
VIO/WHT
I F43
IDISTRIBUTION
BOX
L 6A_J
26Tx19D3a
VIO/WHT/
LOW-NOISE

NCA

BR
MICROPHONE
I

BRN/BLK)

/ BRN/GRY/VEL
1
2
VIO VIO
~C

NCAI

8RN
BRN/

SRN
1.

A-
G310

G312
WHTIREDIVEL 17
I
BLU/RED/YEL I4
1
21
J
T
.
(

'SWITCHMB

I

SWRCN
MB
21
BRN/BLKI

8RN/BLU/VE2~

l
~
' DRIVER'S
NCA

III1/1/1//~~~

DOORHANDLE
SWITCH
Z
(WITHCOLO/WET
SWITCH
MB

~DWIOTCH
AM.R
S

BRN
1
1
PACKAGE)
~J

I

I
TI

I
ERNI
BLK/GRNIVEL

2,I

I
BRN/RED/VEL 1
II
1
G203
BRN/BLU/V
E-21 1I
CRASH
CONTROL
MODULE
BRNIGRYIYEL 2
I

I
.RN/81K 4,
X1+Z54
L______)
BODYELECTRONICS
CONTROL
MODULE
(ZKEIV)

2BLK/BLU
4WHT/GRN
8
FED/RY/YEL
HORNRELAY
l
1 REDIGRY/YEL
2 VIOIWHT
11 VICIGRN/YEL
X10244
ANTI-THEFTCONTROL
MODULE
83414
6RED/GRY/YEL
BRN/GRY/YEL
BRN/BLUIYEL
25N/WT
BLK/BLU _
BLK/
BLU
BRN
ELECTRICALWIRINGDIAGRAMS ELE-147
Anti-Theft
1994LateProduction
AlpineSystem
HOTATALLTIMES

HOTINACCY.RUNANDSTART
r-~

-,AUXILIARYFUSEBOX

r~

-1
FRONTPOWER
L

EJ

L

F43EJ
DISTRIBUTIONBOX
IS
A

5A

I
REDIGRY/
I
VIO/
YEL

WHT
REDIGRY/I

VIO/
YEL

WHT
G312
G-
(4
DOOR)
G203
(2DOOR)
BRN/

BRNI

BRN/

BRN
BRN
SRNIGRY/ EL
22~
BRNIBLU/EL

3I

I
BRNI_BRNI_

W~ I

I
X13254I

I
I

I
WHTT/SRN
22iII
VTOIGRNI
-

YI

I
X1D1B2
L
--I
BODYELECTRONICS
CONTROLMODULE(ZKEIV)
VIOIGRN/EL

2~I
i
ON-BOARD COMPUTER
BRN
/GYELI
BRN/
VEL~

WHTI

WHTI
VIO/G
YELI
VIO/G
YELI
ANT
1-J
,
[7] DRIVERS [7]
PASSENGERS
LEFT

///111/
...
RIGHT
JJ11/
~~..
RADIO

...+1+11/i..
ENGINE
FT

DOOR

DOOR

REAR

REAR

MICRO

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HORN

SWITCH

aSWITCH

CONTACT ~ CONTACT

SWITCH
't
DOOR

SWITCH
THE

ELE-148ELECTRICALWIRINGDIAGRAMS
HORNRELAY
83388
I

ZBL_
44

WH~
8RED/GRY/YEL
6RED/GRY/YE
Anti-Theft
1995-97Except318ti
AlpineSystem
HOTATALLTIMES

HOTINACCY,RUNANDSTART
r

-1
AUXILIARYFUSEBOX

r

-, FRONTPOWER
I

FUSE

I

I

.69
E

IDISTRIBUTION BOX
I
1- I

I SA
L

_.J
PEO/GPY/
YEL
REO/G
YELI

WH7I
I

SWITCHDHANDLE
BLK/
BLU
BRN
I

BRN
BRN/WHT
TRUNK
LIGHT
SWITCH
4 BRN/GRY/YEL
~~ll
6 BRN/BLU/YEL -
71~ l!
fi

BRN/WHT
!~
7 BLK/BLU
( BLU/GRN/YEL
9 WHT/RED/YEL
10 BLUIPED/YEL
11 BRN/WHT
12 BRN/REDIYEL
X
1+02s
~ (1

VIO/GRN/YEL
LOW-NOISE

A,

'k
MICROPHONE

ANTI-

DRIVERS

PASSENGERS LEFT

RIGHT

RADIO

ENGINE
THEFT
DOOR

DOOR

REAR

REAR

MICROSWITCH

HOOD
HORN

JAMB

JAMB

DOOR

DOOR

SWITCH
SWITCH SWITCH

CONTACT CONTACT
SRNI

BRN
(4DOOR)
G203
(2DOOR)
BRN
I

SPIN
BRNI

SPINI
1 1
G200

G200
BLU/REDIYEL
1
G200
BLUIGRN/YEL

2,I

I
---
I
CRASHCONTROL MODULE
i-- 1
SLUIREDIYE ! I
WHT/RED/YEL 17

I
X132B3
I

1
BRNIRED/YEL 1
.BRN/GRY/YEL 2
BRN/BLU/YEL 3
BRN/WHT 6
WHT/GRN 7
VIOIGRN/YEL 17
VIO/GRN/YEL 2
<I

I
X.14192
L
--I
BODYELECTRONICS
CONTROL
MODULE(2KE
IV)
,I
L--I
ON-BOAFOCOMPUTER

4CWHO/GRN
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LOW-NOISE
MICROPHONE
63688
6RED/GRV/YEL
NCA
C 1A

11 RED
NCA
2 V10/
BRN 33 BRN
N`

C

fA

4

BRN
NCA

5

BRNISLU/ EL
NCA 7 BLK/
NCA Be BLU
l
BLU

11BRN/WH
NCA 12 BRN
02
VIOIGRNIVEL
HOTATATLLTIMES

HOTINACCY.RUNANDSTART
r
`FUSE,AUXILIARVFUSEBOX

r
PUBS,
PRONTPOWER
F47

I

I

F43

I
DISTRIBUTIONBOX
I

T
15A

I

I

5A

I
L__J
2s 25D

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RE RY/

viol
VEL

WHT
RED/GRV/I

VIOII
VEL

WHT
ELECTRICALWIRINGDIAGRAMS ELE-149
Anti-Theft
1995-97318ti
AlpineSystem
BRN/GRV/I BRN/BLU/
YEL

VEL
W/CCM
1
W/OOCM
BLK/
BLU
t 1 1

1
G400

G400

G203

G203
VIO/GEN/
VEL
BLUeL1IGENIYEL 2l
1-1
CRASHCONTROL MODULE
SRNIREDIVEL 1
BEN/GRV/
-
YEL 2

I
BRN/BLU/=_3 I

I
X]~254I

I
I

I
WHTWRT/I
I
VIOIGRN/I
I
X~-D~s2L-_I
BODYELECTRON CS
CONTROL MODULE(ZKEIV)
VIOIGRN/~
1
I
ON-BOARDCOMPUTER

ELE-150 ELECTRICALWIRINGDIAGRAMS
JA
HOTATALLTIMES

HOTAT HOTINRUN

HOTINACCY,
ISWITH
NALLTIMES-ALLSTART

RUNANDSTART
I

F
USEFUSE

1FRONTPOWER
LOCK

START

F45IP46

I
DISTRIBUTION
I

FUSE

FUSE

1

IBOX
ACC *
RUN

I F31

F28

(199631811)/(EXCEPT
~Y'J
I

I

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JIA ----
7'5A
T

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SYSTEM
93580
93583
/
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AUTOMATIC
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I

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TgqNSMISSION
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I(OOPF(LOW))
(1ON(HIGH))
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1
2WHTIVIO
f3~GRN/BLN
~4GRN
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BLKIYEL
ELECTRONIC
IMMOBILIZER
CONTROL
MODULE
7BRN

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BR
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fit
i}2

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X16BLUIRED/VEL
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X1659
RED/GRNI GRN/GRYI

VIOIYEL
DATALINK20_W_HT1VI0_
CONNECTOR
STARTING,
SYSTEM
Anti-Theft
1995-98
EWSII
TRANSMISSIONS
SYSTEM
BLK I

BLK/VIO
BRN/
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I 1BLKYEL
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2

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3GRNIBLK

(A/TONLY)
dGRN- ~
5

flE0GRN
ENDNECONTROL
MODULE(DME)
HTAATALLTIMES

HOTAT

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HOTINACCY,
---7IGNITIONALLTIMES
ALLSTART

RUNANDSTART
AUTOMATIC
GRN/BLK

I

ITRANSMISSION
I

IRANGESWITCH
L

I
(A/T)
STARTER
(A/T)7TIMMOBILIZATION
(MIT)2I

SWITCH
(MIT)
MODULE
ENGINECONTROL
r
--__--
MOOULE(OME)
EXCEPT
3188
NCA
NCA
2
IGNITION
SWITCH
I NCA 7
X
90260
BRN/ORG 3
VIOIYEL 2
BLU 1
=I
TRANSMITTER
MODULE(EWSII)
BODYELECTRONICS
CONTROLMODULE(ZKEIV)
BLK/GRN

1,I

I
ON-BOARDCOMPUTER
G203~ 6201
-

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MODULE(EWSII)
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10184
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3186
~14BLURED/YEL

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I
X16so

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IMMOBILIZER
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4

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BLK/I BLK/
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Anti-TheftForcedEntry
1998Except318ti
KOTAT

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,
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1

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,
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SWITCH
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v

v

Y

ELE-152 ELECTRICALWIRINGDIAGRAMS
104754
LOW-NOISE
MICROPHONE
ANTI-THEFT
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MODULE
NCA
NCA
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11
LED

CRASHCONTROL
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NCAi~1 .RED/GRY/YEL
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4 BRN/GRY/YEL
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5 BRN/BLU/YEL
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10244
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VIO/GRN/YEL
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1998318ti-
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BANI

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-97

AL

47
G100

G201

G404

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1992-93
1994-96

ELE-154 ELECTRICAL WIRINGDIAGRAMS
88646
104879
16
RED/
GRY/YEL
Horns
HOTATALLTIMES
-~-

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POWER
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LEFT I RIGHT
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15A

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BOX
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12

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77BRN/VH 10
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BLK/GRV
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Wiper/Washer
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ALLTIMES

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F36

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1

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___
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_____
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F36

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F3

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RED/BLU/YEL REDJBRNl VIO/BLKI
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BRN/GRN/VEL

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WIPER/WASHER
SWITCH
1992-98USA
Except318ti
1998Canada
Except318ti

ELE-156ELECTRICALWIRINGDIAGRAMS
INSTRUMENT
CLUSTER
83025
1NT
E ------rF3SE

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L_111
"
00030A
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7-5-

-
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--------------____
X144166Y

1
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-------
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RED/BLU
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MODULE
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MODULE
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HOTINACCY,

HOTINACCY,

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ALLTIMES
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RUNANDSTART

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~2
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/
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HEADLIGHT/FOGLIGHT
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2(1992)
Wiper/Washer
1992-96CanadaExcept318ti
6 --

-------------
-
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G201

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86

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87

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WA
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MODULE

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(LOWII)

MODULE
mI
ml
I
I
I
1
G201
1
G203
WIPER/
WASHER
MODULE
1995-98
USA
318ti
NCANCA NCA/ N
2
1NC
A/ NCA
1995-96
Canada
318ti

ELE-158 ELECTRICALWIRINGDIAGRAMS
88895
Wiper/Washer
HOTATALLTIMES

HOTINACCY,RUNANDSTART
F~

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....

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1998
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Washer
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HEADLIGHT/
FOGLIGHT
CLEANING
MODULE(SRA)
1995-96
Headlight
Washer

ELE-160 ELECTRICALWIRINGDIAGRAMS
168-156
63564
RearWindowDefogger
HOTINRUNAN START

HOTATALLTIMES
USE23

FUSE6

IFONTPOWER
1DISTRIBUTION
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BOX
---------------------
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-------------
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SUPPLY WINDOW WINDOW

REGULATION
DEF
GGER)EFOGGER
ACTIVATION SWITCH

ICNTROL
MODULE
GROUND GROUND _qtRUtD_j
16
L INT
26X18156
A
SRN
BR
NJ
ANTENNA AMPLIFIER
DIVERSITY
(W13ANTENNA DIVERSITY)
--I
RADIO
F

2WHT
I
I--i
HIFIAMPLIFIER
(W/TENSPEAKER
SYSTEMONLY)
3RNI
IIHKR

------IANENNA
,CONTROL

AMPLIFIER
PANEL

AM/FM
ER
NrA INCA
25Y
I

I~P~
G203-~G201(1992318&325SERIES)
HOTINRUN
ANDSTART

HOTATALLTIMES
F

F
-
US-E
------

jSEJFONT
POWER
I

~F23

6

1
DISTRIBUTION SOX
CAi
0
20SRN/YEL

BLU/BUK

3L
INTEGRATED C[MATE
REGULATION CONTROL MODULE
-----------
--------
I
e
BRN.'
G314
(2DOOR)
G13
(4DOOR)
RER
DEOGGER
REAY
G312;tG310~CO
UPE)

-(SEDAN)
II

SUK

I
NCA

(W/3ANTENNA DIVERSITY)NCA
NCA
NCA
NCA
AT

NCA
NCA
~W3AU~ENNADIVERSITY)
N2CA

NC
NCA
L
NCA
BRN
SUPPESSION
FILTER
REARDEFOGGER
RELAY
REARDEFOGGERI
ANTENNA
SUPPRESSION
FILTER

RearWindowDefogger
IBLK
-~ENCA
-~ENCA
"CA,I
WHT
12
WHT
L-1
HIFIAMPLIFIER
(W/TENSPEAKER
SYSTEMONLY)
64018
AUTOMATIC
CLIMATE
CONTROL
MODULE
12BLUIBL
I-_-I
I,4

BRN/WHT
I
THERMOSTAT
ANTENNA AMPLIFIER
NCA
I i N~-
I
N
CA
I
I

-I

N~

CA
DIVERSITY
(W/3ANTENNA DIVERSITY)
88620
ELECTRICAL WIRING DIAGRAMS ELE-161
HOTINRUNANDSTART HOTATALLTIMES
~c

FRONTPOWER
r'F23E

F6SE
DISTRIBUTION BOX
L15A____---
20A1
6'(

IN
GRNIBLUl

RED/BR
4~

6
REARDEFOGGER
RELAY
2Y
BLKI

BLK
26
I

20

BLU/BLK

8L

~

--I
_-I

REAR
WINDOW
BODYELECTRONICS
INTEGRATED CILMATE

BLOWERRELAY

CCNTROLMODULE
REGULATION CONTROL MODULE

(ZKEIV)
REARWINDOW
BLOWER MICRO
SWITCH
BRN
BRN SRN SPIN
G314
RED/BLK

NCA
REAR NA
WINDOW
BLOWER
INCA
NCNCA
NCA
NCA
NCA
G314
+
BRN".
NCA

REARDEFOGGER/
(2
DOOR)

ANTENNA
G313
ANTENNA AMPLIFIER

I

I

NCA

I
(4DOOR)

INCAil
NCA

INCA
~I

I
NCA

NCA.I

_
16

WHO T
-I

I

DIVERSITY
RADIO
HOTINRUNANDSTART

HOTATALLTIMES
r

FUSE

FUSE
FRONTPOWER
F23

F6

I
DISTRIBUTION BOX
LlL______- 2
OA
J
6T
12T
GRN/BLU-
REDIBRN~
4
,~
6
REARDEFOGGER
RELAY
INTERGRATED 8

2
CLIMATEREGULATION

ILK
BLUIBLK
" BL

I
HEATING

_
CONTROL

BODYELECTRONICS
CONTOLMODULE
7 BLK

1
NCA

(W/3
ANTENNA DIVERSITY)

NCA
NCA

NCA
NCA

NCA
NCA

NCA
I WHT

NCA
NCA

NCA
1~
NCA

SIRNI
I NCA

SUPPRESSION
I,16WHT

G314

FILTER
RADIO

(2DOOR)
F- 12
I WHIT

G313
I--I'
HIFIAMPLIFIER
(4DOOR)
NCA
BRN I
SUPPRESSION
FILTER
(W/3ANTENNA
DIVERSITY)
REARDEFOGGER/
ANTENNA
1994-96
Convertible
1997
Except318ti

ELE-162 ELECTRICALWIRINGDIAGRAMS
83902
SL
ANTENNA AMPLIFIER
(Wl3ANTENNA DIVERSITY)
I 1
I

I,
76
WHIT
I

I
L__I
L-__I
G203
REARDEFOGGER
SWITCH
ANTENNA AMPLIFIER
I O
L__I
RADIO
RearWindowDefogger
_NCA
6WHT
I

