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BMW 3- & 5-Series Service and Repair Manual

1. 120 Intermediate shaft sprocket bolt M20 lt 60 S mp to plock ONS pm dn md iE 9 to 11 Oil pump bolts except M40 22 Oil pump sprocket bolts M10 and M30 engines 10 Oil pump cover plate to engine front end cover M40 engines 9 Front end cover to engine bolts M20 and M40 engines uhi 10 ene cra 22 Crankshaft rear oil seal retainer to block bolts pene ane 25 aes ened ah ets Fea 9 MO DORS eke eee 22 BMW recommend that the cylinder head bolts are renewed as a matter of course 1 General information This Part of Chapter 2 is devoted to in vehicle engine repair procedures All information concerning engine removal and refitting and engine block and cylinder head overhaul can be found in Chapter 2B The following repair procedures are based on the assumption that the engine is still fitted in the vehicle If the engine has been removed from the vehicle and mounted on a stand many of the steps outlined in this Part of Chapter 2 will not apply The Specifications included in this Part of Chapter 2 apply only to the procedures contained in this Part Chapter 2B contains the Specifications n
2. 1 0 maximum 320i with M20 B20 engine L J 1 0 0 5 320i with M20 B20 engine 0 7 40 5 325 with M20 B25 uu vasca Seasoned 3 LOUS 5 Series E28 old shape 518 and 518i with M10 B18 engine 1 0 maximum 525i with M 30 B25 engine 1 0 0 5 528i with M30 B28 GNGING 3 Va ors acd des 1 5 maximum Sool With M30 B34 re E 0 3 to 1 5 M535 with M30 B34 engllie a sucio e eC o 0 3 to 1 5 5 Series E34 new shape ALIOS 44 64 dard a tes ne eA 0 7 350 5 Air filter element LRL PME Champion W155 round or U504 square umu in c P Rm Champion U504 or U527 uk i nc P m Champion U504 or U527 40 engines 3 adco aed ordei ac ex Kah Ear ke Xe Champion U527 Fuel filter all fuel injection engines Champion L206 Ignition system Spark plug type M10 M20 and MEO engllie 3 55225 EXC ee e Champion N9YCC 4 4 65 PR T oe dant nae Spaik PUG 0 8 mm Sparc plug TR T eas 5 do qi Genet Ron Ao ews Champion type not available The spark plug gap quoted is that recommended by Champion for their specifi
3. Internal coolant leakage Leaking cylinder head gasket Chapter 2 Cracked cylinder bore or cylinder head Chapter 2 Coolant loss Too much coolant in system Chapter 1 Coolant boiling away because of overheating see above Internal or external leakage see above Faulty radiator cap Chapter 3 Poor coolant circulation Inoperative water pump Chapter 3 Restriction in cooling system Chapters 1 and 3 Water pump drivebelt defective out of adjustment Chapter 1 Thermostat sticking Chapter 3 Clutch slips engine speed increases with no increase in vehicle speed Clutch plate worn Chapter 8 Clutch plate is oil soaked by leaking rear main seal Chapter 8 Warped pressure plate or flywheel Chapter 8 Weak diaphragm spring Chapter 8 Clutch plate overheated Grabbing chattering as clutch is engaged Oil on clutch plate lining burned or glazed facings Chapter 8 Worn or loose engine or transmission mountings Chapters 2 and 7A Worn splines on clutch plate hub Chapter 8 Warped pressure plate or flywheel Chapter 8 Noise in clutch area Fork improperly fitted Chapter 8 Faulty release bearing Chapter 8 Clutch pedal stays on floor Fork binding in housing Chapter 8 Broken release bearing or fork Chapter 8 High pedal effort Fork binding in housing Chapter 8 Pressure
4. Choke gap abt x P Eee CE Y Ee RR a Throttle positioner spring preload Float level Stage 1 float chamber Stage 2 float chamber 50 120 40 125 2 0 mm 4 0 to 5 5 mm 22 0 to 24 0 mm 27 0 to 29 0 mm 29 0 to 31 0 mm 4 2 Fuel and exhaust systems Carburettor Solex 2BE Main jet bad E 120 110 Air correction jet m 140 SIdUS Z PT EE ERE 70 Venturi diameter Stage D EPI PEE P 24 mm 28 Idle fuel jet oc gaa dus Ss a ne re ey a are ood 47 5 mm Idle air jet co ccr 180 Float needle valve diameter 2 0 mm Throttle positioner coil 0 97 to 1 63 ohms Intake air temperature resistance 21 LETT 8200 to 10 500 ohms E a 2200 to 2700 ohms dew ace ee ee ee ee 300 to 360 ohms Float level 27 0 to 29 0 mm 29 0 to 31 0 mm Stage 1 float chamber Stage 2 float chamber Fuel pressure checks carburettor engines Fuel pump delivery pressure engine 1 0 1 to 0 3 bars Fuel pressure checks fuel injection engines Fuel s
5. 125 to 142 Front control arm 3 Series Upper mounting nut 22 to 24 Control arm to steering knuckle balljoint nut 64 Upper spring mounting to shock absorber locknut 22 to 24 Control arm to subframe balljointnut 83 Trailing arms 3 Series Control arm bush bracket bolts 41 Trailing arm to lower mounting 71to 85 Lower control arm 5 Series Trailing arm to anti roll 22 to 23 Control arm to steering arm balljoint stud nut 85 Trailing arms 5 Series Control arm pivot 77 Trailing arm to rear axle carrier rubber bush Thrust arm 5 Series tirough bolt and NUE sau Suc 63r Eae Er e iden 66 Thrust arm to steering arm balljoint stud nut 85 Trailing arm to axle carrier connecting link 1983 on 126 Thrust arm through bolt 130 Rear wheel bearing drive flange axle nut 5 Series Front hub wheel bearing 290 oto ado ed aceduadr deu d pg edad eed 175 to 210 Steering arm to strut bolts 5 5 65 DEZ ee Ete d RD Red loca 235 to 260 Anti roll bar 3 Series Anti roll bar to connecting link bolt 41 Anti roll bar mounting brackets to subframe 22 Steering system Connecting
6. 2 0 29 2 0 29 U rm 252432 2 1 30 EPa ee D toch a Be gees ge er ae 2 0 29 2 3 33 Torque wrench settings Nm Automatic transmission sump bolts TNES mrem 8 to 9 FOUS POOU 5 to 7 Spark plugs MIENINGS 53555953 83 Gated 20 to 30 Except MIO engines a ex i bed bad os Peewee 30 to 33 Oxygen Sensor 30 to 33 Wieel DOS s aec edicion dodo cse a ew Rc 4 i oc 100 Lubricants and fluids Component or system Lubricant type specification Aunce P r Multigrade engine oil viscositySAE 10W 40 to 20W 50 to API SG Cooling system Ethylene glycol based antifreeze with corrosion inhibitors 1 5 55100 Gear oil viscosity SAE 80 to API GL4 or single grade mineral based engine oil viscosity SAE 20 30 or 40 to API SG Automatic transmission Dexron Il type ATF Final td esaii ob tbr dod oC heel ote doo he d d dO RI PR BMW approved hypoid gear oil viscosity SAE 90 Brake and clutch hydraulic systems Hydraulic brake fluid to SAE J 1703 or DOT 4 Power steering
7. BN b zzrrdgcugerJutfo TO INSTRUMENT CLUSTER BRVI L 5 SEE SHEET 4 OF 4 0 Wi H2473i Typical headlights foglights and interior lights 2 of 4 12 12 Wiring diagrams i wl gt INSTRUMENT CLUSTER SEE SHEET 4 OF 4 F22 F23 O TO FUSE 10 5227 2 SEE SHEET 1 OF 4 SEE SHEET 1 OF 4 Y Y TO INSTRUMENT GNWS o f CLUSTER o 9 9ooonc 2S 2929 SEE SHEET 4 OF e 0mm o o om o N om e mao 3 5 P TO FUSE 24 o lt 0 9 3 52992999 S SEE SHEET 1 OF 4 2 Z 28952595 E 9 5 GE SEE SHEET 2 OF 4 D TO MRIN LIGHT BULB TESTER Y Y 9 5 GESW P SEE SHEET 2 OF 4 9 Gor s 2 99 9999 9 X naa nen 44 38 3 3323372 TOTO 23 2 a Z 4 6 82 889 8 1 0 8 F282 8 p yr DT d4 9 E oto o uU E o D m m ds MON wSSw 53 BLWS BR GNRT 1l 39u9 SMu9 SMH9 0 BLSW BLWS 3949 60 SMHu9 s a J949 s 8 9 u889 Q 0 6 WSSW TO FUSE 19 424732 SEE SHEET 1 OF 4 41 SMH9 SAYI 71 8 0 ASH e 4 39u9 J8N9 O T lt 39u9 e I 1889 S
8. most frequent cause of emission system problems is HiNT simply a leaking vacuum hose or loose wire so always check the hose and wiring connections first This doesn t mean however that emission control systems are particularly difficult to maintain and repair You can quickly and easily perform many checks and do most of the regular maintenance at home with common tune up and hand tools Pay close attention to any special precautions outlined in this Chapter It should be noted that the illustrations of the various systems may not exactly match the system fitted your vehicle because of changes made by the manufacturer during production 2 Motronic engine management system self diagnosis general information The Motronic engine management system control unit computer has a built in self diagnosis system which detects malfunctions in the system sensors and stores them as fault codes in its memory It is not possible without dedicated test equipment to extract these fault codes from the control unit However the procedures given in Chapters 4 and 5 may be used to check individual components and sensors of the Motronic system If this fails to pinpoint a fault then the vehicle should be taken to a BMW dealer who wil have the necessary diagnostic equipment to call up the fault codes from the control unit You will then have the option to repair the fault yourself or alternatively have the fault r
9. dl a STI e 39N9 0 Q KEY ITEMS _ N9u9 HH ST 9e 1889 CHECK CONTROL TRIL LIGHT LEFT TRIL LIGHT RIGHT PARKING LIGHT RIGHT PRRKING LIGHT LEFT NUMBER PLATE LIGHT RIGHT NUMBER PLRTE LIGHT LEFT ADDITIONAL STOP LIGHT STOP LIGHT LEFT STOP LIGHT RIGHT BULB CONTROL UNIT PARKING LIGHT SWITCH 1 5 BR 1 1 5 BR J 13 PARKING LIGHT SWITCH II 14 TAIL AND NUMBER PLATE LIGHT SWITCH 15 STOP LIGHT SWITCH WASHER FLUID LEVEL SWITCH TO HAZARD WARNING TO CIGAR LIGHTER 17 COOLANT LEVEL SWITCH LIGHT SWITCH SEE SHEET 4 OF 4 18 OIL LEVEL SWITCH SEE SHEET 1 OF 4 18 MIRROR CONTROL SWITCH 20 ELECTRIC MIRROR MOTOR TO RERR RSHTRRY ILLUM 21 ELECTRIC MIRROR MOTOR ADDITIONAL SEE SHEET 2 OF 4 W1 POWER RRIL IN POWER DISTRIBUTOR Typical check control electric mirrors stop and parking light 3 of 4 ST 7385S 26 4 4 ug dc E e 8 d 2 Des q E qH O 57 ug ug QO NOU UUN m a m ne 6G ug 1880 6 0 T 9 Wl P 30 133HS 335 MOONIM 031U3H H3AO0 18 Wiring diagrams 12 13 1 TO CHECK CONTROL TO FUSE 1 TO FUSE 12 TO TRIL NUMBER SEE SHEET 3 OF 4 SEE SHEET 1 OF 4 SEE SHEET 1 OF 4 PLRTE LiGHT SWITSH H3 U3H WOR AU 8 Ol te Amando SMN9 S ASSA 50 NO
10. Sometimes bodywork components can be found in HiNT a scrapyard that specialises in used vehicle components often at a considerable saving over the cost of new parts 11 11 4 Bodywork and fittings E E wg m a a U P ah y h ls i i 9 1 Open the bonnet and remove the grille retaining clips arrowed 7 Hinges and locks maintenance Every six months or so the hinges and lock assemblies on the doors bonnet and the boot lid tailgate should be given a few drops of light oil or lock lubricant The door or tailgate lock strikers should also be lubricated with a thin coat of grease to reduce wear and ensure free movement 8 Fixed glass renewal Lh Renewal of the windscreen and fixed glass requires the use of special fast setting adhesive materials and some specialised tools and techniques These operations Should be left to a dealer service department or windscreen specialist 9 Radiator grille removal and refitting 3 Series 1 Detach the clips along the top of the grille see illustration 9 14 Remove the screws and pull the side grille assembly straight out 9 2a The centre grille is held in place by two screws arrowed 2 Remove the screws and lift the centre and Side grilles out see illustrations 3 Refitting is the reverse of removal 5 Series E28 old shape models 6 Remove th
11. 35 Timing belt tensioner DONS usa aca koe RR e CR RI ead 22 Camshaft sprocket to camshaft bolt M10 M30 engines 10 M20 M40 engines 65 Flange to camshaft M30 engine 145 Timing chain or belt covers to engine MODO 222205523555 248 10 IIS DONE aeeie eser PI beeen ee eee hee bes IPIE a 22 M10 bolt size bolts 47 Crankshaft pulley bolts 22 Crankshaft hub bolt or nut MAG aurae v tE dai uil dO deba RE UPON deor diat ate d 190 M20 CONS oscuras scc aerea auo dco ane orc rdc dr de OR CU UB UE 410 M30 enge cox arate sh ain ea meh tos ae TOIT Nan ew shake phat est ek 440 a eben E 310 Cylinder head bolts M10 four cylinder engine codd erra eb ee eee ele oe dae eee a eie X 60 Stage 2 wait 15 minutes Angle tighten an additional 33 Stage 3 engine at normal operating temperature Angle tighten an additional 25 M20 six cylinder engine with hex head bolts vc APP oa ae ee 40 Stage 2 wait 15 minutes 60 Stage 3 engine at normal operating temperature Angle tighten an additional 25 M20 six cylinder engine with Torx head b
12. 26 17 Measuring the width of the crushed Plastigage to determine the big end bearing oil clearance be sure to use the 13 Cut a piece of the appropriate size Plastigage slightly shorter than the width of the connecting rod big end bearing and lay it in place on the No 1 connecting rod journal parallel with the crankshaft centre line 14 Clean the connecting rod cap bearing face remove the protective hoses from the connecting rod bolts and refit the rod cap Make sure the mating mark on the cap is on the same side as the mark on the connecting rod 15 Refit the nuts bolts and tighten them to the torque listed in this Chapter s Specifica tions On M10 and M30 engines work up to the final torque in three stages Note Use a thin wall socket to avoid erroneous torque readings that can result if the socket is wedged between the rod cap and nut If the socket tends to wedge itself between the nut and the cap lift up on it slightly until it no longer contacts the cap Do not rotate the crankshaft at any time during this operation 16 Undo the nuts and remove the rod cap being very careful not to disturb the P lastigage 17 Compare the width of the crushed Plastigage to the scale printed on the Plastigage envelope to obtain the clearance see illustration Compare it to the Specifications to make sure the clearance is correct 18 If the clearance is not as specified the bearing shells may be the wrong size which m
13. FIREWALL 13 1 To adjust the brake pedal height loosen the locknut 1 and turn the pushrod 2 while holding the clevis 3 until dimension A the distance between the lower edge of the brake pedal and the bulkhead firewall is within the range listed in this Chapter s Specifications left hand drive shown right hand drive similar 12 8 Remove the shoes the pushrod while holding the clevis stationary until the distance is correct Note On right hand drive models the adjustment is carried out at the left hand side of the cross shaft after removing the glovebox but the dimension is still measured at the pedal 14 Stop light switch check and adjustment Note stop light switch should be checked and if necessary adjusted after the master cylinder or brake servo has been removed or renewed 1 The stop light switch is located on a bracket at the top of the brake pedal The Switch activates the brake lights whenever the pedal is depressed 2 With the brake pedal in the rest position measure the distance between the switch contact point on the brake pedal and the switch housing see illustration and compare your measurement with dimension A listed in this Chapter s Specifications 3 If your measurement is outside the 14 2 To adjust the stop light switch loosen the locknuts 1 and screw the switch 2 in or out until dimension A is correct Braking system 9 13 is 12 9
14. M20 M40 engines Main bearing journal diameter standard M10 engines Red classification uu aca deg oad eed e ER COR Bide ClassiNCallOl suas TT M20 engines Red classification ok ik ee ak Bile classification toh ame het Aca ee een Oe ee M30 and M40 engines Yellow classification Green White classification Main bearing journal diameter undersizes TS DICIS SI s io dU due dd CC b beste 2AA UNGSISIZS aa ac bacon par Cd P TR 3rd undersize where applicable Main bearing oil clearance MIO 3nd WZOCNGINES 5 5 pra kd Rc de creo we eR de M30 and MAO engines 1 9 29 ordo PEE D ed v Connecting rod journal diameter standard MIO M30 engines M20 M40 engines Connecting rod journal diameter undersizes ISC Ud e SI ZO c dde Re tein on do dde e cie do dde Qe EO ed 224 a eed oe e lcm Rc e e o ee ees 3rd undersize where applicable Connecting rods Connecting rod side play all engines Connecti
15. Rear drum brake self adjuster mechanism faulty when applicable Chapter 9 Grabbing or uneven braking action Malfunction of brake servo unit Chapter 9 Binding brake pedal mechanism Chapter 9 Brake pedal feels spongy when depressed Air in hydraulic lines Chapter 9 Master cylinder mounting bolts loose Chapter 9 _ Master cylinder defective Chapter 9 Brake pedal travels to the floor with little resistance Little or no fluid in the master cylinder reservoir caused by leaking caliper piston s loose damaged or disconnected brake lines Chapter 9 Handbrake does not hold Handbrake linkage incorrectly adjusted Chapter 9 Handbrake shoe linings worn out or contaminated Chapter 9 Suspension and steering Note Before assuming that a problem exists check the following items a Tyre pressures and tyre condition also check for out of round or out of balance tyres and bent wheel rims b Steering universal joints from the column to the steering gear for play or wear c Front and rear suspension and the rack and pinion assembly for loose or damaged parts d Wheel bearings wheel wobble or roughness when spun Vehicle pulls to one side Mismatched or uneven tyres Chapter 10 Broken or sagging springs Chapter 10 Front wheel or rear wheel alignment incorrect Chapter 10 Front brake problem
16. 13 6 From under the vehicle remove the bolt from the lower air conditioning compressor mounting brackets and lift it up and out of the vehicle see illustration Refitting 7 If a new compressor is being fitted follow any instructions supplied with the compressor regarding the draining of excess oil prior to fitting 8 The clutch may have to be transferred to the new compressor 9 Refitting is the reverse of removal All O rings should be replaced with new ones specifically made for use in air conditioning systems Lubricate them with refrigerant oil when fitting 10 Have the system evacuated recharged and leak tested by the qualified engineer who discharged it 14 Air conditioning blower motor Ss E28 old shape 5 WS models removal and refitting X Note Refer to Section 9 for information on new shape E34 5 Series models Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Remove the centre console see Chap ter 11 3 Disconnect the blower motor electrical connector from the motor 4 Unbolt the blower motor mountings from the main case 5 Remove the air conditioning blow
17. Exhaust system Cl Start the engine With your assistant holding a rag over the tailpipe check the entire system for leaks Repair or renew leaking sections 3 Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO TURN Jack up the front and rear of the vehicle and securely support it on axle stands Position the stands clear of the suspension assemblies Ensure that the wheels are clear of the ground and that the steering can be turned from lock to lock Steering mechanism Have your assistant turn the steering from lock to lock Check that the steering turns smoothly and that no part of the steering mechanism including a wheel or tyre fouls any brake hose or pipe or any part of the body structure Examine the steering rack rubber gaiters for damage or insecurity of the retaining clips If power steering is fitted check for signs of damage or leakage of the fluid hoses pipes or connections Also check for excessive stiffness or binding of the steering a missing split pin or locking device or severe corrosion of the body structure within 30 cm of any steering component attachment point MOT Test Checks Front and rear suspension and wheel bearings Starting at the front right hand side grasp the roadwheel at the 3 o clock and 9 o clock positions and shake it vigorously Check for free play or insecurity at the wheel bearings suspension balljoints or suspension mount ings pi
18. Serpentine drivebelt Shim Thin spacer commonly used to adjust the clearance or relative positions between two parts For example shims inserted into or under bucket tappets control valve clearances Clearance 15 adjusted by changing the thickness of the shim Slide hammer A special puller that screws into or hooks onto a component such as a Shaft or bearing a heavy sliding handle on the Shaft bottoms against the end of the shaft to knock the component free Sprocket A tooth or projection on the periphery of a wheel shaped to engage with a chain or drivebelt Commonly used to refer to the sprocket wheel itself Starter inhibitor switch On vehicles with an REF rere24 Glossary of Technical Terms automatic transmission switch that prevents starting if the vehicle is not in Neutral or Park Strut See MacPherson strut T Tappet cylindrical component which transmits motion from the cam to the valve stem either directly or via a pushrod and rocker arm Also called a cam follower Thermostat heat controlled valve that regulates the flow of coolant between the cylinder block and the radiator so maintaining optimum engine operating temperature A thermostat is also used in some air cleaners in which the temperature is regulated Thrust bearing bearing the clutch assembly that is moved in to the release levers by clutch pedal action to disengage the clutch Also referred to as a release bearing Tim
19. BMW 3 amp 5 Series Service and Repair Manual Legg um and Larry Warren Models covered 3 Series E30 316 83 to 88 316i 88 to 91 318i 83 to 91 3201 87 to 91 325i 87 to 91 Also Touring and Convertible versions of these models 5 Series E28 518 81 to 85 518i 85 to 88 525i 81 to 88 5281 81 to 88 5351 85 to 88 M535i 85 to 88 5 Series E34 518i 90 to 91 520i 88 to 91 5251 88 to 91 530i 88 to 91 535i 88 to 91 Engines covered 1596 cc 1766 cc 1795 cc 1990 cc 2494 cc 2788 cc 2986 cc amp 3430 cc Does not cover Diesel dohc or V8 engines or four wheel drive models 1948 256 11AA3 Haynes Publishing 1997 tog Ca O Haynes Sc Co Ld Sparktord Nr veovll somerset KLMNO BA22 7JJ England A book in the Haynes Service and Repair Manual Series Haynes Publishing All rights reserved No part of this book may be reproduced or transmitted Sparkford Nr Yeovil Somerset BA22 7 J England in any form or by any means electronic or mechanical including photocopying recording or by any information storage or retrieval system without permission in writing from the copyright holder Haynes North America Inc 861 Lawrence Drive Newbury Park California 91320 USA Editions Haynes S A ISBN 1 85960 236 3 147 149 rue Saint Honor 75001 PARIS France British Library Cataloguing in Publication Data Haynes Publishing Nordiska AB A catalogue record for this book
20. rac a d eraut wee S20 W987 10 3991 Pee ewe tee bean 3251 1987 t0 199 5 series E28 body style old shape 518 1981 to 1985 518i 1985 to 1988 5251119981 10 2908 a cet eee need Gd RES ERA EE wa os oak Rr eg act oes 535111985 16 1958 ceases des M530 1985 10 19858 dU dios d 5 series E34 body style new shape SIBIO 10 3993 dnd anre am diae 520011998 ener ee er eee ee eee ee ee 530i 1988 to 1981 5 5 55 5 Baws 535111988 10 1993 ee ee Firing order Four cylinder engine Six cylinder engine NO Lubrication system Oil pressure all engines At idle Running for example at 4000 Oil pump rotor clearance M40 engine body to outer rotor outer rotor to inner rotor Oil pump pressure relief valve spring length M40 engine Oil pump removal inspection and refitting 14 Repair operations possible with the engine in the vehicle 2 Rocker arm and shaft assembly dismantling inspection and reassembly See Chapter 2B spark pl
21. Dexron Il type ATF E34 520i amp 525i with air conditioning E34 530i amp 535i Dexron II type ATF Only available in bulk refer to your BMW dealer Capacities Engine oil Manual transmission MIC engllles 065 ace xus bad aci de cu 4 0 litres L CCP 1 2 litres M20 4 3 litres E di ce 1 0 to 1 5 litres M30 s acid rand ica e 5 8 litres Automatic transmission refill ENGINES racaras asa C990 3 4 0 litres B SDGEd E 2 0 litres Cooling system sou debi 312 dolci aoe 3 0 litres 10 lt 7 0 litres Final drive capacity drain and refill M20 lt 10 5 litres 53556166 E30 asado ac o d Ae 0 9 litres M30 enges cd ad TE 12 0 litres 5 Series E28 old shape 0 9 litres MAD GNGINGS vie aA 7 0 litres 5 Series E34 new shape 1 7 litres Fuel tank All capacities approximate 3 Series E30 55 litres early 64 litres later Wagan eae ane aes 63 litres early 70 litres later 5 Series E28 l oldsshlidDe 70 litres 4 new shape sss ru RE Rr men 81 litres 14 Maintenance and se
22. is not possible to test brake efficiency without special equipment but a road test can be carried out later to check that the vehicle pulls up in a straight line Fuel and exhaust systems C Inspect the fuel tank including the filler cap fuel pipes hoses and unions All components must be secure and free from leaks Examine the exhaust system over its entire length checking for any damaged broken or missing mountings security of the retaining clamps and rust or corrosion Wheels and tyres Examine the sidewalls and tread area of each tyre in turn Check for cuts tears lumps bulges separation of the tread and exposure of the ply or cord due to wear or damage Check that the tyre bead is correctly seated on the wheel rim that the valve is sound and MOT Test Checks distorted or damaged Check that the tyres are of the correct size for the vehicle that they are of the same size and type on each axle and that the pressures are correct Check the tyre tread depth The legal minimum at the time of writing is 1 6 mm over at least three quarters of the tread width Abnormal tread wear may indicate incorrect front wheel alignment Body corrosion Check the condition of the entire vehicle structure for signs of corrosion in load bearing areas These include chassis box sections side sills cross members pillars and all suspension steering braking system and seat belt mountings and an
23. 13 Unplug the electrical connector from the airflow meter see Section 12 14 Remove the air cleaner mounting bolts see illustration and lift the air cleaner assembly from the engine compartment 15 Refitting is the reverse of removal Ensure that all ducts are securely refitted or air leaks will result 9 Accelerator cable check EN adjustment and renewal p X Check 1 Separate the air intake duct from the throttle body fuel injection models or remove the air cleaner carburettor models 2 Have an assistant depress the accelerator pedal to the floor while you watch the throttle valve It should move to the fully open position 3 Release the accelerator pedal and make sure the throttle valve returns smoothly to the fully closed position The throttle valve should not contact the body at any time during its movement if it does the unit must be renewed Adjustment 4 Warm the engine to normal operating temperature then switch it off Depress the Fuel and exhaust systems 4 9 8 9 Align the air cleaner cover arrows when refitting accelerator pedal to the floor twice then check the cable free play at the carburettor throttle body Compare it to the value listed this Chapter s Specifications 5 Ifthe free play isn t as specified adjust it by turning the adjustment nut see illustration 6 Have an assistant help you verify the throttle valve is fully open when the accelerator pedal is depressed to
24. 40 antifreeze 60 water i2 Servicing Specifications Fuel system Idle speed 3 Series E30 316 with M IO BIS 2 4550 Voy e Deae 850 50 rom 316i with 40 16 engine 800 40 318i with M 10 B 18 engine manual transmission 850 50 rpm 318i with M10 B18 engine automatic transmission 750 50 rom 318i with MA0 BIS 6ngihe d a d 800 40 rom 320i with M20 B20 engine L J 800 x50 rpm 320i with M20 B20 engine 760 40 rpm 325i with M 20 B25 engine 760 40 rpm 5 Series E28 old shape 518 and 518i with 10 18 engine 800 50 rpm other models cs don kee eee eras teem ds 850 50 rom 5 Series E34 new shape 518i with M40 B18 engine 800 40 rom 520i with M20 B20M engine 760 40 rpm 525i with M20 B 25M engine 760 40 rpm 530i with M 30 B30M engine 800 50 rpm 535i with M30 B35M engine s a 850 50 rpm CO at 3000 rpm 3 Series E30 316 with M10 B18 engine 0 5 to 1 0 316i and 318i with 40 16 engine 0 7 0 5 318i with 10 18 engine
25. Apply touch up paint to the scratch using a fine paint brush continue to apply fine layers of paint until the surface of the paint in the Scratch is level with the surrounding paintwork Allow the new paint at least two weeks to harden then blend it into the Surrounding paintwork by rubbing the scratch area with a paintwork renovator or a very fine cutting paste Finally apply wax polish Where the scratch has penetrated right through to the metal of the bodywork causing the metal to rust a different repair technique is required Remove any loose rust from the bottom of the scratch with a penknife then apply rust inhibiting paint to prevent the formation of rust in the future Using a rubber or nylon applicator fill the scratch with bodystopper paste If required this paste can be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches Before the stopper paste in the scratch hardens wrap a piece of smooth cotton rag around the top of a finger Dip the finger in cellulose thinners and quickly sweep it across the surface of the stopper paste in the scratch this will ensure that the surface of the stopper paste is slightly hollowed The scratch can now be painted over as described earlier in this Section Repairs of dents in bodywork When deep denting of the vehicle s bodywork has taken place the first task is to pull the dent out until the affected bodywork almost attains it
26. Automatic transmission not completely engaged in Park Chap ter 7B or on models with a clutch switch clutch not completely depressed Chapter 8 Broken loose or disconnected wiring in the starting circuit Chapters 5 and 12 Starter motor pinion jammed in flywheel ring gear Chapter 5 Starter solenoid faulty Chapter 5 Starter motor faulty Chapter 5 Ignition switch faulty Chapter 12 Starter pinion or flywheel teeth worn or broken Chapter 5 Engine internal problem Chapter 2B Engine rotates but will not start Fuel tank empty Battery discharged engine rotates slowly Chapter 5 Battery terminal connections loose or corroded Chapter 1 Leaking fuel injector s faulty fuel pump pressure regulator etc Chapter 4 Fuel not reaching fuel injection system or carburettor Chapter 4 Ignition components damp or damaged Chapter 5 Fuel injector stuck open Chapter 4 Worn faulty or incorrectly gapped spark plugs Chapter 1 Broken loose or disconnected wiring in the starting circuit Chapter 5 Loose distributor mounting bolts causing ignition timing to wander Chapters 1 and 5 Broken loose or disconnected wires at the ignition coil or faulty coil Chapter 5 Engine hard to start when cold Battery discharged Chapter 1 Fuel system
27. In car engine repair procedures 2A 17 14 13 Removing the spacer ring from the front of the crankshaft im 14 21 Unscrew the bolts 19 Before refitting the pump new rebuilt or Original on the engine check it for proper operation Fill a clean container to a depth of one inch with fresh engine oil of the recommended viscosity 20 Immerse the oil pump inlet in the oil and turn the driveshaft anti clockwise by hand As the shaft is turned oil should be discharged from the pump outlet M40 engines 21 With the front end cover on the bench unscrew the bolts and remove the cover plate to expose the oil pump rotors see illustrations 22 Identify the rotors for position then remove them from the housing see illustrations 14 22b and outer rotor from the oil pump M40 engine 14 21b and remove the oil pump cover M40 engine 23 Clean the housing and the rotors thoroughly then refit the rotors making sure that they are in their previously noted positions The inner rotor must be fitted with the guide facing the body 24 Using feeler blades measure the clearance between the oil pump body and the outer rotor then check the clearance between the outer and inner rotors see illustrations 25 f the clearance is not as given in the Specifications the complete oil pump and front end cover should be renewed If the Clearance is within tolerance remove the rotors then pour a little
28. 42 to 47 cc 518i and 520i 5 Series models or 20 to 25 cc all other 5 Series models of 6 11 Make sure you align the end of the coil spring with the shoulder of the rubber ring and with the spring retainer Toss MH 6 4 Prise the protective cap off the damper rod nut and remove the large nut arrowed to prevent the damper rod from turning place an Allen key in the end of the shaft engine oil the oil helps cool the shock absorber by transferring heat to the strut housing Note It doesn t matter what viscosity or grade of engine oil is used 11 Refitting is otherwise the reverse of removal Tighten the threaded collar to the torque listed in this Chapter s Specifications Make sure you align the end of the coil spring with the shoulder of the rubber ring and with the spring retainer see illustration Tighten the damper rod nut to the torque listed in this Chapter s Specifications 12 Refit the strut or shock absorber assembly see Section 5 or 11 7 Balljoints check and renewal Why Check Note On 3 Series models there are two balljoints on each control arm one between the middle of the arm and the subframe and the other between the outer end of the arm and the steering knuckle On 5 Series models there are balljoints on the outer ends of the control arm and the thrust arm 1 Raise the vehicle and support it securely on axle stands 2 Visually inspect the rubber boot between the balljoint
29. 7 Ignition timing TCI system a check and adjustment iN A Warning Keep hands equipment and wires well clear of the viscous cooling fan during adjustment of the ignition timing Note This Section describes the procedure for checking and adjusting the ignition timing on engines fitted with the TCI system On engines fitted with the Motronic engine management system the ignition timing is controlled by the electronic control unit and no adjustment is possible The timing can be checked using the following procedure but no ignition timing values were available at the time of writing If the timing is thought to be incorrect refer to a BMW dealer 1 Some special tools are required for this procedure see illustration The engine must be at normal operating temperature and the air conditioning where fitted must be switched off Make sure the idle speed is correct 2 Apply the handbrake and chock the wheels to prevent movement of the vehicle The transmission must be in neutral manual or Park automatic 3 The timing marks are located on the engine flywheel viewed through the timing check 7 9a Flywheel OT timing mark hole in the bellhousing and or on the vibration damper on the front of the engine 4 Where applicable disconnect the vacuum hose from the distributor vacuum advance unit 5 Connect a tachometer and timing light according to the equipment manufacturer s instructions an inductive pick u
30. 7 Prior to repairing a break switch off the circuit and allow it to cool down for a few minutes 8 Lightly buff the element area with fine steel wool then clean it thoroughly 9 Use masking tape to mask off the area of repair leaving a slit to which the epoxy can be applied 10 Mix the epoxy thoroughly according to the instructions on the package 11 Apply the epoxy material to the slit in the masking tape overlapping the undamaged area about 20 mm on each end 16 11 Wiper blade and pivot mechanism on the rear window 5 Series 12 Allow the repair to cure for 24 hours before removing the tape and using the heated rear window 18 Supplemental Restraint System SRS general information Later models are equipped with a Supplemental Restraint System SRS incorporating an airbag This system is designed to protect the driver from serious injury in the event of a head on or frontal collision It consists of an airbag module in the centre of the steering wheel two crash sensors mounted on the front inner wing panels and a crash safety switch located inside the passenger compartment The airbag module contains a housing incorporating the airbag and the inflator units The inflator assembly is mounted on the back of the housing over a hole through which gas is expelled inflating the bag almost instanta neously when an electrical signal is sent from the system This signal is carried by a wire which is specially wound
31. CO level adjustment 1 15 REF 94 Coil 5 5 Coil springs 10 7 10 9 Cold start injectors 4 17 4 18 Compression check 2B 4 Index 25 Compressor 3 8 Condenser 3 9 Connecting rods 2B 12 2B 16 2B 21 Constant velocity CV joint 8 2 8 8 8 9 Continuity check 1292 Control arm 10 4 10 5 Conversion factors REF 17 Coolant 1 3 1 8 Coolant pump 3 5 Coolant temperature sender unit 3 6 Coolant temperature sensor 6 2 Cooling fan 3 4 Cooling heating and air conditioning systems 1921 1924 3 1 et seq Cooling system fault finding REF 12 Crankshaft 2 12 2 13 2A 19 2B 13 2B 17 2B 19 2B 20 Cruise control 1293 12 8 Crushing 0 5 Cushion 11 9 CV joints 8 2 8 8 8 9 Cylinder head 2 13 2B 7 2B 10 2B 12 Cylinder honing 2B 15 D Dents in bodywork 1192 Differential final drive 8 2 8 10 8 11 Differential oil 1 3 1 19 1 26 Direction indicators 1292 1293 Discs 1 22 9 5 Distributor 1 18 5 4 Door 11 6 11 8 REF 2 Drivebelts 1914 Driveplate 2 18 Driveshafts 1 22 8 2 8 9 Drums 1 23 REF REF 26 Index E Earth check 12 2 Electric fan 3 4 Electric shock 0 5 Electric windows 12 9 Electrical equipment REF e2 Electrical system fault finding 12 1 Electronic control system 493 4 14 Electronic control unit ECU 6 1 Engine fault finding REF 10 Engine
32. Wiring diagrams 12 27 Key to wiring diagram for memory power seats 01 Description Plug connection for special equipment plug Plug connection of wire for passenger s seat Plug connection of wire for seat control with memory Connection of wire for seat control with memory Seat control switch Backrest Slide Headrest Height front Height rear Plug connection for seat backrest slide control Plug connection for seat headrest control Plug connection for seat height control Electronic control unit underneath seat Plug connection of wire for seat control with memory Plug connection of wire for seat with memory Plug connection for seat control drive Plug connection for memory switch Plug connection for slide potentiometer Plug connection for front height potentiometer Plug connection for rear height potentiometer Plug connection for headrest motor Plug connection for backrest potentiometer Plug connection for backrest motor Memory switch Motor seat backrest control Motor headrest control Motor height control rear Motor height control front Motor slide 12 12 28 Wiring diagrams 15 26 20 24 14 5 15 yg ug ug 48 49 A9 48 8 518 18 21 20 WE AD MIA A9 26 GY qu BL Typical wiring diagram for power seats with memory 1 of 2 Wiring diagrams 12 29 e N T 9 10 Re EA 7
33. all the way to the stop Caution Don t try to use any other type of lubricant 30 minutes after it s applied this lubricant loses its properties and the bush is permanently located in its proper position Make sure the new bush is pressed on so it s orientated exactly the same way as the old bush 8 Refit the bracket bolts and tighten them to the torque listed in this Chapter s Specifi cations 9 Lower the vehicle and leave it at rest for at least 30 minutes this will give the special lubricant time to dry Control arm removal and refitting Note If either balljoint is worn or damaged the only way to renew it is to renew the control arm If you re fitting a new control arm a new bush must also be fitted The old bush can t be removed from the old control arm and re used in the new control arm 10 Loosen but do not remove the wheel bolts raise the front of the vehicle and Support it on axle stands Remove the wheel bolts and the front wheel 11 Remove the two bolts which attach the rubber bush bracket to the underbody see illustration 3 4 12 Remove the nut which secures the control arm balljoint to the subframe and remove the balljoint stud from the subframe Note It may be necessary to use a balljoint separator to separate the balljoint from the subframe see illustration but take care not to damage the 3 13a Remove the self locking nut from the balljoint stud which attaches the outer end of the
34. it should be pointing directly at the mark you made on the distributor body or timing cover 10 If the rotor is 180 degrees out the No 1 piston is at TDC on the exhaust stroke 11 To get the piston to TDC on the compression stroke turn the crankshaft one complete turn 360 clockwise The rotor Should now be pointing at the mark on the distributor or timing cover When the rotor is pointing at the No 1 spark plug lead terminal in the distributor cap and the ignition timing marks are aligned the No 1 piston is at TDC on the compression stroke Note If it s impossible to align the ignition timing marks when the rotor is pointing at the mark the timing belt or chain may have jumped the teeth on the sprockets or may have been fitted incorrectly 2A 2A 4 In car engine repair procedures 12 After the No 1 piston has been positioned at TDC on the compression stroke TDC for any of the remaining pistons can be located by turning the crankshaft and following the firing order Mark the remaining spark plug lead terminal locations just like you did for the No 1 terminal then number the marks to correspond with the cylinder numbers As you turn the crankshaft the rotor will also turn When it s pointing directly at one of the marks on the distributor the piston for that particular cylinder is at TDC on the compression stroke 4 Valve cover removal and refitting Caution If the radio in your vehicle is equipped wit
35. use a water dispersant aerosol or something similar to dry out the cap and rotor then refit the cap and repeat the spark test 6 If there s still no spark disconnect the coil HT lead from the distributor cap and test this lead as described for the spark plug leads 7 f no spark occurs check the primary wire connections at the coil to make sure they re clean and tight Make any necessary repairs then repeat the check 8 If sparks do occur from the coil HT lead the distributor cap rotor plug HT lead s or spark plug s may be defective If there s still no spark the coil to cap HT lead may be defective If a substitute lead doesn t make any difference check the ignition coil see Section 9 Note Refer to Sections 10 and 11 for more test procedures on the distributors fitted with the TCI ignition system 5 4 Engine electrical systems 7 1 Tools for checking and adjusting the ignition timing 1 Vacuum plugs Vacuum hoses will in most cases have to be disconnected and plugged Moulded plugs in various shapes and sizes can be used for this if wished 2 Inductive pick up timing light Flashes a bright concentrated beam of light when No 1 spark plug fires Connect the leads according to the instructions supplied with the light 3 Distributor spanner On some models the hold down bolt for the distributor is difficult to reach and turn with conventional Spanners or sockets A special spanner like this must be used
36. 1 Loosen the wheel bolts raise the front or rear of the vehicle and place it securely on axle stands Remove the wheel 2 f you re just removing the caliper for access to other components it isn t necessary to detach the brake line If you re removing the caliper for overhaul disconnect the brake line from the caliper for preference using a split ring brake spanner to protect the fitting Plug the line to keep contaminants out of the brake system and to prevent losing brake fluid unnecessarily 3 Refer to Section 3 for the front or rear caliper removal procedure it s part of the brake pad renewal procedure Note The rear caliper is similar in design to the front caliper on 5 series models Overhaul 4 On all calipers except the front calipers on 3 Series models remove the circlip for the dust seal see illustration then remove the dust boot see illustration Before you remove the piston place a block of wood between the piston and caliper to prevent damage as it is removed 5 To remove the piston from the caliper apply compressed air to the brake fluid hose connection on the body see 4 4a An exploded view of a typical rear caliper assembly front calipers similar 1 Caliper assembly 8 Cable clamp 2 Bracket mounting bolt 9 Brake disc 3 Bleed screw 10 Allen bolt 4 Dust cap 11 Shield 5 Anti rattle spring 12 Bolt 6 Guide bolt 13 Washer 7 Brake pad wear warning 14 Plug light wire illustratio
37. 17 When you re finished have the front wheel alignment checked by a dealer service department or qualified garage 4 6a If you re removing the control arm remove the self locking nut and the through bolt arrowed that attach the inner end of the arm to the vehicle 4 7a Remove the self locking nut control arm nut left arrow thrust arm nut right arrow from the balljoint then support the steering arm and press or knock the balljoint out of the steering arm 4 Control and thrust arms 5 Series inspection removal and refitting and bush renewal Why Inspection 1 Inspect the thrust arm rubber bush see illustration 4 6b If the bush is cracked torn or otherwise deteriorated renew it The control arm bush can t be inspected until the control arm is removed 2 Raise the vehicle and place it securely on axle stands 3 To inspect the control arm and thrust arm balljoints for wear grip the top and bottom of each balljoint with a large pair of water pump parrot jaw pliers and try to squeeze them Alternatively use a lever or large screwdriver to move them up and down If there s any free play renew the control arm or thrust arm The balljoints can t be renewed separately Removal Note If a balljoint is worn or damaged the only way to renew it is to renew the control arm or thrust arm If you re fitting a new control arm or thrust arm a new bush must also be fitted The old bush can t be removed f