I,2

WHT
I--I'
HIFI
AMPLIFIER
(10-SPEAKERSYS.CDPLAYER)
88654
HOTINRUNANDSTART HOTATALLTIMES
r'~FUSE

~~~jjj```FUSE
FRONTPOWER
I

(F23

'f~F6

DISTRIBUTION BOX
L,ti5A~L20A
I
Ur
RED/SR
tN
z
GRN/BL
GRN/BLU( RED/SRN
JJJII...
64
REARDEFOGGER
RELAY
BT

2
BLUIBL

BILK
10
~' IRKS
I (CONTROL
(SWITCH
G203
RADIO

"'
I

I,9

WHT

BRNi
!-I
HIFIAMPLIFIER

G404
(W/TENSPEAKER
SYSTEMONLY)
L`1(6_A_~ZOAJ
6I

12T
GRN/BLU"
RED/BRN(
_NCA
NCA
_NCA
INCA
NCA
INCA
REARDEFOGGER/
ANTENNA
BRR~~I
SUPPRESSION
FILTER
HOTINRUNANDSTART HOT~~~AT111...ALLTIMES
rTFUSE

,
FUSEFRONTPOWER
I

F23

/F6

I
DISTRIBUTION BOX
IHKS

4'k 6j,
CONTROL

RDEFOGGER
T
CONTROL

[jjH

REA
I-
-
1

RELAY
1

-4)
1BRN

BRN
I
I

G203

I~"

y

I
I

I

B

2
BLK
10BRN/
)Y EL

~INTEGRATEDHEATING

W/

W/O
I

&CLIMATECONTROL

AERIA AERIAL
L_--I

BLU/BLK
4 BRN/WHT

HEATING

BLK
BRN
i

BRNBR

N-<
CONTROL
ICHI)

"~~I'

REARDEFOGGER
.!
G404
i BLK
NCA

NCA
;CA

NCA
NCA

NCA
NCA

NCA
1 WHT

NCA
NCA

NCA
REARDEFOGGER/
ANTENNA
1995-96
318ti
1997
318ti

GRN/BLU
GRN/BLUj
4
IRKS
CONTROL
SWITCH
I--- .

_..G201
10BRN/EL

ITEGRATEDHEATIN(
EMATECONTROL
---I BLUE
I

4BRN/WHT

HEATING
CONTROL
I

I
REARDEFOGGER

G201
SWITCH
104767
AUTOMATIC
CLIMATE
CONTROL
MODULE
I

I~12BRN/VEL
THERMOSTAT
I~4

BRN/WHT
I--I'
ANTENNA AMPLIFIER
I__I
HIFIAMPLIFIER
104762
RearWindowDefogger
X
1943
)1
BRN
~XLS93

+
G404
2
BLK
X1645
1
VEL/BLU
NCA
A
=
A,fNCA
NCA~fNCA
NCA~ENCA
NCA~ENCA
NCA
_NCA
_NCA
NCA
DIVERSITY
(W/3ANTENNADIVERSITY)
1}
NC
Ir N.A
I

I
I

I16WHT
RADIO
I2WHT
H
ELECTRICALWIRINGDIAGRAMS ELE-163
CLIMATECONTROL
HOTINSUNANDSTART HOTATALLTIMES
r,TFUSE FUSE
,FRONTPOWER
F23

FB

DISTRIBUTIONBOX
5A____--- 30-J
WIAUTOMATIC

I?S
CLIMATECONTROL
E
BLU/BLK
9Y

2
BLK
W/OAUTOMATIC
--

REARDEFOGGER
RELAY
REARDEFOGGER/
ANTENNA
2
BLK
W/IW/0
AERIALAERIAL
BLKI BLKJ
REAR
DEFOGGER
BRNI
1
3404
X380
BLK1
X379
EL/BLU1
~2VEL/GRN

VEL/GRN 2'I
~3 WH

II
'
~~II
ITX19471
X1949
REAR
ANTENNA

DEFOGGER
AMPLIFIER
I
I

__I
2

WH
O T

WHT

3i

--I
HIFIAMPLIFIER

SUBWOOFER
HOTINRUNANDSTART HOTATALLTIMES
rF-SE TFUSE
,FRONTPOWER
I F23

F6
IDISTRIBUTIONBOX
I_,1SA--_----- ;
30AJ
67X14
GRN/BLU
GRN/BLUI

RED/BRN
4
REARDEFOGGER
RELAY
I
BRNI
I
G3121G310
(2DOOR)

(4DOOR)
1998
318ti
1998
Except318ti&
Convertible

ELE-164 ELECTRICALWIRING-DIAGRAMS
RADIO
104784
NCA
_NCA
_NCA
NOA
DIVERSITY
(W/3ANTENNA DIVERSITY)
I -I NCA
I I~ucA
I

I~ NCA
I

I,swHT
I

I~2

VIO/YEL
x]31266
HIFIAMPLIFIER
..TIN.UN

HOTAT

HOTINRUN .
ANDSTART ALLTIMES

ACCYANOSTART
FUSE

FUSE

FUSE

,FRONT POWER
I

F23

F6

F43

I
DISTRIBUTION BOX
L '=______-
_D-____________ -A__J
ex>---z

12x366)-a

2sxi6niB
GRN/~

RED/

GRN/1
BLU

BRN

WT
GRN/I

GRN/
BLU

WHT
4
_

REAR
DEFOGGER
RELAY
RearWindowDefogger
1998Convertible
RED/
BLK
BRN
ELKI

GRN/I
WHY
BRN
1
6312
r
REARDEFOGGERI
ANTENNA
REARWINDOW

SPATIAL
LOWERRELAY

SoU
NORELAY
RB-I BYELI

YIELI
Jf
ED[

ANI

BREL
31
21
NDOW

f~

lI

/

IREARWINDOW
BLOWER

BLOWER
MICROSWITCH
BRNI

BRN
BRNI
GRNIBLK
8
NCA
NCA
SUPPRESSION
FILTER
..N/IGRN/I

CONVERTIBLE
YEL BILK

TOPCONTROL
MODULE

8299
1
/~

EXCEPT
BRAKE

~J
1997
FLUID
IND
A23~.
A16 I

I SRS
IND
A17
81
18
B
B24
J,

CHARGE
PARK

IND
BRAKE
IND
CHECK
ENGINE
IN.
LEFT
TURN
IND
RIGHT
TURN
IND
1997
ONLY
FUEL
CONSUMPTION
METER
CHECK
IND
SEAT
FRONT
BELT
10.LT
IND
IND
HIGH
BEAM
IND
FUEL
RESERVE
IND
FUEL
GAUGE
ILLUM

A22

25
~ (3USED)

EXCEPTy
28 7992
TEMP
GAUGE
INSTRUMENT CLUSTER
InstrumentPanel
1992-97Except318ti(1of2)
B
-ELECTRICALWIRINGDIAGRAMS ELE-165
HOTATALLTIMES
______
__

HOTINRUNANDSTART

HOTATALLTIMES
IGNITION
r

FUSE

FUSEI
FRONT UTION
I

(SWITCH
F21

~F31
DISTRIB1000%
LOCK

START
LOCK

START
L
L
I
5_A
_-__-
ACC
RUN
ACC
RUN

14

2
L---

------- --

OR
N1

RED/
T

V

YEL
11
EXCEPT

2

lo
GRN 1997 VIO
RED/WHT
1 (ORWHT)
2 GRYIRED
3 BLU/BRN
4 BLU/GRN
5 GRVIBRN
BS 7CONVERT-
8
ISLE
ONLY
HEADLIGHTS SYSTEM
INTERIORLIGHTSSYSTEM
EXTERIORLIGHTSSYSTEM
EXTERIORLIGHTSSYSTEM
TRANSMISSION SYSTEM
EXTERIORLIGHTSSYSTEM
9
Iiw.TIBLU
POWERTOPSSYSTEM
11WHT/YEL
12WHT/VIO
13BRN/RED
14BLU/BLK
15VIO
16GRY -
ENGINECONTROLS SYSTEM
17BRN/GRN
18BAN
/V
lo
19YEL
20

BLK

ENGINECONTROLS SYSTEM
A79

21WHT/BLK
22RED/YEL
814

23GRNIVIO
24BRNIORG
SUPPLEMENTAL RESTRAINTS SYSTEM
SPEEDOMETER

816
CONNA
1 WHTIRED
B4 ~2 BLK/WHT
ROLLOVER

338R~N
PROTECTION
IND

B17

4 GRN/BLU
(CONVERTIBLE)

5
GRIN
TACHOMETER

B18

6 BLU

STARTING/
7

CHARGINGSYSTEM
A20

8 YELIBRN
B -K/FED
10WHTIGRY
11GRYIBLK/YEL
12

BL
LISP
N
13GRN/PED
14BLU/VIO/YEL
15WHT/GRN
89

16VIO/YEL

BRN
"

~IG202
17BRNIYEL

GRY/BLK,

BFN
15

18BN/VIO

VEL
B
ANT
19BRNIGRN

1997 LOCK

~`r~i
j

W/OASC W/ASO
83

20
GRYIBLK/VEL

ONLY
SY ES4

STEM
GRV/BLK/VEL
21
(ORBRN)

(ORBRN)
22BLU/BLK
23BRN/GRV/VEL

BRNIGRVIVEL
19
BRN/GRV
OR
BRN/GRN
HEADLIGHTS SYSTEM
BODYCOMPUTER SYSTEM
ANTI-LOCKBRAKESSYSTEM
ANTI-LOCKBRAKESSYSTEM(EX1992A1993)
ENGINECONTROLS SYSTEM(1997ONLY)
BLU/VIO/YEL
J
EXCEPT
1.92.
1993
BIN/
VIO
BRN/GRN
11
OIL

[._~]
PARK

RA11FL11
AL.^

SWITCHI
PRESSURE

BRAKE

LEVELSW
U
ITCH
SWITCH
1 1 1
G202 GROUND

GROUND
REDIYEL
RED/YEL
RED/YEL
WHTIYEL
WHT/VIO
BRN/RED
YEL
GRN/BLU
BLKIWHT
BRN/BLK
BLK/RED
WHTIGRN
VIO/YEL
BRNIYEL
BRN/VIO
BLU/BRNIYEL
BRN/YEL
e
9
0
11
12
13
14
15
16

ELE-166ELECTRICALWIRINGDIAGRAMS
"-
N15WH7/VA

I
CO
LIESSSVSTEM
20
WHT/VIO
DATALINK

WHT/GRN
CONNECTOR

WHT/YEL
1
WHT/VIO
REDIVEL FF"
2 REDIVEL
REDIVEL
17
BRNIYEL
170
I
TAC-I~
RADIO
DRIVER'SSEAT
BELTSWITCH
BLUI

I_

I1BRN
VIO/YEL
2

I -
18
19
BRN/GFY/YEL
20
BLU/VIOIWHT
21
BRN/RED
YEL
82992
YEL
LEFTFRONT
BRAKEPAD
SENSOR
RIGHT EAR
BRAKEPAD
SENSOR
HOTINRUNANDSTART

HOTINACCY,PUNANDSTART

HOTINACCY,RUNANDSTART
rF23
E___

USE
__________-IFFUSE
USE
IDSOTRIBUTIONBOX
BLK/WHT
BRN

"
BAN

,I
G312
BRNIVIO
ENGINECOOLANT
TEMPERATURE
SENSOR
InstrumentPanel
1992-97Except318ti(2of2)
5A_____-TISA ____________ .T7.5AJ
B

32

30Y
GRN/

violI

viol
BLU
I

YEL

WHT
WHT/VEL
WHT/VIO
BRNIRED
EXCEPT
1992&
1993

OIL7EMPESENSOR
7
YEL

(CANADA61997)
. BRNIGRVIYEL
e
GRNIBLU
9
BLKIWHT

DRIVERS
DOOR
0

JAMB
1994
SWITCH1
BIN/ILK

(199261993
BLK/RED

2DOOR,6
VIOI

WICCM

CONVERT
BR
WHTIGRN

YE'I

3

N/GRY~
(EX199267993200
V"'
0R6
VIO/YEL

I
BRAKELIGHT
.
1990CONVERTIBLE)
BRNIYEL

SWITCH
BRN/VIO

I

I

8RN/GRV
BLUIBRN/VEL

- ----+-j W/CCM
.LU/

COMPUTER
REDI

BRN1~

TEMPSENSOR
MMONE
- .
INNER
BRNIYEL I----

I

I--
-

-----
--
W/_I

I

I
CCM
CHECKCONTROL MODULE

ON-BOARD DISPLAYICOMPUTER
BRN
G203
BRNIYEL
FUELTANKI
SENSOR"
FUELLEVEL
SENSORI
8RN/BLK
BRN/BLK
VEHICLE
SPEEDSENSOR
BFRED
an
RED
YEL
GRN/BLU 9I
WIT/
WHT/RED 11-I

I
BRNI.PY12
I

I
BLK/WHT 13I
VIO/WHT 10I
BLU/VIO/WHT 75
I
GRV/RED 18`I

I
BRN 17~I
PEDIYEL 18
I

I
MULTIFUNCTIONCLOCK
WHTwHTRG1
-I
WHT/BLU 3
I

I
I

I
BLKIRED 2{I

I
REOIVEL 4I

I
CHIMEMODULE

HK
ENGINE

W

STEM
IN.

2 GRV/REDS( )

INTERIORLIGHT
ICNDEC

SSYSTEM
~3
-
BLU/BRN
EXTERIORLIGHTSSYSTEM
A14 4 BLU/GRN
j~ EXTERIORLIGHTSSYSTEM
5 GRVIBRN~~ TRANSMISSION SYSTEM
6
7
INSTRUMENT CLUSTER
104628
ELECTRICALWIRINGDIAGRAMS ELE-167
Instrument Panel
1998Except318ti(1of2)
11WHT/VEL
12WHT/VIO
13BRN/RED
14BLUIBLK ISUPPLEMENTAL
1

RESTRAINTS SYSTEM
ifiGRV
17BRN/GR
18BRNIVIO
19YEL
HOTAT

HOTINRUN HOTINACC, HOTINRUN
ALLTIMEE

ANDSTART

RUNANDSTART

ANDSTART
IGNITION

r

FUSE

FUSE

FUSE1
FRONTPOWER
SWITCH

IDISTRIBUTION BOX
I

I

I~F27

~F46

~F23
ILOCK

_START
I

L

SA----

15A--- EA -J
I
ACC* RUNI1

1.'f

32Y

BY
L------IJ

GRNII

violI

GRNII
VELI

BILLI
ENGINECONTROLS SYSTEM
GRN
DATALINK
CONNECTOR
15Y20Y 7Y
j
GIQI
viol

GF.1
VEL

BILL
1

VIO
GRNI

I

I
I

I

I
BLU/ BFN BRN/
VID/VELI

I

I'D
ENGINE

DRIVER'S

BRAKE
FLUID
COOLANT~~
ISEATI

LEVELSWITCH
TEMPERATURE I

]BELT
Ij
SJSWITCHI
BLUR

BRNI
DR
.
BILL//

1
ORGI

SPIN
BRNIRED
BRN/GRN
YEL
RED/VEL
2
10WHT/GRV
89-

l11

GRV

0BODYCOMPUTER SYSTEMSVSTEM
J

- I
ANTI-LOCKBRAKESSYSTEM
12

BLU/BPN

ANTI-LOCKBRAKESSYSTEM
13GRNIREO
1~ENGINE CONTROLS SYSTEM
14BLU/VIO/VEL
15WHTIGRN

GRNIBLU 7
116VIO/VEL
I
812

17BRN/VEL
18BRN/VIO
B73

19BRN/GRN
20
B14

21GRV/BLK/VEL ANTI-LOCK
22BLD iIBLK
BRAKESSVSTEM
B16

23BRN/GRV/VEL

BRNIGRY/VEL
B
24BLU/VIO/WHT

BLUIVIOIWH7
9

ELE-168ELECTRICALWIRINGDIAGRAMS
5
6
7
0
10
104629
GRN/BLU
BRN/YEL
BRN/BLK
BRN/RED
DRIVERS
DOOR
JAMB
SWITCHBANt
YEL
SAW
ELI YEL
InstrumentPanel
1998Except318ti(2of2)
OIL
TEMPERATUR PARK
LEFTFRONT RIGHTREAR
SENSOR

BRAKE

BRAKEPAD

BRAKEPAD

CHECKCONTROL
SWITCH
SENSOR SENSOR

MODULE
I
SREDI
BFI
GRNI
NCAI YELI YELI YELI BR.:
1

I

3I3I3
GROUND
I

BANI

III

III

I

BLK/WHT
CONVERTIBLETOP
BRN/RED

CONTROLMODULE
I
T

BLK/WHT 1I

I
BRN/GRN

I I
I

HIPIAMPLIFIER
L

I

;

BLK/WHT
5
i_--I
REDIYEL
q

WIPERIWASHERMODULE
I
I

-_
BLK/WHT 10I
I

I-- I
CRUISECONTROL
MODULE
I
BLKIWHT

SLK/WHT 10
I

I
PINSUSEDW/
BRN/GRN 11
BLU/RED 22
BLK/RED

WHT/SLU 33
WHT/GRN 44
WHT/GRY
55
BLU/BRN/YEL
6
6
7
STARTING/

BLK/GRN BB
CHARGINGSYSTEM
GRN/BLU 9
WHT/BLU 10
WHTIRED 11
BRN/GRY 12
BLK/WHT 13
V11/WHT1414
BLU/VIOIWHT 1515
EXTERIOR LIGHTS

GRY/RED

1616
H
BRN/GRY/YEL SYSTEM

RAN1717
BLU/VIO/WHT

RED/YEL 1515
BLUIBRN/YEL
MULTI-FUNCTION CLOCK
ON-BOARD
DISPLAY
EXTERIOR LIGHTS
SYSTEM
BRN/
DAY/
YEL
GVEL

BRN/GRY
BRN/
POWER
GRY/I
WINDOWS
YEL

SYSTEM

mI3I
3:1
R.t
HOTAT

HOTINACC,
ALLTIMES

RUNANDSTART
FUSE

y
FUSE
FRONTPOWER
F45

I
DISTRIBUTION 11,
5=____~-5_J
30Y
REDII

V101I
YELI WHTI
vIOf
WHT
ON-BOARD
COMPUTER
MODULE

TEMPERATURE
BRN
"

1

I
VEHICLE FUELLEVEL
FUELTANK
I

"
I

1
BAN/
SPEEDSENSOR

SENSOR

SENSORII

BAN
I

SANI

BAN
I

GASI
1
1

1

1
G312

G202

G203

G203
I
AUTOMATIC CLIMATE
CONTROL MODULE
BLKLKIW

J
T

13

1

I
RADIO
BRN/ORG

83364
LJ

23GRN/VIO

-

BLK/WHT
8
24BRN/ORG

BRNISLK
9
A22

,
25

I

-

BLK/RED

10
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11GRY/BLK/YEL
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21

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1995-97318ti(1of2)
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7
1997
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7 EXCEPT
8
1997
9
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MODULE
1997
ONLY
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1997
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(BELT
7
8
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7
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SYSTEM
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83951
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RUNANDSTART
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_____________________ _-_-I
DISTRIBUTIONBOXI

FUSE

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I F31

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On-BoardComputer
1995-98318ti
ELECTRICALWIRINGDIAGRAMS ELE-173
Lam___________________
2Y
RED/YELL

VIO/YELI
6

BRN/ORG

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0-'201(Z3)
G203(318ti)
1

G302(Z3)
NCA

-~~RN "
-BRN
G202(318ti)
COMBINATION
SWITCH
COMPUTER DATALINESSYSTEM
10COMPUTER DATALINESSYSTEM
10ENGINECONTROLS SYSTEM
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BRN/GRY
ON-BOARD
COMPUTER
TEMPERATURE
SENSOR
BRN
(Z3)G201!-G203(318ti)
32Y

ELE-174 ELECTRICALWIRINGDIAGRAMS
83490
1 BRN/GAY
2 BLUIRED
8 BLK/GRN
9 GRNIBLU
10 WHT/BLU
11 WHT/RED
12 SRN/GRY
13 BLK/WHT
14 V10/WHT
1. GRYIRED
X10Z0
1 BLK/VIO
2
3 BLK/BLU
4
RN/P..
5 WHT/VIO
6 WHT/BLK
7 WHT/YEL
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r

FUSE

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r

F
_
US
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IDISTRIBUTION
BOX

I

F3

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I

F41

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GRNIBLU
6 BLU/BRN/YEL
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14 B
X]97].
ON-BOARDCOMPUTER
5A

7.5.
L~___J
GRNIBLUI

VIO/WHT
.FN
Z
G203
On-BoardComputer
1992-97Except318ti
ALLEXCEPT1997
EXTERIOR
LIGHTSSYSTEM
EXTERIORLIGHTSSYSTEM
INSTRUMENT CLUSTERSYSTEM
STARTINGICHARGING SYSTEM
WARNING SYSTEM
WARNINGSYSTEM
INSTRUMENTCLUSTERSYSTEM
INSTRUMENT CLUSTERSYSTEM
INTERIORLIGHTSSYSTEM
BODYCOMPUTER SYSTEM
ON-BOARD
CGMPUTERTEMP
BODYCOMPUTER SYSTEM

SENSOR
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y1
BRN'
{tCOMPUTER DATALINESSYSTEM
I
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BRN
1
11
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INSTRUMENT CLUSTERSYSTEM
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L

=
5
-J

L

1_5-J
1997

1

1994-1996

104489
2 BLU/RED

GRN/BLU VIO/WHT RED/YEL
EXTERIORLIGHTSSYSTEM
3
4
5
6

BLUJBRN/YEL

INSTRUMENT CLUSTERSYSTEM
7
8

BLK/GRN

STARTING/CHARGING SYSTEM
9 GRN/BLU
10

WHT/BLU

WARNINGSYSTEM
11 WHT/RED
WARNINGSYSTEM
12 BRN/GRY
13

BLK/WHT

INSTRUMENT CLUSTERSYSTEM
14 VIO/WHT
15

BLU/VIO/WHT

INSTRUMENT CLUSTERSYSTEM
17
1

GRYJRED

INTERIORLIGHTSSYSTEM
18
X1070
On-BoardComputer
1998Except318ti
1

BLK/GRN

ANTI-THEFTSYSTEM
j2
EXTERIORLIGHTSSYSTEM
5 WHT/VIO
COMPUTER DATALINESSYSTEM
6 WHT/BLK
ENGINECONTROLS SYSTEM
7 WHT/YEL
10COMPUTER DATALINESSYSTEM
RED/YEL
ELECTRICALWIRINGDIAGRAMS ELE-175
HOTINRUN HOTINRUN HOTAT
ORSTART

ORSTART

ALLTIMES_
FRONTPOWER
DISTRIBUTIONBOX FUSE FUSE FUSE
F23

~
F45

~F31
5A

7.5A 5A
----

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6Y 30Y 2Y
GRN/BLUi

VIO/WHTi

RED/YEL
9

WHT/GRY

10INSTRUMENT CLUSTERSYSTEM
10
11
12
13 BRN
14 BLK/WHT/YEL
gIR
15
CONDITIONINGSYSTEM

BRN~''II
16
ON-BOARD

-

-
COMPUTER MODULE

G203

G203
ON-BOARD
COMPUTER
TEMPERATURE
SENSOR