38. AS X The electrical circuits of the vehicle are protected by a combination of fuses and circuit breakers The fusebox is located in the left corner of the engine compartment see illustration On some later models it is located under the rear seat cushion Each of the fuses is designed to protect a specific circuit and on some models the various circuits are identified on the fuse panel itself Miniaturised fuses are employed in the fuseboxes These compact fuses with blade terminal design allow fingertip removal and renewal If an electrical component fails always check the fuse first A blown fuse is easily identified through the clear plastic body Visually inspect the element for evidence of damage If a continuity check is called for the blade terminal tips are exposed in the fuse body Be sure to renew blown fuses with the correct type Fuses of different ratings are physically interchangeable but only fuses of the proper rating should be used Replacing a fuse with one of a higher or lower value than specified is not recommended Each electrical circuit needs a specific amount of protection The amperage value of each fuse is moulded into the fuse body If the new fuse immediately fails don t renew it again until the cause of the problem is isolated and corrected In most cases the cause will be a short circuit in the wiring caused by a broken or deteriorated wire 3 Fuses general information 4 Relays gene
39. Chapter 9 Braking system Contents Anti lock brake system ABS general information 2 Broke CheCk dS See Chapter 1 Brake disc inspection removal and refitting 5 Brake fluid level check See Chapter 1 Brake hoses and lines inspection and renewal 15 Brake hydraulic system bleeding 16 Brake pedal adjustment 13 Brake vacuum Servo check removal and refitting 8 Disc brake caliper removal overhaul and refitting 4 Degrees of difficulty ENS Easy suitable for novice with little experience Fairly easy suitable for beginner with some experience x ES Specifications General Brake fuld DUBS bars Acid edo on FOR RO ge aed a Disc brakes Minimum brake pad thickness Brake disc minimum permissible thickness wear limit Front 3 Series Solid discs Ventilated discs 5 Series Solid discs Ventilated discs Rear Brake disc minimum thickness after machining Front 3 Series Solid discs Ventilated discs 5 Series Solid discs Ventilated discs Rear Parallelism difference between any two measurements Maximum disc run out Fairly difficult EN suitable for competent X DIY mechanic X Disc brake pads renewal Drum brake shoes renewal General information Handbrake assembly check removal and refitting Hand
40. Depending on model and accessories you may need special extensions and universal joints to reach one or more of the plugs 5 Spark plug gap gauge This gauge for checking the gap comes in a variety of styles Make sure the gap for your engine is included Feeler blades may be used instead Every 12 000 miles battery negative cable and connect the battery charger leads to the battery posts positive to positive negative to negative then plug in the charger Make sure it is set at 12 volts if it has a selector switch Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 14 If you re using a charger with a rate higher than two amps check the battery regularly during charging to make sure it doesn t overheat If you re using a trickle charger you can safely let the battery charge overnight after you ve checked it regularly for the first couple of hours Where a maintenance free battery is fitted special precautions may be necessary when charging it for example the charge rate is normally very low There may be a warning label on the battery but if not consult a BMW dealer or auto electrician 15 If the battery has removable cell caps measure the specific gravity
41. Discard the old gasket On the M40 engine also remove the camshaft cover see illustrations If applicable remove the semi circular rubber seal from the cut out at the front of the cylinder head Refitting 8 Using a scraper remove all traces of old gasket material from the sealing surfaces of the valve cover and cylinder head Caution Be very careful not to scratch or gouge the delicate aluminium surfaces Gasket removal solvents are available at motor factors and may prove helpful After all gasket material has been removed the gasket surfaces can be degreased by wiping them with a rag dampened with a suitable solvent 9 If applicable place a new semi circular rubber seal in the cut out at the front of the cylinder head then apply RTV type gasket sealant to the joints between the seal and the mating surface for the valve cover gasket Note After the sealant is applied you should refit the valve cover and tighten the nuts within ten minutes 10 Refit the camshaft cover M40 engine the valve cover and a new gasket Refit the washers and nuts tighten the nuts evenly and securely Don t overtighten these nuts they 4 7b Removing the camshaft cover on the M40 engine TIMER Pe d 4 6b Valve cover bolt locations arrowed on M20 six cylinder engines should be tight enough to prevent oil from leaking past the gasket but not so tight that they warp the valve cover 11 The remainder of refitting is the revers
42. Radiator 3 3 11 4 Radio 12 4 Receiver drier 3 9 Regulator voltage 5 10 Regulator window 1198 Relays 12 2 Repair procedures REF 8 Respraying 1193 Reversing light switch 7B 4 Rocker arms 2B 11 Rotor 1 18 Routine maintenance and servicing 1 1 et seq Routine maintenance air conditioning system 3 8 Routine maintenance bodywork and underframe 11 1 Routine maintenance hinges and locks 11 4 Routine maintenance interior trim 11 2 Routine maintenance upholstery and carpets 1192 Rust holes in bodywork 11 2 S Safety first 0 5 Scalding 0 5 Scratches in bodywork 11 2 Screw threads and fastenings REF 8 Seat belt 11 9 REF 2 Seats 11 9 REF 2 Selector lever 7B 3 7 5 Selector shaft 7 2 Service Indicator SI board 12 4 Service indicator light 1 26 Servo 9 2 9 10 9 11 Shock absorber 1 21 10 7 10 8 10 9 REF 2 REF 3 Shoes 9 7 Short circuit 1292 Silencer 4 20 Slave cylinder 8 3 Spares REF 19 Spark plug 1 17 1 18 Speed sensors 5 8 Springs 10 7 10 9 REF 3 Starter inhibitor 7B 4 Starter motor 5 12 Starter motor fault REF 10 Starting system 5 11 Steering box 10 15 Steering column 1199 1293 REF 1 Steering gear 10 12 10 13 REF 3 Steering linkage 10 14 Steering wheel 10 16 REF 1 Stop light switch 9 13 Struts 1 21 10 6 10
43. Speaker rear right Special equipment plug RA12 Connection for power windows Amplifier Speaker front left Speaker door left Connection for power supply lead 10 Connection for power aerial 11 Radio 12 Speaker balance control 13 Speaker rear left Wiring diagrams 12 31 12 12 32 Wiring diagrams H 22043 4g ACL uua OF 1 7 19 20 8 14 15 TN u9 49 cluug 5 13 11 3 17 16 Typical radio wiring diagram early models shown 0 25 BR EN L 1 5 GNVI 2 5 RTWS 0 75 SWGE 4 RT 0 75 GN 0 75 SWBL 2 0 75 GE Wiring diagrams 12 33 ENGINE CONNECTOR 1 5 GNVI FUEL PUMP 0 5 BRGN OIL PRESSURE 2 5 GN 15 2 5 SWGE 50 0 75 BL D 0 5 BRWS TEMP GRUGE 15 AIRBAG SERVICE INDICATOR I Sh 9 NNOINS y i nnn p w oou m x C 2 0 wv 2 2 0 2 O wu e mmm nM 9 4 es SCREEN 2 2 T ee 1 5 1 GN OM EI 2 5 SWGE 0 5 BRWS Pih i 18 RT 2 5 SWGE 7 5 Bn SCREEN am TD 1 GN 9 75 BL 3a 0 5 RTWS 0 5 BR 0 5 GE SCREEN 4 ON z oo pp 8 5 SW NO g an NN uut 2 giu D Q utu 50225 DIAGNOSTIC y BhnT CONNECTOR Gr n1 H247
44. Thermostat check and renewal 3 Water pump 6 Water pump removal and refitting Easy Suitable for novice with litte 22 expenence N Fairly easy suitable for beginner with some experience Fairly difficult EN N suitable for competent X 5 DIY mechanic X Difficult suitable for expenenced DIY mechanic x Very difficult suitable forexpet ae A gt DIY or professional gt Specifications General Coolalt Cap aCily 352 533 1 92 93 daro E Thermostat rating Opening temperature Open ain eke dodo bor dicor dish od de ar ipi See Chapter 1 80 176 F 100 C 212 F Cooling fan thermo switch switching temperatures Low speed High Speed Torque wrench settings Mechanical cooling fan clutch to water pump securing nut left hand thread Mechanical cooling fan to clutch bolts Water pump bolts S mall bolts 6 Large bolts M8 Thermostat housing 1 Generalinformation Engine cooling system All vehicles covered by this manual employ a pressurised engine cooling system with thermostatically controlled coolant circulation An impeller type water pump mounted on the front of the block pumps coolant through the engine The coolant flows around each cylinder and towards the rear of the engine Cast in coolant passages direct coolan
45. Weatherstrip adhesive is used to bond weatherstripping around doors windows and boot lids It is sometimes used to attach trim pieces Underseal is a petroleum based tar like substance that is designed to protect metal surfaces on the underside of the vehicle from corrosion It also acts as a sound deadening agent by insulating the bottom of the vehicle Waxes and polishes are used to help protect painted and plated surfaces from the weather Different types of paint may require the use of different types of wax and polish Some polishes utilise a chemical or abrasive cleaner to help remove the top layer of oxidised dull paint on older vehicles In recent years many non wax polishes containing a wide variety of chemicals such as polymers and silicones have been introduced These non wax polishes are usually easier to apply and last longer than conventional waxes and polishes Buying spare parts amp vehicle identification numbers rere Buying spare parts Spare parts are available from many sources for example BMW garages other garages and accessory shops and motor factors Our advice regarding spare part sources 15 as follows Officially appointed BMW garages This is the best source for parts which are peculiar to your vehicle and which are not generally available eg complete cylinder heads internal transmission components badges interior trim etc It is also the only place at which you Should buy parts if the veh
46. You have three attempts to enter the correct code If the correct code isn t entered in three tries you ll have to wait one hour with the radio on before you enter the codes again 5 Once the code has been entered correctly the word CODE should disappear from the display and the radio should play you ll have to tune in and enter your preset stations however 6 If you have lost your code number contact a BMW dealer service department language has been selected continue holding the reset button until the display reads 1 0 Version 2 0 Continue holding the button until it reads H P Version 3 4 then release the button 0 8 Roadside Repairs J acking towing and wheel changing J acking and wheel changing The jack supplied with the vehicle should be used only for raising the vehicle when changing a tyre or placing axle stands under the frame Warning Never crawl under the vehicle or start the engine when this jack is being used as the only means of support When changing a wheel the vehicle should be on level ground with the handbrake firmly applied and the wheels chocked Select reverse gear manual transmission or Park automatic transmission Prise off the hub cap if equipped using the tapered end of the wheel brace Loosen the wheel bolts half a turn leaving them in place until the wheel is raised off the ground Position the head of the jack under the side of the vehicle making sure i
47. and to prevent further fluid loss Caution Even a particle of dirt can damage the servo so be extremely careful to prevent dirt from entering the system while the lines are disconnected 6 Working from inside the passenger compartment remove the lower left trim panels above the brake pedal left hand drive models or glovebox and trim right hand drive models On left hand drive models also disconnect the pedal return spring 7 Prise off the retaining clip and disconnect the pushrod from the brake pedal see illustration 8 9 or cross shaft lever 8 Remove the four mounting nuts and remove the brake servo see illus tration 8 10 9 Refitting is the reverse of removal Tighten the hydraulic lines to the torque listed in this Chapter s Specifications Note Don t try to tighten these fittings without a torque wrench If they re loose they can leak which can affect system operation if they re tight they can be damaged and they ll also leak You ll need a crowfoot type split ring brake attachment for your torque wrench to tighten the fittings properly 10 When you re done bleed the brake hydraulic system Section 16 and adjust the brake pedal travel and the stop light switch see Section 13 10 Handbrake cable s renewal 1 Peel back the boot at the base of the handbrake lever and remove the handbrake cable adjusting nut see illustration which also secures the cable to the handbrake lever Highs
48. assembling them b Make sure you have the correct piston rod assembly for each cylinder C The notch or mark on the piston must face the front of the engine d Lubricate the cylinder walls with clean oil e Lubricate the bearing faces when refitting the rod caps after the oil clearance has been checked 24 After all the piston connecting rod assemblies have been properly fitted rotate the crankshaft a number of times by hand to check for any obvious binding 25 Check the connecting rod side play see Section 13 26 Compare the measured side play to the Specifications to make sure it s correct If it was correct before dismantling and the original crankshaft and rods were refitted it should still be right If new rods or a new crankshaft were fitted the side play may be incorrect If so the rods will have to be removed and taken to a machine shop for attention 27 Initial start up and running in after overhaul Warning Have a fire extinguisher handy when starting the engine for the first time 1 Once the engine has been refitted in the vehicle double check the engine oil and coolant levels 2 With the spark plugs removed and the ignition system disabled see Section 3 crank the engine until oil pressure registers on the gauge or until the oil pressure warning light goes out 3 Refit the spark plugs connect the HT leads and restore the ignition system functions see Section 3 4 Start the engi
49. but the motor still does not operate the problem lies in the fuse the relay the wiring which connects the components or the fan motor itself Carefully check the fuse relay all wiring and connections See Chapter 12 for more information on how to carry out these checks Mechanical fan with viscous clutch 8 Disconnect the battery negative cable and rock the fan back and forth by hand to check for excessive bearing play Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 9 With the engine cold turn the fan blades by hand The fan should turn with slight resistance 10 Visually inspect for substantial fluid leakage from the fan clutch assembly If problems are noted renew the fan clutch assembly 11 With the engine completely warmed up turn off the ignition switch and disconnect the battery negative cable Turn the fan by hand Heavier resistance should be evident If the fan turns easily a new fan clutch may be needed Removal and refitting Electric auxiliary fan 12 Disconnect the battery negative cable 13 To remove the auxiliary fan follow the procedure that applies to your vehicle 5 27 The cooling fan on the water pump is attached to the shaft b
50. carburettor main body 12 7 Throttle positioner bracket to throttle housing screw arrowed 4 12 Fuel and exhaust systems 12 8 Disconnecting the vacuum unit 12 9 Throttle housing to main body 12 10 Primary throttle lever securing nut pullrod securing screws arrowed if removed take care not to disturb the return spring 12 11 Throttle housing removed from the 12 11b Underside of the main with 12 12a Tap out the float pivot pins and carburettor throttle housing removed note gasket remove the floats 12 12b then lift out the needle valves 12 13a Unscrew the bypass jet from the 12 13b Secondary main jet 1 and TM i keeping all components identified side for secondary float chamber thermal starter fuel jet 2 side 12 13c Secondary main jet left and TM 12 13d Secondary bypass air jet 1 TM air 12 The jet positions in the cover fuel jet right tightened in the cover jet 2 and air correction jet 3 arrowed 12 15a Choke linkage arm located in the automatic choke lever 9 Remove the screws securing the throttle housing to the main body see illustration 10 Prise out the intermediate throttle link If this proves difficult unscrew the nut and disconnect the lever from the primary throttle Spindle taking care not to disturb the return spring see illustration 11 Separate the throttle housing from the main body and remove the gasket see illustrations 12 With
51. novice with little EN Fairly easy suitable for beginner with x some expenence expenence N Fairly difficult RAS suitable for competent X experienced DIY DIY mechanic X Fuel injection system fault finding See end of Chapter Fuel injection general information 13 Fuel injection systems 14 Fuel injectors check and renewal 20 Fuel lines and fittings repair and 5 Fuel pressure regulator check and renewal 18 Fuel pump transfer pump and fuel level sender unit removal and refitting 4 Fuel pump fuel pressure check 3 Fuel system Fuel tank removal and refitting 6 Fuel tank cleaning and repair general information 7 General information 1 Idle air stabiliser valve check adjustment and renewal 21 Throttle body check removal and refitting 17 Difficult suitable for Very difficult suitable for expert mechanic DIY or professional Specifications Carburettor Solex 2B4 Main jet Stage 1 Stage 2 Air correction jet Stage 1 Stage 2 Venturi diameter Stage 1 Stage 2 Idle air jet Stage 1 Stage 2 Float needle valve diameter
52. radiator 15 Start the engine and check for leaks Allow the engine to reach normal operating temperature indicated by the upper radiator hose becoming hot Recheck the coolant level and add more if required 16 If you re working on an automatic transmission model check and transmission fluid as needed 5 Enginecoolingfan s and SS clutch check removal and refitting X Warning To avoid possible injury or damage DO NOT operate the engine with a damaged fan Do not attempt to repair fan blades fit a new fan Also the electric auxiliary fan in front of the radiator or air conditioning condenser can come on without the engine running or ignition being on It is controlled by the coolant temperature of the thermo switches located in the radiator Check Electric auxiliary fan Note This fan on most models is controlled by two thermo switches placed in the radiator one for low speed low temperature operation and one for high speed high temperature operation Each switch comes on at a different coolant temperature refer to the Specifica tions at the beginning of this Chapter 1 The thermostatically controlled switches for high and low speed operation of the auxiliary fan are fitted in various locations in the radiator see illustration 4 7 depending on engine or model Two single switches or one dual switch may be fitted 2 Insert a small screwdriver into the connector to lift the lock tab and unp
53. shake or vibration High steering effort Poor steering self centring Abnormal noise at the front end Wandering or poor steering stability Erratic steering when braking Excessive pitching and or rolling around corners or during braking Suspension bottoms Unevenly worn tyres Excessive tyre wear on outside edge Excessive tyre wear on inside edge Tyre tread worn in one place Excessive play or looseness in steering system Rattling or clicking noise in steering gear REF 9 REF uero Fault Finding This Section provides an easy reference guide to the more common problems which may occur during the operation of your vehicle These problems and their possible causes are grouped under headings denoting various components or systems such as Engine Cooling system etc They also refer you to the Chapter and or Section which deals with the problem Remember that successful fault diagnosis is not a mysterious black art practised only by professional mechanics It is simply the result of the right knowledge combined with an intelligent systematic approach to the problem Always work by a process of elimination Starting with the simplest solution and working through to the most Engine Engine will not rotate when attempting to start Battery terminal connections loose or corroded Chapter 1 Battery discharged or faulty Chapter 1
54. the fuel pump for 1 minute by bridging the appropriate relay terminals see Section 3 There must be no fuel dripping from the nozzle If there is the injector is faulty and must be renewed Switch off the ignition and remake the original fuel pump relay connections 2 Now direct the nozzle of the injector into a can or jar Reconnect the electrical connector to the injector Have an assistant switch on the ignition and operate the starter The injector should squirt a conical shaped spray v _ AMA 19 3 Check for a voltage signal about 12 volts at the cold start injector connector when the starter motor is operated Fuel and exhaust systems 4 17 19 2 Watch for a steady conical shaped spray of fuel when the starter motor is operated into the jar see illustration If the spray pattern is good the injector is working properly If the spray pattern is irregular the injector is fouled or damaged and should be cleaned or renewed 3 If the cold start injector does not spray any fuel check for a voltage signal at the electrical connector for the cold start injector when the starter motor is operated see illustration If there is no voltage check the thermotime switch Thermotime switch 4 The thermotime switch detects the temperature of the engine and controls the action of the cold start injector It is usually located up front near the coolant temperature sensor The engine coolant should be below 309C fo
55. the two vehcles MUST NOT TOUCH each other v Make sure that the transmission is in neutral or PARK in the case of automatic transmission to the negative terminal of the booster battery 4 Connect the other end of the black jump lead to a bolt or bracket on the engine block well away from the battery on the vehicle to be started Make sure that the jump leads will not come into contact with the fan drive belts or other moving parts of the engine Start the engine using the booster battery then with the engine running at idle speed disconnect the jump leads in the reverse order of connection o10 Roadside Repairs Identifying leaks obvious wetness under the bonnet or underneath the car suggest a leak that needs investigating It can sometimes be difficult to contaminated clothing without decide where the leak is coming from delay especially if the engine bay is very dirty already Leaking oil or fluid can also be blown rearwards by the passage of air under the car giving a false impression of where the problem lies Puddles on the garage floor or drive or Warning Most automotive oils The smell of a fluid leakin and fluids are poisonous Wash HAYNES f th id 9 them off skin and change out of HiNT clue to what s leaking Some fluids are distinctively coloured It may help to clean the car carefully and to park it over some clean paper overnight as an aid to
56. they should be renewed 3 If the exhaust system components are extremely corroded or rusted together it may be necessary to cut off the old components with a hacksaw Be sure to wear safety goggles to protect your eyes from metal chips and wear work gloves to protect your hands 4 Here are some simple guidelines to follow when repairing the exhaust system a Work from the back to the front of the vehicle when removing exhaust system components b Apply penetrating oil to the exhaust system nuts and bolts to make them easier to remove C Use new gaskets mountings and clamps when fitting exhaust system components d Apply anti seize compound to the threads of all exhaust system nuts and bolts during reassembly e Besure to allow sufficient clearance between newly fitted parts and all points on the underbody to avoid overheating the floorpan and possibly damaging the interior carpet and insulation Pay particularly close attention to the catalytic converters and heat shields Also make sure that the exhaust will not come into contact with suspension parts etc Catalytic converter 5 Although the catalytic converter is an emissions related component it is discussed here because physically it s an integral part of the exhaust system Always check the converter whenever you raise the vehicle to inspect or service the exhaust system 6 Raise and support the vehicle 7 Inspect the catalytic converter for
57. 1 20 19 3 Check and lubricate the throttle linkage at the points shown arrowed fuel injection engine shown drag when the feeler gauge is moved back and forth 6 If the gap is too large or too small loosen the locknut insert a hook made from large diameter metal wire and rotate the eccentric to obtain the correct gap see illustration 7 Once the gap has been set hold the eccentric in position with the hook and retighten the locknut securely Recheck the clearance sometimes it ll change slightly when the locknut is tightened If so re adjust until it s correct 8 On the M10 engine the valves are adjusted in the firing order which is 1 3 4 2 After adjusting No 1 cylinder valves rotate the crankshaft half a turn 1802 then check and adjust the valves on No 3 cylinder Repeat the procedure on the remaining cylinders 9 On M20 and M30 engines the valves are adjusted following the firing order which is 1 5 3 6 2 4 After adjusting No 1 cylinder valves rotate the crankshaft a third of a turn 1209 then check and adjust the valves on No 5 cylinder Repeat the procedure for the remaining cylinders 10 Refit the valve cover use a new gasket and tighten the mounting nuts evenly and securely 11 Start the engine and check for oil leakage between the valve cover and the cylinder head upwards Every 12 000 miles a E 20 4 Detach the duct from the air cleaner housing 19 Throttle l
58. 16 If the wheel cylinder was renewed see Note 2 bleed the hydraulic system as described in Section 16 17 Depress the brake pedal repeatedly to actuate the self adjusting mechanism A clicking sound will be heard from the brake drums as the adjusters take up the slack 18 Check the handbrake adjustment Sec tion 11 19 Refit the wheels and bolts Lower the vehicle to the ground and tighten the wheel bolts to the torque listed in the Chapter 1 Specifications Check the operation of the brakes carefully before driving the vehicle in traffic 7 Mastercylinder removal and refitting Warning Brake fluid is poisonous It is also an effective paint stripper Refer to the warning at the start of Section 16 Note Although master cylinder parts and overhaul kits are available for most models we recommend fitting a new or overhauled master cylinder complete It will take you more time to overhaul the master cylinder than to renew it and you can t even determine whether the master cylinder is in good enough condition to overhaul it until you have dismantled it You may very well find that it 6 13b then hook the lower end of the spring onto the lever as shown stretch the spring and hook the upper end into its hole in the handbrake shoe can t be overhauled because of its internal condition Removal 1 The master cylinder is connected to the brake vacuum Servo and both are attached to the bulkhead locat
59. 19 Refer to Chapter 9 and fit the brake drums 20 Refit the wheels but don t lower the vehicle yet Handbrake 21 The easiest and perhaps most obvious method of checking the handbrake is to park the vehicle on a steep hill with the handbrake applied and the transmission in Neutral stay in the vehicle while performing this check If the handbrake doesn t prevent the vehicle from rolling refer to Chapter 9 and adjust it 27 Wiper blades BN check and renewal 5 X 1 Road film can build up on the wiper blades and affect their efficiency so they should be 1 23 27 6 Detach the end of the wiper element from the end of the frame then slide the element out washed regularly with a mild detergent solution Check 2 The wiper and blade assembly should be inspected periodically If inspection reveals hardened or cracked rubber renew the wiper blades If inspection reveals nothing unusual wet the windscreen turn the wipers on allow them to cycle several times then switch them off An uneven wiper pattern across the glass or streaks over clean glass indicate that the blades should be renewed 3 The operation of the wiper mechanism can loosen the retaining nuts so they should be checked and tightened as necessary at the same time the wiper blades are checked see Chapter 12 for further information regarding the wiper mechanism Wiper blade renewal 4 Pull the wiper blade assembly away from the glass 5 Pr
60. 23 Rack and pinion steering gear 3 Series removal and refitting 19 Rear anti roll bar removal and refitting 12 Rear coil springs 3 Series removal and refitting 10 Rear shock absorbers 3 Series removal and refitting 9 Rear shock absorber coil spring assembly 5 Series removal ONG nos teas hc wd qn EE aed Ea d ex a de 11 Degrees of difficulty Easy suitable for P novice with litte 55 Fairly easy suitable for beginner with x some Specifications General Power steering fluid type Tyres Tyre sizes 3 Series E30 OO eee eee ewe ee eee E i0 A zo TQ Fairly difficult A suitable for competent X experienced DIY gt DIY mechanic X gt 1041 Rear trailing arms 3 Series removal and refitting 13 Rear trailing arms 5 Series removal and refitting 14 Rear wheel bearings renewal 15 Steering and suspension See Chapter 1 Steering box 5 Series removal and refitting 21 Steering gear boots 3 Series 18 Steering linkage 5 Series inspection removal and ku peer TRITT 20 Steering system genera
61. 5 Remove the steering wheel from the arrowed Steering shaft If the wheel is difficult to remove from the shaft use a steering wheel puller to remove it don t hammer on the Shaft Refitting 6 Refitting is the reverse of removal Be sure to align the match marks you made on the Steering wheel and the shaft Tighten the steering wheel nut to the torque listed in this Chapter s Specifications 25 Wheels and tyres general information Note For more information on care maintenance of tyres refer to Chapter 1 1 All vehicles covered by this manual are equipped with steel belted radial tyres as Original equipment Use of other types or sizes of tyres may affect the ride and handling of the vehicle Don t mix different types or sizes of tyres as the handling and braking may be seriously affected It s recommended that tyres be renewed in pairs on the same axle if only one new tyre 15 being fitted be Sure it s the same size structure and tread design as the other 2 Because tyre pressure has a substantial effect on handling and wear the pressure on all tyres should be checked at least once a month or before any extended trips see Chapter 1 3 Wheels must be renewed if they are bent heavily dented leak air or are otherwise damaged 4 Tyre and wheel balance is important in the overall handling braking and performance of the vehicle Unbalanced wheels can adversely affect handling and ride chara
62. 6 Either an L J etronic system or a Motronic system is fitted Later models have an updated version of the original Motronic system 14 Fuel injection systems L J etronic fuel injection system The Bosch L J etronic fuel injection system is used on most 3 Series models up to 1987 and on most E28 old shape 5 Series models It is an electronically controlled fuel injection system that utilises one solenoid operated fuel injector per cylinder The system is governed by an Electronic Control Unit ECU which processes information sent by various sensors and in turn precisely meters the fuel to the cylinders by adjusting the amount of time that the injectors are open An electric fuel pump delivers fuel under high pressure to the injectors through the fuel feed line and an in line filter A pressure regulator keeps fuel available at an optimum pressure allowing pressure to rise or fall depending on engine speed and load Any excess fuel is returned to the fuel tank by a separate line A sensor in the air intake duct constantly measures the mass of the incoming air and the ECU adjusts the fuel mixture to provide an optimum air fuel ratio Other components incorporated in the system are the throttle valve which controls airflow to the engine the coolant temperature sensor the throttle position switch idle stabiliser valve which bypasses air around the throttle plate to control idle speed and associated relays and f
63. 7 Have an assistant switch the ignition on while you listen at the fuel tank You should hear a whirring sound for a couple of seconds Note This test applies to the transfer pump also If there is no whirring sound there is a problem in the fuel pump circuit Check the fuel pump main fuse and relay first see Chapter 12 If the main relay is OK test the fuel pump relay Fuel system pressure check 8 Depressurise the fuel system see Section 2 9 Detach the battery negative cable Caution If the radio in your A vehicle is equipped with an anti theft system make sure you have the correct activation code nu i 3 6d then use jumper wire to bridge the terminals on the connector that correspond to fuel pump relay pins 30 and 8 3 6b On Motronic systems use a jumper wire to bridge the terminals on the connector that correspond to the fuel pump relay pins 30 and 87 before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 10 Detach the fuel feed line from the fuel rail on L J etronic see illustration and early Motronic systems or from the fuel filter to the main fuel line on later Motronic systems 11 Using a tee piece three way fitting a short section of high pressure f
64. Battery maintenance is an important procedure which will help ensure that you are not stranded because of a dead battery Several tools are required for this procedure see illustration 2 Before servicing the battery always switch off the engine and all accessories and disconnect the cable from the negative terminal of the battery Caution If the radio in your A vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 A low maintenance battery is standard equipment The cell caps can be removed and distilled water can be added if necessary Later models may be fitted with a maintenance free battery which is sealed 4 Remove the caps and check the electrolyte level in each of the battery cells It must be above the plates There s usually a split ring indicator in each cell to indicate the correct level If the level is low add distilled water only then refit the cell caps 13 8a Battery terminal corrosion usually appears as light fluffy powder 13 8c Regardless of the type of tool used on the battery posts a clean shiny surface should be the result Caution Overfilling the cells may cause electrolyte to spill over during periods of heavy charging Causing corrosion and da
65. Chapter 5 Check the coil secondary resistance by connecting one of the ohmmeter leads to one of the primary terminals and the other ohmmeter lead to the coil high tension terminal see illustrations On TCI systems different type of coil First remove the coil cover secondary resistance of the coil later Motronic system 5 6 Engine electrical systems connect the ohmmeter to coil terminal 1 and the centre tower On Motronic systems connect the ohmmeter to coil terminal 15 and the centre tower Compare the measured resistance with the values given in the Specifi cations in this Chapter 6 If the measured resistances are not close to those specified the coil is defective and should be renewed Note that the measured resistance will vary according to the temperature of the coil so don t rush to condemn the coil if the resistance is only a little way out 7 It is essential for proper ignition system operation that all coil terminals and wire leads be kept clean and dry 8 Refit the coil in its mounting and reconnect the wiring Refitting is the reverse of removal 10 Impulse generator and BN ignition control unit check X and renewal TCI system X 1 The impulse generator located the distributor and ignition control unit need to be tested in the event there is no spark at the Spark plugs Make sure the plug leads ignition coil and spark plugs are working properly see Sections 6 and
66. Chassis and wheel bearing grease is a heavy grease used where increased loads and friction are encountered such as for wheel bearings balljoints tie rod ends and universal joints High temperature wheel bearing grease is designed to withstand the extreme temperatures encountered by wheel bearings in disc brake equipped vehicles It usually contains molybdenum disulphide moly which is a dry type lubricant White grease is a heavy grease for metal to metal applications where water is a problem White grease stays soft at both low and high temperatures and will not wash off or dilute in the presence of water Assembly lube is a special extreme pressure lubricant usually containing moly used to lubricate high load parts such as main and rod bearings and cam lobes for initial start up of a new engine The assembly lube lubricates the parts without being Squeezed out or washed away until the engine oiling system begins to function Silicone lubricants are used to protect rubber plastic vinyl and nylon parts Graphite lubricants are used where oils cannot be used due to contamination problems such as in locks The dry graphite will lubricate metal parts while remaining uncontaminated by dirt water oil or acids It is electrically conductive and will not foul electrical contacts in locks such as the ignition switch Penetrating oils loosen and lubricate frozen rusted and corroded fasteners and prevent future rusting
67. Check and adjust pressures If you sometimes have to inflate your car s tyres to the higher pressures specified for maximum load or sustained high speed don t forget to reduce the pressures to normal afterwards Uneven Wear Front tyres may wear unevenly as a result of wheel misalignment Most tyre dealers and garages can check and adjust the wheel alignment or tracking for a modest charge Incorrect camber or castor Repair or renew suspension parts Malfunctioning suspension Repair or renew suspension parts Unbalanced wheel Balance tyres Incorrect toe setting Adjust front wheel alignment Note The feathered edge of the tread which typifies toe wear is best checked by feel Every 6000 miles 1 11 Every 6000 miles or 6 months whichever comes first ES X Warning Prolonged skin contact A with used engine oil is hazardous Use a barrier cream and wear gloves during this procedure Change out of oil soaked clothing immediately TW Frequent oil changes are the most important preventive HiNT maintenance procedures that can be done by the home mechanic As engine oil ages it becomes diluted and contaminated which leads to premature engine wear 6 Engine oil and filter change 1 Make sure that you have all the necessary tools before you begin this procedure see illustration You should also have plenty of rags newspapers handy for mopping up oil spills 6 1 These tools are requ
68. Have the ECU tested at a dealer service department or other specialist Faulty position sensor or flywheel or reference pin missing see Chapter 5 Engine difficult to start or fails to start when warm Probable cause Cold start injector leaking or operating continuously early Motronic system only Fuel pressure incorrect Insufficient residual fuel pressure Fuel leak s Coolant temperature sensor faulty or wiring problem Vapour lock in warm weather EVAP system faulty Faulty ECU Idle speed control system faulty Oxygen sensor faulty where applicable Engine misses and hesitates under load Probable cause Fuel injector clogged Fuel pressure incorrect Fuel leak s Engine maintenance Airflow meter flap door binding or stuck in open position Intake air leaks Throttle position sensor TPS incorrectly adjusted Engine idles too fast Probable cause Accelerator pedal cable or throttle valve binding Air leaking past throttle valve Engine has erratic idle speed Probable cause Idle air stabiliser valve faulty No power to the idle air stabiliser valve Idle speed control unit faulty Poor fuel economy Probable cause Cold start injector leaking early Motronic system only Oxygen sensor faulty where applicable Sticking handbrake binding brakes Tyre pressures low Corrective action Test cold start injector and thermotime switch see Section 19 Test fuel pressure see Section 3 Test fuel system hold pre
69. If there is no change in the pedal travel after holding the pedal for 30 seconds the servo is airtight Removal and refitting 5 Dismantling the vacuum servo requires Special tools and cannot be performed by the home mechanic If a problem develops it is recommended that a new unit be fitted 6 Remove the master cylinder as described in Section 7 7 Disconnect the vacuum hose from the brake servo 8 Working in the passenger compartment remove the glovebox and lower left hand trim panels 9 Remove the clip and clevis pin to disconnect the pushrod from the cross shaft lever right hand drive models or brake pedal HIa2 64 8 11 An exploded view of a typical servo pushrod assembly 1Boot 2Holder 4AAir filter 8 9 Disconnect the brake pedal return spring then remove the clip and clevis pin arrows to disconnect the pushrod from the brake pedal left hand drive models left hand drive models see illustration On left hand drive models also disconnect the brake pedal return spring 10 Remove the four mounting nuts see illustration and withdraw the servo unit from the engine compartment 11 Inspect the small foam filter see illustration inside the rubber boot on the pushrod If the filter is clogged it may affect the servo s performance To clean the filter wash it in a mild soapy solution If it s still dirty renew it 12 Refitting is the reverse of the removal procedure Tighten the brake
70. REFe7 REF REF 30 Preserving Our Motoring Heritage The M ode Duesenberg D erham Tourster Only eight of these magnificent cars were ever built this is the only example to be found outside the U nited States of America Almost every car you ve ever loved loathed or desired is gathered under one roof at the Haynes Motor Museum Over 300 immaculately presented cars and motorbikes represent every aspect of our motoring heritage from elegant reminders of bygone days such as the superb M odel J Duesenberg to curiosities like the bug eyed BMW Isetta There are also many old friends and flames Perhaps you remember the 1959 Ford Popular that you did your courting in The magnificent Red Collection is a spectacle of classic sports cars including AC Alfa Romeo Austin Healey Ferrari Lamborghini Maserati MG Riley Porsche and Triumph A Perfect Day Out Each and every vehicle at the Haynes Motor Museum has played its part in the history and culture of Motoring Today they make a wonderful spectacle and a great day out for all the family Bring the kids bring Mum and Dad but above all bring your camera to capture those golden memories for ever You will also find an impressive array of motoring memorabilia a comfortable 70 seat video cinema and one of the most extensive transport book shops in Britain The Pit Stop Cafe serves everything from a cup of tea to wholesome home made meals or if you prefer you can enjoy the
71. Remove the nut refit the old inner race refit the nut and tighten it once more until it bottoms against the splines Remove the nut remove the old inner race refit your piece of pipe refit the old inner race refit the nut and tighten it until it bottoms against the splines Remove the nut the old race and the pipe Refit the drive flange refit the nut and tighten it securely but don t attempt to tighten it to the final torque until the vehicle is lowered to the ground Refit the wheel and lower the vehicle to the ground before tightening the stub axle nut to the torque listed in this Chapter s Specifications 15 The remainder of refitting is the reverse of removal 15 14c Hold the stub axle flange with a large lever while tightening the nut p Jil a Ez 15 14a To refit the new bearing use a large socket or a piece of pipe with an outside diameter the same diameter as the outer race of the bearing don t apply force to the inner race and make sure the bearing is fully seated against the back of its bore 16 Steering system general information On 3 Series models the steering wheel and steering column are connected to a rack and pinion steering gear power assisted where applicable via a short universal joint shaft When the steering wheel is turned the steering column and universal joint turn a pinion gear shaft on top of the rack The pinion gear teeth mesh with the gear teeth o
72. See Chapter 6 Section 4 Check TPS adjustment see Chapter 6 Section 4 Check ignition timing see Chapter 5 Check vacuum advance system Check the fuel and drain the tank if necessary Have the ECU tested at a dealer service department or other specialist Engine difficult to start or fails to start when warm Probable cause Cold start injector leaking or operating continuously Fuel pressure incorrect Insufficient residual fuel pressure Fuel leak s Coolant temperature sensor faulty or wiring problem Vapour lock warm weather EVAP system faulty where applicable Incorrect ignition timing Faulty ECU Idle speed control system faulty Engine misses and hesitates under load Probable cause Fuel injector clogged or faulty Fuel pressure incorrect Fuel leak s Engine maintenance Airflow meter flap door binding or stuck in open position Intake air leaks Engine has erratic idle speed Probable cause Idle air stabiliser valve faulty No power to the idle air stabiliser valve Vacuum advance system faulty Idle speed control unit faulty Motronic fuel injection system Corrective action Test cold start injector and thermotime switch see Section 19 Test fuel pump s Renew if necessary see Section 3 Test residual fuel pressure Renew fuel pump or fuel accumulator as necessary see Section 18 Inspect fuel lines and fuel injectors for leaks Correct leaks as required see Chapter 4 Test coolant te
73. a leak which should be found and repaired before it becomes serious 18 Valve clearances check and adjustment Why Note This procedure does not apply to the M40 engine which has automatic adjusters 1 The valve clearances can be checked with the engine hot or cold but note that different values are specified depending on engine temperature If it is wished to check adjust the valve clearances with the engine hot if necessary start and run the engine until it reaches normal operating temperature then Shut it off Caution If the clearances are checked with the engine hot extra care must be taken to avoid burns 2 Remove the valve cover from the engine see Chapter 2A 3 Turn the engine as necessary until No 1 piston front is at Top Dead Centre TDC on the compression stroke see Chapter 2 4 Check the valve clearances for No 1 cylinder The valve clearances can be found in the Specifications Section at the beginning of this Chapter 5 The clearance is measured by inserting the specified size feeler gauge between the end of the valve stem and the rocker arm adjusting eccentric You should feel a slight amount of F 1 j E n di 4 y 3 a n Dd ium j 1 s 1 D 1 4 a L d 18 6 valve clearance is adjusted by turning the eccentric with a wire hook once the specified clearance is obtained tighten the locknut with a spanner then remove the feeler gauge
74. anti roll bar is attached to the control arms via connecting links and to the suspension subframe 3 Series models or the underbody 5 Series models The independent rear suspension system on 3 Series models see illustration features coil springs and telescopic shock absorbers The upper ends of the shock absorbers are attached to the body the lower ends are connected to trailing arms An anti roll bar is attached to the trailing arms via links and to the body with clamps The independent rear suspension system on 5 Series models see illustration uses coil over shock absorber units instead of separate shock absorbers and coil springs The upper ends are attached to the body the lower ends are connected to the trailing arms The rear suspension of 5 Series models is otherwise similar to that of 3 Series models two trailing arms connected by an anti roll bar The steering system consists of the steering wheel a steering column a universal joint shaft the steering gear the power id A 5 steering pump where fitted and the steering linkage which connects the steering gear to the steering arms On 3 Series models a rack and pinion steering gear is attached directly to the steering arms via the track rods and track rod ends On 5 Series models a recirculating ball steering box is connected to the steering arms via a Pitman arm a centre track rod the outer track rods and the track rod ends Ti LE
75. are available at car accessory shops and service stations and cost very little 1 9 4 22 The windscreen washer fluid reservoir is located in the right front corner of the engine compartment on most models 5 Tyreand tyre pressure checks 1 Periodic inspection of the tyres may save you the inconvenience of being stranded with a flat tyre It can also provide you with vital information regarding possible problems in the steering and suspension systems before major damage occurs 2 Tyres are equipped with bands that will appear when tread depth reaches 1 6 mm at which time the tyres can be considered worn out This represents the legal minimum tread depth most authorities recommend renewing any tyre on which the tread depth is 2 mm or less Tread wear can be monitored with a Simple inexpensive device known as a tread depth indicator see illustration 3 Note any abnormal tyre wear see illustration overleaf Tread pattern irregular ities such as cupping flat spots and more wear on one side than the other are indications of front end alignment and or wheel balance problems If any of these conditions are noted take the vehicle to a tyre specialist to correct the problem 4 Look closely for cuts punctures and embedded nails or tacks Sometimes after a nail has embedded itself in the tread a tyre will hold air pressure for a short time or may 5 4a If a slow puncture is suspected check the valve core first t
76. attach a piston ring compressor to the piston Leave the skirt protruding about 6 or 7 mm to guide the piston into the cylinder The rings must be compressed until they re flush with the piston 8 Rotate the crankshaft until the No 1 connecting rod journal is at BDC bottom dead centre Apply a coat of engine oil to the cylinder walls 9 With the mark or notch on top of the piston facing the front of the engine gently insert the piston connecting rod assembly into the No 1 cylinder bore and rest the bottom edge of the ring compressor on the engine block 10 Tap the top edge of the ring compressor to make sure it s contacting the block around its entire circumference 11 Gently tap on the top of the piston with the end of a wooden hammer handle see illustration while guiding the end of the connecting rod into place on the crankshaft journal Work slowly and if any resistance is felt as the piston enters the cylinder stop immediately Find out what s catching and fix it before proceeding Do not for any reason force the piston into the cylinder you might break a ring and or the piston TE piston rings may try to pop out of the ring HiNT compressor just before entering the cylinder bore so keep some downward pressure on the ring compressor 12 Once the piston connecting rod assembly is fitted the connecting rod big end bearing oil clearance must be checked before the rod is permanently bolted in place
77. bar see illustration Warning Don t attempt to loosen this nut with the vehicle on axle stands The force required to loosen the nut could topple the vehicle from the stands 9 Loosen the rear wheel bolts raise the rear of the vehicle again place it securely on axle stands and remove the wheel 10 Remove the brake caliper and the brake disc see Chapter 9 Hang the caliper out of the way with a piece of wire 11 Remove the drive flange nut Using a suitable puller remove the drive flange see illustration 12 Using a soft faced hammer drive the stub axle out of the bearing see illustration If the bearing inner race comes off with the stub 15 12 Using a soft faced hammer drive the stub axle out of the bearing 10 12 Suspension and steering systems 15 13a Remove the large circlip that retains the bearing in the housing axle it probably will use a puller to remove the race from the stub axle If you can t get the race off with a puller take the stub axle to an engineering works and have it pressed off 13 Remove the large circlip that retains the bearing in the bearing housing see illustration then drive the bearing out of the bearing housing with a large socket or a suitable piece of pipe see illustration 14 Refitting is basically a reversal of removal bearing in mind the following points a Fitthe new bearing using a large socket or a suitable piece of pipe with an outside diamete
78. bar bracket bolt arrowed 3 Series 4 Inspect and if necessary renew any worn or defective bolts washers bushes or links Refitting 5 Refitting is the reverse of removal Tighten all fasteners securely 13 Rear trailing arms 3 Series removal and refitting x EN x Removal 1 Loosen the wheel bolts then chock the front wheels Raise the rear of the vehicle and support it securely on axle stands Remove the wheel s 2 Remove the driveshaft see Chapter 8 or disconnect it from the final drive output flange 3 Disconnect the rear brake hose from the metal brake line at the bracket on the trailing arm see illustration Note For information on disconnecting brake hose to metal line connections see Chapter 9 Plug the line and hose to prevent dirt ingress and loss of brake fluid 4 Disconnect the handbrake cable Chapter 9 5 Disconnect the lower end of the shock see 13 3 Disconnect the rear brake hose middle arrow from the metal brake line fitting right arrow at this bracket on the trailing arm then plug the line and hose immediately the other arrow points to the nut for the inner pivot bolt A m KW am 12 3a A nut and bolt arrowed connect each rear anti roll bar link to the rear trailing arms 3 Series absorber from the trailing arm see Section 9 and lower the trailing arm 6 Remove the trailing arm pivot bolts see illustration and remove the trailing arm 7 Inspe
79. be removed and the heat sink cleaned off using 180 grit sandpaper Apply Curil K2 Bosch part number 81 22 9 243 A silicon dielectric compound can be used as a Substitute This treatment is very important for the long life of these expensive ignition parts Impulse generator Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 16 Disconnect the battery negative cable 17 Remove the distributor from the engine see Section 8 18 Using a pair of circlip pliers remove the circlip retaining the trigger wheel see illustration 19 Use two flat bladed screwdrivers positioned at opposite sides of the trigger wheel and carefully prise it up see illustration Note Push the screwdrivers in as far as possible without bending the trigger wheel Prise only on the strongest centre portion of the trigger wheel In the event the trigger wheel is bent it must be replaced with a new one Note Be sure not to lose the roll pin when lifting out the trigger wheel 20 Remove the mounting screws from the impulse generator electrical connector the vacuum diaphragm and the baseplate 21 Remov
80. block upside down 3 Remove the main bearing cap bolts and lift 24 6 Refitting a thrust main bearing note the flanges in the engine block bearing saddle out the caps Lay them out in the proper order to ensure correct refitting 4 If they re still in place remove the original bearing shells from the block and the main bearing caps Wipe the bearing surfaces of the block and caps with a clean lint free cloth They must be kept spotlessly clean Main bearing oil clearance check 5 Clean the back sides of the new main bearing shells and lay one in each main bearing saddle in the block If one of the bearing shells from each set has a large groove in it make sure the grooved shell is fitted in the block Lay the other bearing from each set in the corresponding main bearing cap Make sure the tab on the bearing shell fits into the recess in the block or cap Caution The oil holes in the block must line up with the oil holes in the bearing shell Do not hammer the bearing into place and don t nick or gouge the bearing faces No lubrication should be used at this time 6 The flanged thrust bearing must be fitted in the No bearing cap and saddle in the M 10 engine in the No 6 bearing cap and saddle in the M20 engine see illustration in the No 4 bearing cap and saddle in the M30 engine and in the No 4 bearing saddle only in the M40 engine 7 Clean the faces of the bearings in the block and the crankshaft main bearing j
81. by a BMW dealer or air conditioning specialist At the very least DO NOT dismantle any part of the system hoses compressor line fittings etc until after the system has been discharged by a qualified engineer Refer to the pre cautions given at the start of Section 12 Removal 1 Have the air conditioning discharged see Warning above 2 Remove the trim panel on the sides of the centre console see Chapter 11 3 Disconnect the electrical lead and remove the evaporator sensor system 4 Remove the evaporator cover exposing the refrigerant lines 5 Disconnect the refrigerant lines from the evaporator matrix 6 Remove the evaporator matrix from the case Refitting 7 Refitting is the reverse procedure of the removal 8 Have the system evacuated recharged and leak tested by the qualified engineer who discharged it Chapter 2 Part B 2B 1 General engine overhaul procedures Contents Compression check 3 Crankshaft inspection 19 Crankshaft refitting and main bearing oil clearance check 24 Crankshant removal aua acid dee 13 Crankshaft rear oil seal refitting 25 Cylinder head and components cleaning and inspection 9 Cylinder head dismantling 8 Cylinder head reassembly 11 Cynder NON
82. check Warning Dust produced by lining wear and deposited on brake components may contain asbestos which is hazardous to your health Do not blow it out with compressed air and don t inhale it Do not use petroleum based solvents to remove the dust Brake system cleaner or methylated spirit should be used to flush the dust into a drain pan After the brake components are wiped with a damp rag dispose of the contaminated rag s and the drain pan contents into a covered and labelled container Try to use asbestos free new parts whenever possible Note In addition to the specified intervals the brake system should be inspected each time the wheels are removed or a malfunction is indicated Because of the obvious safety con siderations the following brake system checks are some of the most important maintenance procedures you can perform on your vehicle of brake system problems 1 The disc brakes have built in electrical wear indicators which cause a warning light on the dash to come on when they re worn to the renewal point When the light comes on renew the pads immediately or expensive damage to the brake discs could result 2 Any of the following symptoms could indicate a potential brake system defect a Vehicle pulls to one side when the brake pedal is depressed b Brakes make squealing or dragging noises when applied c Brake pedal travel excessive 26 11 Look through the caliper inspect
83. connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 Remove the air cleaner assembly see Chapter 4 4 Disconnect the wiring from the distributor mark all wiring for position first if necessary and the HT lead from the coil see Chapter 5 5 Disconnect the lead from the coolant temperature sender unit see Chapter 3 6 Disconnect the fuel lines from the fuel rail or carburettor as applicable see Chapter 4 7 Drain the cooling system See Chapter 3 8 Clearly label then disconnect all other hoses from the throttle body intake manifold carburettor and cylinder head as applicable 9 Disconnect the throttle cable from the throttle linkage or carburettor see Chapter 4 10 Disconnect the exhaust manifold from the cylinder head see Section 6 Depending on the engine type It may not be necessary to disconnect the manifold from the exhaust pipe however on right hand drive models the steering column intermediate shaft may not allow the manifold to clear the studs on the cylinder head 11 Remove or disconnect any remaining hoses or lines from the intake manifold including the ignition advance vacuum line s and the coolant and heater hoses 12 On early carburettor models disconnect the wiring from the alternator and starter motor 13 Remove the intake manifold see Sec tion 5 Do not dismantle or remove any fuel injection sys
84. control Drive motor cruise control Bridge only for automatic transmission Clutch switch Wiring diagrams 12 17 m m m 20 27 H 12033 12 Typical cruise control system wiring diagram 12 18 Wiring diagrams BR BK C BR V t BR V t BR V t gt gt Ce 5 gt 34 4 mo m amp ffi gt c G t a N 2 33 x gt G fan Les y R W BK BR Y 45 OJ 43 BR Y HL eR Ww H 22034 I Typical wiring diagram for the central locking burglar alarm on board computer additional heater and digital clock 1 of 2 Wiring diagrams 12 19 zx c od gt BL BL Y 462 E BR 3 B08 4 gt gt gt 5 5255 55 oo T NN NN 6 60 dumm 68 67 64 62 FR 2166 BR BR d c c a a e m m x So 78 80 79 81 2 69 Tfh h oh mn d H 22034 51 4 444 84 1 85 LI 76 Typical wiring diagram for the central locking burglar alarm on board computer additional heater and digital clock 2 of 2 8 12 12 20 Wiring diagrams CO OQ C9 N Key to wiring diagram for the central locking burglar alarm on board computer additional heater and digital clock Description Plug rear section to centre section Connection
85. coolant temperature reaches approximately 462 C Check this valve to make sure that vacuum is controlled at the proper temperatures The valve is usually located in the intake manifold near the thermo time switch and the coolant temperature sensor 5 Disconnect the small vacuum hose from the purge valve and apply vacuum with a hand held vacuum pump The purge valve should be open and air should be able to pass through an 6 8 When the ignition is switched on there should be a distinct click from the purge valve 6 If the test results are unsatisfactory renew the purge valve Electrically operated purge valve 7 Disconnect any lines from the purge valve and without disconnecting the electrical connector place it in a convenient spot for testing 8 Check that the valve makes a click sound as the ignition is switched on see illustration 9 f the valve does not click disconnect the valve connector and check for power to the valve using a test light or a voltmeter see illustration 10 If battery voltage is present but the valve does not work renew it If there is no voltage present check the Motronic control unit and the wiring Canister 11 Mark all the hoses for position then detach them from the canister 12 Slide the canister out of its mounting clip 6 9 Check for battery voltage at the electrical connector to the purge valve 6 6 Engine management and emission control sys
86. cylinder head servicing procedures On the M40 engine remove the rubber O ring from the groove in the top of the oil pump front end cover housing Refitting 21 The mating surfaces of the cylinder head and block must be perfectly clean when the head is refitted 22 Use a gasket scraper to remove all traces of carbon and old gasket material then clean the mating surfaces with a suitable solvent If there s oil on the mating surfaces when the head is refitted the gasket may not seal correctly and leaks could develop When working on the block stuff the cylinders with Clean rags to keep out debris Use a vacuum Cleaner to remove material that falls into the cylinders 23 Check the block and head mating surfaces for nicks deep scratches and other damage If the damage is slight it can be removed with a file if it s excessive machining may be the only alternative 24 Usea tap of the correct size to chase the threads in the head bolt holes then clean the holes with compressed air make sure that 2 2A 14 In car engine repair procedures 12 24 The cylinder head bolt holes should be cleaned and restored with a tap be sure to remove debris from the holes after this is done nothing including oil water etc remains in the holes see illustration 25 BMW recommend head bolts are renewed but if the old ones are re used mount each bolt in a vice and run a die down the threads to remove corrosion and restore the thr
87. described in paragraph 13 31 With the engine running the current draw should be 450 to 470 mA at 700 to 750 rpm 32 If the control current is not correct turn the adjusting screw until it is within the specified range Note Turn the idle air bypass screw clockwise to increase the current or anti clockwise to decrease the current 22 1 A typical exhaust system rubber mounting Renewal 33 Remove the electrical connector and the bracket from the idle air stabiliser valve Remove the valve disconnecting the hoses 34 Refitting is the reverse of removal 22 Exhaust system servicing general information Warning Inspect or repair exhaust system components only when the system is completely cool When working under the vehicle make sure it is securely supported Silencer and pipes 1 The exhaust system consists of the exhaust manifold catalytic converter silencers and all connecting pipes brackets mountings see illustration and clamps The exhaust system is attached to the body with brackets and rubber mountings If any of the parts are improperly fitted excessive noise and vibration may be transmitted to the body 2 Inspect the exhaust system regularly Look for any damaged or bent parts open seams holes loose connections excessive corrosion or other defects which could allow exhaust fumes to enter the vehicle Generally deteriorated exhaust system components cannot be satisfactorily repaired
88. dowels are used for component location Where a gasket is used between the mating faces of two components a new must be fitted on reassembly fit it dry unless otherwise Stated in the repair procedure Make sure that the mating faces are clean and dry with all traces of old gasket removed When cleaning a joint face use a tool which is unlikely to score or damage the face and remove any burrs or nicks with an oilstone or fine file Make sure that tapped holes are cleaned with a pipe cleaner and keep them free of jointing compound if this is being used unless specifically instructed otherwise Ensure that all orifices channels or pipes are clear and blow through them preferably using compressed air Oil seals Oil seals can be removed by levering them out with a wide flat bladed screwdriver or Similar implement Alternatively a number of self tapping screws may be screwed into the seal and these used as a purchase for pliers or some similar device in order to pull the seal free Whenever an oil seal is removed from its working location either individually or as part of an assembly it should be renewed The very fine sealing lip of the seal is easily damaged and will not seal if the surface it contacts is not completely clean and free from scratches nicks or grooves If the original sealing surface of the component cannot be restored and the manufacturer has not made provision for slight relocation of the seal r
89. down test performed by a garage This test will pinpoint exactly where the leakage is occurring and how severe it is 4 Engine removal methods and precautions If you ve decided that an engine must be removed for overhaul or major repair work several preliminary steps should be taken Locating a suitable place to work is extremely important Adequate work space along with storage space for the vehicle will be needed If a workshop or garage isn t available at the very least a flat level clean work surface made of concrete or asphalt is required Cleaning the engine compartment and engine before beginning the removal procedure will help keep tools clean and organised An engine hoist or A frame will also be necessary Make sure the equipment is rated in excess of the combined weight of the engine and accessories Safety is of primary importance considering the potential hazards involved in lifting the engine out of the vehicle If the engine is being removed by a novice a helper should be available Advice and aid from someone more experienced would also be helpful There are many instances when person cannot simultaneously perform all of the operations required when lifting the engine out of the vehicle Plan the operation ahead of time Arrange for or obtain all the tools and equipment you ll need prior to beginning the job Some of the equipment necessary to perform engine removal and refitting safely and with r
90. effects of a slight mis match in paint colours Bodywork fittings eg chrome strips door handles etc will also need to be masked off Use genuine masking tape and several thicknesses of newspaper for the masking operations Before commencing to spray agitate the aerosol can thoroughly then spray a test area an old tin or similar until the technique is mastered Cover the repair area with a thick coat of primer the thickness should be built up using several thin layers of paint rather than one thick one Using 400 grade wet and dry paper rub down the surface of the primer until it is really smooth While doing this the work area should be thoroughly doused with water and the wet and dry paper periodically rinsed in water Allow to dry before spraying on more paint Spray on the top coat again building up the thickness by using several thin layers of paint Start spraying at one edge of the repair area and then using a side to side motion work until the whole repair area and about 2 inches of the surrounding original paintwork is covered Remove all masking material 10 to 15 minutes after spraying on the final coat of paint Allow the new paint at least two weeks to harden then using a paintwork renovator or a very fine cutting paste blend the edges of the paint into the existing paintwork Finally apply wax polish Plastic components With the use of more and more plastic body components by the vehicle manufactu
91. engine 7 7 Place a socket and ratchet on the centre bolt to keep the pulley stationary and use another socket and ratchet to remove the smaller bolts attaching the pulley to the vibration damper cover remove the vibration damper hub by locking the crankshaft in position and loosening the large centre bolt Since the bolt is on very tight you ll need to use an extension bar and socket to break it loose On M30 engines BMW recommends using a 3 4 inch drive socket and extension bar since the bolt is extremely tight on these engines To lock the crankshaft in place while the bolt is being loosened use BMW Special tool No 11 2 100 or equivalent 9 On the M10 engine if the special tool listed in the previous paragraph is not available you may try locking the crankshaft by removing the flywheel driveplate inspection cover and jamming a wide bladed screwdriver into the ring gear teeth On the M30 engine since the bolt is so extremely tight we don t recommend substitute methods Use the correct tool On the M10 engine after the centre bolt is removed it will probably be necessary to use a jaw type puller to pull the vibration damper off the crankshaft Position the jaws behind the inner pulley groove and tighten the puller centre bolt very slowly checking the pulley to make sure it does not get bent or otherwise damaged by the puller If the pulley seems to be sticking on the crankshaft it HiNT may help
92. engine oil into the housing Refit the rotors and turn them to spread the oil around 7 i z 14 24a Measuring the clearance between the oil pump body and the outer rotor M40 engine 2A 2 18 In car engine repair procedures 14 24b Measuring the clearance between the oil pump outer and inner rotors M40 engine 26 Refit the cover plate and tighten the bolts to the specified torque 27 To check the pressure relief valve extract the circlip and remove the sleeve spring and piston Check that the length of the spring is as given in the Specifications see illustrations Reassemble the pressure relief valve using a reversal of the dismantling procedure Refitting M10 M20 and M30 engines 28 Make sure the mounting surfaces are clean then insert the pump into the engine block recess Refit the bolts and tighten them to the torque specified at the beginning of this Chapter 29 Refitting is the reverse of removal 14 27e Checking the length of the pressure relief valve spring M40 engine 14 27a Extract the circlip from the oil pump M4O engine 40 engines 30 Clean the mating surfaces then refit the front end cover and oil pump to the cylinder block together with a new gasket see illustration Tighten the bolts to the specified torque Note that there are two sizes of bolts and they have different torque settings 31 Fit the spacer ring on the front of the cranksh
93. exposed inside area of the sump with a rag then clean all traces of old gasket material off the area where the gasket was removed Attach the new gasket piece to the Sump with contact cement type gasket adhesive then apply RTV type sealant as described at the beginning of this paragraph 9 Coat both sides of the new retainer gasket with RTV type gasket sealant then attach the gasket to the seal retainer Fit the seal retainer to the rear of the engine then refit the bolts and tighten them evenly to the torque listed in this Chapter s Specifications Work from bolt to bolt in a criss cross pattern to be sure they re tightened evenly Note 1 Tighten the retainer to block bolts first then tighten the Sump to retainer bolts Note 2 After applying RTV type sealant reassembly must be dE C 16 7 Drive the new seal into the retainer with a block of wood ora section of pipe if you have one large enough make sure the seal enters the retainer bore squarely 16 6 After removing the retainer from the block support it on two wood blocks and drive out the old seal with a punch and hammer completed in about 10 minutes so the RTV won t prematurely harden 10 Refit the flywheel driveplate see Sec tion 15 11 Refit the transmission on vehicles with manual transmission see Chapter 7A on vehicles with automatic transmission see Chapter 7B 17 Engine mountings check and renewal 1 Engine mountings
94. fittings securely and the mounting nuts to the torque listed in this Chapter s Specifications 17 Fill the master cylinder reservoir with fluid then bleed the master cylinder only if the cylinder has not already been bled and the brake system as described in Section 16 18 To bleed the cylinder on the vehicle have an assistant pump the brake pedal several 8 10 Remove the four mounting nuts arrows and withdraw the servo unit from the engine compartment left hand drive model shown times and then hold the pedal to the floor Loosen the fitting nut to allow air and fluid to escape then tighten the nut Repeat this procedure on both fittings until the fluid is clear of air bubbles Test the operation of the brake system carefully before returning the vehicle to normal service 8 Brake vacuum servo check removal and refitting Operating check 1 Depress the brake pedal several times with the engine off until there is no change in the pedal travel 2 Depress and hold the pedal then start the engine If the pedal goes down slightly operation is normal Airtightness check 3 Start the engine and turn it off after one or two minutes Depress the brake pedal several times slowly If the pedal goes down further the first time but gradually rises after the second or third depression the servo is airtight 4 Depress the brake pedal while the engine is running then stop the engine with the pedal depressed
95. fluid is an effective paint stripper and will attack HiNT plastics if any is spilt wash it off immediately with copious amounts of water Note Bleeding the hydraulic system is necessary to remove any air which has entered the system during removal and refitting of a hose line caliper or master cylinder 1 It will probably be necessary to bleed the system at all four brakes if air has entered the system due to low fluid level or if the brake lines have been disconnected at the master cylinder 2 Ifa brake line was disconnected at only one wheel then only that caliper or wheel cylinder need be bled 3 If a brake line is disconnected at a fitting located between the master cylinder and any of the brakes that part of the system served by the disconnected line must be bled 4 Bleed the right rear the left rear the right front and the left front brake in that order when the entire system is involved 5 Remove any residual vacuum from the brake servo by applying the brakes about 30 times with the engine off This will also relieve any pressure in the anti lock brake system where applicable 6 Remove the master cylinder reservoir cover and fill the reservoir with brake fluid Refit the cover Note Check the fluid level often during the bleeding operation and add fluid as necessary to prevent the fluid level from falling low enough to allow air into the master cylinder 7 Have an assistant on hand an empty clear p
96. for special equipment plug Connection for central lock control unit Central lock electronic control unit A pillar end plate Plug driver s door wire to rear section Plug central lock connecting wire to driver s door wire 13 pin Piug central lock connecting wire to passenger s door wire Plug driver s door central lock wire to switch Central lock switch unblocking arrest driver s door on lock Connection for central lock motor to driver s door 6 pin Central lock motor driver s door Plug passenger s door wire to microswitch Microswitch passenger s door on lock Central lock motor passenger s door Central lock motor passenger s door Connection for central lock motor to boot lid 6 pin Central lock motor boot lid Connection for central lock motor to fuel filler flap 6 pin Central lock motor fuel filler flap Connection for central lock motor to left rear door 6 pin Central lock motor left rear door Connection for central lock motor to right door 6 pin Plug central lock connecting wire to right rear door 7 pin Plug central lock connecting wire to left rear door 7 pin Central lock motor right rear door Rear window heater switch Burglar alarm electronic control unit left of steering column Connection for burglar alarm electronic control unit 26 pin Connection for relay box 4 Connection for burglar alarm electronic control unit II 4 pin Plug 150 in main wire harness Li
97. from draining out Refitting 9 Refit the components in the reverse order of removal Be sure the rubber pads are in place under the condenser 10 Have the system evacuated recharged and leak tested by the qualified engineer who discharged it system 16 Air conditioner receiver drier removal and refitting Warning Due to the potential dangers associated with the system you are strongly advised to have any work on the air conditioning system carried out by a BMW dealer or air conditioning specialist At the very least DO NOT dismantle any part of the system hoses compressor line fittings etc until after the system has been discharged by a qualified engineer Refer to the precautions given at the start of Section 12 16 4 All models have the receiver drier located behind the right headlight although the configuration of lines and switches may vary 1 High pressure switch 2 Refrigerant lines 3 Low pressure switch 4 Electrical connector Removal 1 Have the system discharged see Warning above 2 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 Remove the windscreen washer fluid reser
98. from the vehicle For information concerning in vehicle engine repair as well as removal and refitting of the external components necessary for the overhaul see Chapter 2A and Section 7 of this Part The Specifications included in this Part are only those necessary for the inspection and overhaul procedures which follow Refer to Part A for additional Specifications 2 Engine overhaul general information It s not always easy to determine when or if an engine should be completely overhauled as a number of factors must be considered High mileage is not necessarily an indication that an overhaul is needed while low mileage doesn t preclude the need for an overhaul Frequency of servicing is probably the most important consideration An engine that s had regular and frequent oil and filter changes as well as other required maintenance will most likely give many thousands of miles of reliable service Conversely a neglected engine may require an overhaul very early in its life Excessive oil consumption is an indication that piston rings valve seals and or valve guides are in need of attention Make sure that oil leaks aren t responsible before deciding that the rings and or guides are worn Perform a cylinder compression check to determine the extent of the work required see Section 3 Check the oil pressure Unscrew the oil pressure sender unit and connect an pressure gauge in its place Measure the oil pressu
99. fuel Should be ejected from the outlet hose Fuel injection engines Note 1 The electric fuel pump is located inside the fuel tank on later models or beside the fuel tank on early models Early models are also equipped with a transfer pump located in the fuel tank The transfer pump feeds the main pump but can t generate the high pressure required by the system Note 2 The fuel pump relay on Motronic systems is activated by an earth signal from the Motronic control unit ECU The fuel pump operates for a few seconds when the ignition is first switched on and then continues to operate only when the engine is actually running um 2 4 Be sure to place a rag under and around any fuel line when disconnecting 4 4 Fuel and exhaust systems 3 6a On L J etronic systems use a jumper wire to bridge the terminals on the connector that correspond to the fuel pump relay pins 30 and 87b Note 3 The following checks assume the fuel filtrer is in good condition If you doubt the condition of your fuel filter renew it see Chapter 1 Note 4 In order to get accurate test results it is recommended that the fuel pressure be checked from both the main fuel pump and transfer pump where applicable Fuel pump transfer pump operational check 6 Bridge the connector terminals that correspond to the fuel pump relay pins 30 and 87b L Jetronic systems or 30 and 87 Motronic systems with a suitable jumper wire see illustrations
100. go out Faulty alternator or charging circuit Chapter 5 Alternator drivebelt defective or out of adjustment Chapter 1 Alternator voltage regulator inoperative Chapter 5 Ignition no charge warning light fails to come on when key is turned Warning light bulb defective Chapter 12 Fault in the printed circuit wiring or bulbholder Chapter 12 REF 12 Fault Finding Fuel system Excessive fuel consumption Dirty or clogged air filter element Chapter 1 Ignition timing incorrect Chapter 5 Emissions system not functioning properly Chapter 6 Fuel injection internal parts or carburettor jets excessively worn or damaged Chapter 4 Low tyre pressure or incorrect tyre size Chapter 1 Unsympathetic driving style or unfavourable conditions Cooling system Overheating Insufficient coolant in system Chapter 1 Water pump drivebelt defective or out of adjustment Chapter 1 Radiator matrix blocked or grille restricted Chapter 3 Thermostat faulty Chapter 3 Radiator cap not maintaining proper pressure Chapter 3 Ignition timing incorrect Chapter 5 Overcooling Faulty thermostat Chapter 3 External coolant leakage Deteriorated damaged hoses loose clamps Chapters 1 and 3 Water pump seal defective Chapters 1 and 3 Leakage from radiator matrix heater matrix or Chapter 3 Radiator engine block drain plugs or water jacket core plugs l
101. heater Ballast resistor in heater Thermoswitch parked car heater Heater motor Overheating switch parked car heater Heater plug for parked car heater Heater Fuel pump Plug on board computer to remote control Plug speed dependent loudness control Plug wire for cruise control Fuel level transmitter Speed transmitter Plug digital clock wire to digital clock 4 pin Plug digital clock wire to digital clock 2 pin Digital clock Wiring diagrams 12 21 yg A CQ Jono L2 1 wio AMG M E HA y8 A 8 88 53 85 15 J 938 J MIAO 1 ug 58 31 12 Typical headlight washer system wiring diagram 12 22 Wiring diagrams Key to headlight washer system wiring diagram Description Control unit for headlight cleaners on fluid reservoir Fuse overnight tail and parking lights Fuse horns wash wipe control unit and headlight cleaners Motor windscreen wipers Wiper switch Pump headlight cleaning system Pump intensive cleaning fluid Pump windscreen washing system Plug headlight cleaner wire to front section washer fluid pump Plug Headlight cleaner wire to front section II plug for headlight cleaners Plug centre section to front section 7 pin Plug for wiper motor Plug centre section to wiper switch Motor windscreen wipers Motor l
102. in Ib in Kilopascals kPa Millibar mbar Millibar mbar Millibar mbar Millibar mbar Millimetres of mercury mmHg Inches of water 0 Pounds force inches lbf in Ib in Pounds force inches lbf in Ib in Pounds force inches lbf in Ib in Pounds force feet Ibf ft Ib ft Pounds force feet Ibf ft Ib ft Newton metres Nm Horsepower hp Miles per hour miles hr mph Miles per gallon mpg tis common practice to convert from miles per gallon mpg to litres 100 kilometres 100 where mpg x 1 100 km 282 Temperature Degrees Fahrenheit x 1 8 32 Degrees Celsius Degrees Centigrade C F 32 x 0 56 REF rereig Automotive chemicals and lubricants A number of automotive chemicals and lubricants are available for use during vehicle maintenance and repair They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber plastic and vinyl Cleaners Carburettor cleaner and choke cleaner is a strong solvent for gum varnish and carbon Most carburettor cleaners leave a dry type lubricant film which will not harden or gum up Because of this film it is not recommended for use electrical components Brake system cleaner is used to remove grease and brake fluid from the brake system where clean surfaces absolutely necessary It leaves no residue and often eliminates brake squeal
103. in this case or the tyres will effectively be under inflated when cold 8 Unscrew the valve cap protruding from the wheel or hubcap and push the gauge firmly onto the valve stem see illustration Note the reading on the gauge and compare the 5 8 To extend the life of the tyres check the air pressure at least once a week with an accurate gauge don t forget the spare figure to the recommended tyre pressures Shown in the Specifications listed at the beginning of this Chapter Be sure to refit the valve cap to keep dirt and moisture out of the valve stem mechanism Check all four tyres and if necessary add enough air to bring them to the recommended pressure 9 Don t forget to keep the spare tyre inflated to the specified pressure Tyre tread wear patterns Shoulder Wear Underinflation wear on both sides Under inflation will cause overheating of the tyre because the tyre will flex too much and the tread will not sit correctly on the road Surface This will cause a loss of grip and excessive wear not to mention the danger of sudden tyre failure due to heat build up Check and adjust pressures Incorrect wheel camber wear on one side Repair or renew suspension parts Hard cornering Reduce speed Centre Wear Overinflation Over inflation will cause rapid wear of the centre part of the tyre tread coupled with reduced grip harsher ride and the danger of shock damage occurring in the tyre casing
104. injection system 4 14 4 19 Language display 0 7 Latch 1198 Leaks 0 10 7B 3 REF 12 REF 13 Locknuts locktabs and washers REF 8 Locks 11 4 1198 Lubricants REF 18 M Main bearings 2B 17 2B 19 Manifolds 2A 4 2 6 Manual transmission 7A 1 et seq Manual transmission fault finding REF 13 Manual transmission oil 193 1 19 1 25 Master cylinder 8 3 9 9 Mechanical fan 3 4 3 5 Mirrors 11 8 REF 1 Misfire REF 11 Mixture REF e4 test checks REFel et seq Motronic engine management system 6 1 Motronic fuel injection system 4 14 4 19 Mountings 2 19 7 3 Oil differential 1 19 1 26 Oil engine 1 3 1 7 1 11 Oil final drive 1 3 Oil manual transmission 1 3 1 19 1 25 Oil filter 1 11 1 12 Oil pump 2 16 Oil seals 2 12 2 13 2A 19 2B 20 7 2 7B 5 8 10 8 12 REF 8 Open circuit 12 2 Output shaft 7A 2 7B 5 Overcooling REF 12 Overheating REF 12 Oxygen sensor 6 2 P Pads 9 2 9 3 Pedals 8 3 9 13 Pinion oil 8 12 Pinking REF 11 Piston rings 2B 18 Pistons 2B 12 2B 16 2B 21 Plastic components 1193 Poisonous or irritant substances 0 5 Position sensors 5 8 Positive crankcase ventilation PCV system 6 4 Power steering 1 14 10 15 10 16 Power steering fluid 1 12 Propeller shaft 8 2 8 6 8 8 Pulse sensor 5 8 Purge valve 6 5 R