ELE-176 ELECTRICALWIRINGDIAGRAMS
(PARTIAL)
BODYELECTRONICS
CONTROLMODULE(ZKEIV)
98665
I)5
16 VIO/WHT
17 BLK7BLK/WH~
18B

WUIGAN
199 BLU/GR
110 GRN/BL

(1998)
POWERWINDOWS
POWERWINDOWS
POWERWINDOWS
POWERWINDOWS
POWERWINDOWS
BodyComputerModule
1996-98318ti
ROTAT HOTAT HOTAT HOTAT HOTINACCY,
ALLTIMES ALLTIMES ALL71MES ALLTIMES AUNANOSTAR
374E

E11

FE

~5A
u25A

1
OA
6~I' ID Y
I

6'

i

7S'
//

//

I

I

I
RED/BLU(

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RED/WHT
(

REDI

VIO/WHT
(
REOIWNTI

REDI

VIC/WHT
I

I
I

I
I

I~13
I

1)
14BRN/WHT

(I99fi)

EXTERIORLIGHTS
I

115 BLU/YEL

(1996)

POWERWINDOWS
I

116BLKIREO

(1996)

pOWERWINDOWS
17BLK/RED

(1996)

POYVERWINDOWS
78BLK/RED
POWERTOPS
I

1
19BLK/GRN
I

I

POWERTOPS

BAN

BRN/ORG
I

I~2o
i

1'21
I

1)22

I

I
I

1)23

BRN
I

BAN/-
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I
I
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i

i
I

1
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I

12

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r---

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I

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I

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I

I
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ACC
16

VIO/WHT

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L

-- -_j
17 BLU/GRN
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I
11
DOORLOCKS

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176 RED/GRNIYEL
1'11

I
I
1,12REDIWHT

I
I~13BLK/WHT
I

PDWERWINDOWS

GRN
14YEL/GRN
I

POWERWINDOWS
15
BAN
IX
,3252
I1WHT/GRN
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WHT/BRN/VEL

DOORLOCKS
I

DOORLOCKS
13WHT/GRN/VEL
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6,
BLU/REDIYEL (1997,96)

ANTI-THEFT

(PARTIAL)
I,5

BODYELECTRONICS
I)6

_
.

CONTROL MODULE(ZKKEIV)
17

BRN/BLK

BRN/BLK/YEL

1
tI

1
SUPPLEMENTALRESTRAINTS

EXTERIOR LIGHTS
I
B

BLK/GRV

pOWERWINDOWS

EXTERIORLIGHTS

G~RV/BLK 2
~{ I I
19
VEL/GRV

POWERWINDOWS

(1990)

GRN 3I

I
1'10

VIOIWHT 4I

I
111

BRN/ORG 6I

I
I),2

6I

i
7~I

I
1)73WHT/RED

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CI

I
IidWHTIBLK

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8CI

I
15WHT/GRY

WHTIYEL 9
I

DOORLOCKS

COMPUTER DATALINES~~

I

I
116

WHT/BLU

DOORLOCKS

EXTERIORLIGHTS

(1996)

BLU/GRN/VEL

10

I

I
17WHT/RED/VEL (ORGAN/WHT)

TIVIOit
I

ANTI-THEFT

COMPUTER OATHLINE

WH
S"~

I

I
18

BLK/GRN 12
STARTINGICHARGING

I
1)

I
119 RED/GRN/VEL (I997,9B)

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I
120 GAN/R..

(i99.I

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14CI

I
1,21

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1

BLK/GRN

iBYI

i
1'22

ON-BOARD COMPUTER"1

(1996)

BLKIVIO

76
~I

I
123 BLK

POWERWINDOWS

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(1996)
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I

I
124 VEL/BLK

POWERWINDOWS

(1997,98)

RED 18

I
16

X19182L---
I)
2
2B

VIOIBLK

(1996)

EXTERIORLIGHTS
IX13253
I1
I)2 BRN/GRV/VEL (1997,98)

01ANTI-THEFT
3 BRN/BLU/YEL (1997,98)
ANTI-THEFT
04

(PARTIAL)
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CONTROL MODULE(ZKEIV)
r_1
7
1

BILK
1

i2 BLUIGRY
I'3
BRN/VEL

(1998)
I) REOIBLK
96672
ELECTRICALWIRINGDIAGRAMS ELE-177
BodyComputerModule
1996-98Except318ti
HOTAT

HOTAT

HOTAT

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HOTAT

HOTINACCY,
ALLTIMES

ALLTIMES

ALLTIMES

ALLTIMES

ALLTIMES

RUNANDSTART
r

FUSE

_-12,
USE

FUSE

FUSE

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FRONTPOWER
F'
1

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L

30----

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1==- ----==----

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DISTRIBUTIONBOX
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I

RED/WHT
I

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I
RED/GRN
I

VIO/WHT
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1998
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(PARTIAL)
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ELECTRONICS
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MODULE(ZKEIV)
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1

r-
POWERWINDOWS
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BLK/YEL 2I

I
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I
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4,
I

POWERWINDOWS

WHTIGRN
1

I

I
I)5

POWERWINDOWS 1

WHT/VELS,I

I
1%6VIO/WHT
7

BW/GRN

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WINDOWS

6
~I

I
1

POWERWINDOWS

POWERWINDOWS
III

ELK/GRV

7I

I
8RED/BLU

I1
9

WHT

POWERWINDOWS1

BLU/GRN

1
I

DOORLOCKS

POWERWINDOWS

BLU/YEL

9

I

I
110REDIGRN/YEL

III
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I
I'11Vi0/BLK

POWFWINDOWS
I
112RED/WHT

F
INTERIORLIGHTS

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WHT/GRN

11

I
12

I
113BLK/WHT

POWERWINDOWS

X1321
B~1

I
114YEL/GRN

-

I

I
POWERWINDOWS
1.16BEN
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EXTERORLIGHTS
BEN/BLK/V L 1{
GRV/BG

K~I
1
XL32~
I72
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13WHT/GRN/VEL

DOORLOCKS

VIO/WHT 4
lI

I
p- 1 FOOORLOCKS

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I
Ia

BLU/RED/VEL

10
ANTI-THEFT

6~I

I
I)6

ANTI-THEFT~
1

W
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7
,I
1l6

(1996) BRN/WHT 8

II
'7SRN/ELK

(1997,98)

INTERIORLIGHTS
1

SUPPLEMENTAL RESTRAINTS

WHT/VEL

9

I
1%8
III
BLKIGRY

COMPUTER DATALINESLINES

10

I

I
1

POWERWINDOWS

WH
T/VIO11(
10YELIG

I
11

I
9YELIGRVRN

(1986)1

FOWERWINDOWS

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LINES4'
1

POWERWINDOWS

BLKIGRN12

I
STARTINGICHARGING

I
`

13I

I
I;
12BLK/GRN

(1996)

4~I

I
iFPOWERWINDOWS

1
1713WHT/RED

BLK/GRN 15(I

I
01OOORLOCKS
114WHT/BLK

ANTI-THEFT

I
15WHT/GRY

DOORLOCKS

(1896)

BLK/VIO IS
I

ON-BOARDCOMPU7ER

I
1
16WHT/BLU

DOORLOCKS
ANTI

(1996) VIO/GRN/VEL 17

I
-THEFT
1

DOORLOCKS

RED/GRN(ORRED)

18

I

I
I
17WHT/RED/VEL

ANTI-THEFT

X1L19Z
L-J
1B
1)19RED/GRN/VEL (1997,99)

DOORLOCKS
120GRN/RED
POWERWINDOWS
I~2z
123BLK/WHT(ORBLK)

11POWERWINDOWS
I'24VEL/BLK

11
POWERWINDOWS
125BLK

10DEFOGGED
126VIO/BLK
,EXTERIORLIGHTS
IlWHT/GRN -
I

I
X1.aaBt
I

I
1BRN/RED/VEL
ANTI-THEFT
I

12
BRN/GRV/VEL
ANTI-THEFT
I

1
3

BRNIBLU/YEL

ANTITHEFT
I

1
I
4BRNIGRV/VEL(ORGRN/WHT/VEL)
I

ANTI-THEFT
5BRNIWHT
I

I

11
ANTITHEFT
I

18
VIO/WHT

POW
.RWINDOWS
I

17
BLK/WHT

POWERWINDOWS
I

18
WHT/GRN
POWERWINDOWS
I

19
BLUIGRN
POWERWINDOWS
I

110GRN/BLU(ORWHT/VEL)
POWERWINDOWS
I

I~11
I

112
I 1~1a
I

I,
14BRN/WHT
I

I

EXTERIORLIGHTS
I

1
15BLU/VEL
POWERWINDOWS
163LK/RED
POWERWINDOWS
I

1
17WHT/RED

POWERWINDOWS
I

1
18BLK/RED

(1997,98)

POWERTOPS
19BLK/GRN

POWERTOPS
(
I~20

SPIN

BRN/ORG
I I)21

"

"
I
I~2z
I

1
23GRY/RED

(1997)

ANTI-THEFT

SPINI

BRN/ORG
I

1
24VIOIWHT/VEL

(1997)

ANTI-THEFT

1

1
I I~26

G203

.203
I__J)X
132s4

ELE-178 ELECTRICALWIRINGDIAGRAMS
104758
68906
HOTATALLTIMES
--_1FRONTPOWER
FUSE
[DISTRIBUTIONBOX
F31
5A I
J
2yX70018
WarningSystem:Chimes
HOTATALLTIMES HOTINRUNANDSTART
r -
N"

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ISOU9

BLK/RED

F31
TONEI

I

5A
(SIGNALXL7.

L
___
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2''X10018

1z}'X14912
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w
GRN/WHT
CLUSTER

Y
1TX522
BRN
-2-G202
I 1

GRN/w
10

r12T
t
I

I

--- --- AUTOMATIC
I 111

TRANSMISSION
I

I

P

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__- X14Z0

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(SWITCH
ON-BOARD

IT-12

I
COMPUTE

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o

w

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33 m

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2

3

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2

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I

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(BACK-UPLIGHTS)
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MODULE
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F26

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I
J
1X522
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rB RN
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I

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SIGNALI

I
9

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11~~

10

X1070
BLK/
RED
2X522
RED/I

WHT/I

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YEL

RED BLU
3,1.---------

3~M_7B
CHIME
MODULE

WarningSystem:Chimes
w
I
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TONE
SIGNAL X17
i)

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w w
INSTRUMENT

¢_
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yw
m
2 3X522
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FUSE

IDISTRIBUTION BOX
5A
JX10018
w~
~ J
CHIME
MODULE
ZI
¢~
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I
G2021 G302
(31811)(Z3)
1997-98
318ti

ELE-180 ELECTRICAL WIRING DIAGRAMS
HIGHI
COMBINATION
I- NORMAL
BEAMISWITCH
SWITCH,
HIGH
HOTINRUNANDSTART

HOTINRUNANDSTART
FRONTPO-R
FUSE

FUSE

I
DISTRIBUTIONBOX
F23

F25
SA
5

4
t~
EXCEPTT
1992 VEL
YEL
EXCEPT3
T
1994

YEL
1994 ONLY
1992
3I
`-RT
GRN/VE
EXTERIOR
LIGHTS
SYSTEM
W/OOOM W/OOM

W/OOM

W/OOOM
YELIBLU

YELIBLU
(ORVELIGRN)I

(ORVEL/GRN)I
LOW
LEFT
IlJIIROWT

RI
LOW

LOW
BEAM BEAM
LIGHT
LIGHT
(EXCEPT (1993)
1993)1
BEN

BRN

BRN
Headlights/Foglights
1992-94(Canada)(1of2)
5A
I

YEL/GRY

VEL/GR
> 1992
EXCEPT>~

>
G
~ONLY
199
1992
ONLY
"
'EL
RED' YEL/GRN
(ORGRNIRED)
30

e6

LOW
BEAM
LIGHTRELAY
876
87

85
2

5

4
WNT/BLU YEL/
BRN
(ORYEL)

BLK
EXCEPT1992

1992
YELIGRN
(ORGRNIRED1I
VEL/GRY
WIGCRASH

I

W/CRASH
CONTROLMODULENTROLMODULE
VEL/GRYIVEL/GRVt
3
.,CRASH
MODULE
I (1992
I

I
ONLY)
9`T(
YELIGRNI

VEL/GRN'
T
BEAM

1(P
II
BEAM
LIGHT

14~ 1LIGHT
L
1m~~
'JL
m~
'J
~"-

13I

12I(1993)
12

13

(EXCEPT
T1993)
VEL/BLU

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(OR
YEL/GRN)

'DRYELIGRN) I

a
I I
BRN
,
BEAM BEAM
LIGHT
LIGHT
(EXCEPT (1993)
,ss3)

1Y

Gill
Gill
63089
(1992ONLY)
DAYTIMERUNNING
LIGHTSCODINGDIODE
1993
ONLY
EL
BRNI

-_
J'G202

3:

3
1X1LD2S
I
FRONT
POWER
I

IDISTRIBUTION
I

FUSE

FUSE

FUSE

FUSE

iBOX
I F71

F12

F30

F29 I
I 7.SA

7.6=----_--------- 7.5A

7.=A-~
21~---=_________=====47xrn91§

20'1
-_____--------BYx
,0D,7
RED
L/BL
IINSTRU-

6fi

30
HIGH
I

HIGH
MENT

BEAM
III
BEAMICLUSTER

-

LIGHT
No
I(1994

---------__-
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RELAY
I

JONLY)
xl&3~TX]7

85

87
2
"

BEN "

BRN
3 EXCEPT
1994
BRNI

I

REDIWHT
t_202 ~ "1
4

83992
RED
RED
YELIBLK
RED/W
G202,fly
B-N

.

SRN

1994
RD)WHTT
EXCEPT
1994
ELECTRICALWIRINGDIAGRAMS ELE-181
Headlights/Foglights
1992-94(Canada)(2of2)
HOTINRUNANDSTART

HOTATALLTIMESr__T________________________
-,FRONT
I

)FUSE

(POWER
F22

DISTRIBUTION
I

T5A

(BOX
L__A-________________________J_J
REAR
FOG
LIGHT
SWITCH
X212
'-G202
1993

I86
ONLY
LIGHT
SWITCH
I

I
I

I
IHEAD

OFF
I
L__

P_R_!
9
_85
4
(1994)
(EXCEPT1994)
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LIGHT
SWITCH
(EXCEPT1994)
(1994)
u13~X]DQ15.
F-1

-1
FUSEFRONT
I

FUSE
I
POWER
I

F17
I
DISTRIBUTION

w
L

10AJ
BOX

8,1X17
(INSTRUMENT
FRONT
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INSTRUMENT
REAR
'CLUSTER
REAR
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(
FOG
LIGHT

I
FOG I
LGHT

I
(1999M
.LY

I

NDIICATORI
(ONLY)
EXCEPT

I

-

1FRONT
1992

I

FUSE

IPOWER
F156A
(1994)

I
DOISTRIBUTION
7
15A (EX1994) '
LEFT
FOG
LIGHT
SRN
RIGHT
FOG
LIGHT
RED
876
30T

IFRONTFOG
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9
X
1OD1B
1uI
X1DO18
I

FOG I
LIGHTS
I

INDICATOR I
3YX]Z
1
G202

ELE-182 ELECTRICALWIRINGDIAGRAMS
IF-
TINRUNANDSTART

HOTINRUNANDSTART

HOTINPUNANDSTART

HOTATALLTIMES
c"E SE
FRONT
OWER
9
W
GRN/VEL

W/ 19920NLV
VEL/GRN
EXTERIOR

CRASH

1---1
9(O~

REL)
-, LIGHTSSYSTEM

'ICONTROL
YEL3I,/~I
NORMAL
HIGH
3
1,1,X16
IINSTRUMENT
HIGH
ICLUSTER
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INDICATORI
LEFT
LOW
BEAM
LIGHT
(EXCEPT
1993)
W
MOOULEf~I"
VE

YEL"

IC
HIGH(
COMBINATION
BEAM
SWITCH
SWITCH
I
WIGOCM

W/CCM

W/CCM

W/OCCM
B7 87b 85
2Y (NOTUSED) a
1

CHECK
I

I
CONTROL
I

I
MODULE
I

I
(1993)
12

13YY
(EXCEPT1993)
YEL/GRN

VEL/GRN/
OR

(OR/'
VELIBLU)

VELIBLU)I
VEL/GRN
.

~ VEL/GRN
(ORI

(ORI
VEL/BLUOI

VEL/BLU)2/
JJJL..

11
LFIGHT
RIOHWI~ILOEFT
W
BEAM

81,
'

BEAM
LIGHT

LIGHT/ LIGHT
(1893)

(EXCEPT1993) (1993)
1
SPIN
BRNT

BRN
G171
Headlights/Foglights
1992-94(USA)
I

HEAD

'"OFF

HEAD

>tOFFI
I

PARK

PARK
J_________-___________t---
4
85
9
BRN
BRNISRN
G202
YEL
CRASNCONTROLMODULE
W/O
CRAB.1
CONTROL MODULE
VEL/GRN(ORYEL)
H
6
LOWBEAM
LIGHTRELAY
E

7SA
E

7SA
F
USE
FUSE BOXFUSE
7-
FIl

F12
BEAM
LIGHT
¢3
-X39035
1~
X7003B
---------- -____-_____
--_--_---'Y tsx----------- ieYx
1oo17
HIGHHIGH
BEAM
LIGHT
RELAY
YEL
EL/GRIN(ORVEL)
I
FRONT
I
POWER
DISTRIBUTION
LEFT
HIGH
2

BEAM
LIGHT
RIGHT
HIGH
S
F0
LIG
0
HT
WITCH
BE
LEFT
FOG
LIGHT
BR
876,t,
(NOTUSED)

5T (7994)
2 (EXCEPT199/)
RIGHT
FOG
LIGHT
1016
to1x+n0+s.
-LG202
__J
FRONTFOG
LIGHTRELAY
-1FRONT
FUSEI
POWER
F75IDISTRIBUTION
-.5=J
Box
83093H
_
8,1,x17
I
I
INSTRUMENT
FOG
CLUSTER
LIGHTS
INDICATORI

133098
HOTINRUNANDSTART

HOTINRUNANDSTART
I
--------------
FUSE
F23
I 5A
L
/YE
EXTERIOR
LIGHTS
SYSTEM
RIGHT
LOW
BEAM
LIGHT
Headlights/Foglights
1995Except318ti(1of2)
3
ELECTRICALWIRINGDIAGRAMS ELE-183
IFRONTPOWER
FUSE

IDISTRIBUTION BOX
F25
5A I
J
YEL
3
YEL

I
"
HIGH
I
COMBINATION

RED

RED

1
NF--jORMAL

SWITCH

YE
W,
TCHI
I
FLASH HIGH

8
I

I

30

86
LOWBEAM
I

LIGHTRELAY
RED
87 876

85
2Y
NOTUSED

a
I

-IINSTRU-
I
(ZHIGHIMENT
I

BEAMCLUSTER
IND
JX-V
oD
LEFT
LOW
BEAM
1(fl
LIGHT
1
BE.

BRN

BEN
"

dI'G711
WH
4
BENI

BRN
SPINI
4LG202
YEL
GR./
RED
8
SRN
---------------------------------- ----
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POWER
I

DISTRIBUTION
I

FUSE

FUSE

FUSE

FUSE

I
BOX
I F11

F12

F30

F29 I
7IA

7-

7.6A_
---------
------
RIGN7

LEFT
HIGH

HIGH
BEAM

BEAM
LIGHT

LIGHT
1

1
X]11086
NIGH
BEAM
LIGHT
RELAY
6r-_________________
`1~
X1DD17
REOIWH

ELE-184ELECTRICALWIRINGDIAGRAMS
83099
RED
G202+
BRN

"

ORNN

)
CANADA
RED/WHT

REDIWHT
(2DOOR)3
G-
9
Headlights/Foglights
1995Except318ti(2of2)
(CANADA)
(EXCEPTCANADA)
EXCEPT
CANADA
(EXCEPTCANADA)

1
(CANADA) 3
13
X11!015
REAR
FOG
LIGHT
SWITCH
HOTINRUNANDSTART

HOTATALLTIMES
~RED

I
RED

I

RED
.
8
88
FOG
LIGHT
SWITCH
F-'F

-I
FRONT
FUSE
POWER
F17
IDISTRIBUTION
10A
,BOX
.CANADA
ONLY
I LEFT
(LEFT
REAR
TRUNK
I

FOG

I
LIGHT

2
I LIGHT
(ASSEMBLY

5X217

LEFT
I

REAR
(INSTRUMENT

LIGHT
4
X31c

FOG

(CLUSTER
I

1t
LIGHTS
(2DOOR)1

INDICATOR I
mI
Tu
m

SPIN
"L

~-
G202

AL
G111
RIGHT
FOG
LIGHT
876
9),X1((01
--1
FRONT
FUSEIPOWER
F15 I
DISTRIBUTION
7.5A
BOX
Lk__J
OIX70m
B,~XSZ
INSTRUMENT
ISFOCNT
'CLUSTER
I
IND
LIGHICTS
ATORI
3
I
XjZ
>-G202
FRONTFOG
LIGHTRELAY

88666
HOTINRUNANDSTART

HOTINRUNANDSTART
FUSE
F27
SA
SWITCH
1,~X1B
(INSTRUMENT
HIGH
(CLUSTER
I BEAM
I

INDICATORI
Headlights/Foglights
1996-97Except318ti(1of2)
3
IFRONTPOWER
FUSE

IDISTRIBUTION BOX
F25
-~ILIGHT
5WITCH
I

I
I ~PARN I
HIGHI
COMBINATION

RED
I

1N'RMA`J
BEAMISWITCH

YEL
I

FLASHrHIGH
;---------------
87~

87b~

85
2Y NOTUSED

e
1I
X10075
w/OCCM

WICCM

W/CCM

W/o
CCM
LEFT
[~] RIGHT
LOW

LOW
OEAM

BEAM
1(fl
LIGHT

LIGHT
1
r
BEN

BRN
"

SRN

J~
G111
ELECTRICALWIRINGDIAGRAMS ELE-185
BEN

BRN
I

BE,
BR.
1
G202
LOWBEAM
LIGHTRELAY
EXCEPT
1997USA
GEN/
YELI
RED
EXCEPT
7997USA
6
HIGH
BEAM
LIGHT
RELAY
X10076
IFRONT__-
(
POWER
DISTRIBUTIONI
I

FUSE

FUSE

FUSE

FUSE

I
Box
I

2?5 7
575A
7A_Jy
RIGHT

LEFT
HIGH

HIGH
BEAM

BEAM
LIGHT

LIGHT
BEN
RED
RED
IHE-,-'I~ OFFI
RED/WHT

ELE-186 ELECTRICALWIRINGDIAGRAMS
88667
RED
RED
RED/WHT

RED/WHT
(2DOOR)
4X313
(2DOOR)1
LEFT
LEFT
TRUNK
.292
AIL
BRN

.
REAR

ILIGHT
FOG
LIGHT
IASSEMBLV
Headlights/Fog'lights
1996-97Except318ti(2of2)
BRN1
1998
CANADA
(1998CANADA)
(EXCEPT199BCANADAI
FOG
LIGHT
SWITCH
(EXCEPT1996CANADA) 1
(1996CANADA)

3
EXCEPT
1996
CANADA
X
,.,e
rUSE
FRONT
FUSE
POWER
I

F17 I
DISTRIBUTION
L

7.s=J
BOX
14YX10016
I 7y~C LIGHT
SWITCH
HEAD

OFFI
~p
REAR
FOG
LIGHT
SWITCH
r
L
HOTINRUNANDSTART

HOTATALLTIMES
,FRONT
FUSE :POWER
F22-_--------------------

DISTRIBUTION
5A

IBOX
J
e
86 -3o

FRONTFOG
LIGHTRELAY
7996CANADA
ONLY
2l.
j.,

(ZLEFT
INSTRUMENT

FOG
~R

iCLUSTER

1t

LIGHT
FOG
LIGHTS
I

INDICATOR I
RIGHT
FOG
LIGHT
RED
RED
(EXCEPT1996CANADA)

2
(1996CANADA)

5
L
9),X19015
1

1_
G2o2
G111
-1FRONT
FUSE POWER
F75 IDISTRIBUTION
=.s=JBOX
01X]0915
8J~X17
r~
FRONT
'INSTRUMENT
M.
CLUSTER
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LIGHTS
INDICATOR

HOTINRUNANDSTART

HOTINRUNANDSTART

HOTINRUNANDSTART

HOTATALLTIMES
I

-~

I
FRONT
I FUSE

FUSE

FUSE

(POWER
F~2

DISTRIBUTION
5A

IA

BOX
-----

-- -------------- ________________I
6
-_-------- ._- ----------_---------0
-_-------_-_
4
X14412
Y
104667
GRNIBLU
WIOCOM IWICCM

WICCM IWIOCCM
CHECK
12I

CONTROL
13
T
MODULE
Headlights/Foglights
1998Except318ti
ELECTRICALWIRINGDIAGRAMS ELE-187
LEFT

~.~.RIGHT

LEFT

'~IRIGHT
LOW

~/~Jo\7LOW

HIGH

/~/~\~'IHIGH
B

B

L
PAN

BEAM
LIGHT

ILIGHT

~ LIGHT

I~/i'LIGHT
IHEAD

bOFF

HEAD

.
4OFF
I PARK

PARK
2
J.X]P
33A
036
~---------

I
FRONT
S

IPOWER
15
I

DISTRIBUTION
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TI

-1

I

FUSE

FUSE (BOX
1
I

F29

F30I
I ",A

7.5A
18Y1441Z --2 -_
v
G100
LEFT
FOG
LIGHT
r-~
FRONT
I

FUSE(
POWER
I

F15IDISTRIBUTION
1

~

7.6=J
Box
G207

107X1DD1a
6,{X12
RIGHT

INSTRUMENT
FOG ~
~
FO

(CLUSTER
G
LIGHT

I

SILNIGDI
NTS

I
I

CATORI

ELE-188ELECTRICALWIRINGDIAGRAMS
83831
HOTINRUNANDSTART

HOTINRUNANDSTART
FRONTFOWER
I
F2
FUSE

FUSE

I
DISTRIBUTIONBOX
3

F25
L
a
ICOMBINATION
NORMAL SWITCH
IFLASH HIGH I
RED/WHT
FUSE
F11
7.SA
I
__J
1~
X1B
(INSTRUMENT
HIGH
(CLUSTER
( BEAM
INDICATORI
1X10933
1j,X1-
2'r

------------------ AYX
1D018
LEFT
Low
BEAM
LIGHT
Headlights/Foglights
1995-96318ti(Canada)(1of2)
BRN
RED
LOWBEAM
LIGHTRELAY
------------
RIGNT
LOW
BEAM
LIGHT
X]I+ll110 Z
.L
G202
HT
HIGH
BEAM
LIGHT
--------- RELAY
ROWER
DISTRIBUTION
FUSE

FUSE

USE

I
BOX
F12

F3D

121 I
7.5A

7
.SA

7.5A
____________ ==__________ __J
20~~---_-__

_

_
1BYx1D
S
RIGHT
(~
LEFT
HIGH

HIGH
BEAM

BEAM
L
FN
IGHT

LIGHT
\1

I
G111

1
G111
RED
RED
RED/WHT
3

Headlights/Foglights
1995-96318ti(Canada)(2of2)
HOTINRUNANDSTART

HOTATALLTIMES
~2
V]
FOG
LIGHT
SWITCH
BRN
ELECTRICALWIRINGDIAGRAMS ELE-189
RED
-1FRONT
FUSE
POWER
-5
.I
DISTRIBUTION
1DYx10P1H
LEFT

RIGHT

INSTRUMENT
FRONT I
FOG

FOG

CLUSTER
LIGHT
LIGHT

FOG
1

LIGHTS
INDICATOR I
m

3
1
G202
FRONTFOG
LIGHTRELAY

ELE-190 ELECTRICALWIRINGDIAGRAMS
83839
HOTINRUNANDSTART

HOTINRUNANDSTART

RUNANDSTART

HOTATALLTIMES
___________________________________T____________-H071- _T__________r__~FRONT
FUSE

FUSE
'F23

/F25
I
111

SA
-------

----------
9
GEHIYEL
EXTERIOR
.LIGHTS
SYSTEM
(NOTUSED)
1
BRN
6RNr

BRN.,
Headlights/Foglights
1995-96318ti(USA)
BRN1 BR
BRN
G202
--------------
HEADt.\
-
OFF

HEADt~\OFF
PARK

PARK
2
.

FOG
LIGHT
SWITC
EL
COMBINATION_
__

H
u
O
CIE
RMAL

HIGH
SWITCH
N__-
Y
BEAM(

>

,1
SWITCH( RED

RED
FLASH HIGH
I

I

6

8

.
ILOWBEI---

-----

ISHTREM

rt
LIGLAY
(NOT (NOT
USED) USED)
X]9035

1~.
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1992-93(USA)(1of3)

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87478
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83139
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1994-96Except318ti(Canada)(1of3)
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1994-96Except318ti(Canada)(2of3)
HOTATLLTIMES HOTATALLTIMES

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7

______-__
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FWIOCHECKCONTROL MODULE

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BLUIVEL
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1994-96Except318ti(Canada)(3of3)
HOTINACCV,RUNANDSTART

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1994-96(USA)&1997Except318ti(1of3)
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L,l------------------------- A,__J-----------------------
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1994-96(USA)&1997Except318ti(2of3)
______________________LIGHT-----------------------
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W/OCHECK
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WICHECK
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GRY/VIO
-------_--~_____--_------- -~
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----------- ----------------- 17
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2I

1

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2,
83138
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(2DOOR)
61

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--------- ----
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(2
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1
BLUIVEL
I

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I
LIGHT

UP
I
1
---------------
GHT
8
(2DOOR)B
ExteriorLights
1994-96(USA)&1997Except318ti(3of3)
HOTINACCY,RUNANDSTART

HOTINRUNANDSTART
II

-------------------------------+FUS~FRONTPOWERFUSE
DISTRIBUTION
46

26
16A

l.A I
___________________________-_-___ _-I
32XIDDtn

12X10017_
0
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2
WIOCHECKCONTROLMODULE

W/OCHECKCONTROLMODULE
I
-----------------
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_____J
91
X1n74
---------
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ELECTRICALWIRINGDIAGRAMS ELE-205
BRAKELIGHT

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!_ZJ
- W/CHECK CONTROL MODULE
--------------I CHECK
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IMOOULE
16312
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STOP
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ELE-206 ELECTRICALWIRINGDIAGRAMS
86601
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1998Except318ti(1of3)
HOTATALLTIMES

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88602
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W/HECK
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LEFT
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ELECTRICALWIRINGDIAGRAMS ELE-207
ExteriorLights
1998Except318ti(2of3)
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LEFT HEADLIGHT

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10
--

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_______________
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-----~~----
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W/CHECK
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GRY/BLK

INTERIOR
,
LIGHTS
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(2DOOR)4
(2DOOR)1

__-__----
I
L__
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(2DOOR)6'
RIGHT
TRUNK
RIGHT
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W/OCHECK
CONTROLMODULE
RIGHT
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PLATE
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ELE-208ELECTRICALWIRINGDIAGRAMS
88603
4
(2DOOR)1
HOTINACCV,PUNANDSTART

HOTINRUNANDSTART
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26 I
DISTRIBUTION
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1998Except318ti(3of3)
BLUIYEL
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(EXCEPT1998)
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---_--_----
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ExteriorLights
1995-98318ti(1of2)
BLU/GRN/VEL

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DISTRIBUTION
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G2
1
0
'
1
BODVELECTRONICS
CONTROLMODULE
G201
CRASH
CONTROL
MODULE

ELE-210ELECTRICALWIRINGDIAGRAMS
63662
HOTINACCY,RUNANDSTART

HOTATALLTIMES

HOTATALLTIMES
-----_ _-_ ____._----------------

-1
FRONTPOWER
I

FUSE

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(DISTRIBUTION
66

33

37
I 16A

10A

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32IX19016O X
10016
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----
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UNIT
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m

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Exterior Lights
1995-98318ti(2of2)
I
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I
I=1G=T1------LIGHT I
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1997,98
3

(1997,96)

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BLY
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HOTINRUNANDSTART

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GRN/VEL
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MODULE
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I
TRANSMISSION
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InteriorLights/Illumination
1992-93(1of2)
U.S.A. CANADA

DAYTIME
GRV/BLK
ELECTRICALWIRINGDIAGRAMS ELE-211
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I

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111X
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EXTERIOR
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ELE-212 ELECTRICALWIRINGDIAGRAMS
68836
HOTATALLTIMES

HOTINACCY,RUNANDSTART

HOTINACCY,RUNANDSTART
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10A

5
A

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F33

F43

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IDISTRIBUTION
I------------------------------------ ----------------- B--I
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26

28
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I

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ANTI-

_

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_
THEFT
SYSTEM
BRN/WHT

INTERIOR

READING
LIGHTS

LIGHTS
CAPACITOR
(1993)
TRUNK

BRN/WHT/VEL
LIGHT
SWITCH
BRN/GRY/YEL
DRIVER'S
DOOR
JAMB
SWITCH
Interior Lights/Illumination
1992-93(2of2)
11X]3914
BAN
BAN
GIVE
OFF

SWITCH

S
WITCH

SWITCH
MAKEUP

AKEUP
FRONTDOME
LIGHT/
MAPREADING
ASSEMBLY
1
BAN

SAN

BAN
BANI
1
G203
CENTRAL
---------- ACTIVATION
DOOR

------------------------------- I
LOCKING
(DRIVER'S

OFINTERIOR

I
MODULE
R

PASSENGER'S
----

---

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-
LIGHTS
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DOOROPEN

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BRN/BLU/VEL
X13933

BRNIBLK 1
X'3014
INSTRUMENT

BRN/GAY/VEL I