105. is possible for the oil to drain out of the hydraulic tappets This would render the tappets unserviceable and damage could possibly occur to the engine when it is next started up 5 Engine removal and refitting BN x Caution If the radio in your A vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Relieve the fuel system pressure see Chapter 4 then disconnect the negative cable from the battery 2 Cover the wings and front panel and remove the bonnet see Chapter 11 Special pads are available to protect the wings but an old bedspread or blanket will also work 3 Remove the air cleaner housing and intake ducts see Chapter 4 4 Drain the cooling system see Chapter 1 5 Label the vacuum lines emissions system hoses wiring connectors earth straps and fuel lines to ensure correct refitting then 2 2B 6 General engine overhaul procedures 5 5 Label each wire before unplugging the connector detach them Pieces of masking tape with numbers or letters written on them work well see illustration TEWAT If there s any possibility of confusion make a sketch of HiNT the engine compartment and clearly label the lines hoses and wires 6 Label and de
106. is included in this Chapter s Specifi cations Where there might be difficulty in inserting the spark plugs into the spark plug holes or the possibility of cross threading them into the head a short piece of rubber or plastic tubing can be fitted over the end of the spark plug The flexible tubing will act as a universal joint to help align the plug with the plug hole and should the plug begin to cross thread the hose will slip on the spark plug preventing thread damage Every 12 000 miles 14 7 Use a socket spanner with an extension to unscrew the spark plugs 10 Before pushing the HT lead onto the end of the plug inspect it as outlined in Section 15 11 Attach the HT lead to the new spark plug again using a twisting motion on the connector until it is firmly seated on the spark plug 12 Follow the above procedure for the remaining spark plugs renewing them one at a time to prevent mixing up the spark plug HT leads 15 Spark plug HT leads distributor cap and rotor check and renewal 1 The spark plug HT leads should be checked at the recommended intervals and whenever new spark plugs are fitted in the engine 2 Begin this procedure by making a visual check of the spark plug HT leads while the engine is running In a darkened garage make Sure there is ventilation start the engine and observe each HT lead Be careful not to come into contact with any moving engine parts If there is a break in the w
107. it and remove it from the door 7 Refitting is the reverse of removal Rear door 8 Carry out the operations described in paragraphs 1 to 5 3 Series models 9 Disengage the glass from the front guide roller and prise out the rubber window guides 10 Remove the door handle screws and allow the handle assembly to hang out of the Way 11 Remove the rear window frame bolts push the frame into the door and remove the window glass 12 Refitting is the reverse of removal 5 Series models 13 Loosen the rear window guide mounting bolt 14 Detach the glass from the front guide roller disengage the glass from the guide rails then slide the glass to the rear and remove by lifting from above 15 The fixed glass can be removed by removing the guide rail bolts then pulling the rail down to the rear and detaching the glass 16 Refitting is the reverse of removal The rear window glass can be adjusted by loosening the adjustment bolts then raising the glass to within one inch of the top of the door opening Adjust the glass to opening gap evenly then tighten the bolts securely 17 Door window regulator x removal and refitting x Removal 1 Remove the door window glass Sec tion 16 2 Remove the securing bolts or nuts and lift the window regulator assembly out of the door withdraw the regulator mechanism through the access hole On models with electric windows unplug the electrical connector Re
108. it securely on axle Stands Remove the rear wheels Remove the brake discs See Section 5 Work on only one side at a time so you can use the other side as a reference during reassembly and to avoid mixing up parts 7 Remove the shoe return and hold down Springs see illustrations 8 Remove the shoes see illustration 9 Refitting is the reverse of removal When you re done the actuator should be properly seated between the two shoes as shown see illustration 10 After refitting the brake disc adjust the handbrake shoes Temporarily refit two wheel bolts turn the adjuster see illustration 5 6d and expand the shoes until the disc locks 12 7b Remove the upper shoe return spring 12 7 Remove the shoe hold down springs then back off the adjuster until the shoes don t drag See Section 11 Refit the wheel bolts and tighten them to the torque given in Chapter 1 Specifications 13 Brake pedal adjustment Note You should always adjust brake pedal height after the master cylinder or brake servo has been removed or renewed You should also adjust the stop light switch see Sec tion 14 1 Measure the distance between the lower edge of the brake pedal footpad ie the edge furthest from the bulkhead and the bulkhead see illustration and compare your measurement with the dimension listed in this Chapter s Specifications If it s not as listed loosen the locknut on the pushrod and rotate amp
109. it with a piece of an old timing belt toothed side engaging the sprocket teeth or 10 11b The BMW camshaft holding tool in position on the M40 engine a piece of leather then hold the sprocket using a strap spanner If a strap spanner is not available clamp the ends of the piece of belt or leather tightly together with a pair of grips Before loosening the bolt make sure you have the necessary tool for positioning the camshaft as described in the following paragraph see illustration Caution Do not use the timing belt you re planning to refit to hold the sprocket Also be sure to hold the camshaft sprocket very steady because if it moves more than a few degrees the valves could hit the pistons Note On the M40 engine the sprocket is not directly located on the camshaft with a key as the groove in the end of the camshaft allows the sprocket to move several degrees in either direction The retaining bolt locks the sprocket onto a taper after positioning the camshaft with a special tool 11 The BMW tool for positioning the camshaft on the M40 engine consists of a metal plate which locates over the square lug near the No 1 cylinder lobes on the camshaft the valve cover must be removed first see illustrations If the BMW tool cannot be obtained a home made tool should be fabricated out of metal plate The tool must be made to hold the square lug on the camshaft at right angles to the upper face of the cylinder head i
110. large picnic area nestled in the beautiful rural surroundings of Somerset gt John Haynes O B E Founder and Chairman of the museum at the wheel of a Haynes Light 12 Graham Hill s Lola Cosworth Formula 1 car next to a 1934 Riley Sports A303 ANDOVER gt HAYNES PUBLISHING 4 The Museum is situated on the A359 Yeovil to Frome road at Sparkford just off the A303 in Somerset It is about 40 miles south of Bristol and 25 minutes drive from the M5 intersection at Taunton Open 9 30am 5 30pm 10 00am 4 00pm Winter 7 days a week except Christmas Day Boxing Day and N ew Years Day Special rates available for schools coach parties and outings Charitable Trust No 292048 Contents LIVING WITH YOUR BMW Introduction Safety First Anti theft audio system Instrument panel language display Roadside Repairs J acking towing and wheel changing J ump starting Identifying leaks ROUTINE MAINTENANCE Routine Maintenance and Servicing Lubricants and fluids Maintenance schedule Weekly checks Every 6000 miles Every 12 000 miles Every 24 000 miles Every 60 000 miles Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page 0 4 0 6 0 7 0 8 0 9 0 10 1 1 193 1 4 1 7 1 11 1 16 1 23 1 26 REPAIRS amp OVERHAUL Engine and Associated Systems In car engine repair procedures General engine overhaul procedures Cooling heating a
111. lower the engine and tighten the mounting nuts or bolts see illustration Rubber preservative should be applied to the mountings to slow deterioration 6 On models with the M40 engine check the condition of the dampers on each mounting by disconnecting them and attempting to 17 6 Engine mounting damper the M40 engine compress and expand them see illustration If there is very little resistance to movement the dampers should be renewed Renewal 7 If the dampers on the M40 engine are to be renewed simply unscrew the bolts then fit the new dampers and tighten the bolts 8 To renew the mountings disconnect the battery negative cable then raise the vehicle and support it securely on axle stands if you haven t already done so Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code 17 10 To remove an engine mounting first remove the stud nut arrowed M30 engine shown others similar before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 9 Support the engine as described in paragraph 3 10 Remove the large bracket to mounting nut see illustration Raise the engine slightly then remove the lower mounting to frame bolts nuts and detach the mounting 11 Refitting of the mountings i
112. m and remove the relevant handbrake cable adjusting nut both arrowed 10 4b then remove the pin securing the cable to the inner cam and remove the inner cam Braking system 9 11 There are two cables one for each rear wheel and a nut for each cable On some models it may be necessary to remove the centre console completely for access 2 Raise the vehicle and support it securely on axle stands 3 Remove the rear brake drum see Section 6 or rear brake disc see Section 5 4 rear drum models unhook the handbrake cable from the lever on the rear brake shoe see Section 6 On rear disc models remove the handbrake shoes and the actuator see Section 12 and unhook the handbrake cable from the actuator see illustrations 5 On rear drum models pull the cable and cable conduit tube out of the back of the brake backplate then detach the cable conduit from the cable clips on the back of the trailing arm it s easier to pull out the old cable and fit the new cable with the conduit straight instead of curved On rear disc models it s unnecessary to detach the cable conduit from the brake backplate but it s a good idea to detach the conduit from the clips and guides securing it to the trailing arm to take some of the bend out of the conduit 6 Working from the wheel end of the cable conduit pull the cable out of the conduit see illustration 7 Lubricate the new cable with multi purpose grease then ins
113. models are equipped with an updated version of the Motronic system this system is easily distinguished from the earlier system by the absence of a cold start injector The electric fuel pump is located beneath the rear of the vehicle or inside the fuel tank The fuel pump relay on Motronic systems is activated from a earth signal from the Motronic control unit ECU The fuel pump operates for a few seconds when the ignition is first switched on and it continues to operate only when the engine is actually running Air intake system The air intake system consists of the air filter housing the airflow meter and throttle body fuel injection models and the intake manifold All components except the intake manifold are covered in this Chapter for information on removing and refitting the intake manifold refer to Chapter 2A The throttle valve inside the throttle body or carburettor is actuated by the accelerator cable When you depress the accelerator pedal the throttle plate opens and airflow through the intake system increases On fuel injection systems a flap inside the airflow meter opens wider as the airflow increases A throttle position switch attached to the pivot shaft of the flap detects the angle of the flap how much it s open and converts this to a voltage signal which it sends to the computer Fuel system On carburettor models the fuel pump Supplies fuel under pressure to the carburettor A needle valv
114. of plastic used At one time the use of a universal paint was not possible owing to the complex range of plastics encountered in body component applications Standard paints generally speaking will not bond to plastic or rubber satisfactorily However it is now possible to obtain a plastic body parts finishing kit which consists of a pre primer treatment a primer and coloured top coat Full instructions are normally supplied with a kit but basically the method of use is to first apply the pre primer to the component concerned and allow it to dry for up to 30 minutes Then the primer is applied and left to dry for about an hour before finally applying the special coloured top coat The result is a correctly coloured component where the paint will flex with the plastic or rubber a property that standard paint does not normally possess 6 Bodywork repair major damage HERE 1 Major damage must be repaired by a qualified bodywork repair specialist or preferably by a BMW dealer Specialised equipment is required to do the job properly 2 f the damage is extensive the bodyshell must be checked for proper alignment or the vehicle s handling characteristics may be adversely affected and other components may wear at an accelerated rate 3 Due to the fact that all of the major body components bonnet wings etc are separate units any seriously damaged components should be replaced with new ones rather than repaired
115. on the engine if it s mounted on a portable engine stand A stand can often be hired quite cheaply from a tool hire shop Before the engine is mounted on a stand the flywheel driveplate should be removed from the engine 2 If a stand isn t available it s possible to dismantle the engine with it blocked up on the floor Be extra careful not to tip or drop the engine when working without a stand 3 If you re going to obtain a rebuilt engine all the external components listed below must come off first to be transferred to the new engine if applicable This is also the case if you re doing a complete engine overhaul yourself Note When removing the external components from the engine pay close attention to details that may be helpful or important during refitting Note the fitted position of gaskets seals spacers pins brackets washers bolts and other small items Alternator and brackets Emissions control components Distributor HT leads and spark plugs Thermostat and housing cover Water pump Fuel injection carburettor and fuel system components Intake and exhaust manifolds Oil filter and oil pressure sending unit Engine mounting brackets see illustration Clutch and flywheel driveplate Engine rear plate where applicable 4 If you re obtaining a short block which consists of the engine block crankshaft pistons and connecting rods all assembled then the cylinder head sump and oil pump will have to be removed
116. one pressed on Timing chain 8 The chain should be renewed if the sprockets are worn or if the chain is loose indicated by excessive noise in operation It s a good idea to renew the chain anyway if the engine is stripped down for overhaul The rollers on a very badly worn chain may be slightly grooved To avoid future problems if there s any doubt at all about the chain s condition renew it Chain rail and tensioner 9 Inspect the chain guide rail and tensioner rail for deep grooves caused by chain contact Renew them if they are excessively worn The rails can be renewed after removing the circlips with a pointed tool or needle nose pliers see illustration 10 Shake the tensioner plunger and listen for a rattling sound from the check ball If you can t hear the ball rattling renew the plunger 11 To further check the tensioner plunger blow through it first from the closed end then from the slotted guide end No air should flow through the plunger when you blow through the closed end and air should flow through it freely when you blow through the slotted end If the tensioner fails either test renew it Refitting 12 Refit the tensioner rail and chain guide rail if removed 13 Temporarily refit the lower timing chain cover and vibration damper so you can check the crankshaft timing marks Once you ve verified the TDC marks are aligned remove the damper and cover 14 Loop the timing chain over the crankshaft s
117. or freezing Heat sink grease is a special electrically non conductive grease that is used for mounting electronic ignition modules where it is essential that heat is transferred away from the module Sealants RTV sealant is one of the most widely used gasket compounds Made from silicone RTV is air curing it seals bonds waterproofs fills surface irregularities remains flexible doesn t shrink is relatively easy to remove and is used as a supplementary sealer with almost all low and medium temperature gaskets Anaerobic sealant is much like RTV in that it can be used either to seal gaskets or to form gaskets by itself It remains flexible is solvent resistant and fills surface imperfections The difference between an anaerobic sealant and an RTV type sealant is in the curing RTV cures when exposed to air while an anaerobic sealant cures only in the absence of air This means that an anaerobic sealant cures only after the assembly of parts sealing them together Thread and pipe sealant is used for sealing hydraulic and pneumatic fittings and vacuum lines It is usually made from a Teflon compound and comes in a spray a paint on liquid and as a wrap around tape Chemicals Anti seize compound prevents seizing chafing cold welding rust and corrosion in fasteners High temperature anti seize usually made with copper and graphite lubricants is used for exhaust system and exhaust manifold bolts Anaero
118. otherwise damage the bore in the housing or oil leaks could develop 4 Make sure the retainer is clean then apply a thin coat of engine oil to the outer edge of the new seal The seal must be pressed squarely into the housing bore so hammering it into place is not recommended At the very least use a block of wood as shown or a section of large diameter pipe see illustration If you don t have access to a press sandwich the housing and seal between two smooth pieces of wood and press the seal into place with the jaws of a large vice The pieces of wood must be thick enough to distribute the force evenly around the entire circumference of the seal Work Ii s 25 5 Lubricate the lip of the seal and bolt the retainer to the rear of the engine block Slowly and make sure the seal enters the bore Squarely 5 The seal lips must be lubricated with multi purpose grease or clean engine oil before the seal retainer is slipped over the crankshaft and bolted to the block see illustration Use a new gasket no sealant is required and make sure the dowel pins are in place before refitting the retainer 6 Tighten the retainer nuts screws a little at a time until they re all snug then tighten them to the torque listed in the Specifications in Chapter 2A 26 Pistons connecting rods N refitting and big end bearing oil clearance check h 1 Before refitting the piston connecting rod assemblies the cylinder
119. pH BR gt gt gt gt gt gt gt E gt a e E ec 25 20 26 15 17 5 23 22 16 21 4 13 8444 2 4 x ES e 5 x a N a 18 1 2 3 4 6 18 GR R GR BK 12 Typical wiring diagram for power seats with memory 2 of 2 12 12 30 Wiring diagrams H 22040 Typical wiring diagram for power seats without memory Key to wiring diagram for power seats without memory No Description 1 Plug connection with special equipment plug 2 Backrest 3 Seat forward backward 4 Headrest 5 Seat up down front 6 Seat up down rear 7 Plug switch for backrest seat control 8 Plug switch for headrest control 9 Plug switch for front rear seat up down control 10 Switch for power seats 11 Plug power seat wire to power seat electronic control unit 12 Electronic control unit for power seats below seats 13 Plug power seat drive to power seat electronic control unit 14 Plug power backrest and headrest wire to power seat electronic control unit 15 Plug power backrest and headrest wire to backrest motor 16 Plug power backrest and headrest wire to the headrest motor 17 Plug power seat wire on driver s side to wire on passenger s side 18 Motor seat up down front 19 Motor seat up down rear 20 Motor seat forward backward 21 Motor backrest 22 Motor headrest Key to radio wiring diagram 2 Description Speaker door right Speaker front right
120. renewing the anti roll bar itself or disconnecting the bar to renew the strut assembly on a 3 Series model disconnect it from the anti roll bar links see illustrations If you re renewing the strut assembly on a 5 Series model disconnect the anti roll bar link from the strut housing 3 On 3 Series models disconnect the left control arm rubber bush from the underbody see Section 3 4 Remove the bolts from the anti roll bar brackets which attach the anti roll bar to the subframe see illustration 5 Remove the anti roll bar from the vehicle Where necessary separate the anti roll bar from the strut bar bracket Refitting 6 Refitting is the reverse of the removal procedure Be sure to tighten all nuts and bolts to the torques listed in this Chapter s Specifications 3 4 Remove the two bolts arrowed securing the bush bracket to the underbody 2 2b On 5 Series models remove the nut arrowed securing the anti roll bar to the connecting link left side shown right side similar 3 Control arm 3 Series inspection removal and refitting and bush renewal Inspection 1 Raise the front end of the vehicle and Support it securely on axle stands 2 Grip the top and bottom of each balljoint with a large pair of water pump parrot jaw pliers and squeeze to check for free play Alternatively insert a lever or large screwdriver between the control arm and the subframe or strut housing If there
121. reverse of removal Crankshaft front seal M40 engines 28 Remove the timing belt and crankshaft sprocket see Section 10 29 Remove the Woodruff key from the groove in the end of the crankshaft 30 Note the fitted position of the oil seal then prise it out from the front cover using a screwdriver but take care not to damage the bore of the cover or the surface of the In car engine repair procedures 2A 13 crankshaft If the seal is tight drill two small holes in the metal end of the seal and use two self tapping screws to pull out the seal Make sure all remains of swarf are removed 31 Coat the outside diameter and lip of the new seal with multi purpose grease then drive it into the cover with a hammer and a Socket slightly smaller in diameter than the outside diameter of the seal Make sure the seal enters squarely 32 The remainder of refitting is the reverse of removal Note that it is recommended that the timing belt be renewed see Section 10 12 Cylinder head removal and refitting Removal 1 Relieve the fuel pressure on all fuel injection engines see Chapter 4 2 Disconnect the negative cable from the battery Where the battery is located in the engine compartment the battery may be removed completely see Chapter 5 Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after
122. rod end is refitted in the same position and unscrew the track rod end from the inner track rod 3 Loosen the clamp bolt that locks the track rod end to the inner track rod Measure the length of the track rod end or paint an alignment mark on the threads to ensure the track rod end is refitted in the same position see illustration Unscrew the track rod end from the inner track rod 4 Refitting is the reverse of removal Make Sure the mark you made on the threads of the track rod end is aligned correctly if applicable If you measured the track rod end make sure it is refitted to the same distance 5 Have the toe in checked and if necessary adjusted at a dealer service department or qualified garage 5 Series models 6 Measure the length of the track rod and record your measurement or paint an alignment mark on the threads to ensure the track rod end is refitted in the same position see illustration Loosen the clamp bolt 7 Use a balljoint separator or a puller to separate the track rod end from the steering arm see illustration 8 Unscrew the track rod end 9 Refitting is the reverse of removal Make sure you align the paint mark made on the threads of the track rod end if applicable If you measured the track rod end make sure it is refitted to the same distance 10 Have the toe in checked and if necessary adjusted at a dealer service department or qualified garage 18 Steering gear boots 3 Series ren
123. rotate the assembly out of the notches 4 18b On models with mounting nuts remove the nuts arrowed to release the assembly from the fuel tank an _ 4 18 On later Motronic systems first remove the fuel level sender unit 4 18d then pull the fuel pump straight up and out of the turret at the bottom of the fuel tank keep all the fuel lines intact 4 17a Transfer pump 1 and fuel level sender unit 2 electrical connectors on an early Motronic system unplug them Also disconnect the fuel inlet and return lines 18 On some models the assembly must be rotated anti clockwise to disengage the locking lugs from the fuel tank see illustration On other models the assembly is secured to the tank with nuts see illustration Carefully lift the assembly from the fuel tank see illustrations It may be necessary to twist the assembly slightly to get the float to clear the opening 19 On early models remove the transfer pump mounting screws and clamps and separate the transfer pump from the assembly 20 Refitting is the reverse of removal If the gasket between the fuel pump and fuel tank is dried cracked or damaged renew it Fuel level sender unit check and renewal 21 Remove the main fuel pump or transfer pump as described previously along with the fuel level sender unit 22 Connect an ohmmeter across the designated terminals and check for the FUEL GAUGE SENDING UN
124. rotor see illustrations 7 Remove the lower fan drivebelt pulley and vibration damper Secure the crankshaft pulley centre bolt while you loosen the outer pulley damper bolts see illustration 7 7 8 Remove the bolts nuts attaching the timing belt covers to the engine see illustration 9 Remove the upper cover first then the lower cover see illustrations Note The upper cover has two alignment sleeves in the top bolt positions Be sure these are in place upon reassembly 10 Refitting is the reverse of the removal procedure Tighten the cover bolts securely 10 Timing belt and sprockets removal inspection and refitting Note 1 This procedure applies to M20 and M40 engines Note 2 Before removing the camshaft sprocket on the M40 engine it is necessary to obtain a tool to hold the camshaft for the refitting procedure see paragraph 10 In car engine repair procedures 2A 9 9 6c 9 95 Removing the upper timing belt cover on the M40 engine Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the negative cable from the battery 2 Remove the timing belt covers see Sec tion 9 3
125. seal M10 and M30 engines 5 Remove the crankshaft pulley and vibration damper See Section 7 6 Carefully prise the old seal out of the cover with a large screwdriver Be very careful not to damage the seal bore or the crankshaft with the tool Wrap the tip of the screwdriver with a piece of tape to prevent damage 7 Clean the bore in the cover and coat the outer edge of the new seal with engine oil or multi purpose grease Also lubricate the lips of the seal with multi purpose grease Using a socket with an outside diameter slightly smaller than the outside diameter of the seal carefully drive the new Seal into place with a hammer see illustration If a socket isn t available a short section of large diameter pipe will work Check the seal after refitting to be sure the spring around the inside of the Seal lip didn t pop out of place 8 The remainder of refitting is the reverse of removal M20 and M40 timing belt engines Camshaft front seal M20 and M40 engines 9 Remove the timing belt and camshaft Sprocket See Section 10 10 On the M20 engine only remove the two screws and separate the camshaft seal housing from the cylinder head by pulling it as you rotate it back and forth 11 On the M20 engine only support the housing on two blocks of wood and drive the seal out of the housing from behind using a 11 7 The crankshaft front oil seal is pressed into the front of the lower timing chain cover cover
126. seldom require attention but broken or deteriorated mountings should be renewed immediately or the added strain placed on the driveline components may cause damage or wear Check 2 During the check the engine must be raised slightly to remove its weight from the mounts 3 Raise the vehicle and support it securely on axle stands then position a jack under the engine sump Place a large block of wood between the jack head and the sump then carefully raise the engine just enough to take its weight off the mounts Warning DO NOT place any part of your body under the engine when it s supported only by a jack 17 4 As engine mountings wear or age they should be inspected for cracking or separation from their metal plates 2A 2 20 In car engine repair procedures a 1 1 J E T E E AW zd Bh 1 1 i L E W 4 5 if Pi amp a p 4 L j 17 5 Lever gently between the block the engine mounting attachment point arrowed if there is movement tighten the bolts 4 Check the mountings to see if the rubber is cracked see illustration hardened or separated from the metal plates Sometimes the rubber will split right down the centre 5 Check for relative movement between the mounting plates and the engine or frame use a large screwdriver or lever to attempt to move the mountings If movement is noted
127. servo mounting nuts to the torque listed in this Chapter s Specifications Before you slide the boot into place over the servo pushrod air filter make sure the notches in the filter offset the notches in the damper by 180 degrees 13 On 3 Series models adjust the basic setting of the pushrod s threaded clevis until the dimension is correct see illustration When the basic setting is correct tighten the locknut then adjust the brake pedal travel and 8 13 On 3 Series models adjust dimension A the distance between the middle of the brake lever and the bulkhead firewall by loosening the locknut 1 at the pushrod clevis 2 and turning the threaded part of the pushrod until dimension A matches the dimension listed in this Chapter s Specifications When the basic setting is correct tighten the locknut then adjust the brake pedal height and the stop light switch the stop light switch see Section 13 Note On right hand drive models the brake pedal in on the right hand side of the vehicle and is connected to the left hand side by a cross Shaft The adjustment is carried out on the pushrod at the left hand side but the dimension is measured at the pedal on the right hand side 14 On 5 Series models adjust the brake pedal height and the stop light switch see Section 13 15 Refit the master cylinder see Section 7 and attach the vacuum hose 16 Carefully test the operation of the brakes before returning the vehicle
128. shrouds see Chapter 11 4 Where necessary remove the direction indicator headlight control switch see Sec tion 6 5 Detach the clips by inserting a small Screwdriver into the openings on the sides while pulling out on the switch see illustration 6 Unplug the electrical connector from the harness at the base of the steering column and remove the switch Refitting 7 Refitting is the reverse of removal 6 9 Cruise control switch removal 12 4 Body electrical systems ail a tm 7 5 Insert a screwdriver into the openings arrowed on each side of the switch to release the clip while pulling out 8 Radio removal and refitting gt gt x Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 The radios on most models are held in place by internal clips which are usually located at the sides or corners of the unit faceplate Removal requires a special tool which is inserted into the holes to release the clips so the radio can be pulled out These tools can be fabricated from heavy wire or are availa
129. system 3 2 3 7 3 8 3 9 3 10 Air filter 1 20 Air gap 5 7 Air intake system 4 2 4 14 Airflow meter 4 15 6 4 Alternator 5 10 Anti lock Braking system ABS 9 2 Anti roll bar 10 4 10 9 Anti theft audio system 0 7 Antifreeze 1 3 1 8 3 2 Asbestos 0 5 ATF 1 3 1 13 1 23 Automatic choke 4 13 Automatic transmission 7B 1 et seq Automatic transmission fault finding 7 4 REF 13 Automatic transmission fluid 1 3 1 13 1923 Backfire REF 11 Balljoints 10 7 Battery 0 5 1 16 5 2 Battery fault REF 11 Big end bearings 2B 17 2B 21 Bleeding brakes 9 14 Bleeding clutch 8 4 Bleeding power steering 10 16 Block 2B 14 2B 15 Blower motor 3 7 Body corrosion REFe4 Body electrical systems 12 1 et seq Bodywork and fittings 11 1 et seq Bonnet 11 4 Boot lid 11 6 Boots 8 9 10 13 Brake fluid 1 3 1 9 Brake lines and hoses 1 22 9 13 Braking system 1 22 9 1 et seq REF 1 REF 2 REF 3 Braking system fault finding REF 14 Bulbs 12 6 Bumpers 11 6 Burning 0 5 C Cables 4 9 5 2 7B 3 9 12 Calipers 9 4 Cam followers 2B 11 Camshaft 24 12 2B 11 Carburettor 4 10 4 11 Carpets 11 2 Catalytic converter 4 20 6 6 Central locking 12 8 Charging 1917 5 9 Chemicals REFe18 Choke 4 13 Clutch and driveline 8 1 et seq Clutch fault finding REF 12 Clutch fluid 1 3 1 9
130. the first few trips 29 Cooling system draining flushing and refilling Warning Do not allow antifreeze to come in contact with your skin or with the painted surfaces of the vehicle Rinse off spills immediately with plenty of water Antifreeze is highly toxic if ingested Never leave antifreeze lying around in an open container or in puddles on the floor children and pets are attracted by its sweet smell and may drink it Check with local authorities about disposing of used antifreeze Local collection centres may exist to see that antifreeze is disposed of safely 28 10b then remove the fluid filter from the transmission 28 6 Use a socket and extension to remove the bolts and brackets 1 Periodically the cooling system should be drained flushed and refilled This will restore the effectiveness of the antifreeze mixture and prevent formation of rust and corrosion which can impair the performance of the cooling system and cause engine damage When the cooling system is serviced all hoses and the radiator cap should be checked and renewed if necessary Draining 2 If the vehicle has just been driven wait several hours to allow the engine to cool down before beginning this procedure 3 Once the engine is completely cool remove the expansion tank cap or radiator cap If the cap must be removed while the engine is still warm unscrew it slowly and take adequate precautions to avoid scalding
131. the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Remove all door trim panel retaining screws and door pull armrest assemblies i n 13 4 Detach the circlip arrowed from the tapered end of the pin 3 On models with manual non electric windows remove the window regulator handle see illustration On models with electric windows prise off the control switch assembly and unplug it 4 Disengage the trim panel to door retaining clips Work around the outer edge until the panel is free 5 Once all of the clips are disengaged detach the trim panel unplug any electrical connectors and remove the trim panel from the vehicle 6 For access to the inner door carefully peel back the plastic water shield Refitting 7 Prior to refitting the door trim panel be sure to renew any clips in the panel which may have come out or got broken during the removal procedure 8 Plug in the electrical connectors where applicable and place the panel in position in the door Press the door panel into place until the clips are seated then refit the armrest door pulls Refit the window regulator handle where applicable 13 Door removal refitting and adjustment Removal 1 Remove the
132. the bonnet can be made by loosening the roller guide bolt nuts and moving the guide position until it Slides into the catch properly see illustration 4 10 12 Unscrew the hinge through bolts arrowed 10 19 Screw the bonnet stops in or out after making other adjustments 11 11 6 Bodywork and fittings 12 3 On models without electric windows prise off the window regulator handle trim piece for access to the retaining screw 19 After adjustment screw the stop pads in or out to support the bonnet in its new position see illustration 20 The bonnet mechanism should be lubricated periodically with grease to prevent sticking or jamming 11 Bumpers removal and refitting Removal 1 Detach the bumper cover if applicable and where necessary the front spoiler 2 Disconnect any wiring or other components that would interfere with bumper removal 3 Support the bumper with a jack or axle stand Alternatively have an assistant support the bumper as the bolts are removed 4 Remove the retaining bolts and detach the bumper Refitting 5 Refitting is a reversal of removal Tighten the retaining bolts securely then refit the bumper cover and any other components that were removed 12 Door trim panel removal and refitting Caution If the radio your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to
133. the excess with a clean syringe Refit the cap 7 If frequent topping up is needed check the power steering hoses and connections for leaks and wear see Section 10 8 Check the condition and tension of the drivebelt see Section 11 8 Automatic transmission fluid BN level check SS RN Caution The use of transmission fluid other than the type listed in this Chapter s Specifications could result in transmission malfunctions or failure l The automatic transmission fluid should be carefully maintained Low fluid level can lead to slipping or loss of drive while overfilling can cause foaming and loss of fluid Either condition can cause transmission damage 2 Since transmission fluid expands as it heats up the fluid level should only be checked when the transmission is warm at normal operating temperature If the vehicle has just been driven over 20 miles 32 km the transmission can be considered warm You can also check the fluid level when the transmission is cold If the vehicle has not been driven for over five hours and the fluid is about room temperature 20 C the transmission is cold However the fluid level is normally checked with the transmission warm to ensure accurate results Caution If the vehicle has just been driven for a long time at high speed or in city traffic in hot weather or if it has been pulling a trailer an accurate fluid level reading cannot be obtained Allow the trans mission to cool dow
134. the original piston rings removed from the pistons Note Always use new piston rings when the engine is reassembled 2 Using a piston ring refitting tool carefully remove the rings from the pistons Be careful not to nick or gouge the pistons in the process see illustration 3 Scrape all traces of carbon from the top of the piston A hand held wire brush or a piece of fine emery cloth can be used once the majority of the deposits have been scraped away Do not under any circumstances use a wire brush mounted in a drill motor to remove deposits from the pistons The piston material is soft and may be damaged by the wire brush 4 Use a piston ring groove cleaning tool to remove carbon deposits from the ring grooves Be very careful to remove only the 18 4 The piston ring grooves can be cleaned with a special tool as shown here carbon deposits don t remove any metal and do not nick or scratch the sides of the ring grooves see illustration If a groove cleaning tool isn t available a piece broken off the old ring will do the job but protect your hands piston rings can be sharp 5 Once the deposits have been removed clean the piston rod assemblies with solvent and dry them with compressed air if available M ake sure the oil return holes in the back sides of the ring grooves are clear 6 If the pistons and cylinder walls aren t damaged or worn excessively and if the engine block is not rebored new piston
135. the rear window if necessary after removing the trim panels see illustration or swivel the cover up 16 9 Removing the tailgate wiper arm nut 3 Series washer 16 11 Removing the tailgate wiper motor 3 Series 12 12 8 Body electrical systems 12 Refitting is a reversal of removal When fitting the motor if necessary plug in the connector and run the motor briefly until it is in the neutral wiper parked position 17 Heated rear window check and repair 1 The heated rear window consists of number of horizontal elements on the glass Surface 2 Small breaks in the element can be repaired without removing the rear window Check 3 Switch on the ignition and the heated rear window 4 Place the positive lead of a voltmeter to the heater element nearest to the incoming power source 5 Wrap a piece of aluminium foil around the negative lead of the voltmeter on the positive side of the suspected broken element and Slide it slowly towards the negative side Watch the voltmeter needle when it moves from zero you have located the break Repair 6 Repair the break in the line using a repair kit recommended specifically for this purpose such as BMW repair kit No 81 22 9 or equivalent Included in this kit is plastic conductive epoxy The following paragraphs give general instructions for this type of repair follow the instructions supplied with the repair kit if they are different
136. the stereo inoperative if stolen If the power source to the stereo is cut the stereo won t work even if the power source is immediately re connected If your vehicle is equipped with this anti theft system do not disconnect the battery or remove the stereo unless you have the individual code number for the stereo Refer to the owner s handbook supplied with the vehicle for more complete information on this audio system and its anti theft feature Unlocking procedure 1 Turn on the radio The word CODE should appear on the display 2 Using the station preset selector buttons enter the five digit code If you make a mistake when entering the code continue the five digit sequence anyway If you hear a beep however stop immediately and Instrument panel language display On some later models disconnecting the battery may cause the instrument panel display to default to the German language this does not usually apply to UK models If it is necessary to reset the correct language after the battery is reconnected proceed as follows With all the doors shut and the ignition on engine not running press the trip reset button until the panel displays the desired language There are eight languages available If you wish to bypass a particular selection release the reset button and press again this will cause the display to advance to the next language Once the correct 0 7 start the sequence over again Note
137. the stud Studs or bolts which have broken off below the surface of the component in which they are mounted can sometimes be removed using a stud extractor Always ensure that a blind tapped hole is completely free from oil grease water or other fluid before installing the bolt or stud Failure to do this could cause the housing to crack due to the hydraulic action of the bolt or stud as it is screwed in When tightening a castellated nut to accept a split pin tighten the nut to the specified torque where applicable and then tighten further to the next split pin hole Never slacken the nut to align the split pin hole unless stated the repair procedure When checking or retightening a nut or bolt to a specified torque setting slacken the nut or bolt by a quarter of a turn and then retighten to the specified setting However this should not be attempted where angular tightening has been used For some screw fastenings notably cylinder head bolts or nuts torque wrench settings are no longer specified for the latter Stages of tightening angle tightening being called up instead Typically a fairly low torque wrench setting will be applied to the bolts nuts in the correct sequence followed by one or more stages of tightening through Specified angles Locknuts locktabs and washers Any fastening which will rotate against a component or housing during tightening Should always have a washer between it and the relevant
138. the upper part of the intake manifold should be removed by unscrewing the bolts and nuts Remove the gaskets see illustrations 10 On fuel injection engines disconnect the vacuum hose from the fuel pressure regulator and disconnect the electrical connectors from the fuel injectors see Chapter 4 11 Disconnect the fuel lines from the fuel rail or carburettor as applicable see Chapter 4 12 On the M40 engine unbolt and remove the support bracket from the bottom of the intake manifold see illustration 13 Disconnect all remaining hoses and wires attached between the intake manifold throttle body assembly and the engine or chassis 14 Remove the bolts and or nuts that attach the manifold to the cylinder head see illustrations Start at the ends and work toward the middle loosening each one a little at a time until they can be removed by hand Support the manifold while removing the fasteners so it doesn t fall Note You can remove the manifold without removing the throttle body injectors vacuum thermo nuts M40 engine In car engine repair procedures 2A 5 5 9b and remove the upper part of the intake manifold valves fuel pressure regulator or carburettor If you re fitting a new manifold transfer the components see Chapter 4 and lines to the new manifold before it is fitted on the cylinder head 15 Move the manifold up and down to break the gasket seal then lift it away from the head an