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ANTI-

I

BRN/BLUIYEL
ANTI-
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,
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"
,
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I

SYSTEM

I

SYSTEM
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I

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BRN/BLU/YEL
2t
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SYSTEM
PASSENGER'S
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SWITCH
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jG312

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1G310

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G203

(2DOOR)

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WINDOWS

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RIGHTREAR
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JAMB
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BLU/GRNIGRV/RED
84212
EXTERIOR
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SYSTEM
(TURN/HAZARD
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GRN/VEL

GRN/YEL
I

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17
I
LIGHT
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.

I

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HOTINRUNANDSTART

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F22

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7
BR
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121

GRV/BLK
GRV/BLK

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GRYIBLKI

GRY/BLKI

16

14

2
SPIN
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CASSETTE
BOX
LIGHT
J1G202
InteriorLights/Illumination
1994-97Convertible(1of2)
4

2
BRNI

GRV/RED
FRONT
CIGAR
LIGHTER
y LIGHT
2t
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FRONT
ASHTRAY I'

ASHTRAY
LIGHT

t
l

LIGHT
ELECTRICALWIRINGDIAGRAMS ELE-213
U.S.A. CANADA

DAYTIME
RUNNING
LIGHTS
CODINGDIODE
RED/BLU
DIMMER
4
YEL16N~

YEL/GRN

EXTERIOR
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LIGHTS
SYSTEM
I

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ELE-214 ELECTRICAL WIRINGDIAGRAMS
84213
VIO/WHTI VIO/WHT
BRN
HOTINACCY,RUNANDSTART
r

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InteriorLights/Illumination
1994-97Convertible(2of2)
IBODYELECTRONICS
I

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(ZKE
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2fi7X
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81X39182
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VIO/BLKI

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1
I
J

LEFT

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COMPARTMENT COMPARTMENT
LIGHT

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REDIBLK RED/BLK

REDIBLKI
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FOOTWELL l
LEFT

I

,IFOOTWELL
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ER
2
G2311
VIOIBLKI BRNIWHT
1

2
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4
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BRN
1
G230
1
G312
FRONT
DOME
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MAP
READING
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HARD
TOP
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2
GLOVE
BOX
LIGHT
REO/WHTI
RED/WHTI RED/WHT
FIGHT
FEAR

FEAR
I
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HOTINRUN,

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104830
ELECTRICAL
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Interior Lights/Instrument
Illumination
1998
318ti

ELE-226ELECTRICALWIRINGDIAGRAMS
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FRONTPOWER
F5

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I
DISTRIBUTION BOX
IF

________ _
30A
-
J
10XLDQLS

20YXI0018
RED/BLK

RED/VEL
5
GRNIVIOf
BLK/VIOTBLUIGRYTVIOIGRYI

GRN/YEL( BLK/YEL' VIO/REDI BLU/REDTBRNr SRNAI
RED/
BL
jjJK
5
SEATBACK HEIGHT I POSITION
rnm rnmm~l
BACKFRONT
1- __2~ 1~ __21

7'
__2~ I~

G312
GANT- BLKT

GLUT- VIOT

GRN'- BLKT

V1101'

BLOT
DRIVER'SSEATBACK

DRIVER'SSEAT

DRIVER'SSEAT

DRIVERSSEAT
RECLINERMOTOR

HEIGHTMOTOR

MOVEMENTMOTOR CUSHION TILTMOTOR
SEATBACK HEIGHT
BACKFRONT
I
BLK/VI
yyy
RN/VOBLUIGRYT VIO/GRYBLK/YELT

T
88740
835¢7
(2DOOR)
BILK -RN BLU VIO

G310
(4DOOR)
BLKI

GRNI

BLUI

VIO
PASSENGER'SSEATBACWASSENGER'SSEAT PASSENGER'SSEATPASSENGER'SSEAT
RECLINERMOTOR

HEIGHTMOTOR

MOVEMENT MOTORCUSHIONTILT MOTOR
HOTATALL_TIM_ES

HOTATALLTIM_ES___
+++FFUSE

5F-USE~FRONTPOWER
,
F5

F40

iDISTRIBUTIONBOX
L
_Z-
-
______________t30A____I
10X199L4

20TX10018
RED/YEL

RED/VELI
DRIVER'SSEAT5
CONTROLSWITCH
SEATBACK
BACKFRONT
GRNIVIO f

BLKIVi2'BLU/GR
12

V~VIOIGZV
mmm mm
ONLUP--J

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IBACKLFRONT
GRNI

BLKI

BLUI

VIOI

GRNI

BLKI

VI.I

BLUI

BRN"
DRIVER'SSEATBACK

DRIVER'SSEAT

DRIVER'SSEAT

DRIVER'SSEAT
RECLINERMOTOR

HEIGHTMOTOR

MOVEMENTMOTOR

CUSHIONTILTMOTOR
RED/VEL
5
SEATBACK
HEIGHT
mm
BACKFRONT
ELECTRICALWIRINGDIAGRAMS ELE-243
PowerSeats
BACKFRONT
BACKFRONT
BACKFRONT
CUSHIONTILT
POSITION CUSHIONTILT
GRN/YE41BLU/REDI

vRIOpIeRN
HEIGHT I
POSITION CUSHIONTILT
GRNIYEL/

BLKIYEL
I
VIO/RED/BLU/REOT

BAN
1.'k-
-
2';' 1 `_ 2
-nmm1
PASSENGER'SSEAT
CONTROL
SWITCH
POSITION CUSHIONTILT
BLK/VIOTGRN/VIOTBLUIGRY~ VIOIGRYi

GRNIYELIBLKIYELi VIO/REDiBLUIREDt

BANI
1

_2
lll
1
L
..

1

__2
lll
1
L
..

1

1

__2

I
BLK

GRN

BLU

MVIG

GRN

LK

VIO

MBLU

BRG203
PASSENGER'S SEATBACK PASSENGER'S SEAT

PASSENGER'S SEAT

PASSENGER'SSEAT
RECLINERMOTOR

HEIGHTMOTOR

MOVEMENTMOTOR

CUSHIONTILTMOTOR
DRIVER'S
SEAT,
(SEAT
CONTROL
SWITCH
PASSENGER'S
SEAT,
SEAT
CONTROL
SWITCH
BAN
G203
1993
1994-98
Except318ti

ELE-244ELECTRICALWIRINGDIAGRAMS
HO_TA_TALL_TIM_ES_

H_O_TA_TALL_TIMES_
I

FUSE

FUSE

FRONTPOWER
I FB

F40
IDISTRISUTIONBOX
30=
10

X1_0015

20TX10018
RED/YEL

RED/YELI
5
83942
SEATBACK HEIGHT I POSITION CUSHIONTILT
BACKFRONT
Power Seats
BACKFRONT
DRIVER'SSEATCO
NTROLSWITCH
y

y..._..y

...

..y-» .
RN/V'O'

BLK/VI2

11,
12

'of
BLU/GRV'^`O/GZVI

GRN/VEL' BLK/YEL, VIO/R2.L.LLU/REO'

BRN
GRINI

BLKI

BLUI

VIOI

GRNI

ELKI

VI.I

BLUI

SPIN.'
RED/YEL
5
SEATBACK
HEIGHT
BACKIFRONT
DRIVER'SSEATBACK DRIVER'SSEAT

ORIVER'SSEAT DRIVER'SSEAT
RECLINERMOTOR

HEIGHTMOTOR

MOVEMENTMOTOR

CUSHIONTILTMOTOR
POSITION CUSHIONTIL
BACKFRONT
2

__1

1

__2

1

__2

'-
-T-T
BRN
1SGRN BLU VIOT GRN ELKT VIOBLUi
G201
PASSENGER'SSEAT
CONTROLSWITCH
BLK/VIOT
GRNIVIOTBLU/GRVT VIOIGRVT

GRN/VELT BLK/YELT VIO/REDTBLU/REDT

BRN
PASSENGER'S
SEATBACKPASSENGER'SSEAT

PASSENGER'SSEAT

PASSENGER'SSEAT
RECLINERMOTOR

HEIGHTMOTOR

MOVEMENTMOTOR

CUSHIONTILTMOTOR

83550
ELECTRICALWIRINGDIAGRAMS ELE-245
HeatedSeats
1992-98Except318ti
HOTIN
RUN.1
~ANDSTART

HOTATALLTIMES
rIF-SE----------------------------------- PUSS
-1FRONTPOWER
123

yFE

IDISTRIBUTION BOX
SA

16A
L~_____________________________________-i----J
SIx19o~

Bx>-D
GENIBLU

RED/-
G203J-G310
(2DOOR)

(4DOOR)
INTERIOR
LIGHTS
SYSTEM
PASSENGER'S
BEATHEATER
SWITCH

ELE-246 ELECTRICALWIRINGDIAGRAMS
63939
HOTINRUNTANDSTART

HOTATALLTIMES
rTFUSE -------------------------_--------- FUSE
,FRONTPOWER
'F23

14

1DISTRIBUTIONBOX
5-_____________________________________
aI"'D"1.

B
I
~
GRNIBLU

RED/VIO
UNLOADER
fifi

30
RELAY.
85
-----_-_-__--------------------

TERMINAL15
HeatedSeats
1995-97318ti

HOTATALLTIMES__
---1FRONTPOWER
FUSE
F40

DISTRIBUTIONBOX
30A--
20TX10018
RED/YEL
RED/YE
Ll3
LumbarControl
1998
4

2
WHT/RED WHT/BLU
ELECTRICALWIRINGDIAGRAMS ELE-247
2^ 4^
NCA NCA
DRIVER'S
SEAT
M

LUMBAR
SUPPORT
MOTOR/
NCA

NCA VALVE
1..

3...
BRNI

BRN
DRIVER'S
SEAT
LUMBAR
SWITCH

ELE-248 ELECTRICALWIRINGDIAGRAMS
1
69042
83567
HOTATALLTIMES
~FRONT POWER
DISTRIBUTION BOX
RED
RED
SUNROOF
SUNROOF

SUNROOF
CONTROL
SWITCH

-_ MOTOR
ASSEMBLY
M
i
HOTATALLTIMES
~ 1FRONTPOWER
DISTRIBUTION BOX
COMFORT
________---_ __-_-____
RELAY
Z
2y/

4
RED/BLU1

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RED/BLU
1

5

79
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DISTRIBUTION BOX
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J
STEP-BY-

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RED
PowerSunroof
85
2y'

8

y'
RED/VIO' SPIN VIO/YEL
9
I
"F-1992
VIO/YEL~
9_X_13012
" ICOMFORTI
BRNI
RELAY
1ICONTROLI
POWERWINDOWS
G202
CENTRALLOCKING
SYSTEM

MODULE
BRNT
BRNI
t
G203
FRONT
POWER
Fi/9E
~
DISTRIBUTION BOX
5A-I

!_I
SUNROOF
SUNROOF

SUNROOF
CONTROL
SWITCH

MOTOR
ASSEMBLY
1

M
-
Y
I
I
STEP-BY-

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STEP

I
SWITCH
NCA
BRNI
BRNI
1
G203
BODY
ELECTRONICS
CONTRO MODULE
(ZKEIV)
COMFORT
RELAY
1992-93
1994

2
RED/VIO
HOTINACCY,RUNANDSTART
fiFUSEI
FRONTPOWER
Jj

DISTRIBUTIONBOX
V30A

I
84194
2
RED/VIO
HOTATALLTIMES
r

FUSE1FRONT POWER
Fl

DISTRIBUTION BOX
L soA
PowerSunroof
NCA
SUNROOF
SUNROOF

SUNROOF
CONTROL
SWITCH

-_ MOTOR
ASSEMBLY
M
I
STEP-BY-

MICROSWITCH
--
STEP
SWITCH
ELECTRICALWIRINGDIAGRAMS ELE-249
NCA
.1911
2y
BRNI
AL
G203
INTERIORLIGHTS
GRY/REDr
SYSTEM
6
OPEN CLOSE
4

3
BRNNI

BLK/YES WHT/YELl
1X272

X13176
2X272

3T

11
X13176
N

BLK/REDIBLK/GRN
1q 10
BRNI

BODYELECTRONICS
I ~CONTROLMODULE
1

I

i(ZKEIV)
SUNROOF
SWITCH
SUNROOFCONTROL
ASSEMBLY
1995
Except318ti
1996-97
Except318ti

ELE-250 ELECTRICALWIRINGDIAGRAMS
104866
HOTATALLTIMES
FUSE,FRONTPOWER
F1

DISTRIBUTIONBOX
L30A
~--
J
I

INTERIORLIGHTS
RED/V10

GRY/REDr
SYSTEM
PowerSunroof
1998Except318ti
3
OPENiCLOSE
.7OFF
4
L

2 1
t
BRN

BLK/YEL

WHT/YEL
X272

6

5

4X13176
2X272

3

1X3176
t
BRN

BLK/RED

BLK/GRN
18 19
SUNROOF
SWITCH
SUNROOFCONTROL
ASSEMBLY
BRN

BODYELECTRONICS
ICONTROLMODULE
~-G203

I

i(ZKEIV)

84238
GRY/RED
84240
INTERIOR
LIGHTS
SYSTEM
HOTATALLTIMES
FRONTPOWER
DISTRIBUTIONBOX
-.I
RED

RED
OMFORT
--------

----------
RELAY
C
T
2
REDIBLU~
REDIBLU
1

19I
X13254
r-FRONTPOWER

BODY
I

FUSEI
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BOX

I

ELECTRONICS
I

I

ICONTROL
I

30.4J

I

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REDIVIDI
NCA
ELECTRICALWIRINGDIAGRAMS ELE-251
PowerSunroof
HOTATALLTIMES
6
RED/VI
1
SUNROOF
SWITCH
NCAI
.L2
BRNI
BRNI
1
G203
BLKIYELI
WHT/YELI

BRNIBLK/GRNI BLKIRED
1u 18j,X132
54.
r

1
BOGY
I

ELECTRONICS
I

ICONTROL
I

----

MODULE
1995Early
SUNROOFProduction
CONTROL
ASSEMBLY

3
18ti
SUNROOF
CONTROL
ASSEMBLY
1995Late
2T

Production&
BRN1

1996-98318ti
BRN
s

SlidingSunroof
I
t
G203

ELE-252
ELECTRICAL WIRING DIAGRAMS
88588
SL
BLK
104876
8
GRN
GRN
HOTATALLTIMES
FflONT
POWER
DISTRIBUTION BOX
BLK/GRN
RED/BL
.
I

19
r

FUSEIFRONTPOWER

I--I
BODY
DISTRIBUTION BOX

ELECTRONICS
F1
I
ICONTROL
Z30AJ

-I
MODULE
RED/V1110'

1997
NCA

SUNROOF318tiFolding
SUNROOF

SUNROOF
CONTROL
Sunroof
SWITCH

-_ MOTOR
ASSEMBLY
M
~E~7

111
3
BLKIGRN
BLK/GRN
PowerSunroof
STEP-BY I.
MICROSWITCH
1---

SWITCH
7
BLK/RED
BLKIRED
U
2J.
1
191 181
X7325
I
I

I
FOLDING BODY
SUNROOF
ELECTRONICS
MOTOR
CONTROL
MODULE
HOTATALLT_IMES
FPONTPOWER
-iDISTRIBUTIONBOX
RED
REDIV
1
IO
9
BLK/YEL
NCA
BRNI
BRNI
1
G203
r-FRONTPOWER
FUSE
DISTRIBUTIONSOX
F1I
I,30AJ
4
BLK/YEL
TIP CLOSE
OPEN
GRY/RED
6
SRN
FOLDING
4
SUNROOF
BRN
1
SWITCH
FOLDINGSUNROOF
COMFORTRELAY
1998
318tiFolding
Sunroof

I
671-E L
I

11~V/HT/GRN
I
-3

BLKIYEL
CTRL
BIG

4

SLUIRED
,
CTRLSIGI5

GRV/RED
END
B
BRN

SPIN G205
'X11399
CONVERTIBLETOPDONTRGLMODULE
BODY
ELECTRONICS
CONTROL MODULE(ZKEIV)
03584
I.SPIN
BLK/BLU
I
- _I
w
HARD
OFCONNECTOR1
(INCONVERTIBLE
TOP
BR
B~
G~
RN/BLK
REARWINDOW BLOWER
MICRO
SWITCH
9 WHT/BLK
10 WHT/BLU
DEFOGGER
SYSTEM
BRNI
j
G202
ELECTRICAL WIRING DIAGRAMS ELE-253
Convertible Top
1994-97
NANDSTART
HOTATA,~LLTIMES

HOTACCV,-RU,,NANDSTART

HOTAT777AIIBL~~LTIMES

HOTACCV,R 'U~

HOTATALLTIMES
r/FUSE--___-
/FUSE-------
FUSE
-_____-/FPOWER
FUS

US

FU

42E------~F27E
DINT
TIDRSRBUTIONBOX
7 BLK/RED
B BLU/GRN
CTRLSIG
9 GRYIBLK
CTRLSIG
12V
10 RED/GRNIYEL
J
X13
15fi
TRUNKLIOSIG
20
21
BRN/WHT
WHT/VEL
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22
23 WHT/BLU
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GRN1VI0
DATASIG
24
25 BRNIORG
GND
PWRSUPPLY
2B~
X]1]`z4
DATASIG

-II1I.
INTERIORLIGHTS
SYSTEM
CONVERTIBLE
TOPMOTOR
BLK/BRN
GRV/RED 4
BRNIORG 1
BRN/ORG 2
BRN/ORG
tSUPPLY
I YEL/BLU
2
BLK/BLU
POSTNSIG
3 BLU/VEL
POSTNSIG
4 VEL/BRN
END
LK/GRN
CTRLSIG
POSTNSIG
B
6 VEL/GRN
x1
157
TOPOPENBIG

1
2

BLK/BRN
14 WHT/VIO
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GND
B BLKIBLU
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6 VIO/WHT
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l
REARWDOBLWPSIG

B

GRNIBLK
10 WHT/GRN
DATASIG
11
12 GRN/GRY

LEFT
DATASIG

IIROLLOVER
SPOSIG
1B ILK HT

PROTECTION
TOP
CLOSEDBIG

14

BLKIGRN

ACTUATOR
DATASIG
1S
16 WHT/VEL
17
16
19 WHTIVIO
VIO/GRN 1
GRN/VIO 2
BLK/WHT 3
BLKIBLU 4
GRN/GRV 5
WHT/VIO B
BRN/ORG 7
BLKIVIO 10
BLKIGRN 11
BLKIGRN
am
BLK/VIO
BLK/BLU
BLKIWHT
ROLLOVERSENSOR
RIGHT
IIROLLOVER
PROTECTION
ACTUATOR
BLK/GRN 57

CLOSE
OFFN-H
CONVERTIBLE TOP
ACTUATING SWITCH
BRN/ORG- f I
BLK/BLU
BLK/ ,
BRNIORRG
CONVERTIBLETOP
POSITIONMICROSWITCH
WHTIBLU ~~BLU
CONVERTIBLE
TOPEND-
POSITION
MICROSW
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BLKIRED BLU
ELK-. /EEL RED
BRN/ORG~~

BRN
LOCKED
WHT/BLK
~~
CRY UNLOCKED
WINDSCREENCOWLPANEL
LOCK
CONVERTIBLE
TOPSTORAGE MOTOR

MICROSwITCH
(1996-97)

ELE-254 ELECTRICALWIRINGDIAGRAMS
CONVERTIBLETOP
CONTROL MODULE
I
18WHT/RED
I

1
X1
3254
I

I
15WHT/YEL
I

1711WHTIGRN
I

__I X13255
BODYELECTRONICS
CONTROLMODULE(ZKE
IV)
I
I
NCA BLC-/BL U
I

NCA

,
BRN
I __I
HARDTOP
CONNECTOR 1
REARWINDOW BLOWER
MICRO
SWITCH
104867
,2
LOCKCTRL
;
CTRLSIG
4
8-t.)/RED
TOPOPENSIG
Ir
J2
J3
DATASIG
GND
PWRSUPPLY
J7
HOTAT
HOTINRUN,

HOTAT

HOTINRUN HOTINRUN, HOTAT
ALLTIMES ACCYANGSTART

ALLTIMES
7II~~

ANOSTART ACCYANDSTART ALLTIMES
AUXILIARYF

_
FUS
_
E,

r7`7F_US_E
__

FUSE

FUSE

FUSE

FUSE
~FRONT POWER
FUSE
BOXI

=35

I

IL,F43-

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F7

F24

F42

P271

1-

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L 20-J

S
.

S
.-0-7-0-
5A_j
L

SS
OUTPUT
CTRLSIG
5 GRYIRED

III

I I

II

I

I

INSTRUMENTCLUSTER
N
GND

8

BR

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I

VIO/GRN

2
LOCK
CTRL

17

BLK/RED
BLK/WHT
4
CTRLSIG J3

BLU/GRN

-
8LK/BLU
B
"
CTRLSIG
9 GRYLK

II

III

IIIIII

III

GRN/BLK 8
12V
,D
RED

IIII I

III

II II

I

I II

BRNIORG
~nlzo-

WHT/BLU 12
BLK/VIO 11
isUPPLY
1
YEL/BLU
WHTIVIO 20
ITIONSIG
2
BLK/BLU
BLK/GRN 21
...
POSITIONSIG

3

BLU/YEL
GND
4
YEL/BRN
ROLLOVER SENSOR
BLKIGRN
IIq
RIGHT
ROLLO
ER
OUATOR
N
POSITIONSIG
li
S

BLK/GRN
CTRLSIG 1
8

YEL/GRN
157
8LK/BRN
WHT/VIO
BLK/BLU
VIO/WHT
REARBLOWER
18 GRNI.LK
ALG312
NN=A(
BRN/YEL

DEFOGGER
SYSTEM
NCA
BLK
NCABRN
ConvertibleTop
1998
2
1
281
Xt00
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BIx1oo17 241x190]7
141X70012
RED
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GRN/I

GBNKI GRNI
GRNI
VIO

GRN/VIO 23
DATALINK
W~T
CONNECTOR GqN
[ GRN/J VIOLj _ ROLLOVER I
ELK

GRN

I

PROTECTION 1
20Y ,BT

I
WARNING I
I
HT/

WHTlBLU

10

IND
1
EL
J9
DATASIG

1_10

WHT/GRN
11
Jlz
SPEEDSIG
113 BLK/WHT
TOPCLOSESIG I
14
BLK/GRN
rrrr
CONVERTIBLE
UNLOCK LOCK

I TOPMOTOR
WINOSCREENCOWLPANEL
LOCKMICROSWITCH
" BLKK/WHT
2I

I
CONVERTIBLE
TOP-END
TRUNKLID
POSITION
MICROSWITCH
MICROSWITCH
BLKIVIO
BLK/BLU
BLK/WHT
RED/GRN
BRN
LEFT
IIROLLOVER
PROTECTION
ACTUATOR
CONVERTIBLETOP
STORAGE
LIDLOCKMOTOR

Radio/Cassette/CD/Speakers
RADIO
_I
ANTENNA
AMPLIFIERAM/FM
1 YEL/RED
2 BLU/RED
3 YEL/VIO
4 WHT/BRN
5 VIO/WHT
6 BLU/VIO
IVSSI 2 BLK/WHT
PUTPUTI
1
~
INSTRUMENT CLUSTER
TELEPHONE TRANSCEIVER
87730
RADIO
IVSSI 2BLKIWHT I
pUTPuT
INSTRUMENTCLUSTER
WHT/
I

1I-_
I
10B~ BER-N
TELEPHONETRANSCEIVERI
86095
TELEPHONE
WHT/
CONNECTOR
6
BRN
X40
ELECTRICALWIRINGDIAGRAMS ELE-255
HOTAT

HOTINACCY,
ALLTIMES RUNANDSTART
1994
TO
1996
1997
I

I
I

(
I_1
ANTENNA
AMPLIFIER
1993
I
1992
7
8 YEL/BRN
9 RED/WHT
10BLK/WHT
11BLUIBRN
12YEL/GRY
f3

GRY/RED

INTERIORLIGHTS
14
BLU/GRY

SYSTEM
15BRN
G202
6WHT
20A(1997)
Ll------ J__JJ--
1--1,10

BLK

WHT/BRN

1

I

BLU/VIO4
HOTINACCY,RUNANDSTART

HOTATALLTIMES
FUSE

FUS,
FRONTPOWER
'I

F44

F9

I
DISTRIBUTION BOX
I

15A(OTHERS)

20A
I YEL/RED
2

BLU/RED(1994-1996) BLU/BLK(7997)
3 YEL/VIO
4 WHT/BRN
5 VIO/WHT
6 BLU/VIO
7

YEL(1997
8 YEL/BRN
9
RED/WHT
10
BLK/WHT
11BLU/BRN
_
12

YEL/GRY
13
GRY/RED
14
BLU/GRY
f5BAN

BRN {
16
WHT

6202

`

I
BLU/BLK (1994-1996)
BLU/BLK(1997)

-li
YEL/VIO4
LEFT
REAR
YELIGRY I.,

SPEAKEF
6LU/RED RIGHT
FRONT
8LU/BRN
LOW
RANGE
SPEAKEF
BLU/RED2
BLU/BRN
I
ID
II
REAR
SEAKEF
RIGHT
BLU/GRY I,
BLU/RED
BLU/BRN
BLUIVIO
BLU/GRY
CD
CHANGER
(1997)
LEFT
FRONT
LO
W
RANGE
`V
SPEAKER

199497-
LEFT
FRONT

Except318tiHIGH
RANGE
SPEAKER

10Speaker
RIGHT
FRNT
"

BLU/BRN
`1yIILO
RANGE
SPEAKER
RIGHT
FRONT
HIGH
RANGE
SPEAKEF
LEFT
REAR
SPEAKER
1992-93
LEFT

6Speaker
FRONT
HIGHSystem
RANGE
SPEAKE
RIGHT
FRONT
HIGH
RANGE
SPEAKER
RIGHT
REAR
SPEAKER
System

ELE-256 ELECTRICALWIRINGDIAGRAMS
RADIO
VSSI

2

BLK/WHT
(OUTPUT(}------"
INSTRUMENT
CLUSTER
TELEPHONE 6WHT/BRN
CONNECTOR X400
108825
Radio/Cassette/CD/Speakers
1998Except318ti6SpeakerSystem
HOTINACCY,RUNANDSTART

HOTATALLTIMES
IT------7F-----j FRONTPOWER
FUSE.

IDISTRIBUTIONBOX
F9
20AI
FUSE
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Except318ti
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1998
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ELE-258 ELECTRICALWIRINGDIAGRAMS
RADIO
108830
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12 BRN/ORG
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Radio/Cassette/CD/Speakers
1998Convertible10Speakerw/CD&TopHIF!System
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ELECTRICALWIRINGDIAGRAMS ELE-259
Radio/Cassette/CD/Speakers
RADIO
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ELE-262ELECTRICALWIRINGDIAGRAMS
186702
CDCHANGER
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4 WHT/BRN
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6 BLU/BLK
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10 BLK/WHT
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Radio/Cassette/CD/Speakers
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2
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9

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1993LateProduction10SpeakerSystem
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ELE-264ELECTRICALWIRINGDIAGRAMS
86093
CDCHANGER
INTERIOR
LIGHTS
SYSTEM
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1994-97Except318ti10SpeakerSystem
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nn
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(1997)BLU/WHT 7
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(19977BLU/BRN 8
8 BRN/OR6
9 RED/WHT
10 BLK/WHT
11 BRN/DRG
12

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605
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98&1997)

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12 BRN/ORG
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Radio/Cassette/CD/Speakers
1995-97318ti10SpeakerSystem
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F9 I
20A I
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LVEL/GRY ,11
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BLU/BLK 12
(1995-1996)

BLU/GRY 13
BEN(1997)

BRN/ORG 14
BLU/RED 15
YEL/
RED
16
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0-
17
ELECTRICALWIRINGDIAGRAMS ELE-265
VEL/BRN 26
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1111111

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(1995EARLYPROD)
6
1996&1997)

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BLU/WHT

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10
(1995LATEPROD

18
1996&1997)-

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(1995EARLYPROD)
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LEFTFRONT I
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---- SPEAKER
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RIGHTREARSPEAKER

WARNING
Yourcommonsense,goodjudge-
ment,andgeneralalertnessarecru-
cialtosafeandsuccessfulservice
work.Beforeattemptinganyworkon
yourBMW,readthewarningsand
cautionsonpagevi¡andthecopyright
pageatthefrontofthemanual.
Reviewthesewarningsandcautions
eachtimeyoupreparetoworkon
yourBMW.Pleasealsoreadany
warningsandcautionsthataccom-
panytheproceduresinthemanual.
A
ABS(anti-lockbrakes)
SeeBrakes
Acceleratorandthrottlelinkage
SeeMaintenanceprogram
Airconditioning
generalinformation640-1
airdistributionmotor,replacing(rotary
knob)640-10
airdistributionmotors640-9
blowermotor,removing/installing
640-1
blowermotorresistorpack,replacing
640-3
compressor,replacing640-12
compressorclutch640-13
condenser,replacing640-14
controlhead640-7
removing/installing(digital-display)
640-8
removing/installing(rotaryknob)
640-7
controlmodule
removing/installing(digital-display)
640-8
removing/installing(rotaryknob)
640-8
evaporator,removinglinstalling
640-17
evaporatortemperaturesensor,
replacing640-17
expansionvalve,removing/installing
640-16
microfilter,replacing640-18
receiverldrier,replacing640-15
sensorfanforinteriortemperature,
replacing640-9
warningsandcautions640-11
Airdistribution(flap)motor
SeeAirconditioning
SeealsoHeating
Airfilter
SeeMaintenanceprogram
Airbagsystem(SRS)
generalinformation721-1
contactring,replacing721-3
driversideairbag,removing/installing
721-5
frontcrashsensor,replacing721-4
frontside-impactairbag,removing/
installing721-7
frontside-impactairbagcrashsensor,
removing/installing721-5
passengersideairbag,removing/
installing721-6
sensorsandelectronics721-1
SRSwarninglightandfaultdisplay
721-2
systems721-1
ZAEcontrolmodule,replacing721-5
Alarmsystem
SeeCentrallockingandanti-theft
Alternator
SeeBattery,starter,alternator
Anti-freeze(Enginecoolant)
SeeMaintenanceprogram
Anti-theft
SeeCentrallockíngandanti-theft
AST(Al¡seasontraction)300-4
ATF(Automatictransmissionfluid)
SeeAutomatictransmission
Automatictransmission
SeealsoTransmission-general
generalinformation240-1
ATF,drainingandfilling240-2
ATFleve¡,checking240-1
transmissionremovalandínstallation
240-4
transmission,removinglinstalling
240-4
transmissionservice240-1
Auxiliaryfan
SeeCoolingsystem
Axlejoint
SeeMaintenanceprogram
B
Back-uplightswitch
SeeManualtransmission
Balljoint
SeeFrontsuspension
Battery
SeeBattery,starter,alternator
Battery,starter,alternator
SeealsoMaintenanceprogram
generalinformation121-1
alternator,removing/installing(4-
cylinderengine)121-5
alternator,removinglinstalling(6-
cylinderengine)121-6
alternatorbrushes,inspecting/
replacing121-7
alternatorservice121-4
batterycharging121-4
batteryloadvoltagetest121-4
batteryopen-circuitvoltagetest121-4
batteryservice121-3
INDEX1
Battery,starter,alternator(cont.)
batterytesting121-3
chargingsystemquickcheck121-2
chargingsystemtroubleshooting121-
2
hydrometertesting121-3
solenoidswitch,removinglinstalling
121-10
starterservice121-7
startertroubleshooting121-7
starter,removing/installing(4-cylinder
engine)121-8
starter,removing/installing(6-cylinder
enginewithautomatictransmission)
121-9
starter,removing/installing(6-cylinder
enginewithmanualtransmission)
121-8
staticcurrentdraw,checking121-2
voltageregulator,removing/installing
121-6
Bearing,wheel
SeeFrontsuspensionorRear
suspension
Blowermotor
SeeAirconditioning
SeealsoHeatíng
BMWemblem
SeeExteriortrim,bumpers
Body-general
generalinformation400-1
bodyassembly400-1
centralbodyelectronics400-4
convertiblemodels400-2
coupemodels400-2
electronicimmobilizatíonsystem400-
4
exteriorandaerodynamics400-2
heatingafhdairconditioning400-5
instrumentsandcontrols400-4
interiorequipment400-3
seatsandseatbelts400-3
Bodysidemolding
SeeExteriortrim,bumpers
Brakefluid
SeeMaintenanceprogram
Brakes
generalinformation340-1
antilockbrakesystem(ABS)340-11
inspection340-12
wheelspeedsensors,replacing
340-12
bleedingbrakes340-3
brakebooster,removinglinstalling
340-8
brakecaliper,removing/installing
340-6
brakepads,calipers,androtors340-3
brakepads,replacing340-4
brakerotor,removing/installing
340-7
mastercylinder,removing/installing
340-7
parkingbrake340-10
adjusting340-10.
cable,replacing340-11
shoes,removinglinstalling340-11

2INDEX
Brakes(cont.)
pressurebleedingbrakes(exceptcars
wíthAST)340-3
troubleshooting340-1
Brushes,alternator
SeeBattery,starter,alternator
Bulbs
SeeExteriorlighting
SeealsoInstruments
Bumpers
SeeExteriortrim,bumpers
C
Camber
SeeSteeringandwheelalignment
Camshaft
SeeCylinderheadandvalvetrain
Camshaftpositionsensor
SeeIgnitionsystem
Camshafttimingchain
generalinformation117-1
camshafttimingchain,4-cylinder117-
2
camshafttimingchains,6-cylinder
117-6
camshafttimingchain,removing
(4-cylinderengines)117-2
camshafttimingchains,removing
(6-cylinderengines)117-7
vanos(variablevalvetiming)117-14
controlunit,removing117-16
systemoperation,testing117-14
Caster
SeeSteeringandwheelalignment
Catalyticconvertor
SeeExhaustsystem
Cautionsviü
Centerbearing
SeeDriveshaft
Centerconsole
Seeinteriortrim
Centralbodyelectronics(ZKEIV)515-8
Centrallockingsystem(ZVM)515-7
Centrallockingandanti-theft
generalinformation515-1
doorhandlesandIocks515-1
doorstriker,replacing515-6
frontdoorhandle,removing/
installing515-3
frontdoorlock,removing/installing
515-1
reardoorhandle,removing/installing
515-5
reardoorlock,removing/installing
515-4
EWSIIcontrolmodule,replacing515-
10
EWSIIringantenna,replacing515-10
EWSIItransmitter/receivermodule,
replacing515-11
lockingsystemandelectronic
immobilization515-7
luggagecompartmentlocking
actuator,removing/installing515-6
Clutch
generalinformation210-1
clutchhydraulicsystem,bleedingand
flushing210-2
clutch,inspectingandinstalling
210-5
clutchmastercylinder,replacing
210-2
clutch,removing210-4
clutchslavecylinder,replacing
210-3
transmissionpilotbearing,replacing
210-6
Clutchfluid
SeeMaintenanceprogram
Coil
SeeIgnitionsystem
Coilspring
SeeRearsuspension
Componentlocations
SeeElectricalcomponentlocations
Compressor
SeeAirconditioning
Compressorclutch
SeeAirconditioning
Condenser
SeeAirconditioning
Controlarms
SeeFrontsuspension
SeealsoRearsuspension
Convertibletop
generalinformation541-1
manualconvertibletop541-1
lidreleasemechanism541-2
replacing541-2
visorlatch541-1
visorlatchpíate541-1
powerconvertibletop541-2
drivemotor,replacing541-7
emergencyoperation541-7
frontlatchingmechanism541-4
lid541-9
replacing541-5
visorlatch541-4
visorlatchmotor541-5
visorlatchplate541-4
rolloverprotectionsystem541-9
Coolant(Anti-freeze)
SeeMaintenanceprogram
Coolantpump
SeeCoolingsystem
Coolingsystem
generalinformation170-1
coolingfan,replacing170-8
coolantpump,replacing170-10
coolantpumpandthermostat
170-1