139. the upper shroud screws see illustration 4 Remove the two screws from the underside of the column see illustration 5 Detach the lower shroud then lift the upper half off the column see illustrations Refitting 6 Refitting is the reverse of removal 20 Seats removal and refitting ES X Front seat 1 Remove the four bolts securing the seat track to the floorpan and lift the seat from the vehicle see illustration On some models it will be necessary to disconnect the seat heating wiring it may also be necessary to detach the seat belt from the seat 19 4 The lower screws are located under the tilt lever where fitted 2 Refitting is the reverse of removal Tighten the retaining bolts securely Rear seat cushion 3 If applicable first remove the two retaining bolts Grasp the front of the cushion Saloon Convertible models or the rear of the cushion Touring Estate models securely and pull up sharply see illustration 4 Refitting is the reverse of the removal 21 Seat belt check 1 Check the seat belts buckles lock plates and guide loops for obvious damage and Signs of wear 2 Where applicable check that the seat belt reminder light comes on when the ignition key is turned to the Run or Start position 3 The seat belts are designed to lock up during a sudden stop or impact yet allow free movement during normal driving Check that 20 1 The front seats are held in plac
140. three wire valve as follows 24 On two wire valves connect an ammeter 0 to 1000 mA range as described in paragraph 13 Start the engine and allow it to idle With the engine running the current 4 20 Fuel and exhaust systems a m 21 26 Check for battery voltage on the centre terminal reading should be between 400 and 500 mA Adjust the valve if the current reading is not as specified Note The idle air stabiliser current will fluctuate between 400 and 1100 mA if the engine is too cold if the coolant temperature sensor is faulty if there is an engine vacuum leak or if electrical accessories are on 25 If there is no current reading have the idle speed control unit under the facia checked by a BMW dealer or other specialist 26 On three wire valves check for voltage at the electrical connector With the ignition on there should be battery voltage present at the centre terminal see illustration There should be about 10 volts between the centre terminal and each of the outer terminals 27 f there is no voltage reading have the idle speed control unit early models or the ECU later models checked by a dealer service department or other specialist Adjustment early models only 28 With the ignition switched off connect a tachometer in accordance with the equipment manufacturer s instructions 29 Make sure the ignition timing is correct see Chapter 5 30 Connect an ammeter to the valve as
141. tight see illustration 3 At the same time inspect the underside of the body for holes corrosion open seams 1 21 etc which may allow exhaust gases to enter the passenger compartment Seal all body Openings with suitable sealant 4 Rattles and other noises can often be traced to the exhaust system especially the mountings and heat shields Try to move the pipes silencers and where applicable the catalytic converter If the components can come in contact with the body or suspension parts re hang the exhaust system with new mountings 5 The running condition of the engine may be checked by inspecting inside the end of the tailpipe The exhaust deposits here are an indication of the engine s state of tune If the pipe is black and sooty the engine may be running too rich indicating the need for a thorough fuel system inspection 24 Steering and suspension check Note The steering linkage and suspension components should be checked periodically Worn or damaged suspension and steering linkage components can result in excessive and abnormal tyre wear poor ride quality and vehicle handling and reduced fuel economy For detailed illustrations of the steering and Suspension components refer to Chapter 10 Strut shock absorber check 1 Park the vehicle on level ground turn the engine off and apply the handbrake Check the tyre pressures 2 Push down at one corner of the vehicle then release it while notin
142. times to bring the pads into contact with the discs The pedal should piston 5 Series be at normal height above the floor and firm Check the level of the brake fluid adding some if necessary Check carefully for leaks and check the operation of the brakes before returning the vehicle to normal service 9 Avoid heavy braking as far as possible for the first hundred miles or so until the new pads have bedded in 4 Disc brake caliper removal overhaul and refitting Warning Dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes Do not under any circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only Warning Brake fluid is poisonous It is also an effective paint stripper Refer to the warning at the start of Section 16 Note If an overhaul is indicated usually because of fluid leakage explore all options before beginning the job Overhauled calipers may be available on an exchange basis which makes this job quite easy If you decide to overhaul the calipers make sure that an 2 aim C 3 51 Hang the caliper out of the way with a piece of wire overhaul kit is available before proceeding Always overhaul the calipers in pairs never overhaul just one of them Removal
143. to expand the shoes anti clockwise to retract them until the brake shoes just contact the brake drum see illustration 5 6d Back off the brake shoes so the wheel spins freely three to four teeth on the adjuster Note If the adjuster starwheel is hard to turn remove the wheel and brake disc lubricate the adjuster wheel and try again 11 With the disc fitted apply the handbrake three times to stretch and seat the cables then slowly pull up on the handbrake lever to the fifth click Tighten the cable adjusting nuts by equal amounts until the rear brake shoes just touch the brake drum Verify that both wheels have the same amount of resistance 12 Release the handbrake and verify that both rear wheels rotate freely 13 Tighten the wheel bolts to the torque listed in Chapter 1 Specifications 12 Handbrake assembly check removal and refitting Warning handbrake linings on rear disc brake models may be manufactured of asbestos based material Refer to the warning at the start of Section 6 When servicing these components do not create dust by grinding or sanding the linings 1 The handbrake system should be checked regularly With the vehicle parked on a hill apply the handbrake select neutral and check that the handbrake alone will hold the vehicle when the footbrake is released be Sure to stay in the vehicle during this check However every 2 years or whenever a fault is Suspected the assembly itse
144. upper mounting nuts To get at the upper mounting nuts on later models first remove the rear seat cushion see Chap ter 11 then remove the two bolts holding the rear seat backrest and remove the backrest Support the trailing arm with a jack and remove the upper mounting nuts see illustration Lower the jack and remove the Shock absorber and the gasket To separate the shock absorber and spring refer to Section 6 Refitting 4 Refitting is the reverse of removal Don t forget to fit the gasket between the upper end of the shock absorber and the body Tighten the upper nuts to the torque listed in this Chapter s Specifications Don t tighten the lower bolt until the vehicle is lowered 5 Lower the vehicle and with it sitting at the normal ride height tighten the lower bolt to the torque listed in this Chapter s Specifi cations 12 Rear anti roll bar removal and refitting Removal Note The rear anti roll bar is mounted basically the same way on all models Follow these general removal refitting procedures keeping in mind any variations 1 Chock the front wheels then raise the rear of the vehicle and support it securely on axle Stands 2 Remove the anti roll bar bracket bolts or nuts see illustration 3 Disconnect the anti roll bar from the link at each end of the bar see illustrations and detach the anti roll bar 10 10 10 Suspension and steering systems 12 2 Rear anti roll
145. very small voltage signal To verify it is working check for voltage with a digital voltmeter the voltage signals usually range from 0 1 to 1 0 volt Check 12 Warm up the engine and let it run at idle Disconnect the oxygen sensor electrical connector and connect the positive probe of a voltmeter to the oxygen sensor output connector terminal refer to the following table and the negative probe to earth see illustrations Note Most oxygen sensor electrical connectors are located at the rear of the engine near the bulkhead Look for a large rubber boot attached to a thick wire harness On early 535i models the connector for the oxygen sensor heater circuit is under the vehicle Look for a small protective cover These models should have the updated oxygen sensor fitted to make access similar to other models Consult your dealer service department for additional information 13 Increase and then decrease the engine speed and monitor the voltage 14 When the speed is increased the voltage should increase to 0 5 to 1 0 volts When the speed is decreased the voltage should fall to about 0 to 0 4 volts 15 Also where applicable inspect the oxygen sensor heater models with multi wire sensors With the ignition on disconnect the oxygen sensor electrical connector and connect a voltmeter across the terminals designated in the chart see below There should be battery voltage approximately 12 volts 16 If the readin
146. where available consists of a reground crankshaft with matched undersize new main and connecting big end bearings Sometimes reconditioned connecting rods and new pistons and rings are included with the kit such a kit is sometimes called an engine kit If the block is in good condition but the crankshaft journals are scored or worn a crankshaft kit and other individual parts may be the most economical alternative Short block A short block consists of an engine block with a crankshaft and piston connecting rod assemblies already fitted New bearings are fitted and all clearances will be correct The existing camshaft valve train components cylinder head and external parts can be bolted to the short block with little or no machine shop work necessary Full block A full or complete block consists of a short block plus an oil pump sump cylinder head valve cover camshaft and valve train components timing sprockets and chain or belt and timing cover All components are fitted with new bearings seals and gaskets used throughout The refitting of manifolds and external parts is all that s necessary Give careful thought to which alternative is best for you and discuss the situation with local machine shops parts dealers and experienced rebuilders before ordering or purchasing new parts General engine overhaul procedures 7 Engine overhaul dismantling sequence 1 It s much easier to dismantle and work
147. wiring diagram 2 of 2 12 16 Wiring diagrams Key to Motronic engine control system wiring diagram Description No Description Electronic Control Unit ECU 18 Distributor Speed control relay 19 Ignition coil Temperature switch 20 Starter Air conditioner 21 Alternator Car wire harness connection 22 Position transmitter Throttle switch 23 Plug disconnected for automatic transmission Airflow sensor 24 Coolant temperature sensor Speed sensor 25 Fuel injector Reference mark sensor 26 Solenoid m Relay 1 27 Electric power distributor Relay 2 28 Oil pressure Oil pressure switch 29 Temperature gauge Temperature transmitter 30 Electric fuel pump Diagnosis connection 31 Service indicator Engine plug 32 Drive motor Battery 33 Temperature switch Spark plugs Key to cruise control system wiring diagram Description Plug connection centre section to instrument cluster 26 pin Steering column switch Instrument cluster Plug connection range indicator Range indicator D Range indicator N Range indicator R Plug connection speedometer outlet Connection instrument cluster 2 pin Plug connection steering column switch Plug connection special equipment Steering column switch Plug connection rear section to centre section 29 pin Stoplight switch Plug connection drive motor Connection clutch switch to bridge Stoplight left Stoplight right Electronic control cruise
148. with several turns 50 the signal will be transmitted regardless of the steering wheel position The SRS system has three sensors two at the front mounted on the inner wing panels see illustration and a safety switch located inside the passenger compartment The crash sensors are basically pressure sensitive Switches which complete an electrical circuit during an impact of sufficient force The electrical signal from the crash sensors is sent to a third sensor which then completes the circuit and inflates the airbag The module containing the safety switch monitors the system operation It checks the system every time the vehicle is started causing the AIRBAG warning light to come on then go out if the system is operating correctly If there is a fault in the system the light will stay on If the AIRBAG warning light does stay on or if it comes on while driving take the vehicle to your dealer immediately 18 3 The SRS system crash sensors arrowed are located in the engine compartment check the wiring regularly for damage 19 Cruise control system description and check cruise control system maintains vehicle Speed using a vacuum actuated servo motor located in the engine compartment which is connected to the throttle linkage by a cable The system consists of the servo motor clutch switch brake switch control switches a relay and associated vacuum hoses Because of the complexity of the cru
149. x Specifications Engine Oil filter M10 engines M20 engines M30 engines 3 Series 5 Series M40 engines Valve clearances intake and exhaust M10 engines Fairly difficult suitable for competent X DIY mechanic X Fuel system check Introduction Manual transmission lubricant change Manual transmission lubricant level check Power steering fluid level check Routine maintenance Service light resetting Spark plug check and renewal Spark plug HT leads distributor cap and rotor check and renewal Steering and suspension check Throttle linkage check and lubrication Tyre and tyre pressure checks Tyre rotation Tune up general information Underbonnet hoses check and renewal Valve clearances check and adjustment Wiper blades check and renewal Difficult suitable for expenenced DIY mechanic Very difficult suitable for expert DIY or professional amp A Champion C121 Champion C160 Champion C160 Champion X115 Champion X120 uu 0 20 mm Chee 0 25 20 engines CO 0 25 0 30 30 engines goo aes 0 30 0 35 mm CNGINGS Hydraulic adjusters Cooling system Antifreeze mixture
150. you do the power steering pump could be damaged 2 On some models the power steering fluid reservoir is located on the left side of the engine compartment and has a twist off cap with an integral fluid level dipstick see illustration Other models use a hydraulic power steering and brake servo system which combines the fluid in one reservoir located at the right rear corner of the engine compartment 3 Park the vehicle on level ground and apply the handbrake 4 On models with a fluid dipstick run the engine until it has reached normal operating temperature With the engine at idle turn the steering wheel back and forth several times to get any air out of the steering system Switch off the engine remove the cap by turning it anti clockwise wipe the dipstick clean and refit the cap Remove the cap again and note the fluid level It must be between the two lines see illustration 5 On hydraulic servo models pump the brake pedal about ten times or until the pedal is firm Remove the nut lift the cap off and make sure the fluid is within 6 0 mm of the top of the reservoir 6 Add small amounts of fluid until the level is correct see illustration 7 6 Adding fluid to the power steering reservoir 8 5 The automatic transmission fluid dipstick arrowed is located near the bulkhead on the left side of the engine compartment Caution Do not overfill the reservoir If too much fluid is added remove
151. 1 Before beginning obtain the necessary tools which will include a spark plug socket and a set of feeler blades Special spark plug gap gauges can be obtained from certain Spark plug manufacturers see illustration 2 The best procedure to follow when renewing the spark plugs is to purchase the new spark plugs beforehand adjust them to the proper gap and then renew each plug one at a time When buying the new spark plugs it is important to obtain the correct plugs for your specific engine This information can be found in the Specifications section in the front of this Chapter 3 With the new spark plugs at hand allow the engine to cool completely before attempting plug removal During this time each of the new spark plugs can be inspected for defects and the gaps can be checked 4 The gap is checked by inserting the proper thickness gauge between the electrodes at the tip of the plug see illustration The gap between the electrodes should be the same as that given in the Specifications The wire should just touch each of the electrodes If the gap is incorrect use the notched adjuster to bend the curved side of the electrode slightly until the proper gap is achieved see illustration Note When adjusting the gap of a new plug bend only the base of the earth electrode do not touch the tip If the earth electrode is not exactly over the centre electrode use the notched adjuster to align the two Check for cracks in the porc
152. 13 1 060 may be required to make the adjustment Motronic 10 Connect a tachometer and CO meter to the engine BMW technicians use a special CO tester with a probe connected into the exhaust manifold but the normal type of tester which locates in the exhaust tailpipe may be used instead Note however that on models with a catalytic converter meaningful CO readings will not be obtained at the tailpipe 11 It is not possible to adjust the idle speed manually as the idle air stabiliser valve is activated by the electronic control unit If the idle speed is not within the specified range with the engine at normal operating temperature check for a leak in the air inlet system and also check the operation of the idle air stabiliser valve see Chapter 4 12 Check that the CO reading 15 as given in the Specifications If adjustment is required prise out the tamperproof plug from the airflow meter and turn the adjustment screw to set the CO content on some models an Allen key will be required Fit a new tamperproof plug on completion see illustrations 12 12b Adjusting the CO on the Motronic system 1 16 Every 12 000 miles Every 12 000 miles or 12 months whichever comes first 13 Battery check maintenance and charging WU Check and maintenance Warning Certain precautions must be followed when checking and servicing the battery Hydrogen gas which is highly flammable is always present in the battery cell
153. 22 Steering wheel retaining 79 Connecting link bracket to control arm 41 Steering column universal joint pinch bolt 22 Anti roll bar 5 Series Steering gear to subframe mounting bolts 3 Series 41 Anti roll bar mounting brackets 22 Steering box to front suspension subframe bolts b Series 42 Anti roll bar link to strut housing locknut Track rod end to steering arm 37 Yellow chome 2222s guter PEDCEIeaie 20 Track rod end clamping DolE i usos yi ed Rr e 14 WWE Chro E EX ERA 33 Pitman arm to steering box 5 5 140 Yellow 58 Steering linkage balljoints all 37 1 General information Warning Whenever any of the suspension or steering fasteners are loosened or removed they must be inspected and if necessary new ones fitted of the same part number or of original equipment quality and design Torque specifications must be followed for proper reassembly and component retention Never attempt to heat straighten or weld any suspension or steering component Any bent or damaged parts must be renewed The front suspension see illustrations is a MacPherson strut design The struts are secured at the upper ends to reinforced areas at the top of the wheel arches and at the lower ends to the steering arms control arms An
154. 3 0 5 RTWS _ 8 5 BRBK 1 5 BR PN 0 0 5 RTWS gt L5 BR d Q 75 BR Uo 2 L 2 KEY TO ITEMS 1 BATTERY 2 DISTRIBUTOR 3 IGNITION COIL 0 5 RTWS 4 POSITION SENSOR 0 5 RTWS 5 SPARK PLUGS 0 5 RTWS 6 ALTERNATOR 0 5 RTWS 2 STARTER 0 5 RTWS 8 OIL PRESSURE SWITCH 2 5 RTWS 9 TEMPERATURE TRANSMITTER ON 18 COOLANT TEMPERATURE SENSOR on 11 INJECTION CONTROL UNIT ur Do 12 WIRE HARNESS CONNECTION 3 x D 13 THROTTLE SWITCH 14 AIR FLOW SENSOR 15 FUEL INJECTORS 2 5 RTWS 2 5 RTWS 16 FUEL PUMP RELAY 12 0 75 BR 0 75 BR 17 IGNITION MODULE Typical L J etronic system wiring diagram Chapter 11 Bodywork fittings Contents Bodywork and underframe maintenance Bodywork repair major damage Bodywork repair minor damage Bonnet removal refitting and adjustment Boot lid tailgate removal refitting and adjustment 14 Bumpers removal and refitting Door removal refitting and adjustment Door trim panel removal and refitting Door window glass removal and refitting Door window regulator removal and refitting Exterior mirror removal and refitting Degrees of difficulty Easy suitable for A novice with little X experience X 1 General information These models feature an all steel welded construction where the floorpan and body components are welded together and attached to
155. 3 To remove the sensor depress the spring lock unplug the electrical connector then carefully unscrew the sensor Be prepared for some coolant spillage to reduce this have the new sensor ready for fitting as quickly as possible 4 2 Check the resistance of the coolant temperature sensor at different temperatures Caution Handle the coolant sensor with care Damage to this sensor will affect the operation of the entire fuel injection system Note It may be necessary to drain a small amount of coolant from the radiator before removing the sensor 4 Before the sensor is fitted ensure its threads are clean and apply a little sealant to them 5 Refitting is the reverse of removal Oxygen sensor General description Note Oxygen sensors are normally only fitted to those vehicles equipped with a catalytic converter Most oxygen sensors are located in the exhaust pipe downstream from the exhaust manifold On 535 models the oxygen sensor is mounted in the catalytic converter The sensor s electrical connector is located near the bulkhead left side for easy access 6 The oxygen sensor which is located in the exhaust system see illustration monitors the oxygen content of the exhaust gas The oxygen content in the exhaust reacts with the oxygen sensor to produce a voltage output which varies from 0 1 volts high oxygen lean mixture to 0 9 volts low oxygen rich mixture The ECU constantly monitors this variable vol
156. 4 7 4 8 Fume or gas intoxication 0 5 Fuses 12 2 Gaiters 1 22 8 9 10 13 Gashes in bodywork 11 2 Gaskets REFe8 Gear lever 7 1 Gearbox See Manual transmission Gearbox oil 1 3 1919 1 25 General engine overhaul procedures 2 1 et seq Glass 11 4 11 8 Glossary of technical terms REF 20 Grille 1194 Handbrake 1 23 9 2 9 12 REF 1 Handbrake fault REF 14 Handles 11 8 Hazard warning flasher 12 2 HC emissions 4 Headlights 12 3 125 12 6 Heated rear window 12 8 Heater 3 2 3 7 3 8 Hinges 11 4 HT leads 1 18 Hubs 10 8 10 11 REF 3 Hydraulic servo 9 11 Hydraulic tappets 2B 11 Hydrofluoric acid 0 5 Idle air stabiliser valve 4 18 Idle speed adjustment 1 15 Ignition coil 5 5 Ignition control unit 5 6 5 7 Ignition sensors 5 8 Ignition switch 1293 Ignition system 5 3 Ignition timing 5 4 Ignition timing sensors 6 4 Impulse generator 5 6 5 7 In car engine repair procedures 2 1 et seq Indicators 12 2 1293 Information sensors 6 2 Injectors 4 18 Input shaft 7 2 Instrument cluster 12 4 Instrument panel language display 0 7 Intake manifold 2A 4 Intermediate shaft 2A 12 2B 14 2B 19 Introduction to the BMW 3 and 5 Series 0 4 J acking 0 8 oint mating faces REF 8 J ump starting 0 9 K Kickdown cable 7B 3 L L J etronic fuel
157. 4 Move a large container under the radiator to catch the coolant Where a drain plug is fitted unscrew it a pair of pliers or screwdriver may be required to turn it depending on the model see illustration Where there is no drain plug it will be necessary to disconnect the bottom hose from the radiator 5 While the coolant is draining check the condition of the radiator hoses heater hoses and clamps see Section 21 if necessary 6 Renew any damaged clamps or hoses see Chapter 3 for detailed renewal procedures i 28 10c Remove the O ring from the transmission If it is in good condition clean it and transfer it to the new fluid filter otherwise renew it 29 4 Radiator drain plug location arrowed not fitted to all models Flushing 7 Once the system is completely drained flush the radiator with fresh water from a garden hose until the water runs clear at the drain or bottom hose If the radiator is severely corroded damaged or leaking it Should be removed see Chapter 3 and taken to a radiator repair specialist 8 Flushing in this way will remove sediments from the radiator but will not remove rust and scale from the engine and cooling tube surfaces These deposits can be removed by using a chemical cleaner Follow the procedure outlined the Cleaner manufacturer s instructions Remove the cylinder block drain plug before flushing the engine 9 On models so equipped remove the overflow
158. 6 Section 4 Check the handbrake braking system see Chapter 9 Check tyre pressures Chapter 1 Chapter 3 3 1 Cooling heating and air conditioning systems Contents Air conditioner receiver drier removal and refitting 16 Air conditioning blower motor E28 old shape 5 series models removal and refitting 14 Air conditioning compressor removal and refitting 13 Air conditioning condenser removal and refitting 15 Air conditioning system precautions and maintenance 12 Antifreeze general information 2 Coolant level check See Chapter 1 Coolant temperature sender unit check and renewal 8 Cooling system See Chapter 1 Cooling system servicing draining flushing and refilling 5 ee Chapter 1 Degrees of difficulty Engine cooling fan s and clutch check removal and refitting 5 Evaporator matrix removal and refitting 17 General IN OMMAUON Hobe ich RR EC P erae d 1 Heater and air conditioner control assembly removal and refitting 10 Heater and air conditioning blower motor removal testing and SUMING te bps Gee eee 9 Heater matrix removal and refitting 11 Radiator removal and refitting 4
159. 6 months whichever comes first All items listed above plus Change the engine oil and oil filter Section 6 Check the power steering fluid level Section 7 Check the tyres and rotate if necessary Section 9 Check the automatic transmission fluid level Section 8 Check the underbonnet hoses Section 10 Check adjust the drivebelts Section 11 Check engine idle speed and CO Section 12 Every 12 000 miles or 12 months whichever comes first All items listed above plus Check service the battery Section 13 Check the spark plugs Section 14 Check renew the HT leads distributor cap and rotor Section 15 Check top up the manual transmission lubricant Section 16 Check the differential oil level Section 17 Check the valve clearances and adjust if necessary does not apply to M40 engines Section 18 Check and lubricate the throttle linkage Section 19 Renew the air filter Section 20 Check the fuel system Section 21 Inspect the cooling system Section 22 Inspect the exhaust system Section 23 Inspect the steering and suspension components Section 24 Check the driveshaft gaiter s Section 25 Inspect the brakes Section 26 Inspect renew the windscreen wiper blade
160. 7 Sump 2 15 Supplemental Restraint System SRS 1298 Suspension and steering systems 1921 1922 10 1 et seq REF 2 REF 3 Suspension and steering fault finding REFe15 Switches 7B 4 9 13 1293 T Tailgate 11 6 Tappets 2B 11 Thermostat 3 2 Thermotime switch 4 17 4 18 Throttle body 4 16 Throttle linkage 1 20 Throttle Position Sensor TPS 6 3 Throttle positioner 4 13 4 14 Thrust arm 10 5 Timing 5 4 Timing belt 1 26 2A 8 2A 9 Timing chain 2A 6 2A 8 Timing sensors 6 4 Tools REF 5 REF 7 REF 8 Top Dead Centre TDC for No 1 piston 2A 3 Index REF 27 Torque converter 7B 5 Towing 0 8 Track rod ends 10 13 Trailing arms 10 10 Transmission See Manual transmission or Automatic transmission Trim 11 2 11 6 Tyres 1 9 1 14 10 16 REF e4 REF 15 U Underframe 11 1 Universal joints 8 8 Upholstery 11 2 V Vacuum hoses 1914 Vacuum servo 9 10 Valve clearances 1 19 Valve cover 2 4 Valves 2B 10 2Be11 Vehicle identification REFe2 REF 19 Voltage checks 12 1 Voltage regulator 5 10 W Washer fluid 1 9 Water pump 3 5 Weekly checks 1 7 et seq Wheel alignment 10 17 Wheel bearings 10 8 10 11 REF 3 Wheel changing 0 8 Wheels 10 16 REF 4 Windows 1198 12 9 Windscreen REF 1 Wiper blades 1 23 Wiper motor 12 7 Wiring diagrams 12 9 et seq Working faclities
161. 700 ohms at 209 C 5 f the resistance readings are correct check the wiring harness see Chapter 12 Plug in the connector to the airflow meter Ensure that the ignition is switched off Disconnect the electrical connector from the ECU located under the right hand side of the facia and probe terminals 7 and 8 see illustration with an ohmmeter Carefully move the door of the airflow meter and observe the change in resistance as it moves from closed to fully open The test results should be the same as paragraph 3 If there are any differences in the test results there may be a shorted out or broken wire in the harness Check Motronic systems 6 Ensure that the ignition is switched off 16 7a Connect the ohmmeter probes to terminals 7 and 12 later Motronic systems of the ECU connector and check for a smooth change in resistance as the door on the airflow meter is slowly opened and closed Fuel and exhaust systems 4 15 131211 109 876 54 3 2 1 16 5 The ECU is located under the right hand side of the facia Unplug the electrical connector and check the resistance between terminals 7 and 8 as in paragraph 3 The test results should be the same Remove the ECU access cover see Chap ter 6 and disconnect the harness connector see illustration 7 Using an ohmmeter probe the designated terminals of the ECU electrical connector see illustrations and check for the proper change in resistance while moving the s
162. 9 There are two types of control units Bosch or Siemens Telefunken The two types see illustration can be distinguished by their electrical connectors The Bosch type uses a single large rectangular connector at the bottom of the unit while Siemens Telefunken control unit uses two round electrical connectors at the front of the unit Check 10 1 Schematic of the ignition components used on engines with the TCI system aH Voltage supply and earth to ignition 1 Coil HT lead 8 Distributor housing with 15 Ignition rotor control unit 2 Ignition coil centrifugal advance 16 Distributor 2 With the ignition off remove the harness 3 Spark plug HT lead counterweights 17 Roll pin connectors from the ignition control unit see 4 Spark plug 9 Vacuum diaphragm 18 Trigger wheel and impulse illustrations Connect a voltmeter between 5 Ignition control unit Bosch 10 Circlip generator tabs connector terminals 2 and 4 on Bosch 6 Ignition control unit 11 Impulse generator 19 Cap retaining clip systems or between terminals 6 and 3 on Siemens Telefunken 12 Trigger wheel 20 Impulse generator Siemens Telefunken systems 7 Wiring harness 13 Circlip connector 3 Turn the ignition on There should be 14 Dust shield battery voltage on the designated terminals If there is no voltage check the wiring harness for an open circuit see Chapter 12 4 Using an ohmmeter check for continuity between connector terminal 2 Bosch or 6 S
163. 946 Imperial gallons Imp gal 4 546 Imperial gallons Imp gal x 1 201 US gallons US gal 3 785 Mass weight Ounces 02 26 35 Pounds Ib x 0 454 Force Ounces force ozf oz x 0 278 Pounds force Ibf Ib x 4 448 Newtons N x 0 1 Pressure Pounds force per square inch x 0 070 psi Ibf in Ib in Pounds force per square inch x 0 068 psi Ibf in Ib in Pounds force per square inch x 0 069 psi Ibf in Ib in Pounds force per square inch x 6 895 psi Ibf in Ib in Kilopascals kPa x 0 01 Millibar mbar x 100 Millibar mbar x 0 0145 Millibar mbar 0 75 Millibar mbar x 0 401 Millimetres of mercury mmHg X 0 535 Inches of water inH5O x 0 036 Torque moment of force Pounds force inches lbf in Ib in x 1 152 Pounds force inches lbf in Ib in x 0 113 Pounds force inches lbf in Ib in x 0 083 Pounds force feet Ibf ft Ib ft x 0 138 Pounds force feet Ibf ft Ib ft x 1 356 Newton metres Nm x 0 102 Power Horsepower hp x 745 7 Velocity speed Miles per hour miles hr mph x 1 609 Fuel consumption Miles per gallon mpg x 0 354 Conversion Factors acri Millimetres mm Metres m Kilometres km Cubic centimetres cc cm Litres l Litres l US quarts US qt Litres l Litres l US gallons US gal Litres l Grams g Kilograms kg Newtons N Newtons N Kilograms force kgf kg Kilograms force per square centimetre kgf cm kg cm At
164. Another cause of fire is an electrical overload or short circuit Take care when repairing or modifying the vehicle wiring Keep a fire extinguisher handy of a type suitable for use on fuel and electrical fires Electric shock gnition HT p voltage canbe dangerous m especially to people with heart u xr F problems or a pacemaker Don t work on or near the J ignition system with the engine running or the ignition switched on Mains voltage is also dangerous Make sure that any mains operated equipment is correctly earthed Mains power points should be protected by a residual current device RCD circuit breaker Fume or gas intoxication Exhaust fumes are n poisonous they often M contain carbon monoxide which is rapidly fatal if inhaled Never run the engine confined space such as a garage with the doors shut Fuel vapour is also poisonous as are the vapours from some cleaning solvents and paint thinners Poisonous or irritant substances Avoid skin contact with battery acid and with any fuel fluid or lubricant especially antifreeze brake hydraulic fluid and Diesel fuel Don t syphon them by mouth If such a substance is swallowed or gets into the eyes seek medical advice Prolonged contact with used engine oil can cause skin cancer Wear gloves or use a barrier cream if necessary Change out of oil soaked clothes and do not keep oily rags in your pocket Air con
165. Brake disc The component of a disc brake that rotates with the wheels Brake drum The component of a drum brake that rotates with the wheels Brake linings The friction material which contacts the brake disc or drum to retard the vehicle s speed The linings are bonded or riveted to the brake pads or shoes Brake pads replaceable friction pads that pinch the brake disc when the brakes are applied Brake pads consist of a friction material bonded or riveted to a rigid backing plate Brake shoe The crescent shaped carrier to which the brake linings are mounted and which forces the lining against the rotating drum during braking Braking systems For more information on braking systems consult the Haynes Automotive Brake Manual Breaker bar A long socket wrench handle providing greater leverage Bulkhead The insulated partition between the engine and the passenger compartment C Caliper The non rotating part of a disc brake assembly that straddles the disc and carries the brake pads The caliper also contains the hydraulic components that cause the pads to pinch the disc when the brakes are applied A caliper is also a measuring tool that can be set to measure inside or outside dimensions of an object Camshaft A rotating shaft on which series of cam lobes operate the valve mechanisms The camshaft may be driven by gears by Sprockets and chain or by sprockets and a belt Canister A container in an evaporative emi
166. Chapter 9 Abnormal or excessive tyre wear 1 Front wheel or rear wheel alignment incorrect Chapter 10 Sagging or broken springs Chapter 10 Tyre out of balance Chapter 10 Worn shock absorber Chapter 10 Overloaded vehicle or unsympathetic driving style Tyres not rotated regularly Wheel makes a thumping noise Blister or bump on tyre Chapter 10 Faulty shock absorber action Chapter 10 Wheel bolts loose Shimmy shake or vibration Tyre or wheel out of balance or out of round Chapter 10 Loose worn or incorrectly adjusted wheel bearings Chapter 1 Worn tie rod ends Chapter 10 Worn balljoints Chapter 10 Excessive wheel run out Chapter 10 Blister or bump on tyre Chapter 10 Wheel bolts loose High steering effort Lack of lubrication at balljoints tie rod ends and steering gear Chapter 1 Incorrect front wheel alignment Chapter 10 Low tyre pressure s Chapter 1 Power steering fluid low or steering pump drivebelt slipping where applicable Chapter 10 Poor steering self centring Lack of lubrication at balljoints and tie rod ends Chapter 1 1 Binding in balljoints Chapter 10 Binding in steering column Chapter 10 Lack of lubricant in steering gear Chapter 10 Inaccurate front wheel alignment Chapter 10 Abnormal noise at the front end Lack of lubrication at balljoints and tie rod ends Chapter 1 Damaged shock absorber mounting C
167. Check 1 Depressurise the fuel system see Sec tion 2 2 Detach the battery negative cable 3 Disconnect the fuel line and connect a fuel pressure gauge see Section 3 Reconnect the battery 17 11 Remove the nuts arrowed and lift the throttle body from the intake manifold the two lower bolts are hidden from view 4 Pressurise the fuel system refit the fuel pump fuse and switch on the ignition and check for leakage around the gauge connections 5 Connect a vacuum pump to the fuel pressure regulator see illustration 6 Run the fuel pump see Section 3 Read the fuel pressure gauge with vacuum applied to the pressure regulator and also with no vacuum applied The fuel pressure should decrease as vacuum increases 7 Stop the fuel pump and reconnect the vacuum hose to the regulator Start the engine and check the fuel system pressure at idle comparing your reading with the value listed in this Chapter s Specifications Disconnect the vacuum hose and watch the gauge the pressure should jump up to maximum as soon as the hose is disconnected 8 If the fuel pressure is low pinch the fuel return line shut and watch the gauge If the pressure doesn t rise the fuel pump is defective or there is a restriction in the fuel feed line If the pressure now rises sharply renew the pressure regulator 9 f the indicated fuel pressure is too high stop the engine disconnect the fuel return line and blow through it to check
168. DER LOCK CYLINDER CLIP SOLENOID 0564H 15 2 Typical door latch lock cylinder and handle details Interior handle 9 Disconnect the operating rod from the handle 10 Remove the retaining screws and lift the handle from the door 11 Refitting is the reverse of removal Exterior handle 12 Lift up the handle for access remove the two retaining screws then detach the handle from the door 13 Refitting is the reverse of removal 16 Door window glass removal and refitting Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 Remove the door trim panel and the plastic water shield see Section 12 3 Prise the door inner and outer weatherstrips from the door Front door 4 Raise the window so that the mounting bolts can be reached through the access hole If electric windows are fitted temporarily reconnect the battery cable to accomplish this 5 Support the glass and remove the retaining bolts securing the glass to the regulator 6 Lift the window glass up and out of the door window slot then tilt
169. Don t fully tighten the nuts on the pivot bolts or the shock absorber yet 13 Bleed the brakes as described in Chap ter 9 14 Support the trailing arm with a trolley jack and raise it to simulate normal ride height Tighten the bolts and nuts to the torques listed in this Chapter s Specifications 15 Rear wheel bearings renewal 3 Series models 1 Loosen the driveshaft nut and the rear wheel bolts then chock the front wheels Raise the rear of the vehicle and place it securely on axle stands Remove the rear wheel Note Depending on the type of rear wheel it may be necessary to remove the wheel first remove the hubcap then refit the wheel and loosen the driveshaft nut 2 Remove the driveshaft see Chapter 8 15 8 Lower the vehicle and loosen the drive flange nut Suspension and steering systems 10 11 WHEEL BEARING HOUSING WHEEL BEARING 15 4 An exploded view of the 3 Series rear wheel bearing assembly 3 On models with rear brake drums remove the drum On models with rear disc brakes remove the brake caliper and mounting bracket Don t disconnect the hose Hang the caliper out of the way with a piece of wire Remove the brake disc See Chapter 9 Working from behind drive the wheel hub out of the wheel bearing with a large socket ora piece of pipe TNA If the bearing inner race sticks to the hub it probably HiNT will use a puller to remove the race from the hub 4 Remo
170. INDOW 1 HAZARD WARNING LIGHT RELAY 14 STARTER MOTOR 15 IGNITION SWITCH 16 HORN SWITCH 17 HAZARD WARNING LIGHT SWITCH 18 DIRECTION INDICATOR SWITCH 19 REVERSING LIGHT SWITCH Wi POWER RAIL IN POWER DISTRIBUTOR Q9e 8518 at 571 SATA oe 391A Hg 71 el 39 O _ _ ASE e 51 SA 51 Gr 01 2 ug 57 w 7 it qH 4 19718 S9 INSTRUMENT CLUSTER SEE SHEET 4 OF 4 HLFT3Q qH ug 51 qH 51 Typical starting charging horn hazard flasher and direction indicators 1 of 4 ro el e N r Un gt 5 V 0 5 GR a TO C 0 5 GRBL E 5 INSTRUMENT CLUSTER SEE SHEET 4 OF 4 TO CHECK CONTROL j 1 0 GEVI ao oe 0 5 GEBR 1 LIGHT SWITCH SEE SHEET 1 OF 4 xo um 0 5 GRBL 2 5 bHBIL 9 1 0 BR 1 0 1 f 1 0 BR TO HAZARD WARNING CIGAR LIGH em 1 5 BR 4 769 15 SEE SHEET 4 OF 4 0 5 BRWS 0 5 BRWS 5 BRWS 1 BRWS 31g GRBL BR 12 Oo 0 5 gt tr m 2 2 N T a Lr PLATE LIGHT SWITSH SEE
171. INO 3 ELT T ESTO CIR T LT 17 Engine removal and refitting 5 Engine block 15 Engine block inspectiolr aeos or e a 16 Engine overhaul alternatives 6 Engine overhaul dismantling sequence 7 Degrees of difficulty Easy suitable for A novice with little X Fairly easy suitable for beginner with x some expenence expenence N Specifications General Cylinder compression pressure all engines Oil pressure all engines At idle Running for example at 4000 Cylinder head warpage limit Except M40 engine 4 P tie ia M40 engine Fairly difficult AT N suitable for competent X experienced DIY gt DIY mechanic X gt Engine overhaul general information Engine overhaul reassembly sequence Engine removal methods and precautions General INMONNSUON i oe kc ee eda Initial start up and break in after overhaul Intermediate shaft refitting Intermediate shaft removal and Main and connecting big end bearings inspection Piston rings refitting Pistons connecting rods inspection Pistons connecting rods refitting and big end bearing oil clearance check Pis
172. IT COUPLING NUT PRESSURE DAMPER PUMP CONSOLE PUMP HOLDER FUEL PUMP 29 SCREEN WE 4 18e Exploded view of the fuel pump assembly on later Motronic systems 4 22 Fuel level sender unit terminal designations on L J etronic and early Motronic systems correct resistance On L J etronic and early Motronic systems follow the table below On later Motronic systems connect the ohmmeter probes onto the fuel level sender unit terminals that correspond to pins 1 and 3 on the electrical connector see illustrations The resistance should decrease as the plunger rises L J etronic and early Motronic systems Terminals Float position Resistance G and 31 Slowly moving Resistance fromthe EMPTY slowly position to the decreases FULL position EMPTY 71 7 2 3 ohms FULL 3 2 0 7 ohms W and 31 EMPTY low Continuity fuel warning 23 If the resistance readings are incorrect renew the sender unit 24 Refitting is the reverse of removal 5 Fuel lines and fittings repair and renewal Why Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Don t work ina garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any