coolant,draining/filling170-5
coolingfans170-2
coolingfan,testing170-4
coolingsystemservice170-5
coolingsystem,bleeding(radiatorwith
integralexpansiontank)170-6
coolingsystempressuretest170-3
electriccoolingfan,replacing170-8
radiator,removing/installing170-11
Coolingsystem(cont.)
radiatorandexpansiontank170-1
radiatorservice170-11
temperaturegaugequickcheck
170-3
thermostatquickcheck170-3
thermostat,replacing170-9
troubleshooting170-2
warningsandcautions170-2
Crankshaftposition/rpmsensor
SeeIgnitionsystem
Crashsensor
SeeAirbagsystem(SRS)
CVjoint
SeeMaintenanceprogram
SeealsoRearsuspension
Cylinderheadandvalvetrain
generalinformation116-1
camshaft116-7
camshafts,removing/installing
(M42engine)116-1
camshafts,removing/installing
(M44engine)116-3
camshafts,removing/installing
(6-cylinderengine)116-4
cylinderhead,disassembly/assembly
116-1
cylinderheadandvalvetrain,
reconditioning116-7
cylinderhead116-7
hydrauliccamfollowers,checkingand
replacing(M42andal]6-cylinder
engines)116-9
hydraulicvalveadjusters,checking
andreplacing(M44Engine)116-8
valveguides116-10
valveseats116-12
valvesprings116-12
valvestemoilseals116-11
valves116-11
valves,leaktest116-11
valves,removing/installing116-6
Cylinderheadremovalandinstallation
generalinformation113-1
cylinderhead,removing/installing(4-
cylinderengine)113-1
cylinderhead(6-cylinderengine),
removing/installing113-10
Dashboard
SeeInteriortrim
Decklid
SeeTrunklid
Defogger
SeeHeating
Differential
SeeFinaldrive
DISA(dualresonanceintakesystem)
SeeFuelinjection
SeealsoEngine-general
DME(digitalmotorelectronics)
SeeIgnitionsystem
SeealsoFuelinjection

WARNING
Yourcommonsense,goodjudge-
ment,andgeneralalertnessarecru-
cialtosafeandsuccessfulservice
work.Befcreattemptinganyworkon
yourBMW,readthewarningsand
cautionsonpagevi¡andthecopyright
pageatthefrontofthemanual.
Reviewthesewarningsandcautions
eachtimeyoupreparetoworkon
yourBMW.Pleasealsoreadany
warningsandcautionsthataccom-
panytheproceduresinthemanual.
Doorglass
SeeDoorwindows
Doorwindows
generalinformation512-1
frontdoorwindow(2-doormodels)
adjusting512-7
removing/installing512-5
frontdoorwindow(4-doormodels)
initíalizing512-1
removing/installing512-2
reardoorwindow(4-doormodels)
removing/installing512-4
fixedglass,removing/installing512-
4
rearventwindoworventlatch,
replacing(2-doormodels)512-11
windowregulatorandmotor,
removing/installing512-12
windowregulatorservice512-12
Doorcheck
SeeDoors
Doorhandle
SeeCentrallockingandanti-theft
Doorpanel
SeeDoors
Doors
generalinformation411-1
dooradjustment411-2
doorcheck,replacing411-2
doorpanels411-3
doors411-1
frontorreardoor,removing/installing
411-1
frontdoorpanel,removing/installing
411-3
reardoorpanel,removing/installing
411-4
rearsidepanel,removing/installing
(two-doormodel)411-4
Driveaxle
SeeRearsuspension
Driveabilitytroubleshooting
SeeEngine-general
Driveshaft
generalinformation260-1
centerbearingassembly,replacing
260-6
driveshaft,aligning260-3
driveshaft,installing260-4
Driveshaft(cont.)
driveshaft,removing260-4
driveshaftservice260-3
flex-disc,replacing260-5
frontcenteringguide,replacing
260-7
guibo
Seeflex-disc
troubleshooting260-1
ECM(enginecontrolmodule)pin
assignment
SeeFuelinjection
Electricalcircuit
SeeElectricalsystem-general
Electricalcomponentlocations
generalinformation610-1
auxíliaryrelaypanel610-2
componentlocationtable610-9
componentlocations610-3
fusepositiontables610-19
fusepositions610-1
relaypositions610-2
splicepanel,left610-2
splicepanel,right610-3
Electricalsystem-general
generalinformation600-1
continuity,checking600-5
electricaltestequipment600-2
safetyprecautions600-1
shortcircuits600-5
shortcircuit,testingwithohmmeter
600-6
shortcircuit,testingwithvoltmeter
600-6
troubleshooting600-3
voltage,measuring600-4
voltageandpolarity600-1
voltageandvoltagedrops600-4
voltagedrop,testing600-4
wiringcodesandabbreviations600-2
wiringdiagrams600-2
wiring,fusesandrelays600-1
Electricalwiringdiagrams
generalinformationELE-1
wiringdiagramsELE-2
ABSELE-117
ABS/ASTELE-120
airbag(supplemental
restraintsystem)ELE-140
airconditioningandheatingELE-
129
anti-theft(Alpine)systemELE-144
anti-theft(EWSII)ELE-150
bodycomputermoduleELE-176
chargingsystemELE-67
convertibletopELE-253
cruisecontrolELE-112
datalinkconnectorELE-86
enginecoolingELE-94
enginemanagementELE-70
exteriorlightsELE-194
grounddistributionELE-35
headlights/foglightsELE-180
INDEX3
Electricalwiringdiagrams(cont.)
heatedseatsELE-245
hornsELE-153
instrumentpanelELE-165
interiorlights/illuminationELE-211
lumbarcontrolELE-247
on-boardcomputerELE-173
parkventilationELE-139
powerdistributionELE-2
powerdoorlocksELE-226
powermirrorsELE-241
powerseatsELE-243
powersunroofELE-248
powerwindowsELE-231
radio/cassette/CD/speakersELE-
255
rearwindowdefoggerELE-160
shiftinterlockELE-110
startingELE-63
transmissionelectronicsELE-96
warningsystems`.chimesELE-178
wiper/washerELE-154
Emergencies
SeeFundamentalsforthedo-it-
yourselfowner
Engine-general
generalinformation100-1
airflowmeasurementandvacuum
leaks100-12
basicenginesettings100-11
basicrequirements100-11
batteryvoltage100-12
connectingrodsandpistons100-1
coolingsystem100-5
cylinderblockandcrankshaft100-1
cylindercompression,checking100-6
cylinderheadandvalvetrain100-2
DISA(dualresonanceintakesystem)
100-3,130-3
driveabilitytroubleshooting100-8
enginemanagementsystem100-3
fueldelivery100-5
fuelsupply100-14
groundconnections100-13
ignition100-5
lubricationsystem100-5
mechanicaltroubleshooting100-5
on-boarddiagnostics(OBD)100-8
oxygensensors100-11
preventivemaintenance100-11
VANOS(variablevalvetiming)100-2
warningsandcautions100-5
wiringandharnessconnections100-
13
Enginecontrolmodule(ECM)
SeeFuelinjection
Engineremovalandinstallation
generalinformation110-1
engine,removing/installing(4-cylinder
engines)110-1
engine,removing/installing(6-cylinder
engines)110-4
Enginecoolanttemperature(ECT)
sensor
SeeFuelinjection
Enginehood
SeeFenders,enginehood

4INDEX
Evaporator
SeeAirconditioning
EWS(Electronicimmobilization
system)515-8
Exhaustsystem
SeealsoMaintenanceprogram
generalinformation180-1
exhaustmanifolds,removingAnstalling
180-5
exhaustsystem,removing/installing
180-3
Expansionvalve
SeeAirconditioning
Exteriorlighting
generalinformation630-1
centerbrakelighthousing,replacing
(4-doorandcoupemodels)630-5
foglightassembly,removing/installing
630-3
frontturnsignalassembly,removing/
installing630-4
headlightassembly,removing/
installing630-2
headlightbulb,replacing630-1
licenseplatelight,removing/installing
630-6
sidemarkerlights630-4
taillightassembly,removing/installing
630-5
taillightbulbs,replacing630-4
Exteriortrim,bumpers
generalinformation510-1
BMWembiem,removing/installing
510-7
bodysidemolding,replacing-7
bumperheight,adjusting510-6
frontbumper,removing/installing510-
3
frontbumperimpactabsorber,
replacing510-4
frontpanel,removing/installing510-7
outsiderearviewmirrors510-1
mirrorhousing,removing/installing
510-1
mírror,removing/installing510-2
mirrorglass,replacing510-1
radiatorgrille,removing/installing
510-7
rearbumper,removingfinstalling510-
4
rearbumperimpactabsorber,
replacing510-4
F
Fenders,enginehood
generalinformation410-1
frontfenders410-1
frontfender,removing/installing
410-1
hoodaligning410-4
hood,raisingtoserviceposition410-2
hoodreleasecableandlatches,
adjusting410-4
hood,removing/installing410-3
Finaldrive
generalinformation331-1
finaldriveservice331-1
flangeoilsea¡,replacing331-2
inputshaftoilsea¡,replacing331-3
oil,draining/filling331-1
oilseals331-1
removing/installing331-3
Finaldrivecarrier
SeeRearsuspension
Firingorder
SeeIgnitionsystem
Flexdisc
SeeDriveshaft
Fluidsandlubricants
SeeMaintenanceprogram
Foglight
SeeExteriorlighting
Frontsuspension
generalinformation310-1
balljoint
Seeoutercontrolarmballjoint
controlarm,removing/installing
310-5
controlarmbushing,replacing310-7
controlarms310-5
frontwheelbearing,replacing310-8
frontwheelbearings310-8
outercontrolarmballjoint,replacing
(exceptM3)310-6
rideheight310-4
shockabsorbersandsprings310-2
stabilizerbar310-9
stabilizerbar,removing/installing
310-9
strutassembly,disassembling/
assembling310-4
strutassembly,removing/installing
310-2
subframecrossmember310-9
subframecrossmember,removing/
installing310-9
Fuelinjection
generalinformation130-2
basicenginesettings130-2
principiesofoperatínn130-2
BoschDMEMl.7componenttests
andrepairs130-14
airfloivsensor,testing/replacing
130-14
enginecoolanttemperature(ECT)
sensor,testing/replacing130-15
¡dlespeedcontrolvalve,testing/
replacing130-16
throttlepositionsensor(TPS),
testing/replacing130-16
BoschDMEM3.1andM3.3.1
componenttestsandrepairs130-17
enginecoolanttemperature(ECT)
sensor,testing/replacing130-18
¡dlespeedcontrolvalve,replacing
130-21
¡dlespeedcontrolvalve,testing130-
20
intakeairtemperature(IAT)sensor,
testing/replacing130-19
massairflowsensor130-17
BoschDMEM3.1andM3.3.1(cont)
massairflowsensor(hotfilm)
testing/replacing130-18
massairflowsensor(hotwire)
testing/replacing130-17
throttlepositionsensor(TPS),
testing/replacing130-19
BoschDMEM5.2component
replacement130-21
enginecoolanttemperature(ECT)
sensor,replacing130-22
ldlespeedcontrolvalve,replacing
130-23
intakeairtemperature(IAT)sensor,
replacing130-22
massairflowsensor,replacing130-
22
throttlepositionsensor(TPS),
replacing130-22
DISA(dualresonanceintakesystem)
130-3
ECMpinassignments130-26
electricalchecksandcomponent
testing130-7
enginecontrolmodule(ECM),
accessing130-26
fueldeliverytests130-9
fuelpressureregulatorresponseto
engineload,testing130-11
fuelpressureregulator130-13
fuelpressureregulator,replacing
(fuelrailmount)130-13
fuelpressureregulator,replacing
(undercarmount)130-14
fuelpumprelay,testing130-7
fuelrailandinjectors,checking
130-11
fuelrailandinjectors,replacing130-
12
fueldeliverytests(cont.)
operatíngfuelpumpfortests130-9
relievingfuelpressureand
connectingfuelpressuregauge
130-10
residualfuelpressure,testing130-10
mainrelay,testing130-7
on-boarddiagnostics(OBD)andfault
diagnosis130-4
oxygensensor,testing(Bosch
systemsonly)130-8
secondaryairinjection130-5
SiemensMS41.1component
replacement130-23
enginecoolanttemperature(ECT)
sensor,replacing130-25
¡dlespeedcontrolvalve,replacing
130-26
lntakeairtemperature(IAT)sensor,
replacing130-25
massairflowsensor,replacing130-
25
throttlepositionsensor(TPS),
replacing130-26
warningsandcautions130-6
Fuelfilter
SeeMaintenanceprogram

WARNING
Yourcommonsense,goodjudge-
ment,andgeneralalertnessarecru-
cialtosafeandsuccessfulservice
work.Beforeattemptinganyworkon
yourBMW,readthewarningsand
cautionsonpagevi¡andthecopyright
pageatthefrontofthemanual.
Reviewthesewarningsandcautions
eachtimeyoupreparetoworkon
yourBMW.Pleasealsoreadany
warningsandcautionsthataccom-
panytheproceduresinthemanual.
Fuelpressureregulator
SeeFuelinjection
Fue]pump
generalinformation160-1
electricaltests160-7
powerconsumption,testing160-7
deliverytests160-8
deliveryvolume,testingg160-9
electricalcircuit,checking160-7
fuseandrelay160-6
levelsender
Seepump/fuelleve¡sender
operatingfuelpumpfortests160-6
pump/fuellevelsender(leftside),
removing/installing160-6
pump/fuelleve¡sender(rightside),
removing/installing160-5
relievingfuelpressureandconnecting
fue¡pressuregauge160-8
Fueltankandlines
generalinformation160-1
draining160-2
evaporativecontrolsystem160-4
leve¡senders,testing160-5
removing/installing160-3
Fundamentalsforthedo-it-yourself
owner
generalinformation010-1
adviceforthebeginner010-4
cleanliness010-4
electricaltesting010-6
gasketsandseals010-5
non-reusablefasteners010-5
planningahead010-4
tighteningfasteners010-5
wirerepairs010-6
buyingparts010-6
genuineBMWparts010-6
informationyouneedtoknow010-7
non-returnableparts010-7
emergencies010-11
brakefluidleve¡010-13
carwillnotstart010-11
changingatire010-11
checkenginewarninglight010-13
dimIights010-13
jumpstartingcar010-12
lowo]Ipressure010-13
overheating010-12
Emergencies(cont.)
sparepartskit010-14
towing010-13
gettingstarted010-2
liftingthecar010-3
raisingcarsafely010-3
safety010-2
workingundercarsafely010-4
howtousethismanual010-2
warnings,cautionsandnotes010-2
service010-7
tools010-7
basictoolrequirements010-8
BMWspecialtools010-11
feelergauges010-10
jackstands010-9
oilchangeequipment010-9
torquewrench010-10
volt-ohmmeter(VOM)orMulti-
meter010-10
Fuses
SeeElectricalcomponentlocations
G
Gaskets
SeeFundamentalsforthedo-it-
yourselfowner
Gearshift
SeeGearshiftlinkage
Gearshiftlinkage
generalinformation250-1
automaticshiftlock,checkingfunction
250-5
automatictransmissiongearshift250-
3
gearposition/neutralsafetyswitch,
replacing(automatictransmission)
250-4
gearshiftlever,installing(manual
transmission)250-2
gearshiftlever,removing(manual
transmission)250-1
gearshiftmechanism,adjusting
(automatictransmission)250-3
manualtransmissiongearshift250-1
shiftinterlock,checkingfunction
(automatictransmission)250-6
Glass
SeeDoorwindows
Glovecompartment
SeeInteriortrim
Grille
SeeExteriortrim,bumpers
Guibo(flexdisc)
SeeDriveshaft
Handle,door
SeeDoors
Hardtop
SeeBody-general
Headlight
SeeExteriorlighting
Headlightswitch
SeeSwitchesandelectrical
accessories
Heaterbox
SeeHeating
Heatercore
SeeHeating
Heatervalve
SeeHeating
Heating
generalinformation640-1
airdistributionmotors640-9
airdistributionmotor,replacing(rotary
knob)640-10
blowermotor,removing/installing