173. MS 70 p 50 2 133 5 335 T 35 3 01 ENGINE HARNESS SEE SHEET 3 OF 4 TO ALTERNATOR T SEE SHEET 1 OF 4 PLUG MRIN HRRNESS PLUG MRIN HRRNESS 9 lt 5 1 H9H8 SOB N9H8 8 F28 ENGINE HRRNESS 1HH9 S O IT i 3 650 1 S O q lt d iE sSecRE2 lt 51 ags gt 1449 s e 5488 0 i1uu9 5 26 S a UU uo W D a m D D 0 lt r D x 9 gt gt v lt TO REAR FOG SWITCH SEE SHEET 2 OF 4 TO FUSE 29 SEE SHEET 2 OF 4 TO HAZARD WARNING LIGHT SWITCH TO FUSE 1 SEE SHEET 1 OF 4 SEE SHEET 2 OF 4 TO REAR ASHTRAY ILLUM SEE SHEET 2 OF 4 SAYA S O del EB S O lt 5 2 4733 S KEY TO ITEMS 1 INSTRUMENT CLUSTER 2 HRNDBRRKE WARNING SWITCH 4 OIL PRESSURE SWITCH HRNDBRRKE WARNING LIGHT k ECONOMY CONTROL 5 COOLANT TEMPERATURE SENDER BRAKE FLUID WARNING LIGHT 1 DIRECTION INDICATOR LEFT 6 BRAKE PAD WEAR SENSOR REAR RIGHT OIL PRESSURE WARNING LIGHT m DIRECTION INDICATOR RIGHT BRAKE PAD WEAR SENSOR FRONT LEFT CENTRAL WARNING LIGHT n SPEEDOMETER 8 FUEL LEVEL SENDER SERVICE INDICATOR HIGH BEAM WARNING LIGHT 9 FUEL LEVEL SENDER II PAD WEAR WARNING LIGHT p FR
174. ONT FOG WARNING LIGHT 1 SPEEDOMETER SENDER COOLANT TEMP GRUGE q REAR FOG WARNING LIGHT 11 CIGAR LIGHTER LOW FUEL WARNING LIGHT r NO CHARGE WARNING LIGHT 12 HEATER CONTROL LIGHT FUEL GAUGE s INSTRUMENT ILLUMINATION Wi POWER RAIL IN POWER DISTRIBUTOR TACHOMETER Typical instrument cluster and cigar lighter 4 of 4 12 12 14 Wiring diagrams FEF 6 Bl COE Ex BR Bn EE ELS E 1 4 5 E pom Scat de 11 ENSE NE __ _ e a BR BR BR 24 BR R J BR W 25 J R W _ 25 BR W RIW Ni ES i J 8R Y 25 E 0 25 J BR Y REN ES DLL 26 J BR BK an D PEE 15 30 50 v 94 is Lu i 4 16 9 4 RE OLS 28 29 27 3031 Typical Motronic system wiring diagram 1 of 2 1 GN H 22032 Wiring diagrams 12 15 12 7 8 9 10 11 28 8 TU Dp reer VIII org 212 5 5 MLM o yas ua S A u9 8l III a 1 ANM 14 H 22032 D a A Wi gt Haag 2 155 8 Horde BE Ta o yarg F a TLE de EE BILL Les CN NAD BIS ES USE Gu 49 lt 2 CN ak a 4 11 ES strand Typical Motronic system
175. On the M40 engine drain the cooling system see Chapter 1 then disconnect the 10 5a Align the groove in the hub on the end of the crankshaft with the notch in the front inner cover arrowed and mark them for assembly reference later on that attach the upper and lower covers M20 engine removed for clarity _ 9 9 Removing the lower timing belt cover on the M40 engine hose unbolt the thermostat housing and remove the thermostat see Chapter 3 4 Set the No 1 piston at TDC see Section 3 Caution Once the engine is set at TDC do not rotate the camshaft or crankshaft until the timing belt is refitted If the crankshaft or camshaft is rotated with the timing belt removed the valves could hit the pistons causing expensive internal engine damage 5 On the M20 engine the crankshaft mark Should be aligned with the mark on the inner cover see illustration The mark on the camshaft sprocket should be aligned with the Stamped line on the cylinder head see illustration On the M40 engine make an 10 5b Align the mark on the camshaft sprocket with the mark on the cylinder head arrowed 2 10 In car engine repair procedures 10 6 Loosen the idler pulley bolts arrowed to relieve the tension on the timing belt so it can be removed A 10 95 Removing the timing belt from the camshaft sprocket on the M40 engine 10 10 Removing the camshaft sprocket on the M40 engine 10 11a The BMW
176. S a i b ri i DLE 2 i i 1 8 1 1 Front suspension and steering components 3 Series models 3 Anti roll bar link 4 Control arm 1 Subframe 2 Anti roll bar 5 Strut 6 Track rod end 7 Steering gear m 1 1b Front suspension and steering components 5 Series models left hand drive shown Subframe Anti roll bar Anti roll bar link Centre track rod Outer track rod Track rod end Steering arm Control arm Thrust arm Strut XO CO HP 1 3 Rear suspension components 5 Series models left hand drive shown 1 Shock absorber coil spring assembly 2 Driveshaft 3 Anti roll bar link 4 Anti roll bar 5 Trailing arm 6 Rear axle carrier Suspension and steering systems 10 3 1 2 Rear suspension components 3 Series models 1 Shock absorber 2 Coil spring 3 Driveshaft 4 Trailing arm 5 Rear axle carrier 6 Anti roll bar link 10 10 4 Suspension steering systems E 2 2a On 3 Series models remove the nut upper arrow securing the anti roll bar to the upper end of the connecting link left side shown right side similar If a new control arm is being fitted remove the lower nut lower arrow and disconnect the link assembly and bracket from the arm 2 Frontanti roll bar removal and refitting Removal 1 Raise the front of the vehicle and support it securely on axle stands 2 f you re removing or
177. SHEET 3 4 1 5 BR re oF BR GEGR GEBL SEE SHEET 3 OF 4 0 5 GRVI 4 86 T LL 0 5 GNWS 86 85 0 5 GEGN 1 0 GEWS a 0 5 GNWS 6 X 0 5 GEGN aa 9 j 1 0 5 GNWS 86 85 0 5 GEGN m o6 6 m zn 1 0 GERT 430 87 1 8 GEWS Go LL e2 E L 1 9 I uo m O J x u O ro Oz zt OE 1 0 GERT GERT m GEWS NV ES Bree 0 5 GE N 0 le I pu 59 LEPE LETEO gt 0 5 WS deu e BN 7 0 5 GEGN lt De 1 5 BR 2 65 Fr IO We 9 2 2 12227 55882222688 0 5 GEGN 0 5 GEGN EN aE 86 85 5 1 9 0 1 0 BR ELESSES2 GOSS z 87 j 1 0 WSVI 9 1 0 BR io 0 we cn 2 TO INSTRUMENT CLUSTER lt 1 9 5 WSVI E 2 SEE SHEET 4 OF 4 lt 4 05 Gavi BR BRVI 6 9 5 4 T E e T mc l 2 TO CHECK CONTROL wesc oe SEE SHEET 3 OF 4 a M Ce gt BRVI BRY b 5 II EbR Crib wo MVMebtru GALztZzZe jGrsayes ae 2 RTGN Q Q 4 BRVI 3 RTGN BRV CIOHCGCiLi fuo0 c 1804 n 2 2
178. Steering column switches removal and refitting 6 Headlight housing removal and refitting 14 Supplemental Restraint System SRS general information 18 Headlights adjustment 13 Windscreen tailgate wiper motor removal and refitting 16 Headlights bulb 12 Wiring diagrams general information 22 Degrees of difficulty Easy suitable for novice with little expenence 1 General information The chassis electrical system of this vehicle is of 12 volt negative earth type Power for the lights and all electrical accessories is Supplied by a lead acid type battery which is charged by the alternator This Chapter covers repair and service procedures for various chassis non engine related electrical components For information regarding the engine electrical system components battery alternator distributor and starter motor see Chapter 5 Warning To prevent electrical short circuits fires and injury always disconnect the battery negative terminal before checking repairing or renewing electrical components Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Not
179. To renew the fuel filter disconnect the hoses A then unscrew the nut and detach the filter from the bracket fuel injection type shown Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 4 Place a pan or rags under the fuel filter to catch any spilled fuel If suitable hose clamps are available clamp the inlet and outlet hoses 5 Detach the hoses and remove the bracket screws nuts then remove the filter and where applicable the bracket assembly see illustration 6 Detach the filter from the bracket 7 Refitting is the reverse of removal Be sure the arrow on the filter points in the direction of fuel flow 31 Manual transmission lubricant change 1 Tools necessary for this job include axle Stands to support the vehicle in a raised position an Allen key to remove the drain plug a drain pan newspapers and clean rags The correct amount of the specified lubricant Should also be available see Lubricants and fluids at the start of this Chapter 2 The lubricant should be drained when it is hot ie immediately after the vehicle has been driven this will remove any contaminants better than if the lubricant were cold Because plug arrowed from the bottom of the transmission 1 26 32 4 Remove the differential drain plug with an Allen key the lubricant will be hot it would be wise to wear rub
180. When you re done the actuator should be properly seated between the two shoes as shown hub removed for clarity indicated dimension disconnect the wires from the switch Loosen the locknuts screw the switch in or out until the plunger dimension is correct and retighten the locknuts Reconnect the wires and check for Correct operation 15 Brake hoses and lines inspection and renewal Warning Brake fluid is poisonous It is also an effective paint stripper Refer to the warning at the start of Section 16 Inspection 1 At the intervals specified in Chapter 1 the brake hoses and lines should be inspected With the vehicle raised and placed securely on axle stands the flexible hoses should be checked for cracks chafing of the outer cover leaks blisters and other damage These are important and vulnerable parts of the brake system and inspection should be thorough The metal pipes should be checked for excessive pitting and corrosion If a hose or pipe exhibits any of the conditions described renew it YNN A torch and mirror will prove helpful for a complete hose HiNT and line check Flexible hose renewal 2 Clean all dirt away from the ends of the hose Have ready a Suitable container to catch Spilled brake fluid when the hose is disconnected 3 To disconnect the hose at the chassis end use a Spanner to hold the hex shaped fitting on the end of the flexible hose and loosen the nut on the meta
181. a power drill although it can be done just as effectively by hand using sheets of abrasive paper To complete the preparation for filling score the surface of the bare metal with a screwdriver or the tang of a file or alternatively drill small holes in the affected area This will provide a really good key for the filler paste To complete the repair see the Section on filling and respraying of rust holes gashes in bodywork Remove all paint from the affected area and from an inch or so of the surrounding sound bodywork using an abrasive pad ora wire brush on a power drill If these are not available a few sheets of abrasive paper will do the job most effectively With the paint removed you will be able to judge the severity of the corrosion and therefore decide whether to renew the whole panel if this is possible or to repair the affected area New body panels are not as expensive as most people think and it is often quicker and more Satisfactory to fit a new panel than to attempt to repair large areas of corrosion Remove all fittings from the affected area except those which will act as a guide to the Original shape of the damaged bodywork eg headlight shells etc Then using tin snips ora hacksaw blade remove all loose metal and any other metal badly affected by corrosion Hammer the edges of the hole inwards in order to create a slight depression for the filler paste Wire brush the affecte
182. a matter of Course 9 Refit the main bearing caps and tighten the bolts finger tight 10 After coating the sealing surfaces of the new core plugs with a suitable sealant refit them in the engine block see illustration Make sure they re driven in straight and seated properly or leakage could result S pecial tools are available for this purpose but a large socket with an outside diameter that will just slip into the core plug a 1 2 inch drive extension and a hammer will work just as well 11 Apply non hardening sealant to the new oil gallery plugs and thread them into the holes in the block Make sure they re tightened securely 12 If the engine isn t going to be reassembled right away cover it with a large plastic bag to keep it clean 15 10 A large socket on an extension can be used to drive the new core plugs into the block 16 4a Measure the diameter of each cylinder just under the wear ridge A at the centre B and at the bottom C 16 Engine block inspection N EN x 1 Before the block is inspected it should be cleaned see Section 15 2 Visually check the block for cracks rust and corrosion Look for stripped threads in the threaded holes It s also a good idea to have the block checked for hidden cracks by a machine shop that has the special equipment to do this type of work If defects are found have the block repaired if possible otherwise a new block will be required 3 Check the c
183. a narrow flat bladed screwdriver through one of the holes in the hub flange see illustration and back off the adjuster wheel until the drum can be removed 3 Inspect the drum for cracks score marks deep scratches and hard spots which will appear as small discoloured areas If the hard spots can t be removed with emery cloth or if any of the other conditions exist the drum must be taken to a specialist to have the drum resurfaced Note Professionals recommend Braking system 6 2b If the drum is stuck to the hub apply penetrating oil around the hub drum area and give it a few minutes to loosen up any rust 6 2c If the brake shoes have worn a groove in the drum and it won t come off insert a thin flat bladed screwdriver through one of the wheel bolt holes in the flange and loosen the automatic adjuster mechanism for the sake of clarity the drum has already been removed in this photo and the screwdriver is being inserted underneath the flange instead of though a wheel bolt hole resurfacing the drums whenever a brake job is done Resurfacing will eliminate the possibility of out of round drums If the drums are worn so much that they can t be resurfaced without exceeding the maximum allowable diameter which is cast into the drum see illustration then new ones will be required At the very least if you elect not to have the drums resurfaced remove the glazing from the surface with emery cloth or sandpaper using a sw
184. a stamped line on the camshaft flange that aligns with a cast mark on the top of the cylinder head also the camshaft sprocket dowel pin hole will be at its lowest point On six cylinder M30 engines a line drawn through two of the camshaft sprocket bolts opposite each other would be exactly vertical while a line drawn through the other two bolts would be horizontal Additionally the locating pin should be in the lower left corner between the 7 and 8 o clock positions Be sure you ve identified the correct camshaft TDC position before dismantling because correct valve timing depends on you aligning them exactly on reassembly Note As the engine is mounted in the engine compartment at an 8 9 To remove the tensioner or chain guide rail remove the circlips with a pointed tool or needle nose pliers the circlips tend to fly off when they re released so make sure you catch them or they ll get lost or worse wind up in the engine angle all references to horizontal and vertical whilst timing the camshafts are in relation to the crankshaft and not the ground 4 Hold the crankshaft stationary with a socket and ratchet on the vibration damper centre bolt then loosen but don t unscrew completely the four bolts attaching the camshaft sprocket to the camshaft Be very careful not to rotate the camshaft or crankshaft Note Some earlier models may have locking tabs for the camshaft sprocket bolts Bend the tabs down before loose
185. ace Compression ratio The relationship between cylinder volume when the piston is at top dead centre and cylinder volume when the piston is at bottom dead centre Constant velocity CV joint type of universal joint that cancels out vibrations caused by driving power being transmitted through an angle Core plug A disc or cup shaped metal device inserted in a hole in a casting through which core was removed when the casting was formed Also known as a freeze plug or expansion plug Crankcase The lower part of the engine block in which the crankshaft rotates Crankshaft The main rotating member or shaft running the length of the crankcase with offset throws to which the connecting rods are attached Crankshaft assembly Crocodile clip See Alligator clip D Diagnostic code Code numbers obtained by accessing the diagnostic mode of an engine management computer This code can be used to determine the area in the system where a malfunction may be located Disc brake brake design incorporating a rotating disc onto which brake pads are squeezed The resulting friction converts the energy of a moving vehicle into heat Double overhead cam DOHC engine that uses two overhead camshafts usually one for the intake valves and one for the exhaust valves Drivebelt s The belt s used to drive accessories such as the alternator water pump power steering pump air conditioning compressor etc off the crankshaft pulle
186. ace area 6 Margin 9 10 Check the cylinder head gasket surface for warpage by trying to slip a feeler gauge under the straightedge see this Chapter s Specifications for the maximum warpage allowed and use a feeler gauge of that thickness 12 Check the valve stem to guide clearance by measuring the lateral movement of the valve stem with a dial indicator see illustration The valve must be in the guide and approximately 2 0 mm off the seat The total valve stem movement indicated by the gauge needle must be divided by two to obtain the actual clearance After this is done if there s still some doubt regarding the condition of the valve guides they should be checked by a machine shop the cost should be minimal Valves 13 Carefully inspect each valve face for uneven wear deformation cracks pits and burned areas see illustration Check the valve stem for scuffing and the neck for cracks Rotate the valve and check for any obvious indication that it s bent Look for pits and excessive wear on the end of the stem The presence of any of these conditions indicates the need for valve service as described in the next Section 14 Measure the margin width on each valve see illustration Any valve with a margin narrower than specified will have to be replaced with a new one Valve components 15 Check each valve spring for wear on the ends The tension of all springs should be checked with a special fixture before deci
187. adlamp bulb surface clean it with HiNT methylated spirit 8 From behind the headlight assembly remove the outer cover see illustration 9 Twist and release the inner cover from the rear of the headlight see illustration 10 Disconnect the wire from the rear of the headlight bulb see illustration 11 Release the clips and withdraw the bulb from the headlight unit see illustration 12 Fit the new bulb using a reversal of the removal procedure Make sure that the clips engage the bulb correctly 13 Connect the battery negative cable 12 11 Removing the headlight bulb do not touch the surface of the bulb with your fingers 12 12 6 Body electrical systems 13 Headlights adjustment Note The headlights must be aimed correctly If adjusted incorrectly they could momentarily blind the driver of an oncoming vehicle and Cause a serious accident or seriously reduce your ability to see the road The headlights Should be checked for proper aim every 12 months as is done during the MOT test and any time a new headlight is fitted or front end body work is performed It should be emphasised that the following procedure will only provide a temporary setting until the headlights can be adjusted by a properly equipped garage 1 Each headlight has two adjusting screws one controlling up and down movement and one controlling left and right movement see illustration It may be necessary to remove the grille see C
188. aft 32 Apply engine oil to the lips of the new oil seal then press it into the housing to its previously noted position To ensure the oil seal enters the housing squarely use a large socket and the crankshaft pulley bolt to pull it into position see illustration 33 Refit the key to the groove in the nose of the crankshaft Ja P 14 30 Locating a new gasket on the front of the cylinder block M40 engine 14 27b and remove the sleeve 34 Refit the stabilising roller to the front end cover and tighten the bolt 35 Refit the sprocket spacer and crankshaft pulley bolt Tighten the bolt to the specified torque while holding the crankshaft stationary using one of the methods previously described 36 Refit the timing belt tensioning roller but do not tighten the bolt at this stage 37 Refit the cylinder head as described in Section 12 38 Refit the timing belt as described in Section 10 39 Refit the sump See Section 13 15 Flywheel driveplate removal and refitting Why 1 Remove the transmission on vehicles with manual transmission see Chapter 7A on vehicles with automatic transmission see Chapter 7B 2 On vehicles with manual transmission remove the clutch see Chapter 8 3 Where necessary mark the relationship of the flywheel driveplate to the crankshaft so it can be refitted the same way 4 The flywheel driveplate is attached to the rear of the crankshaft with eight bolts Loosen and r
189. age 0 7 for the language resetting procedure Removal 1 Detach the battery negative cable 16 4a Remove the nuts and lift off the small terminal protector from the alternator cover then remove the nuts and the cover 2 Detach the electrical connectors from the alternator noting their locations for refitting see illustration Note On some models it may be necessary to remove the air cleaner assembly and airflow meter to gain access to the alternator 3 Loosen the alternator adjustment and pivot bolts and slip off the drivebelt see Chap ter 1 4 Remove the adjustment and pivot bolts and separate the alternator from the engine Refitting 5 f you are renewing the alternator take the old one with you when purchasing a new or reconditioned unit Make sure the new unit looks identical to the old alternator Look at the terminals they should be the same in number size and location as the terminals on the old alternator Finally look at the identifi cation numbers they will be stamped into the housing or printed on a tag attached to the housing Make sure the numbers are the same on both alternators 6 Many new alternators do not come with a pulley fitted so you may have to transfer the pulley from the old unit to the new one 7 Refitting is the reverse of removal 8 After the alternator is fitted adjust the drivebelt tension see Chapter 1 9 Check the charging voltage to verify proper operation of the al
190. age resetting procedure 2 With the ignition off connect a 12 volt test light between the battery negative post and the disconnected negative cable clamp If the test light does not come on refit the cable and proceed to paragraph 4 If the test light comes on there is a short drain in the electrical system of the vehicle The short must be repaired before the charging system can be checked Note Accessories which are always on such as the clock or the radio station memory must be disconnected before performing this check 3 Disconnect the alternator wiring harness If the test light now goes out the alternator is faulty If the light stays on remove each fuse in turn until the light goes out this will tell you which component is shorting out 4 Using a voltmeter check the battery voltage with the engine off It should be approximately 12 volts 5 Start the engine and check the battery voltage again It should now be approximately 14 to 15 volts 6 Turn on the headlights The voltage should drop and then come back up if the charging system is working properly 7 f the voltage reading is more than the specified charging voltage renew the voltage regulator refer to Section 16 If the voltage is less the alternator diode s stator or rotor may be faulty or the voltage regulator may be malfunctioning 8 If there is no short circuit causing battery drain but the battery is constantly discharging then either the batt
191. ain relay arrowed from the left side of the engine compartment to disable the fuel and ignition systems 525i model shown other models similar otherwise a small brush or even a bicycle tyre pump will work The idea is to prevent dirt from getting into the cylinders as the compression check is being done 3 Remove all the spark plugs from the engine see Chapter 1 4 Block the throttle wide open or have an assistant hold the throttle pedal down 5 On carburettor models disconnect the LT lead from the coil On fuel injection models disable the fuel pump and ignition circuit by removing the main relay see illustration This is to avoid the possibility of a fire from fuel being sprayed the engine compartment The location of the main relay is generally near the fuse panel area under the bonnet but refer to Chapter 12 for the specific location on your model 6 Fit the compression gauge in the No 1 spark plug hole No 1 cylinder is nearest the radiator 7 Turn the engine on the starter motor over at least seven compression strokes and watch the gauge The compression should build up quickly in a healthy engine Low compression on the first stroke followed by gradually increasing pressure on successive strokes indicates worn piston rings A low compression reading on the first stroke which doesn t build up during successive strokes indicates leaking valves or a blown head gasket a cracked head could also be the cau
192. aint stripper Refer to the warning at the start of Section 16 Note This procedure applies to both the front and rear disc brakes 1 Remove the cap s from the brake fluid reservoir and syphon off about two thirds of the fluid from the reservoir Failing to do this 3 5b Unplug the electrical connector for the brake pad wear sensor 3 Series 3 5e Remove the outer brake pad 3 Series to fit the new pads reverse the removal procedure Braking system 9 3 could result in the reservoir overflowing when the caliper pistons are pressed back into their bores 2 Loosen the wheel bolts raise the front or rear of the vehicle and support it securely on axle stands 3 Remove the front or rear wheels as applicable Work on one brake assembly at a time using the assembled brake for reference if necessary 4 Inspect the brake disc carefully as outlined in Section 5 If machining is necessary follow the information in that Section to remove the disc at which time the pads can be removed from the calipers as well 5 Follow the accompanying photos beginning with illustration 3 5a for the pad removal procedure Be sure to stay in order and read the caption under each illustration Note 1 Different types of front calipers are used on 3 and 5 Series models Illustrations 3 5a to 3 5e are for the front calipers on 3 Series models Illustrations 3 5f to 3 5m are for the front calipers on 5 Series models There s no photo sequence fo
193. akdown Every 6000 miles 9 Check all rubber fuel hoses for deterioration and chafing Check especially for cracks in areas where the hose bends and just before connectors such as where a hose attaches to the fuel pump or fuel filter for example 10 Only high quality fuel hose should be used Never under any circumstances use unreinforced vacuum hose clear plastic tubing or water hose for fuel hoses 11 Band type clamps are commonly used on fuel hoses These clamps often lose their tension over a period of time and can be sprung during removal Renew all band type clamps with screw clamps whenever a hose is renewed Metal lines 12 Sections of metal line are often used between the fuel pump and fuel injection system Check carefully to make sure the line isn t bent crimped or cracked 13 Ifa section of metal line must be renewed use seamless steel tubing only since copper and aluminium tubing do not have the strength necessary to withstand the vibration caused by the engine 14 Check the metal brake lines where they enter the master cylinder and brake proportioning or ABS unit if used for cracks in the lines and loose fittings Any sign of brake fluid leakage calls for an immediate thorough inspection of the braking system Power steering hoses 15 Check the power steering hoses for leaks loose connections and worn clamps Tighten loose connections Worn clamps or leaky hoses should be renewed 11 Drivebe
194. aks at the sump drain plug and around the oil filter If 7 2 The power steering fluid reservoir arrowed is located on the left side of the engine compartment Every 6000 miles 6 17c and lift out the cartridge either one is leaking stop the engine and tighten the plug or filter slightly 23 Wait a few minutes then recheck the level on the dipstick Add oil as necessary 24 During the first few days after an oil change make it a point to check frequently for leaks and proper oil level 25 The old oil drained from the engine cannot be re used in its present state and should be discarded Oil reclamation centres and some service stations will accept the oil which can be recycled After the oil has cooled it can be transferred into a container for transport to a disposal site Note It is antisocial and illegal to dump oil down the drain To find the location of your local oil recycling QU B ANE LINE bank call this 0800 66 33 66 number free 7 Power steering fluid level BN check SS A 1 Check the power steering fluid level periodically to avoid steering system problems such as damage to the pump Proceed as follows 7 4 The power steering fluid level should be kept between the two arrows near the upper step on the dipstick 6 19 Renewing the rubber O ring in the cover Caution Do not hold the steering wheel against either stop full left or full right lock for more than five seconds If
195. al The steering must be unlocked ignition switch turned to position 1 Remember that power assisted steering where fitted and the brake servo will not work with the engine switched off Roadside Repairs HAYNES J ump starting will get you out of trouble but you must correct HiNT whatever made the battery go flat in the first place There are three possibilities The battery has been drained by repeated attempts to start or by v leaving the lights on When jump starting a car using a booster battery observe the following precautions Before connecting the booster battery make sure that the ignition is The charging system is not working switched off properly alternator drivebelt slack or broken alternator wiring fault or alternator itself faulty Ensure that all electrical equipment lights heater wipers etc is Switched off The battery itself is at fault electrolyte low or battery worn out Connect the other end of the red lead to the positive terminal of the booster battery 1 Connect one end of the red jump lead to the positive terminal of the flat battery ee n V 1 l l l 0 9 J ump starting v sure that the booster battery is the same voltage as the discharged one in the vehicle v Ifthe battery is being jump started from the battery in another vehicle
196. al and refitting 8 Drivebelt check adjustment and renewal See Chapter 1 General Jh POTIS d uc uci race dede dole CACERES ee RED en 1 Ignition coil check and renewal Degrees of difficulty Easy Suitable for a novice with little Fairly easy suitable for beginner with X experience Fairly difficult A suitable for competent X experienced DIY gt DIY mechanic X X Ignition sensors Motronic system check and renewal 12 Ignition system e 6 Ignition system general information and precautions 5 Ignition timing TCI system check and adjustment 7 Impulse generator and ignition control unit check and renewal TC SySEOll 10 Spark plug HT lead check and renewal See Chapter 1 Spark plug renewal See Chapter 1 Starter motor in vehicle 19 Starter motor removal refitting 20 Starter solenoid removal and refitting 21 Starting system general information and precautions 18 Voltage regulator 16 Difficult suitable for Very difficult suitable for expert mechanic DIY or professional Specifications General Application Models with carburettor or L J
197. amage to the CV joints when the trailing arms are lowered to remove the Springs 4 Place a trolley jack under the trailing arm 5 f the vehicle has a rear anti roll bar disconnect the bar from its connecting links or disconnect the links from the trailing arms see Section 12 6 Loop a chain through the coil spring and bolt the chain together to prevent the coil Spring from popping out when the trailing arm is lowered Be sure to leave enough slack in the chain to allow the spring to extend completely 7 Disconnect the shock absorber lower mounting bolt see Section 9 carefully lower the trailing arm and remove the coil spring Refitting 8 Refitting is the reverse of removal As the trailing arm is raised back up make sure the Spring seats properly 11 Rear shock absorber coil spring assembly 5 Series removal and refitting Removal Note Although shock absorbers don t always wear out simultaneously renew both left and right shock absorbers at the same time to prevent handling peculiarities or abnormal ride quality 11 3 Shock absorber upper mounting nuts arrowed on a later E34 5 Series model 1 Loosen the wheel bolts then chock the front wheels Raise the vehicle and support it securely on axle stands Remove the wheels 2 Remove the shock absorber lower mounting bolt see illustration 3 On early models peel back the trim inside the luggage compartment far enough to access the
198. and the subframe or steering knuckle etc for cuts tears or leaking grease If you note any of these conditions renew the control arm or thrust arm the balljoints are not available separately 3 Place a large lever under the balljoint and try to push the balljoint up Next position the lever between the arm and the subframe or between the arm and steering knuckle If you can see or feel any movement during either check a worn balljoint is indicated 4 Have an assistant grasp the tyre at the top and bottom and shake the top of the tyre with an in and out motion Touch the balljoint stud nut If any looseness is felt suspect a worn balljoint stud or a widened hole in the subframe or steering knuckle If the latter 10 10 8 8 2 Using a hammer and chisel knock out the dust cap in the centre of the hub problem exists a new subframe or steering arm 5 Series or steering knuckle 3 Series which is integral with the strut housing should be fitted as well as the new balljoint Renewal Note None of these balljoints can be serviced or renewed individually If one of them is worn a complete new arm must be fitted 8 Front hub and wheel bearing gt assembly removal and refitting X Note Removing the front hub bearing assembly renders it unfit for re use A new assembly will be required for refitting Removal 1 Loosen the wheel bolts then raise the front of the vehicle and support it securely on axle s
199. ap isn t critical unless it s greater than 1 0 mm Again double check to make sure you have the correct rings for your engine 7 Repeat the procedure for each ring that will be fitted in the first cylinder and for each ring in the remaining cylinders Remember to keep rings pistons and cylinders matched up 8 Once the ring end gaps have been checked corrected the rings can be fitted on the pistons 9 The oil control ring lowest one on the piston is usually fitted first It s normally composed of three separate components Slip the spacer expander into the groove see illustration If an anti rotation tang is used make sure it s inserted into the drilled hole in the ring groove Next refit the lower side rail Don t use a piston ring refitting tool on the oil ring side rails as they may be damaged Instead place one end of the side rail into the groove between the spacer expander and the ring land hold it firmly in place and slide a finger around the piston while pushing the rail into the groove see illustration Next refit the upper side rail in the same manner 10 After the three oil ring components have been fitted check to make sure that both the upper and lower side rails can be turned smoothly in the ring groove 11 The middle ring is fitted next It s usually stamped with a mark which must face up towards the top of the piston Note Always follow the instructions printed on the ring package or box different ma
200. approximately 750 rpm If the idle speed rises above approximately 950 rpm the idle air stabiliser valve closes and stops extra air from bypassing the throttle plate reducing the idle speed stabiliser valve it should typically be 9 to 10 ohms L J etronic system 2 1 etronic systems are equipped with a separate idle speed control unit computer located under the facia The idle air stabiliser valve has an adjusting screw Early models are equipped with plastic valves but they still can be adjusted by removing the hose and inserting a very thin screwdriver inside 3 Early Motronic systems are also equipped with a separate idle speed control unit computer located under the facia The idle air stabiliser valve has an adjusting screw 4 On later Motronic systems the idle air stabiliser valve is ECU controlled and no provision is made for adjustment Preliminary check 5 Before performing any checks on the idle air stabiliser valve make sure these criteria are met a The engine must be at operating temperature 60 b Turn off all electrical accessories air conditioning heater controls headlights auxiliary cooling fan etc C The throttle position sensor must be operating correctly see Chapter 6 d There must not be any exhaust leaks e There must not be any vacuum leaks f Where fitted the oxygen sensor must be operating properly see Chapter 6 6 Connect a tachometer in accordance with the manufa
201. apter s Specifications On M10 M20 and M30 engines tighten the bolts in three stages On the M40 engine tighten all the bolts initially to the Stage 1 torque then angle tighten them by the angle given in the Specifications Carry out the angle tightening on each bolt in one controlled movement Don t rotate the crankshaft at any time during the tightening operation 14 Remove the bolts and carefully lift off the main bearing caps Keep them in order Don t disturb the Plastigage rotate the crankshaft If any of the main bearing caps are difficult to remove tap them gently from side to side with a soft face hammer to loosen them 15 Compare the width of the crushed Plastigage on each journal to the scale printed on the Plastigage envelope to obtain the main bearing oil clearance see illustration Check the Specifications to make sure it s correct 16 If the clearance is not as specified the 25 3 After removing the retainer from the block support it on two wooden blocks and drive out the old seal with a punch and hammer bearing shells may be the wrong size which means different ones will be required Before deciding that different shells are needed make sure that no dirt or oil was between the bearing shells and the caps or block when the Clearance was measured If the Plastigage was wider at one end than the other the journal may be tapered see Section 19 17 Carefuly scrape all traces of the Plastigage mat
202. ar 14 Refit the steering box Align the mark on the pinion gear shaft with the mark on the universal joint shaft and tighten the steering box bolts to the torque listed in this Chapter s Specifications 15 The remainder of refitting is the reverse of removal Be sure to use new Self locking nuts on the universal joint shaft the centre track rod the steering box and the crossmember Also use new sealing washers on the hydraulic line fittings 16 Refer to Chapter 1 and fill the power 21 10b This bolt arrowed attaches the steering box to the body the nut not visible in this photo is on the front side of the steering box 21 10a This bolt arrowed secures the steering box to the subframe crossmember The nut not visible in this photo is accessed through a hole in the crossmember engine removed for clarity left hand drive shown steering reservoir with the recommended fluid then bleed the system as described in Section 23 Check for leakage from the lines and connections 22 Power steering pump removal and refitting Removal 1 Raise the vehicle and support it securely on axle stands Remove the engine undertray 2 On 5 Series E28 old shape models discharge the hydraulic system by depressing the brake pedal about 20 times before loosening the hydraulic line fittings 3 Disconnect the fluid return hose and drain the power steering fluid from the reservoir into a clean containe
203. ar crossmember and Slightly lower the rear of the transmission 22 Remove the transmission to engine block bolts using a Torx socket Note The bolts holding the bellhousing to the engine block will require a swivel at the socket and a very long extension going back towards the transmission 23 Remove the engine mounting to frame bracket nuts On the M40 engine unbolt the dampers from the mountings 24 Recheck to be sure nothing is still connecting the engine to the transmission or vehicle Disconnect anything still remaining 25 Raise the engine slightly Carefully work it forwards to separate it from the transmission If you re working on a vehicle with an automatic transmission you may find the torque converter comes forward with the engine If it stays with the transmission leave it but you may find it easier to let it come forward until it can be grasped easier and be pulled from the crankshaft Note When refitting the torque converter to the transmission before the engine is refitted be Sure to renew the transmission front pump seal which will probably be damaged when the converter comes out with the engine Either method is acceptable but be prepared for some fluid to leak from the torque converter if it comes out of the transmission If you re working on a vehicle with a manual transmission draw the engine forwards until the input shaft is completely disengaged from the clutch Slowly raise the engine out of the engine c
204. ary to use force press or drive only against the bearing inner race see illustration 11 Fit a new hub nut and tighten it finger tight at this stage 12 Refit the brake disc its countersunk retaining screw and the brake caliper see Chapter 9 13 Refit the wheel and lower the vehicle to the ground 14 Tighten the hub nut to the torque listed in of pipe to drive against the inner race of the new bearing 8 8a If the hub sticks knock it loose with a hammer this Chapter s Specifications Again make sure you do this with the vehicle on the ground not up on axle stands 15 Raise the front of the vehicle and place it securely on axle stands Remove the wheel 16 Stake the collar of the nut into the groove of the spindle 17 Apply suitable sealant to a new grease cap and fit the cap by driving it into place with a soft faced mallet 18 Refit the wheel and wheel bolts Lower the vehicle to the ground and tighten the wheel bolts to the torque listed in the Chapter 1 Specifications 9 Rearshock absorbers 3 Series removal and refitting Removal Note Although shock absorbers don t always wear out simultaneously renew both left and right shock absorbers at the same time to prevent handling peculiarities or abnormal ride quality 1 Chock the front wheels 2 Raise the rear of the vehicle and support it securely on axle stands Support the trailing arm with a trolley jack Place a block of wood o
205. as well See Section 6 for additional information regarding the different possibilities to be considered 5 f you re planning a complete overhaul the engine must be dismantled and the internal components removed in the following general order Valve cover Intake and exhaust manifolds Timing belt or chain covers Timing chain belt Water pump Cylinder head Sump Oil pump Piston connecting rod assemblies Crankshaft and main bearings Camshaft Rocker shafts and rocker arms M 10 M 20 and M30 engines Cam followers and hydraulic tappets M40 engine Valve spring retainers and springs Valves 6 Before beginning the dismantling and 2Be Er E 7 3 Engine left hand mounting bracket 40 engine overhaul procedures make sure the following items are available Also refer to Section 21 for a list of tools and materials needed for engine reassembly Common hand tools Small cardboard boxes or plastic bags for storing parts Compartment type metal box for storing the hydraulic tappets M40 engine Gasket scraper Ridge reamer Vibration damper puller Micrometers Telescoping gauges Dial indicator set Valve spring compressor Cylinder surfacing hone Piston ring groove cleaning tool Electric drill motor Tap and die set Wire brushes Oil gallery brushes Cleaning solvent 8 Cylinder head dismantling N A 1 Remove the cylinder head see Chapter 2A 2 Remove the oil supply tube from its moun
206. ate If the blower motor spins the fan blades rapidly this test simulates high speed operation the blower motor is OK If the blower motor does not operate or operates slowly or noisily renew it Note If the fan blade assemblies need to be removed mark their relationship to the shaft The assemblies are balanced during production and excessive noise or shortened bearing life could result if they are not refitted in exactly the same position in relation to the shaft Refitting 8 Refitting is the reverse of removal Note The blower motor may have to be rotated to allow the retaining clip to line up correctly 10 Heater and air conditioner control assembly removal and refitting Removal 1 Disconnect the battery negative cable 9 5b and unclip the centre strap that secures the blower motor assembly 9 2b a fastener from the top secure the panel Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 Series models 2 Remove the centre console and side trim pieces 3 Remove the radio see Chapter 12 then pull the knobs off the heater air conditioning control levers 4 Remove the heater trim panel to gain access to the contr
207. ate on some models it s located under the rear seat cushion on others it s located under the carpet in the luggage compartment Disconnect the output hose from the transfer pump and connect a fuel pressure gauge to the outlet pipe 32 Reconnect the battery 33 Using a jumper wire bridge the terminals of the fuel pump relay 34 Turn the ignition switch on to operate the fuel pump 35 Note the pressure reading on the gauge and compare to the value listed in this Chapter s Specifications 36 If the indicated pressure is less than specified renew the transfer pump Fuel pump relay check 37 Switch on the ignition 38 Using a voltmeter probe the following terminals from the back of the relay electrical connector Check for battery voltage at terminal 30 M20 and M30 engines or terminal 15 M10 and M40 engines Note If there is no voltage on models with luggage compartment mounted batteries check for a faulty fusible link The 50 amp link is about 6 inches from the battery in a black wire 39 Turn the ignition off and disconnect the relay from the electrical connector Using a voltmeter probe the connector terminals that correspond to fuel pump relay pins 85 and 86 on M20 and M30 engines or terminal 50 and earth on M10 and 40 engines Have assistant turn the engine over on the starter and observe the voltage reading Battery voltage should be indicated 40 If there is no voltage check the fuse s an
208. ate identification number or code being essential to correct identification of the component concerned F The VIN arrowed is stamped on the bulkhead When ordering spare parts always give as much information as possible Quote the vehicle model year of manufacture Vehicle Identification Number and engine numbers as appropriate The Vehicle Identification Number VIN is located on the right hand front wheel arch next to the front suspension strut upper mounting on the driver s door and on a plate on top of the facia just inside the windscreen see illustrations The engine number is stamped on a machined face on the left hand side of the cylinder block near the base of the oil level dipstick tube The body number is located on the seam between the left hand front wing and inner panel The VIN is also present on the edge of the driver s door REF rere20 Glossary of Technical Terms A ABS Anti lock brake system system usually electronically controlled that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheels that are about to skid Air bag An inflatable bag hidden in the steering wheel driver s side or the dash or glovebox passenger side In a head on collision the bags inflate preventing the driver and front passenger from being thrown forward into the steering wheel or windscreen Air cleaner A metal or plastic housing containing a filter elemen
209. attery Sec tion 13 Renew the spark plugs Section 14 Inspect the spark plug HT leads distributor cap and rotor Section 15 Check the air filter Section 20 Check the cooling system Section 22 Major tune up All items listed under minor tune up plus Check the ignition system See Chapter 5 Check the charging system see Chapter 5 Check the fuel system See Chapter 4 Renew the spark plug HT leads distributor cap and rotor Section 15 the two notches or marks see illustration 5 It takes one litre of oil to raise the level from the lower mark to the upper mark on the dipstick Do not allow the level to drop below the lower mark or oil starvation may cause 4 4 The oil level should be kept between the two marks preferably at or near the upper one if it isn t add enough oil to bring the level to the upper mark 1 8 M 4 The threaded oil filler is located in the valve cover always make sure the area around the opening is clean before unscrewing the cap engine damage Conversely overfilling the engine adding oil above the upper mark may cause oil fouled spark plugs oil leaks or oil seal failures 6 To add oil remove the filler cap located on the valve cover see illustrations After adding oil wait a few minutes to allow the level to stabilise then pull the dipstick out and check the level again Add more oil if required Refit the filler cap tightening it by hand onl
210. ber gloves 3 Raise the vehicle and place it on axle Stands Make sure it is safely supported and as level as possible 4 Move the necessary equipment under the vehicle being careful not to touch any of the hot exhaust components 5 Place the drain pan under the transmission and remove the filler level plug from the side of the transmission Loosen the drain plug see illustration 6 Carefully remove the drain plug Be careful not to burn yourself on the lubricant 7 Allow the lubricant to drain completely Clean the drain plug thoroughly then refit and tighten it securely 8 Refer to Section 16 and fill the transmission with new lubricant then refit the filler level plug tightening it securely 9 Lower the vehicle Check for leaks at the drain plug after the first few miles of driving 32 Differential lubricant change EN SS N 1 Drive the vehicle for several miles to warm up the differential lubricant then raise the vehicle and support it securely on axle stands 2 Move a drain pan rags newspapers and an Allen key under the vehicle Since the lubricant will be hot wear rubber gloves to prevent burns 3 Remove the filler level plug from the differential this is the upper of the two plugs 4 With the drain pan under the differential loosen the drain plug this is the lower of the two plugs see illustration 5 Carefully unscrew the drain plug until you can remove it from the case 6 Allow all the oil to drain
211. bic locking compounds are used to keep fasteners from vibrating or working loose and cure only after installation in the absence of air Medium strength locking compound is used for small nuts bolts and screws that may be removed later High strength locking compound is for large nuts bolts and studs which aren t removed on a regular basis Oil additives range from viscosity index improvers to chemical treatments that claim to reduce internal engine friction It should be noted that most oil manufacturers caution against using additives with their oils Fuel additives perform several functions depending on their chemical make up They usually contain solvents that help dissolve gum and varnish that build up on carburettor fuel injection and intake parts They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers Some additives contain upper cylinder lubricants for valves and piston rings and others contain chemicals to remove condensation from the fuel tank Miscellaneous Brake fluid is specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake systems It is poisonous and inflammable Care must be taken so this fluid does not come in contact with painted surfaces or plastics An opened container should always be resealed to prevent contamination by water or dirt Brake fluid absorbs moisture from the air if left in an unsealed container
212. bility chipped sagging or cracked coil springs explore all options before beginning any work Strut or shock absorber assemblies complete with springs may be available on an exchange basis which eliminates much time and work Whichever route you choose to take check on the cost and availability of parts before dismantling the vehicle Warning Dismantling a strut or coil over shock absorber assembly is a potentially dangerous undertaking and utmost attention must be directed to the job or serious injury may result Use only a high quality spring compressor and carefully follow the manufacturer s instructions supplied with the tool After removing the coil spring from the strut assembly set it aside in a safe isolated area 2 Remove the strut or shock absorber assembly see Section 5 or 11 Mount the assembly in a vice Line the vice jaws with wood or rags to prevent damage to the unit and don t tighten the vice excessively 3 Following the tool manufacturer s instructions fit the spring compressor these can be obtained at most car accessory shops or it may be possible to hire one on the Spring and compress it sufficiently to relieve all pressure from the suspension support see illustration This can be verified by wiggling the spring 4 Prise the protective cap off the damper rod self locking nut Loosen the nut see illustration with a spanner while holding the 6 9 Loosen and remove the threaded collar and p
213. ble from your dealer or a car audio specialist On anti theft radios the clips are moved in and out by internal screws which require another type of tool Insert the tool into the holes until the clips release then withdraw the radio from the dash panel Disconnect the wiring from the radio and remove it c P yes uli 10 3 Use a Phillips screwdriver to remove the instrument cluster retaining screws 3 On some models the radio is held in place by screws located beneath the faceplate The control knobs must be pulled off before the faceplate can be withdrawn Refitting 4 Refitting is the reverse of removal 9 Aerial removal and refitting gt gt N theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Use circlip pliers to unscrew the aerial mounting nut 3 Open the boot lid tailgate and remove the left side trim panel On some models the jack and tail light cluster cover will have to be removed first 4 Unplug the aerial power and radio lead connectors as applicable remove the retaining bolts and remove the aerial and motor assembly Refitting 5 Ref
214. ble at a suitable working height Any workbench needs a vice one with a jaw opening of 100 mm is suitable for most jobs As mentioned previously some clean dry storage space is also required for tools as well as for any lubricants cleaning fluids touch up paints and so on which become necessary Another item which may be required and which has a much more general usage is an electric drill with a chuck capacity of at least 8 mm This together with a good range of twist drills is virtually essential for fitting accessories Last but not least always keep a supply of old newspapers and clean lint free rags available and try to keep any working area as Clean as possible Tap and die set REF uer General Repair Procedures Whenever servicing repair or overhaul work is Carried out on the car or its components observe the following procedures and instructions This will assist in carrying out the operation efficiently and to a professional standard of workmanship J oint mating faces and gaskets When separating components at their mating faces never insert screwdrivers or Similar implements into the joint between the faces in order to prise them apart This can cause severe damage which results oil leaks coolant leaks etc upon reassembly Separation is usually achieved by tapping along the joint with a soft faced hammer in order to break the seal However note that this method may not be suitable where
215. block but be sure to follow the directions on the filter or container 6 17 Unscrew the bolt 1 12 6 17b remove the cover Cartridge type oil filter 17 Some models are equipped with a cartridge type oil filter Unscrew the bolt remove the cover and lift the filter out see illustrations 18 Compare the new cartridge with the old one to make sure they are the same type then lower it into the housing 19 Using a clean rag wipe off the mounting Surface of the housing and cover If necessary renew the rubber O ring see illustration Smear some clean oil on the O ring and refit the cover and bolt Tighten the bolt securely All models 20 Remove all tools and materials from under the vehicle being careful not to spill the oil from the drain pan then lower the vehicle 21 Add new oil to the engine through the oil filler cap in the valve cover Use a funnel to prevent oil from spilling onto the top of the engine Pour the specified quantity of fresh oil into the engine Wait a few minutes to allow the oil to drain into the sump then check the level on the dipstick see Section 4 if necessary If the oil level is correct refit the filler cap 22 Start the engine and run it for about a minute The oil pressure warning light may take a few seconds to go out while the new filter fills with oil don t rev the engine while the light is on While the engine is running look under the vehicle and check for le
216. brake adjustment Handbrake cable s renewal Hydraulic brake servo description removal and refitting Master cylinder removal and refitting Stop light switch check and adjustment Difficult suitable for experienced DIY mechanic Very difficult suitable for expert N gt DIY or professional See Chapter 1 See Chapter 1 0 2mm Refer to marks cast into the disc they supersede information printed here Brake pedal adjustments Brake pedal servo pushrod adjustment A 3 Series Brake pedal height pedal to bulkhead distance 3 Series Left hand drive Right hand drive Stop light switch adjustment dimension A see Handbrake Handbrake shoe lining minimum thickness Handbrake lever travel 245 mm 5 0 mm to 6 0 mm 1 5 mm 5 to 8 clicks 9 2 Braking system Torque wrench settings Front disc brake caliper Caliper guide mounting bolts Caliper bracket to strut housing bolts 3 Serles 0 5 Series E28 old shape 5 Series E34 new shape Rear disc brake caliper Caliper guide mounting bolts Carrier to trailing arm bolts Brake hose to caliper fitting Master cylinder to brake servo nuts 3 Series 5 Series Brake servo mounting nuts Hydraulic line to hydraulic brake servo threaded fittings 5 Series E28 old shape Wheel bolts 1 General information All 3 Series models and 5 Series E28 ol
217. brasive cleaner polisher is required to avoid damage to the finish Always check that the door and ventilator opening drain holes and pipes are completely clear so that water can be drained out Brightwork should be treated in the same way as paintwork Windscreens and windows can be kept clear of the smeary film which often appears by the use of proprietary glass cleaner Never use any form of wax or other body or chromium polish on glass 11 11 2 Bodywork and fittings 3 Interior trim maintenance EN 55 Interior trim panels can be kept clean by wiping with a damp cloth If they do become stained which can be more apparent on light coloured trim use a little liquid detergent and a soft nail brush to scour the grime out of the grain of the material Do not forget to keep the headlining clean in the same way After cleaning application of a high quality rubber and vinyl protector will help prevent oxidation and cracks The protector can also be applied to weatherstrips vacuum lines and rubber hoses which often fail as a result of chemical degradation and to the tyres 4 Upholstery and carpets maintenance Mats and carpets should be brushed or vacuum cleaned regularly to keep them free of grit If they are badly stained remove them from the vehicle for scrubbing or sponging and make quite sure they are dry before refitting Seats and interior trim panels can be kept clean by wiping with a damp cloth If t
218. c types that there are no fluid leaks or damaged pipes C Inspect the shock absorbers for signs of serious fluid leakage Check for wear of the mounting bushes or attachments or damage to the body of the unit Driveshafts fwd vehicles only Rotate each front wheel in turn and inspect the constant velocity joint gaiters for splits or damage Also check that each driveshaft is straight and undamaged Braking system LI If possible without dismantling check brake pad wear and disc condition Ensure that the friction lining material has not worn excessively A and that the discs are not fractured pitted scored or badly worn Examine all the rigid brake pipes underneath the vehicle and the flexible hose s at the rear Look for corrosion chafing or insecurity of the pipes and for signs of bulging under pressure chafing splits or deterioration of the flexible hoses C Look for signs of fluid leaks at the brake calipers or on the brake backplates Repair or renew leaking components C Slowly spin each wheel while your assistant depresses and releases the footbrake Ensure that each brake is operating and does not bind when the pedal is released REF REF 4 d Examine the handbrake mechanism checking for frayed or broken cables excessive corrosion or wear or insecurity of the linkage Check that the mechanism works on each relevant wheel and releases fully without binding
219. cally enough the best time to clean the underframe and wheel arches is in wet weather when the mud is thoroughly wet and soft In very wet weather the underframe is usually cleaned of large accumulations automatically and this is a good time for inspection Periodically except on vehicles with a wax based underbody protective coating it is a good idea to have the whole of the underframe of the vehicle steam cleaned engine compartment included so that a thorough inspection can be carried out to see what minor repairs and renovations are necessary Steam cleaning is available at many garages and is necessary for the removal of the accumulation of oily grime which sometimes is allowed to become thick in certain areas If steam cleaning facilities are not available there are some excellent grease solvents available which can be brush applied the dirt can then be simply hosed off Note that these methods should not be used Difficult suitable for experienced DIY mechanic losa wd oh prance ea 2 Fixed glass renewal 8B Tr 6 1 dl TTE 5 Hinges and locks 7 TOIT 10 Interior trim maintenance 3 Latch lock cylinder and handles removal refitting and EEE a 11 abs PI 98 LD ee E 13 Radiator grille re
220. caused by contaminants Electrical cleaner removes oxidation corrosion and carbon deposits from electrical contacts restoring full current flow It can also be used to clean spark plugs carburettor jets voltage regulators and other parts where an oil free surface Is desired Moisture dispersants remove water and moisture from electrical components such as alternators voltage regulators electrical connectors and fuse blocks They are non conductive and non corrosive Degreasers are heavy duty solvents used to remove grease from the outside of the engine and from chassis components They can be sprayed or brushed on and are usually rinsed off with water Lubricants Engine oil is the lubricant formulated for use in engines It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear Engine oil comes in various weights viscosity ratings from 5 to 60 The recommended weight of the oil depends on the season temperature and the demands on the engine Light oil is used in cold climates and under light load conditions Heavy oil is used in hot climates and where high loads are encountered Multi viscosity multigrade oils are designed to have characteristics of both light and heavy oils and are available in a number of weights from 5W 20 to 20W 50 Gear oil is designed to be used in differentials manual transmissions and other areas where high temperature lubrication is required
221. chorages Any corrosion which has seriously reduced the thickness of a load bearing area is likely to cause the vehicle to fail In this case professional repairs are likely to be needed Damage or corrosion which causes sharp or otherwise dangerous edges to be exposed will also cause the vehicle to fail 4 Checks carried out on YOUR VEHICLE S EXHAUST EMISSION SYSTEM Petrol models Have the engine at normal operating temperature and make sure that it is in good tune ignition system in good order air filter element clean etc Before any measurements are carried out raise the engine speed to around 2500 rpm and hold it at this speed for 20 seconds Allow the engine speed to return to idle and watch for smoke emissions from the exhaust tailpipe If the idle speed is obviously much too high or if dense blue or clearly visible black smoke comes from the tailpipe for more than 5 seconds the vehicle will fail As a rule of thumb blue smoke signifies oil being burnt engine wear while black smoke signifies unburnt fuel dirty air cleaner element or other carburettor or fuel system fault An exhaust gas analyser capable of measuring carbon monoxide CO and hydrocarbons HC is now needed If such an instrument cannot be hired or borrowed a local garage may agree to perform the check for a small fee CO emissions mixture At the time of writing the maximum CO level at idle is 3 596 for vehicles firs
222. ckthe fuses e Follow the wiring harness to each front and rear wheel and verify that all connections are secure and that the wiring is undamaged If the above preliminary checks do not rectify the problem the vehicle should be 3 5a On 3 Series models unscrew the caliper mounting bolts left arrows right arrows point to the caliper bracket bolts which should only be removed if you re removing the brake disc 3 5d Remove the caliper brake pad wear sensor and inner pad all at the same time 3 Series then refit the inner pad on the piston and press the piston fully into the bore with a C clamp diagnosed by a dealer service department Due to the complex nature of this system all actual repair work must be done by a dealer service department 3 Disc brake pads renewal Warning Disc brake pads must be renewed on both front wheels or both rear wheels at the same time NEVER renew the pads on only one wheel Also the dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes Do not under any circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only When servicing the disc brakes use only original equipment or high quality brand name pads Warning Brake fluid is poisonous It is also an effective p
223. clip the handbrake cable from the trailing arm see Chapter 9 5 Remove the ABS wheel sensor if applicable from the trailing arm and unclip the sensor wire harness from the arm Position the sensor aside so it won t be damaged during removal of the trailing arm 6 If you re removing the right trailing arm unplug the connector for the brake pad wear sensor if applicable 7 Disconnect the rear anti roll bar from the trailing arm see Section 12 8 On 1983 and later models remove one of the rear axle carrier bolts see illustration 9 Disconnect the shock absorber lower mounting bolt see Section 11 10 Remove the two trailing arm pivot bolts and nuts and remove the trailing arm from the vehicle 11 Inspect the pivot bolt bushes If they re cracked dried out or torn take the trailing arm to an engineering works and have new ones fitted The bush inner sleeve is longer on one side Make sure the bushes are fitted with 14 3 Disconnect the brake hose left arrow from the fitting on the metal brake line right arrow at this bracket 14 8 1983 and later models remove one of these trailing arm to axle carrier bolts it doesn t matter which one you remove one attaches the link to the trailing arm and the other attaches the link to the axle carrier the longer side of the sleeve facing towards the centre of the vehicle Refitting 12 Refitting is the reverse of removal Refit the inner pivot bolt first
224. complete have the front wheel alignment checked and if necessary adjusted 21 7 Subframe crossmember bolts arrowed 21 Steering box 5 Series removal and refitting Removal Note If you find that the steering box is defective it is not recommended that you overhaul it Because of the special tools needed to do the job it is best to let your dealer service department overhaul it for you otherwise fit a new unit Removal and refitting the steering box is outlined here 1 5 Series E28 old shape models discharge the hydraulic system by depressing the brake pedal about 20 times 2 Using a large syringe or hand pump empty the power steering fluid reservoir see Chap ter 1 3 Raise the front of the vehicle and support it securely on axle stands 4 Support the front of the engine with a trolley jack Place a block of wood between the jack head and the sump to protect the sump from damage 5 Remove the pivot bolts from the inner ends of the front control arms see Section 4 6 Remove the nuts from the left and right engine mountings see Chapter 2 7 Remove the mounting bolts two on each side on earlier models three on each side on later models from the subframe crossmember see illustration and remove the subframe 8 Remove the nuts and bolts that secure the universal joint shaft to the steering box worm shaft Slide the universal joint shaft up and off the worm shaft Inspect the u
225. component or housing Spring or split washers should always be renewed when they are used to lock a critical component such as a big end bearing retaining bolt or nut Locktabs which are folded over to retain a nut or bolt should always be renewed Self locking nuts can be re used in non critical areas providing resistance can be felt when the locking portion passes over the bolt or stud thread However it should be noted that self locking stiffnuts tend to lose their effectiveness after long periods of use and should then be renewed as a matter of course Split pins must always be replaced with new ones of the correct size for the hole When thread locking compound is found on the threads of a fastener which is to be re used it should be cleaned off with a wire brush and solvent and fresh compound applied on reassembly Special tools Some repair procedures in this manual entail the use of special tools such as a press two or three legged pullers spring com pressors etc Wherever possible suitable readily available alternatives to the manu facturer s special tools are described and are shown in use In some instances where no alternative is possible it has been necessary to resort to the use of a manufacturer s tool and this has been done for reasons of safety as well as the efficient completion of the repair operation Unless you are highly skilled and have a thorough understanding of the procedures described nev
226. components are discussed separately from body related electrical devices such as the lights the instruments etc which are included in Chapter 12 Always observe the following precautions when working on the electrical systems Be extremely careful when servicing engine electrical components They are easily damaged if improperly checked connected or handled b Never leave the ignition switched on for long periods of time with the engine off c Don t disconnect the battery cables while the engine is running d Observe the rules when jump starting your vehicle Read the precautions at the front of this manual e Always disconnect the battery negative cable first and connect it last to reduce the risk of accidental short circuits f Don t charge the battery with the cables connected to the terminals It s also a good idea to review the safety related information regarding the engine electrical systems in the Safety first section near the front of this manual before beginning any operation included in this Chapter Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetti
227. control arm to the steering knuckle If you don t have a balljoint separator tool dust boot If the boot does become damaged and you re refitting the same control arm and balljoint be sure to fit a new boot 13 Unscrew the nut which secures the outer control arm balljoint to the steering knuckle see illustration and detach the balljoint stud from the knuckle see illustration Ideally you should use purpose made balljoint separator tool for this job Using a hammer is OK if you re going to fit new parts anyway but is not recommended if you re planning to re use parts 14 Remove the control arm i E 4 L ur T A 4 5 If you re removing the control arm remove the three bolts arrowed from the steering arm and separate the strut assembly from the arm 4 6b If you re removing the thrust arm remove the nut and bolt arrowed that secure the rear end of the arm Suspension and steering systems 10 5 3 13b give the steering knuckle a few sharp knocks with a hammer to release the balljoint stud from the strut housing and remove the control arm 15 If you re renewing the control arm you ll have to fit a new bush see above The old bush can t be removed re used in another control arm 16 Refitting is the reverse of removal Be sure to use new self locking nuts on the balljoint studs and tighten them and the bush bracket bolts to the torques listed in this Chapter s Specifications
228. cracks or damage 8 Check the converter connections for tightness 9 Check the insulation covers welded onto the catalytic converter for damage or a loose fit Caution If an insulation cover is dented so that it touches the converter housing inside excessive heat may be transferred to the floor 10 Start the engine and run it at idle speed Check all converter connections for exhaust gas leakage Fuel exhaust systems 4 21 Fuel injection system fault finding L J etronic fuel injection system Engine difficult to start or fails to start when cold Probable cause Cold start injector or thermotime switch faulty Fuel pump inoperative Airflow meter flap door binding or stuck in open position Fuel pressure incorrect Intake air leaks Fuel injectors clogged or not operating Coolant temperature sensor faulty or wiring problem Throttle position sensor TPS incorrectly adjusted Incorrect ignition timing Dirt or other contaminants in fuel Faulty ECU Corrective action Test cold start injector and thermotime switch Renew faulty components See Section 19 Check fuel pump fuse and fuel pump relay See Sections 3 and 4 Inspect the airflow meter for damage see Section 16 Test system pressure See Section 3 Test fuel pressure regulator Section 18 Inspect all vacuum lines air ducts and oil filler and dipstick seals Check fuel injectors see Section 20 and wiring harness Test coolant temperature sensor
229. ct the pivot bolt bushes If they re cracked dried out or torn take the trailing arm to an engineering works and have them new ones fitted Each bush has a larger diameter shoulder on one end Make sure this larger diameter shoulder on each bush faces away from the trailing arm ie the inner bush shoulder faces the centre of the vehicle and the outer bush shoulder faces away from the vehicle Refitting 8 Refitting is the reverse of removal Support the trailing arm with a trolley jack and raise it to simulate normal ride height then tighten the nuts and bolts to the torque listed in this Chapter s Specifications Be sure to bleed the brakes as described in Chapter 9 14 Rear trailing arms 5 Series removal and refitting x X x Removal 1 Loosen the wheel bolts then chock the front wheels Raise the rear of the vehicle and support it securely on axle stands Remove the wheel s 13 6 Nut arrowed for the outer pivot bolt 72 E a1 12 3b Bolt arrowed connecting rear anti roll bar link to trailing arm 5 Series 2 Remove the driveshaft see Chapter 8 3 Disconnect the rear brake hose from the metal brake line at the bracket on the trailing arm see illustration Note For information on disconnecting brake hose to metal line connections see Chapter 9 Plug the line and hose to prevent dirt ingress and loss of brake fluid 4 Disconnect the handbrake cable from the handbrake actuator and un
230. cteristics as well as tyre life Whenever a new tyre is fitted the tyre and wheel should be balanced Vertical of Vehicle Camber Angle Front View Vertical of Ball Joint Axis rwo Caster Angle Side View 26 1 Wheel alignment details 1 Aminus B degrees camber 2 minus F toe in expressed in inches or mm 3 toe in expressed in degrees Suspension and steering systems 10 17 26 Wheel alignment general information HIK Wheel alignment refers to the adjustments made to the wheels so they are in proper angular relationship to the suspension and the road Wheels that are out of proper alignment not only affect vehicle control but also increase tyre wear The front end angles normally measured are camber castor and toe in see illustration Front wheel toe in is adjustable on all models castor is not adjustable Camber is only adjustable by replacing the strut upper mount with a special eccentric version Toe in is adjustable on the rear wheels but only by replacing the trailing arm outer bushings with special eccentric bushings Setting the proper wheel alignment is a very exacting process one in which complicated and expensive equipment is necessary to perform the job properly Because of this you should have a technician with the proper equipment perform these tasks We will however use this space to give you a basic idea of what is involved with wheel alignment so yo
231. ctor lever pointing to a gear other than the one actually being used Vehicle moves when in Park Refer to Chapter 7B for the shift linkage adjustment procedure Engine will start in gears other than Park or Neutral Inhibitor switch malfunctioning Chapter 7B Transmission slips shifts roughly is noisy or has no drive in forward or reverse gears There are many probable causes for the above problems but the home mechanic should be concerned with only one possibility fluid level Before taking the vehicle to an automatic transmission specialist check the level and condition of the fluid as described in Chapter 1 Correct the fluid level as necessary or change the fluid if needed If the problem persists have a professional diagnose the probable cause REF Fault Finding Brakes Note Before assuming that a brake problem exists make sure that a The tyres are in good condition and properly inflated Chapter 1 b The wheel alignment tracking is correct Chapter 10 c The vehicle is not loaded with weight in an unequal manner Vehicle pulls to one side during braking Incorrect tyre pressures Chapter 1 Wheel alignment tracking incorrect Chapter 10 Unmatched tyres on same axle Restricted brake lines or hoses Chapter 9 Malfunctioning caliper assembly Chapter 9 Loose suspension parts Chapter 10 Loose calipers Chapter 9 Noise high pitche
232. cturer s instructions Caution The ignition must be switched off before making any electrical connections 7 The idle air stabiliser valve operates continuously when the ignition is on Start the engine and make sure the valve is vibrating and humming slightly L J etronic system Check 8 With the engine running disconnect the electrical connector from the valve The idle speed should increase to about 2 000 rpm 9 f the idle speed does not increase turn the engine off Using an ohmmeter check the resistance across the terminals of the valve 21 19 Location of the adjustment screw on the metal type idle air stabiliser valve L J etronic system see illustration It should be 9 to 10 ohms with the ambient air temperature at about 209 C 10 Using a pair of jumper wires apply battery voltage to the valve and confirm that the valve closes tightly When the voltage is removed the valve should re open 11 If the idle air stabiliser valve fails any of the tests renew it 12 If the idle air stabiliser valve passes the tests check the control current 13 Unplug the electrical connector from the valve Using a jumper wire connect one terminal of the electrical connector to one of the terminals on the valve Connect an ammeter 0 to 1000 mA range between the other terminal on the electrical connector and the remaining terminal on the valve Start the engine and allow it to idle With the engine running the current
233. cult suitable for experienced DIY mechanic d Edo ak wh es 7 Jona SENSOIS s c S ees didi ace fara 2 ores ee ee 3 Motronic engine management system self diagnosis PT 6 general information _2 See Chapter 1 Positive crankcase ventilation PCV system 5 N Very difficult suitable forexpet ay gt DIY or professional X 1 General information To prevent pollution of the atmosphere from incomplete combustion or evaporation of the fuel and to maintain good driveability and fuel economy a number of emission control systems are used on these vehicles Not all of these systems are fitted to all models but they include the following Catalytic converter Evaporative emission control EVAP system Positive crankcase ventilation PCV system Electronic engine management The Sections in this Chapter include general descriptions checking procedures within the scope of the home mechanic as well as component renewal procedures when possible for each of the systems listed above Before assuming that an emissions control system is malfunctioning check the fuel and ignition systems carefully The diagnosis of some emission control devices requires specialised tools equipment and training If checking and servicing become too difficult or if a procedure is beyond your ability consult a dealer service department or other specialist
234. d Shape models are equipped with front disc brakes and either rear drum or rear disc brakes 5 Series E34 new shape models have disc brakes front and rear Front and rear brakes are self adjusting on all models Some later models are equipped with an Anti lock Braking System ABS this is described in Section 2 Hydraulic system The hydraulic system consists of two separate circuits The master cylinder has separate reservoirs for the two circuits in the event of a leak or failure in one hydraulic circuit the other circuit will remain operative Brake servo The vacuum brake servo utilising engine manifold vacuum and atmospheric pressure to provide assistance to the hydraulically operated brakes is mounted on the bulkhead in the engine compartment A hydraulic brake servo system is used on 5 Series E28 models This system uses hydraulic pressure from the power steering pump to assist braking Handbrake The handbrake operates the rear brakes and is cable operated via a lever mounted in the centre console The handbrake assembly on rear drum brake models is part of the rear drum brake assembly and is self adjusting On rear disc brake models the handbrake uses a pair of brake shoes located inside the centre portion of the rear brake disc and is manually adjusted Brake pad wear warning system The brake pad wear warning system is linked to a red warning light in the instrument Nm 30 to 35 67 14
235. d See paragraph 10 Cleaning 2 Scrape all traces of old gasket material and sealing compound off the cylinder head intake manifold and exhaust manifold sealing Surfaces Be very careful not to gouge the cylinder head Special gasket removal solvents are available at motor factors 3 Remove all built up scale from the coolant passages 4 Run a Stiff brush through the various holes to remove deposits that may have formed in them 5 Run an appropriate size tap into each of the threaded holes to remove corrosion and thread sealant that may be present If compressed air is available use it to clear the holes of debris produced by this operation Warning Wear eye protection when using compressed air 6 Clean the cylinder head with solvent and dry it thoroughly Compressed air will speed the drying process and ensure that all holes b 9 12 dial indicator be used to determine the valve stem to guide clearance move the valve as indicated by the arrows and recessed areas are clean Note Decarbonising chemicals are available and may prove very useful when cleaning cylinder heads and valve train components They are very caustic however and should be used with caution Be sure to follow the instructions on the container 7 Clean all the rocker shafts arms followers Springs valve springs spring seats keepers and retainers with solvent and dry them thoroughly Clean the components from on
236. d air to clean the condenser d Make sure the system has the correct refrigerant charge as described below 2 It s a good idea to operate the system for about 10 minutes at least once a month particularly during the winter Long term non use can cause hardening and subsequent failure of the seals 3 Because of the complexity of the air conditioning system and the special equipment necessary to service it in depth fault diagnosis and repair procedures are not included in this manual However simple checks and component renewal procedures are provided in this Chapter 4 The most common cause of poor cooling is simply a low system refrigerant charge If a noticeable loss of cool air output occurs the following quick check may help you determine if the refrigerant level is low 5 Warm the engine up to normal operating temperature 6 Set the air conditioning temperature selector at the coldest setting and put the blower at the highest setting Open the doors to make sure the air conditioning system doesn t switch off as soon as it cools the passenger compartment 7 With the compressor engaged the compressor clutch will make an audible click and the centre of the clutch will rotate feel the tube located adjacent to the right front frame rail near the radiator 8 If a significant temperature drop is noticed the refrigerant level is probably OK 9 f the inlet line has frost accumulation or feels cooler than the receiv
237. d area to remove the powdery rust from the Surface of the remaining metal Paint the affected area with rust inhibiting paint if the back of the rusted area is accessible treat this also Before filling can take place it will be necessary to block the hole in some way This can be achieved by the use of aluminium or plastic mesh or aluminium tape Aluminium or plastic mesh or glass fibre matting is probably the best material to use for a large hole Cut a piece to the approximate size and shape of the hole to be filled then position it in the hole so that its edges are below the level of the surrounding bodywork It can be retained in position by several blobs of filler paste around its periphery Aluminium tape should be used for small or very narrow holes Pull a piece off the roll trim it to the approximate size and shape required then pull off the backing paper if used and Stick the tape over the hole it can be overlapped if the thickness of one piece is insufficient Burnish down the edges of the tape with the handle of a screwdriver or similar to ensure that the tape is securely attached to the metal underneath Bodywork repairs filling and respraying Before using this Section see the Sections on dent deep scratch rust holes and gash repairs Many types of bodyfiller are available but generally speaking those proprietary kits which contain a tin of filler paste and a tube of resin hardener are best for th
238. d check that there are no oil leaks from the sump gasket or other disturbed components 14 Oil pump removal inspection and refitting Removal 1 Remove the sump see Section 13 M10 M20 and M30 engines 2 On M10 and M30 engines remove the three bolts that attach the gear to the front of the pump see illustration Note Some models have a single centre nut attaching the gear to the oil pump 3 Unbolt the oil pump from the engine block see illustrations and remove it 4 On the M20 engine the intermediate shaft drives the oil pump driveshaft which drives the oil pump To remove the driveshaft remove the hold down plate from the block and lift out the plug Check the condition of the O ring and renew it if necessary Lift the driveshaft out and check both gears for wear renewing them if worn or damaged see illustration 5 Ifthe gear on the intermediate shaft is worn or the intermediate shaft bearing is worn or damaged the intermediate shaft must be removed Remove the engine see Chap ter 2B then remove the timing belt crankshaft and intermediate shaft sprockets see Section 10 and the engine front cover see Section 11 The intermediate shaft can be slid out the front of the engine M40 engines 6 Remove the timing belt as described in Section 10 7 Remove the cylinder head as described in Section 12 8 Unscrew the nut and remove the timing belt tensioner from the front end cover see illustrati
239. d from the exhaust This is common to many catalytic converter equipped cars and seems to be due to the small amount of sulphur found in some petrols reacting with hydrogen in the exhaust to produce hydrogen sulphide H2S gas while this gas is toxic it is not produced in sufficient amounts to be a problem Once the car has covered a few thousand miles the problem should disappear in the meanwhile a change of driving style or of the brand of petrol used may effect a solution k The catalytic converter used on a well maintained and well driven car should last for 50 000 to 100 000 miles from this point on the CO level should be carefully checked regularly to ensure that the converter is still operating efficiently If the converter is no longer effective it must be renewed 941 Chapter 5 Engine electrical systems Contents Air gap TCI system check and 11 Alternator removal and refitting 15 Alternator brushes check and 17 Battery emergency jump starting 2 Battery removal refitting 3 Battery cables check and 4 Battery check and maintenance Charging system check 14 Charging system general information and precautions 13 Distributor remov