640-1
blowermotorresistorpack,replacing
640-3
controlhead640-7
removing/installing(digital-display)
640-8
removing/installing(rotaryknob)
640-7
controlmodule
removing/installing(digital-display)
640-8
removing/installing(rotaryknob)
640-8
heaterbox,removing640-4
heatercore,replacing640-6
heatercoretemperaturesensor,
replacing640-7
heatervalve,replacing640-3
rearwindowblower(convertible
models)640-10
reaswindowdefogger640-10
sensorfanforinteriortemperature,
replacing640-9
warningsandcautions640-11
Hood
SeeFenders,enginehood
Idlespeed
SeeMaintenanceprogram
Idlespeedcontrolvalve
SeeFuelinjection
Ignitionswitch
SeeSwitchesandelectrical
accessories
INDEX5

6INDEX
Ignitionsystem
generalinformation120-1
basictroubleshootingprincipies120-3
camshaftposition(CMP)sensor120-
6
camshaftpositíon(CMP)sensor,
replacing(4-cylinderengine)120-6
camshaftposition(CMP)sensor,
replacing(6-cylinderengines)120-7
checkingforspark120-3
crankshaftposition/rpmsensor120-5
crankshaftposition/rpmsensor,
testing/replacing(frontmounted
sensor)120-6
crankshaftpositíon/rpmsensor,
testing(rearmountedsensor)120-6
disablingignitionsystem120-2
ignitioncoil,testingandreplacing(4-
cylinderengines)120-3
ignitioncoil,testingandreplacing(6-
cylinderengines)120-4
ignítionfiringorder120-7
ignitionsystemdiagnostics120-3
ignitionsystemschematics120-7
ignitionsystemservice120-3
knocksensors,replacing120-7
warningsandcautions120-2
InspectíonIandInspectionII
SeeMaintenanceprogram
Instrumentpanel
Seeinteriortrim
Instruments
generalinformation620-1
instrumentcluster,removinglinstalling
620-1
instrumentcluster,self-testing620-1
instrumentclusterbulbs,replacing
620-2
multi-informationdisplay(MID),620-4
multi-informationdisplay(MID),
removing/installing620-4
odometercodingplug,replacing620-
2
vehiclespeedsensor,replacing620-3
Intakemanifold
4-cylinderengíne,removing113-3
6-cylinderengine,removing113-11
SeealsoCylinderheadremoval
andinstallation
Intakeairtemperaturesensor
SeeFuelinjection
Interiortrim
generalinformation513-1
centerconsole,removing/installing
513-1
dashboard,removing/installing513-3
glovecompartment,removing/
installing513-2
lowerleftdashpanel,removing/
installing513-2
J
Jumpstartíng010-12
K
Knocksensor
SeeIgnitionsystem
L
Leatherupholstery
SeeMaíntenanceprogram
Leve¡sender
SeeFuelpump
Lubricationsystem
generalinformation119-1
oilpan,removing/installing
(4-cylinderengines)119-2
oilpan,removing/installing
(6-cylinderengine,1992models)
119-4
oilpan119-2
oilpan,removing/installing
(6-cylinderengine,1993andlater
models)119-6
oilpressure,checking119-1
oilpressurewarningsystem,testing
119-2
oilpump119-8
oilpump,removing/installing
(4-cylinderengine)119-8
oilpump,removing/installing
(6-cylinderengine)119-9
troubleshooting119-1
M
Maíntenanceprogram
generalinformation020-2
acceleratorandthrottlelinkage
020-13
airfilter,replacing020-11
automatictransmissionfluid
020-8
automatictransmissionservice
020-18
battery,checkingandcleaning
020-12
battery,replacing020-12
BMWserviceindicator020-2
bodyandhinges,lubricating020-19
brakefluid020-9
brakefluid,replacing020-17
brakepad/rotorwear,checking
020-17
brakesystem,inspecting020-17
clutchfluid,checking020-19
coolingsystemservice020-14
driveaxlejointboots,inspecting
020-19
enginecoolant(anti-freeze)020-9
enginedrivebelts020-13
engineoil,checkingleve¡020-9
Maintenanceprogram(cont.)
engineoilandfilter,changing020-9
engineoilservice020-9
exhaustsystem,inspecting020-18
exteriorwashing020-20
finaldrivegearoil020-9
finaldriveoillevel,checking020-18
frontsuspensionandsteering
linkages,inspecting020-18
fuelfilter,replacing020-16
fueltankandfuellines,inspecting
020-19
¡dlespeed020-12
inspectionIandinspection11020-2
interiorcare020-20
leatherupholsteryandtrim020-20
maintenancetables020-3
manualtransmissionfluid,checking
andfilling020-18
manualtransmissionfluid020-8
manualtransmissionservice020-18
oxygensensors020-15
parkingbrake,checking020-17
polishing020-20
poly-ribbedbelt,replacing020-13
powersteeringfluid020-9
powersteeringfluid,checkingleve¡
020-14
rearsuspension,inspecting020-18
resettingserviceindicator020-3
seatbelts020-20
sparkplugs,replacing020-11
specialcleaning020-20
tires,checkinginflationpressure
020-17
tires,rotating020-17
v-belt,replacing020-13
washingchassis020-20
waxing020-20
windshieldwiperblademaintenance
020-19
wheels,aligníng020-17
Manualtransmission
SeealsoMaintenanceprogram
SeealsoTransmission-general
generalinformation230-1
back-uplightswitch,replacing230-2
inputshaftsea¡,replacing
(transmissioninstalled)230-5
outputshaftsea¡,replacing
(transmissioninstalled)230-4
selectorshaftsea¡,replacing
(transmissioninstalled)230-3
transmissionfluid,replacing230-2
transmissionfluidlevel,checking230-
2
transmissionfluidservice230-1
transmissionremovalandinstallation
230-5
transmission,removing/installing230-
6
transmissionservice230-2
Massairflowsensor
SeeFuelInjection

N
WARNING
Yourcommonsense,goodjudge-
ment,andgeneralalertnessarecru-
cialtosafeandsuccessfulservice
work.Beforeattemptinganyworkon
yourBMW,readthewarningsand
cautionsonpagevi¡andthecopyright
pageatthefrontofthemanual.
Reviewthesewarningsandcautions
eachtimeyoupreparetoworkon
yourBMW.Pleasealsoreadany
warningsandcautionsthataccom-
panytheproceduresinthemanual.
Mastercylinder
SeeBrakes
SeealsoClutch
Mechanicaltroubleshooting
SeeEngine-general
Microfilter
SeeAirconditioning
Mirror
SeeExteriortrim,bumpers
Muffler
SeeExhaustsystem
Multi-informationdisplay(MID)
SeeInstruments
Neutralsafetyswitch
SeeGearshiftlinkage
O
Oil,changing
SeeMaintenanceprogram
Oilpan
SeeLubricationsystem
Oilpressure
SeeLubricationsystem
Oilpump
SeeLubricationsystem
On-boarddiagnostics(OBD)
SeeEngine-general
SeealsoFuelinjection
SeealsoIgnitionsystem
On-boardtripcomputer
SeeMulti-informationdisplay620-4
Oxygensensor
SeeEngine-general
SeealsoFuelinjection
SeealsoMaintenanceprogram
P
Parkingbrake
SeeBrakes
SeealsoMaintenanceprogram
Parts
SeeFundamentalsforthedo-it-
yourselfowner
Poly-ribbedbelt
SeeMaintenanceprogram
Powersteering
SeeSteeringandwheelalignment
Powersteering(luid
SeeMaintenanceprogram
R
Radiator
SeeCoolingsystem
Radio
generalinformation650-1
audiosystem650-1
radioconnector650-6
removing/installing650-2
speakers
doorpanelspeaker,removing/
installing650-5
leftfootwellspeaker,removing/
installing650-3
rearspeaker,removing/installing
650-5
rightfootwellspeaker,removing/
installing650-4
Rearsuspension
SeealsoMaintenanceprogram
generalinformation330-1
coilspring,removing/installing330-4
CVboot,replacing330-8
driveaxle,removing/installing330-6
driveaxles330-6
finaldrivecarrier330-12
finaldrivecarrier,removing/installing
330-12
lowercontrolarm,removing/installing
330-12
rearshockabsorber,removing/
installing330-3
rearsuspensionarms330-9
rideheíght330-1
shockabsorbersandsprings330-2
trailingarm,removing/installing
330-10
trailingarmbushing,replacing
330-11
uppercontrolarm,removing/installing
330-12
rearwheelbearing,replacing330-5
rearwheelbearings330-4
Rearviewmirror
SeeExteriortrim,bumpers
Receiver/drivr
SeeAirconditioning
Relays
SeeElectricalcomponentlocations
INDEX7
Rideheight
SeeFrontsuspensionorRear
suspension
Ringantenna
SeeCentrallockingandanti-theft
Roof
SeeConvertibletop
SeealsoSunroof
Roundel
SeeExteriortrim,bumpers
S
Seatbelts
generalinformation720-1
automaticfrontseatbeltlock
tensioners720-2
centerrearlap-belt,removing/
installing720-5
frontseatbeltreel,removing/installing
720-3
mechanicalspringtensioner,
disarming720-2
rearseatbelt,removing/installing
(fixedseatbackmodels)720-4
rearseatbelt,removing/installing
(fold-downseatbackmodels)720-5
Seats
generalinformation520-1
frontseats520-1
manualfrontseatassembly520-3
powerfrontseatassembly520-4
removing/installing520-1
rearseats520-5
rearseatcushionandbackrest,
removing/installing(fixedseatback
models)520-5
rearseatcushionandbackrest,
removing/installing(fold-downseat
backmodels)520-5
rearseatbackrestsidesection,
removing/installing(fold-downseat
backmodels)520-6
Shiftinterlock
SeeGearshiftlinkage
Shiftlever
SeeGearshiftlinkage
Shíftlock
SeeGearshiftlinkage
Shockabsorber
SeeFrontsuspension
SeealsoRearsuspension
Side-impactairbag
SeeAirbagsystem(SRS)
Slavecylinder
SeeClutch
Serviceindicator
SeeMaintenanceprogram
Solenoid
SeeBattery,starter,alternator
Spark
SeeIgnitionsystem
Sparkplugs
SeeMaintenanceprogram

8INDEX
Speakers
SeeRadio
SRS(Supplementalrestraintsystem)
SeeAirbagsystem(SRS)
Starter
SeeBattery,starter,alternator
Steeringandwheelalignment
generalinformation320-1
casterandcamber320-5
fronttoe-inandtoedifferenceangle
320-6
outertierodend,replacing320-4
powersteeringpump,removing/
installing320-2
powersteeringsystem320-2
powersteeringsystem,bleeding/filling
320-3
reartoe-in320-6
steeringgear320-3
steeringgearrack,removing/installing
320-3
steeringwheel320-1
steeringwheel,removing/installing
320-1
tierod,replacing320-5
wheelalignment320-5
wheelalignmentspecifications320-6
Steeringgear
Seesteeringandwheelalignment
Strut
SeeFrontsuspension
Subframe
SeeFrontsuspension
Sunroof
generalinformation540-1
motor,removing/installing540-3
panel,adjusting540-2
panel,emergencyclosing540-2
Suspension,front
SeeFrontsuspension
Suspension,rear
SeeRearsuspension
Suspension,steeringandbrakes
generalinformation300-1
al¡seasontraction(AST)300-4
antilockbrakesystem(ABS)300-2
brakes300-2
frontsuspension300-1
integratedsystems300-2
M3suspensionandbrakes300-7
steering300-2
rearsuspension300-2
suspensionandsteering
troubleshooting300-7
tiresandwheels300-2
T
Switchesandelectricalaccessories
generalinformation612-1
domelight,rearmaplights,trunklight,
replacingbulbs612-7
hazardwarningswitch,replacing
612-5
headlightswitch,replacing612-5
foglightswitch,replacing612-5
ignitionelectricalswitch,replacing
612-3
ignitionlockcylinder,replacing612-4
ignitionswitchassembly612-3
outsidemirrorswitch,replacing612-6
powerwindowswitch,replacing612-5
turnsignalswitchandwiperswitch,
removing/installing612-1
wiperswitch
Seeturnsignalandwiperswitch
Taillight
SeeExteriorlighting
Thermostat
SeeCoolingsystem
Throttlepositionsensor(TPS)
SeeFuelinjection
Throw-outbearing
SeeClutch
Tierod
SeeSteeringandwheelalignment
Tires
SeeSuspension,steeringand
brakes-general
SeealsoMaintenanceprogram
Timingchain
SeeCamshafttimingchain
Toe-in
SeeSteeringandwheelalignment
Tools
SeeFundamentalsforthedo-it-
yourselfowner
Torqueconvector
SeeAutomatictransmission
Towing
SeeFundamentalsforthedo-it-
yourselfowner
Tractioncontrol
SeealsoSuspension,steeringand
brakes-general
Trailingarm
SeeRearsuspension
Transmission-general
SeealsoAutomatictransmission
SeealsoManualtransmission
generalinformation200-1
automatictransmission200-1
manualtransmission200-1
transmissionIDcodes200-2
Transmissionfluid
SeeMaintenanceprogram
SeealsoAutomatictransmission
Transmissioninputshaft
SeeManualtransmission
Transmissionoutputshaft
SeeManualtransmission
Trim,interior
SeeInteriortrim
Trunklid
generalinformation412-1
trunklid,412-1
trunklid,aligning412-1
trunklid,removing/installing412-1
trunklidsupportstrut,removing/
installing412-2
U
Upholstery
SeeMaintenanceprogram
U-joints
SeeDriveshaft
V
V-belt
SeeMaintenanceprogram
Vacuumbooster
SeeBrakes
Vacuumleaks
SeeEngine-general
Valveguides
SeeCylinderheadandvalvetrain
Valveseals
SeeCylinderheadandvalvetrain
Valveseats
SeeCylinderheadandvalvetrain
Valves
SeeCylinderheadandvalvetrain
Valvetrain
SeeCylinderheadandvalvetrain
VANOS(variablevalvetiming)
SeeCamshafttimingchaín
SeealsoEngine-general
Vehicleidentificationnumber(VIN)
SeeFundamentalsforthedo-it-
yourselfowner
Vehiclespeedsensor
SeeInstruments
Ventilation
SeeAirconditioning
SeealsoHeating
Voltageregulator
SeeBattery,starter,alternator
Voltagetests
SeeElectricalsystem-general
W
Warningsvi¡
Washerfluidpump
SeeWipersandwashers
Washers
SeeWipersandwashers
Waterpump
SeeCoolingsystem
Waxing
SeeMaintenanceprogram

WARNING
Yourcommonsense,goodjudge-
ment,andgeneralalertnessarecru-
cialtosafeandsuccessfulservice
work.Beforeattemptinganyworkon
yourBMW,readthewarningsand
cautionsonpagevi¡andthecopyright
pageatthefrontofthemanual.
Reviewthesewarningsandcautions
eachtimeyoupreparetoworkon
yourBMW.Pleasealsoreadany
warningsandcautionsthataccom-
panytheproceduresinthemanual.
Wheelbearings
SeeFrontsuspensionorRear
suspension
Wheel,steering
SeeSteeringandwheelalignment
Wheels
SeeMaintenanceprogram
Windowregulator
SeeDoorwindows
Windowswitch
SeeSwitchesandelectrical
accessories
Windows,door
SeeDoorwindows
Windshieldwipersandwashers
SeeWipersandwashers
SeealsoMaintenanceprogram
Wipermotor
SeeWipersandwashers
Wipersandwashers
generalinformation611-1
washerfluidleve¡sensor,replacing
(modelswithcheckcontrol)611-10
washer(luidpump,replacing611-9
washerfluidreservoir,replacing611-9
windshieldspraynozzle,removing/
installing611-9
windshieldwiperassembly,removing/
installing(4-doormodels)611-3
windshieldwiperassembly,removing/
installing(2-doormodels)611-5
wiperarms,removing/installing611-2
wiperbladeinserts,replacing611-2
wiperbladecleaningproblems611-1
wiperblades,replacing611-1
wipermotor,removing/installing611-8
Wiringdiagrams
SeeElectricalwiringdiagrams
Z
INDEX 9
ZAE
SeeAirbagsystem(SRS)
ZKE
SeeCentralbodyelectronics
ZVM
SeeCentrallocking
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Categories
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