240. d remove the gasket see illustrations Refitting 16 Remove the old gasket then carefully scrape all traces of sealant off the head and the manifold mating surfaces Be very careful not to nick or scratch the delicate aluminium mating surfaces Gasket removal solvents are available at motor factors and may prove helpful Make sure the surfaces are perfectly Clean and free of dirt and oil 5 12 Removing the support bracket from the bottom of the intake manifold M40 engine 5 15a Removing the lower intake manifold M40 engine 5 9c and gaskets 17 Check the manifold for corrosion at the coolant passages cracks warping and other damage Cracks and warping normally show up near the gasket surface around the stud holes If defects are found have the manifold repaired or renew it as necessary 18 When refitting the manifold always use a new gasket Where one side of the gasket has a graphite surface this must face the cylinder head 19 Refit the nuts and bolts and tighten them gradually working from the centre out to the ends to the torque listed in this Chapter s Specifications 20 The remainder of refitting is the reverse of removal On the M40 engine renew the gaskets between the upper and lower parts of the manifold 5 14a Remove the intake manifold nuts with a socket ratchet and long extension M20 engine 5 15b Removing the lower intake manifold gasket M40 engine 2A 2A 6 In car engi
241. d squeal when the brakes are applied Front and or rear disc brake pads worn out The noise comes from the wear sensor rubbing against the disc Renew the pads immediately Chapter 9 Brake vibration pedal pulsates Note If the vehicle has ABS it is normal for the brake pedal to pulsate when the system is working Excessive lateral disc run out Chapter 9 Parallelism not within specifications Chapter 9 Uneven pad wear caused by caliper not sliding due to improper clearance or dirt Chapter 9 Defective disc Chapter 9 Excessive brake pedal travel Partial brake system failure Chapter 9 Insufficient fluid in master cylinder Chapters 1 and 9 Air trapped in system Chapters 1 and 9 Excessive pedal effort required to stop vehicle Malfunctioning brake servo unit Chapter 9 Partial system failure Chapter 9 Excessively worn pads or shoes Chapter 9 Caliper piston stuck or sluggish Chapter 9 Brake pads contaminated with oil or grease Chapter 9 New pads fitted and not yet seated It will take a while for the new material to seat against the disc Dragging brakes Master cylinder pistons not returning correctly Chapter 9 Restricted brakes lines or hoses Chapters 1 and 9 Incorrect handbrake adjustment Chapter 9
242. d the wiring circuit for the fuel pump relay If the voltage readings are correct and the fuel pump only runs with the jumper wire in place then renew the relay 41 If the fuel pump still does not run check for the proper voltage at the fuel pump terminals see Section 4 If necessary renew the fuel pump 4 Fuel pump transfer pump and fuel level sender unit removal and refitting Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Also don t work in a garage where a natural gas type appliance with a pilot light is present Fuel pump carburettor engines 1 Disconnect the battery negative cable Disconnect both hoses from the pump and unscrew and remove the two securing nuts see illustration 2 Carefully withdraw the pump from the cylinder head If it s stuck a slight downward tap on the thick insulating distance piece with a piece of wood should free it 3 Remove the two thin gaskets 4 The fuel pump is a sealed unit and it is not possible to renew any of the internal components Should an internal fault occur it must be renewed complete Fuel and exhaust systems 4 5 ny 4 1 Fuel pump on carburettor engines 5 Refitting is a reversal of the removal procedure but renew the thin gaskets each side of the insulating distance piece and tighten the fuel pump down e
243. dal 12 Repeat paragraphs 10 and 11 until no more air is seen leaving the tube then tighten the bleed screw and proceed to the left rear wheel the right front wheel and the left front wheel in that order and perform the same procedure Be sure to check the fluid in the master cylinder reservoir frequently Warning Never re use old brake fluid It absorbs moisture from the atmosphere which can allow the fluid to boil and render the brakes inoperative 13 Refill the master cylinder with fluid at the end of the operation 14 Check the operation of the brakes The pedal should feel solid when depressed with no sponginess If necessary repeat the entire process Do not operate the vehicle if you are in doubt about the effectiveness of the brake system 6 Ny 16 9 Place one end of the tubing over the bleed screw and submerge the other end in brake fluid in the container 2 A TA 254 Chapter 6 Engine management emission control systems Contents Catalytic converter Electronic Control Unit ECU removal and refitting Evaporative emissions control EVAP system Evaporative emissions control system inspection General information Degrees of difficulty Fairly easy suitable for beginner with some experience Easy suitable for CUN novice with little experience Fairly difficult A Q suitable for competent S X DIY mechanic Diffi
244. der head insert two bolts in the special lugs at the top and bottom of the pump and tighten them evenly to press the pump out of the head see illustrations ks i 7 23 Fita new O ring on the M40 engine water pump 7 18a With the water pump mounting bolts removed screw two bolts into the special lugs one top and one bottom Refitting 19 Clean the bolt threads and the threaded holes in the engine to remove corrosion and sealant 20 Compare the new pump to the old one to make sure they re identical 21 Remove all traces of old gasket material from the engine with a gasket scraper 22 Clean the water pump mating surfaces 23 On the M40 engine locate a new O ring on the pump see illustration 24 Locate the gasket on the pump and offer the pump up to the engine see illustration Slip a couple of bolts through the pump mounting holes to hold the gasket in place 25 Carefully attach the pump and gasket to the engine threading the bolts into the holes finger tight Note On the M 20 engine refit the lower bolt finger tight then rotate the water pump into position with the drivebelt tensioner spring and pin in position 26 Refit the remaining bolts if they also hold an accessory bracket in place be sure to reposition the bracket at this time Tighten them to the torque listed in this Chapter s Specifications in quarter turn increments Don t overtighten them or the pump may be distorted 27 Refit all parts remo
245. ding VALVE MARGIN WIDTH 9 14 The margin width on each valve must be as specified if no margin exists the valve cannot be reused 9 16 Check each valve spring for squareness that they re suitable for use in a rebuilt engine take the springs to a machine shop for this check 16 Stand each spring on a flat surface and check it for squareness see illustration If any of the springs are distorted or sagged or possibly have a broken coil fit new parts 17 Check the spring retainers and keepers for obvious wear and cracks Any questionable parts should be renewed as extensive damage will occur if they fail during engine operation Rocker arms M10 M20 and M30 engines Note The rocker arms for the exhaust valves are the most subject to wear and should be checked with particular care 18 Inspect all the rocker arms for excessive wear on the tips that contact the valve stem and camshaft see illustration 19 Check the rocker arm radial clearance see Section 8 If it s excessive either the rocker arm bush or the shaft or both is excessively worn To determine which is more worn slide the rocker arm onto an unworn portion of the rocker arm shaft and check the radial clearance again If it s now within speci fications the shaft is probably the most worn component If it s not within specifications the rocker arm bushes should be renewed Rocker arm shafts M10 M20 and M30 engines 20 Check the
246. ditioning refrigerant forms a poisonous gas if exposed to a naked flame including a cigarette It can also cause skin burns on contact Asbestos Asbestos dust can cause cancer if inhaled or swallowed Asbestos may be found in gaskets and in brake and clutch linings When dealing with such components it is safest to assume that they contain asbestos Remember DO Do use eye protection when using power tools and when working under the vehicle Do wear gloves or use barrier cream to protect your hands when necessary Do get someone to check periodically that all is well when working alone on the vehicle Do keep loose clothing and long hair well out of the way of moving mechanical parts Do remove rings wristwatch etc before working on the vehicle especially the electrical system Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job Special hazards Hydrofluoric acid This extremely corrosive acid is formed when certain types of synthetic rubber found in some O rings oil seals fuel hoses etc are exposed to temperatures above 400 C The rubber changes into a charred or sticky substance containing the acid Once formed the acid remains dangerous for years If it gets onto the skin it may be necessary to amputate the limb concerned When dealing with a vehicle which has suffered a fire or with components salvaged from such a vehicle w
247. djusting screw until it is within the correct range see illustration Note On metal type valves the adjusting screw is mounted externally On plastic type valves the adjustment screw is inside and can be reached by removing the hose at the end of the valve Motronic systems Check Note There are two types of idle air stabiliser valve on these systems early models usually have a two wire valve while later models are equipped with a three wire valve 20 With the engine running disconnect the electrical connector from the valve The idle speed should increase to about 2000 rpm 21 Ifthe idle speed does not increase a Two wire valve Using a pair of jumper wires apply battery voltage to the valve and confirm that the valve closes tightly When the voltage is removed the valve should re open Also check the resistance of the valve see illus tration 21 9 The resistance should be about 9 or 10 ohms b Three wire valve Turn the engine off and unplug the electrical connector from the valve Using an ohmmeter check the resistance on the two outer terminals of the valve see illustration It should be about 40 ohms Check the resistance on the centre and outside terminals of the valve They should both be about 20 ohms 22 f the idle air stabiliser valve fails any of the tests renew it 23 If the idle air stabiliser valve tests are all correct check the control current two wire valve or the voltage
248. done raise the vehicle and support it securely on axle stands Remove the front wheels 10 The disc brake calipers containing the pads are now visible Each caliper has an outer and an inner pad all pads should be checked 11 Note the pad thickness by looking through the inspection hole in the caliper see illustration If the lining material is 2 0 mm thick or less or if it is tapered from end to end the pads should be renewed see Chapter 9 Keep in mind that the lining 26 15 If the lining is bonded to the brake shoe measure the lining thickness from the outer surface to the metal shoe as shown here A if the lining is riveted to the shoe measure from the lining outer surface to the rivet head material is bonded to a metal plate or shoe the metal portion is not included in this measurement Always renew the pads on both sides of the vehicle in axle sets even if only one pad of the four is worn or uneven braking may result 12 Remove the calipers without disconnecting the brake hoses see Chap ter 9 13 Check the condition of the brake disc Look for score marks deep scratches and overheated areas they will appear blue or discoloured If damage or wear is noted the disc can be removed and resurfaced by an engineering workshop otherwise it will have to be renewed In either case both discs Should be involved even if only one is worn Refer to Chapter 9 for more detailed inspection and repair proce
249. door trim panel See Section 12 Disconnect any electrical connectors and A 13 5 Remove the nuts arrowed and detach the door from the hinges push them through the door opening so they won t interfere with door removal 2 Place a trolley jack or axle stand under the door or have an assistant on hand to support it when the hinge bolts are removed Note If a jack or axle stand is used place a rag between it and the door to protect the door s painted surfaces 3 Scribe or mark around the door hinges 4 Disconnect the door check strap by prising the circlip out of the end of the pin then slide the pin out see illustration A roll pin is fitted to some models this is removed by driving it out with a pin punch 5 Remove the hinge to door nuts carefully lift off the door see illustration Refitting and adjustment 6 Refitting is the reverse of removal 7 Following refitting of the door check the alignment and adjust it if necessary as follows a Up and down and fore and aft adjustments are made by loosening the hinge to body nuts and moving the door as necessary b The door lock striker can also be adjusted both up and down and sideways to provide positive engagement with the lock mechanism This is done by loosening the mounting bolts and moving the striker as necessary see illustration and 14 Boot lid tailgate removal refitting and adjustment Boot lid 1 Open the boot lid and cover t
250. doubt about its condition fit a new one them to the new cap in the exact same location do not simultaneously remove all the HT leads or firing order mix ups may occur 16 Manual transmission lubricant level check 1 The transmission has filler level plug which must be removed to check the lubricant level If the vehicle is raised to gain access to the plug be sure to support it safely do not crawl under a vehicle which 15 supported only by a jack Note The vehicle should be level to give an accurate lubricant check 2 Remove the plug from the side of the 16 2 Use a large Allen key to remove the filler level plug arrowed and check the lubricant level with your little finger It should be level with the bottom of the hole if it s low add lubricant Every 12 000 miles INSUFFICIENT SPRING TENSION EVIDENCE OF PHYSICAL CONTACT WITH CAP ROTOR CORRODED 15 114 The rotor arm should be checked for wear and corrosion as indicated here if in doubt about its condition buy a new one transmission see illustration and use your little finger to reach inside the plug from the housing and feel the lubricant level It should be at or very near the bottom of the plug hole 3 If it isn t add the recommended lubricant through the plug hole with a syringe or squeeze bottle until it just starts to run out of the hole Refer to Lubricants and fluids at the beginning of this Chapter for
251. dures Drum brakes 14 Refer to Chapter 9 and remove the rear brake drums 15 Note the thickness of the lining material on the rear brake shoes and look for signs of contamination by brake fluid or grease see illustration If the material is within 2 0 mm of the recessed rivets or metal shoes renew the brake shoes The shoes should also be renewed if they are cracked glazed shiny lining surfaces or contaminated with brake fluid or grease See Chapter 9 for the renewal procedure 16 Check the shoe return and hold down springs and the adjusting mechanism Make sure all these components are fitted correctly Every 12 000 miles 27 5 Press the retaining tab in then slide the wiper blade assembly down and out of the hook in the end of the wiper arm and are in good condition Deteriorated or distorted springs if not renewed could allow the linings to drag and wear prematurely 17 Check the wheel cylinders for leakage by carefully peeling back the rubber boots Slight moisture behind the boots is acceptable If brake fluid is noted behind the boots or if it runs out of the wheel cylinder the wheel cylinders must be overhauled or renewed see Chapter 9 18 Check the drums for cracks score marks deep scratches and high spots which will appear as small discoloured areas If imperfections cannot be removed with emery cloth both drums must be resurfaced by a specialist see Chapter 9 for more detailed information
252. during reassembly Series E28 old shape models pump the brake pedal five or six times before turning the steering wheel Once the fluid level remains constant continue turning the wheel back and forth until no more bubbles appear in the fluid in the reservoir 5 Lower the vehicle to the ground Run the engine and again turn the wheels from lock to lock several more times Recheck the fluid level Position the wheels straight ahead 24 Steering wheel removal and refitting Warning If the vehicle is equipped with an airbag do not attempt this procedure Have it performed by a dealer service department or other qualified specialist as there is a risk of injury if the airbag is accidentally triggered Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Using a small screwdriver prise off the BMW emblem in the centre of the steering wheel 3 Remove the steering wheel nut and mark the relationship of the steering wheel hub to the shaft See illustration 4 On all 3 Series models and on 1986 and later 5 Series models turn the ignition key to the first position to unlock the ignition lock
253. e has cooled completely and there s no pressure remaining in the cooling system Removing the cap from a hot engine risks personal injury by scalding Heating system The heating system consists of a blower fan and heater matrix located in the heater box with hoses connecting the heater matrix to the engine cooling system and the heater air conditioning control head on the dashboard Hot engine coolant is circulated through the heater matrix passages all the time the engine is running Switching the heater on opens a flap door to direct air through the heater matrix and the warmed air enters the passenger compartment A fan switch on the control head activates the blower motor which forces more air through the heater matrix giving additional heater output for demisting etc Air conditioning system The air conditioning system consists of a condenser mounted in front of the radiator an evaporator mounted adjacent to the heater matrix a Compressor mounted on the engine a filter drier receiver drier which contains a high pressure relief valve and the plumbing connecting all of the above components A blower fan forces the warmer air of the passenger compartment through the evaporator matrix a radiator in reverse transferring the heat from the air to the refrigerant The liquid refrigerant boils off into low pressure vapour taking the heat with it when it leaves the evaporator Note Refer to the precautions at the sta
254. e If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Fairly easy Suitable for beginner with some experience Fairly difficult SS X suitable for competent X gt DIY mechanic X mechanic 2 Electrical system fault EN finding general information x A typical electrical circuit consists of an electrical component any switches relays motors fuses fusible links or circuit breakers etc related to that component and the wiring and connectors that link the components to both the battery and the chassis To help you pinpoint an electrical circuit problem wiring diagrams are included at the end of this book Before tackling any troublesome electrical circuit first study the appropriate wiring diagrams to get a complete understanding of what makes up that individual circuit Troublespots for instance can often be isolated by noting if other components related to that circuit are routed through the same fuse and earth connections Electrical problems usually stem from Simple causes such as loose or corroded connectors a blown fuse a melted fusible link or a bad relay Inspect all fuses wires and connectors in a problem circuit first The basic tools needed include a circuit tester a high impedance digital voltmeter a continuity tester and a jumper wire with an in line circuit breaker for bypassing electrical component
255. e valve at a time to avoid mixing up the parts Caution DO NOT clean the hydraulic tappets of the M40 engine leave them completely immersed in oil 8 Scrape off any heavy deposits that may have formed on the valves then use a motorised wire brush to remove deposits from the valve heads and stems Again make sure the valves don t get mixed up Inspection Note Be sure to perform all of the following inspection procedures before concluding that machine shop work is required Make a list of the items that need attention Cylinder head 9 Inspect the head very carefully for cracks evidence of coolant leakage and other damage If cracks are found check with an machine shop concerning repair If repair isn t possible a new cylinder head should be obtained 10 Using a straightedge and feeler gauge check the head gasket mating surface for warpage see illustration If the warpage exceeds the limit listed in this Chapter s Specifications it may be possible to have it resurfaced at a machine shop providing the head is not reduced to less than the specified minimum thickness 11 Examine the valve seats in each of the combustion chambers If they re badly pitted cracked or burned the head will require servicing that s beyond the scope of the home mechanic WORN VALVE NEW VALVE 9 13 Check for valve wear at the points shown here 1 Valve tip 4 Stem most worn 2 Collet groove area 3 Stem least worn 5 Valve f
256. e by bolts arrowed Bodywork and fittings 11 9 ur s 4 19 5a Pull the tilt lever down where fitted and lower the shroud from the steering column i 19 5b Rotate the upper shroud up and off the steering column the retractors return the belt against your chest while driving and rewind the belt fully when the buckle is unlocked 4 If any of the above checks reveal problems with the seat belt system renew parts as necessary 5 Belts which have been subject to impact loads must be renewed 20 3 Grasp the seat at the front edge and pull up sharply Saloon Convertible models 11 Chapter 10 Suspension and steering systems Contents Balljoints check and renewal 7 Control arm 3 Series inspection removal and refitting and BUSTO iuuenes dub tiaia aetas ed 3 Control and thrust arms 5 Series inspection removal and refitting and bush renewal 4 Front anti roll bar removal and refitting 2 Front hub and wheel bearing assembly removal and refitting 8 Front strut assembly removal and refitting 5 General information i e OR eae ee RC 1 Power steering fluid level check See Chapter 1 Power steering pump removal refitting 22 Power steering system 0
257. e clips and withdraw the bonnet support pins see illustration 10 Remove the pins from the hinges see illustration 11 Have an assistant hold onto the bonnet on one side while you hold the other side 12 Remove the bonnet to hinge through bolt on your side of the bonnet then hold your side of the bonnet while your assistant removes the through bolt on the other side see illustration 13 Remove the bonnet Place it somewhere safe where it will not be knocked over with rags to protect the paintwork where it rests on the ground or against a wall 14 Refitting is the reverse of the removal M i 10 10 Support the bonnet and withdraw the pin 10 18 Loosen the bolts A and adjust the roller guide from side to side until it engages securely in the catch Bodywork and fittings 11 5 a 10 8b prise the retainer out Adjustment 15 The bonnet can be adjusted to obtain a flush fit between the bonnet and wings after loosening the bonnet hinge bolts On some 5 Series models it will be necessary to remove the Side grille sections for access to the hinge bolts 16 Move the bonnet from side to side or front to rear until the bonnet is properly aligned with the wings at the front Tighten the bolts securely 17 The rear height of the bonnet can be adjusted by loosening the bolts and raising or lowering the catch see illustration After adjustment tighten the bolts securely 18 Side to side adjustment of
258. e economic to buy many of these tools Where this is the case you could consider clubbing together with friends or joining a motorists club to make a joint purchase or borrowing the tools against a deposit from a local garage or tool hire specialist It is worth noting that many of the larger DIY superstores now carry a large range of special tools for hire at modest rates The following list contains only those tools and instruments freely available to the public and not those special tools produced by the vehicle manufacturer specifically for its dealer network You will find occasional references to these manufacturers special tools in the text of this manual Generally an alternative method of doing the job without the vehicle manufacturers special tool is given However sometimes there is no alternative to using them Where this is the case and the relevant tool cannot be bought or borrowed you will have to entrust the work to a franchised garage Valve spring compressor see illustration Valve grinding tool Piston ring compressor see illustration Piston ring removal installation tool see illustration Cylinder bore hone see illustration Balljoint separator 1 Coil spring compressors where applicable Two three legged hub and bearing puller see illustration Spline bit set REF rere Tools and Working Facilities Spline key set Valve spring compressor Piston r
259. e generator resistance Warning Do not crank the engine over for an excessive length of time If necessary disconnect the cold start injector electrical connector see Chapter 4 to stop the flow of fuel into the engine 10 To check the resistance in the impulse generator proceed as described for your system below a On Bosch units measure the resistance between connector terminals 5 and 6 see illustration 10 8 The reading should be 1000 to 1200 ohms b On Siemens Telefunken units measure the resistance between the terminals of the smaller connector The reading should be 1000 to 1200 ohms 11 If the resistance readings are incorrect renew the impulse generator If the resistance readings for the impulse generator are correct and the control unit voltages supply voltage paragraphs 1 to 6 and signal voltage paragraphs 7 to 9 are incorrect renew the control unit Renewal Ignition control unit 12 Make sure the ignition is switched off 13 Disconnect the electrical connector s from the control unit 14 Remove the mounting screws from the control unit and lift it from the engine compartment 10 18 Use circlip pliers and remove the circlip from the distributor shaft 15 Refitting is the reverse of removal Note On Bosch control units a special dielectric grease is used between the heat sink and the back of the control unit In the event the two are separated renewal or testing the old grease must
260. e illustrations 11 Working from underneath the driver s side of the facia reach up and detach the accelerator cable from the top of the pedal 12 Pull the cable through the bulkhead from the engine compartment side 13 Refitting is the reverse of removal Adjust the cable as described earlier 10 Carburettor general information 1 Early models are fitted with a Solex 2B4 carburettor and later models are fitted with a Solex 2BE carburettor Both carburettors are of downdraught two stage type The first stage is operated mechanically by the accelerator pedal and the second stage by vacuum control 2 Each stage has its own float chamber float assembly and needle valve designed to reduce the effects of braking and centrifugal forces 3 On the 2B4 version the primary stage choke valve is operated by an automatic choke a bi metal spring which is electrically heated during the warm up period Warm up enrichment is also provided by a coolant operated thermal valve and air temperature controlled flow valve 4 On the 2BE version an electronic control 11 6 Note the locations of the carburettor vacuum hoses arrowed before disconnecting them 9 10a Rotate the throttle valve and remove the cable end from the slotted portion of the valve unit is used to automatically adjust the carburettor settings during warm up and normal temperature operation The control unit is located beneath the right hand side of the fac
261. e in the float chamber maintains the fuel at a constant level A fuel return system channels excess fuel back to the fuel tank On fuel injection models an electric fuel pump supplies fuel under constant pressure to the fuel rail which distributes fuel to the injectors The electric fuel pump is located inside the fuel tank on later models or beside the fuel tank on early models Early models also have a transfer pump located in the fuel tank The transfer pump acts as an aid to the larger main pump for delivering the necessary pressure A fuel pressure regulator controls the pressure in the fuel system The fuel system also has a fuel pulsation damper located near the fuel filter The damper reduces the pressure pulsations caused by fuel pump operation and the opening and closing of the injectors The amount of fuel injected into the intake ports is precisely controlled by an Electronic Control Unit ECU or computer Some later 5 Series models have a fuel cooler in the return line Electronic control system fuel injection system Besides altering the injector opening duration as described above the electronic control unit performs a number of other tasks related to fuel and emissions control It accomplishes these tasks by using data relayed to it by a wide array of information located throughout the engine Sensors 2 1a Removing the fuel pump fuse on 3 Series models compartment comparing this information to its sto
262. e of removal 5 Intake manifold gt gt removal and refitting N Removal 1 Allow the engine to cool completely then relieve the fuel pressure on fuel injection engines see Chapter 4 2 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 Drain the engine coolant see Chapter 1 below the level of the intake manifold If the coolant is in good condition it can be saved and reused 4 On fuel injection engines loosen the hose clamp and disconnect the large air inlet hose from the throttle body It may also be necessary to remove the entire air cleaner inlet hose assembly to provide enough working room see Chapter 4 4 7 Removing the valve cover gasket on the M40 engine 5 On the M40 engine remove the nuts and special bolts 5 On carburettor engines remove the complete air cleaner assembly see Chap ter 4 6 Disconnect the coolant hoses from the throttle body intake manifold as applicable 7 Disconnect the throttle cable and if applicable cruise control cable see Chap ter 4 8 Remove the EGR valve and line where applicable see Chapter 6 9 At this stage on the M40 engine
263. e pump see illustration 10 Using hose clamps pinch shut the fuel hoses on each side of the fuel pump If you don t have any hose clamps wrap the hoses with rags and clamp them shut with self locking pliers tightened just enough to prevent fuel from flowing out 11 Disconnect the hoses from the pump 12 Remove the fuel pump mounting screws 4 6 Fuel and exhaust systems 4 9 Lift up the rubber boots arrowed and detach the electrical connectors from the fuel pump 4 15 Remove the fuel pump cover screws arrowed and lift the cover off the floor of the vehicle on some models the fuel pump cover is located under the rear seat on other models it s located in the luggage compartment and clamps and remove the fuel pump from the under the vehicle 13 Refitting is the reverse of removal In tank fuel pump or transfer pump 14 Onsome models access to the fuel pump is gained by removing the rear seat cushion On other models access is gained by removing the carpet from the luggage compartment 15 Remove the screws from the fuel pump access cover see illustration 16 Remove the cover 17 Locate the fuel pump and sender unit electrical connectors see illustrations and B pr 4 17b To unplug the connector prise the bracket until the notch aligns with the slot on the retaining clip and release the connector from the assembly TEE 4 18a On models with locking lugs use two screwdrivers to
264. e screws and detach the centre and side grille pieces 7 Refitting is the reverse of removal E34 new shape models Centre grille 8 Remove the screws and detach the headlight covers in the engine compartment for access 9 Remove the screw and lift out the plastic cover behind the centre grille for access to the clips 10 From the engine compartment reach under the headlight housings and detach the clips retaining the centre grille valances then push the grille forwards see illustration 11 Use a screwdriver to depress the clips detach the grille assembly and remove it by pulling it straight out 12 Refit the centre grille by placing it in position and pushing it straight back until it clips into place Side grille 13 Remove the centre grille 14 Remove the screws and lift the side grille assembly out see illustration 15 Refitting is the reverse of removal cmm 10 1 Use paint or a marking pen to mark on the hinge plate around the bolt heads mark around the entire hinge plate if desired before adjusting the bonnet 9 2b Side grille screw locations arrowed 10 Bonnet removal refitting and BN adjustment SS A Note The bonnet is heavy and somewhat awkward to remove and refit at least two people should perform this procedure Removal and refitting 3 Series models 1 Open the bonnet Scribe or draw alignment marks around the bolt heads to ensure proper alignment on refitting see illust
265. e the contact face of the valve cover 12 If it s necessary to remove the crankshaft Sprocket remove the crankshaft hub centre bolt while holding the crankshaft steady Note The removal of the crankshaft hub mounting bolt requires a heavy duty holding device because of the high torque used to tighten the bolt BMW has a special tool numbered 112150 M20 engines or 112170 M40 engines for this purpose If this tool cannot be bought or borrowed check with a tool dealer or motor factors for a tool capable of doing the job Note that the tool number 112170 bolts on the rear of the cylinder head and engages with the flywheel ring gear so it will only be possible to use this tool if the gearbox has been removed or if the engine is out of the vehicle see illustrations On 10 12a Home made tool for holding the crankshaft stationary while the crankshaft pulley bolt is being loosened engine removed for clarity models with a two piece hub after removing the outer hub piece you ll then need to remove the sprocket with a bolt type puller available at most motor factors When using the puller thread the crankshaft centre bolt in approximately three turns and use this as a bearing point for the puller s centre bolt Inspection 13 Check for a cracked worn or damaged belt Renew it if any of these conditions are found see illustrations Also look at the sprockets for any signs of irregular wear or damage indicating the n
266. e the two screws from the vacuum advance unit and separate it from the distributor by moving the assembly down while unhooking it from the baseplate pin 22 Use circlip pliers to remove the circlip that retains the impulse generator and the baseplate assembly 23 Carefully remove the impulse generator and the baseplate assembly as a single unit 10 19 Carefully prise the trigger wheel off the distributor shaft 24 Remove the three screws and separate the baseplate assembly from the impulse generator 25 Refitting is the reverse of removal Note Be sure to position the insulating ring between the generator coil and the baseplate It must be centred before tightening the mounting screws Also it will be necessary to check adjust the air gap if the trigger wheel has been removed or tampered with to the point that the clearance is incorrect see Section 11 11 Air gap TCI system check and adjustment WU Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 Insert a brass feeler gauge between the trigger wheel tab and the impu
267. eads Dirt corrosion sealant and damaged threads will affect torque readings see illustration If the bolts or their threads are damaged do not re use the bolts fit a new set 26 Refit any components removed from the head prior to cleaning and inspection On the M40 engine locate a new rubber O ring in the groove in the top of the oil pump front end cover housing see illustration 27 Make sure the gasket sealing surfaces of 12 25 A die should be used to remove sealant and corrosion from the head bolt threads prior to installation the engine block and cylinder head are clean and oil free Lay the head gasket in place on the block with the manufacturer s stamped mark facing up it usually says UP OBEN or something similar Use the dowel pins in the top of the block to properly locate the gasket 28 Carefully set the cylinder head in place on the block Use the dowel pins to properly align it Where the engine is tilted slightly ie M40 engine you may find it helpful to fit guide studs to ensure correct positioning of the cylinder head on the block Use two old head bolts one screwed into each end of the block Cut the heads off the bolts and use a hacksaw to cut slots in the tops of the bolts so they can be removed once 12 26 Fitting a new rubber O ring in the groove in the top of the oil pump front end cover on the M40 engine the cylinder head is in position see illustration 29 Fit the illustration 30 T
268. eaking Chapters 2 and 3 Clutch Pedal travels to floor no pressure or very little resistance Master or slave cylinder faulty Chapter 8 Fluid line burst or leaking Chapter 8 Connections leaking Chapter 8 No fluid in reservoir Chapter 1 If fluid is present in master cylinder dust cover master cylinder rear Seal has failed Chapter 8 Broken release bearing or fork Chapter 8 header tank Fluid in area of master cylinder dust cover and on pedal Rear seal failure in master cylinder Chapter 8 Fluid on slave cylinder Slave cylinder plunger seal faulty Chapter 8 Pedal feels spongy when depressed Air in system Chapter 8 Unable to select gears Faulty transmission Chapter 7 Faulty clutch plate Chapter 8 Fork and bearing not assembled properly Chapter 8 Faulty pressure plate Chapter 8 Pressure plate to flywheel bolts loose Chapter 8 Fuel leakage and or fuel odour Warning Don t drive the vehicle if a fuel leak is suspected Leaking fuel in the engine compartment could catch fire Leak in a fuel feed or vent line Chapter 4 Tank overfilled Fuel injector or carburettor parts excessively worn or fuel system gaskets leaking Chapter 4
269. eans different ones will be required Before deciding that different shells are needed make sure that no dirt or oil was between the bearing shells and the connecting rod or cap when the clearance was measured Also recheck the journal diameter If the Plastigage was wider at one end than the other the journal may be tapered see Section 19 Final connecting rod refitting 19 Carefully scrape all traces of the Plastigage material off the rod journal and or bearing face Be very careful not to scratch correct scale standard and metric ones are included 2B 2B 22 General engine overhaul procedures the bearing use your fingernail or the edge of a credit card 20 Make sure the bearing faces are perfectly clean then apply a uniform layer of molybdenum disulphide moly grease or engine assembly oil to both of them You ll have to push the piston into the cylinder to expose the face of the bearing shell in the connecting rod be sure to slip the protective hoses over the rod bolts first where applicable 21 Slide the connecting rod back into place on the journal and remove the protective hoses from the rod cap bolts Refit the rod cap and tighten the nuts bolts to the specified torque 22 Repeat the entire procedure for the remaining pistons connecting rods 23 The important points to remember are a Keep the back sides of the bearing shells and the insides of the connecting rods and caps perfectly clean when
270. ear protective gloves and discard them after use The battery Batteries contain sulphuric acid which attacks clothing eyes and skin Take care when topping up or carrying the battery The hydrogen gas given off by the battery is highly explosive Never cause a spark or allow a naked light nearby Be careful when connecting and disconnecting battery chargers or jump leads Air bags Air bags can cause injury if they go off accidentally Take care when removing the steering wheel and or facia Special storage instructions may apply Diesel injection equipment Diesel injection pumps supply fuel at very high pressure Take care when working on the fuel injectors and fuel pipes Warning Never expose the hands face or any other part of the body to injector spray the fuel can penetrate the skin with potentially fatal results DON T Don t attempt to lift a heavy component which may be beyond your capability get assistance Don t rush to finish a job or take unverified short cuts Don t use ill fitting tools which may slip and cause injury Don t leave tools or parts lying around where someone can trip over them Mop up oil and fuel spills at once Don t allow children or pets to play in or near a vehicle being worked on Anti theft audio system Anti theft audio system General information Some models are equipped with an audio system having an anti theft feature that will render
271. ecautions Warning The air conditioning system is under high pressure DO NOT loosen any hose or line fittings or remove any components until after the system has been discharged Air conditioning refrigerant should be properly discharged by a qualified refrigeration engineer The refrigerant used in the system must not be allowed into contact with your skin or eyes or there is a risk of frostbite Should the refrigerant come into contact with a naked flame a poisonous gas will be produced Smoking in the presence of refrigerant is therefore highly dangerous particularly if refrigerant vapour is inhaled through a lighted cigarette The refrigerant is heavier than air and it may cause suffocation if discharged in an enclosed space such as a domestic garage Finally uncontrolled release of the refrigerant causes environmental damage by contributing to the greenhouse effect Maintenance 1 The following maintenance checks should be performed on a regular basis to ensure the air conditioner continues to operate at peak efficiency Check the drivebelt If it s worn or deteriorated renew it see Chapter 1 b Checkthe system hoses Look for cracks bubbles hard spots and deterioration Inspect the hoses and all fittings for oil bubbles and seepage If there s any evidence of wear damage or leaks have new hose s fitted C Inspect the condenser fins for leaves flies and other debris Use a fin comb or compresse
272. ecessary for cylinder head and engine block rebuilding The single overhead camshaft four and six cylinder engines covered in this manual are very similar in design Where there are differences they will be pointed out The means by which the overhead camshaft is driven varies according to engine type M10 and M30 engines use a timing chain while M20 and M40 engines have a timing belt 2 Repair operations possible with the engine in the vehicle Many major repair operations can be accomplished without removing the engine from the vehicle Clean the engine compartment and the exterior of the engine with some type of degreaser before any work is done It will make the job easier and help keep dirt out of the internal areas of the engine Depending on the components involved it may be helpful to remove the bonnet to improve access to the engine as repairs are performed see Chapter 11 if necessary Cover the wings to prevent damage to the paint Special pads are available but an old bedspread or blanket will also work If vacuum exhaust oil or coolant leaks develop indicating a need for gasket or seal renewal the repairs can generally be made with the engine in the vehicle The intake and exhaust manifold gaskets sump gasket crankshaft oil seals and cylinder head gasket are all accessible with the engine in place Exterior components such as the intake and exhaust manifolds the sump the oil pump the water pump the s
273. ed 12 Using a small screwdriver or similar instrument remove the key from the groove in the nose of the crankshaft see illustration 13 Pull the spacer ring off the crankshaft see illustration 14 Unscrew the remaining bolts and remove the front end cover and oil pump from the cylinder block Note the locations of the front cover bolts as they are of different sizes With the cover removed extract the rubber O ring from the groove in the nose of the crankshaft see illustrations 15 Note the fitted location of the oil seal then prise it out of the housing 14 11b Removing the guide roller from the front end cover M40 engine 14 12 Removing the key from the groove in the nose of the crankshaft M40 engine 14 14b Extract the rubber O ring from the groove in the nose of the crankshaft M40 engine Inspection Note Considering that a malfunctioning oil pump can easily cause major engine damage we recommend that the oil pump should always be renewed during engine overhaul unless it s in as new condition M10 M20 and M30 engines 16 Remove the cover and check the pump body gears or rotors and cover for cracks and wear especially in the gear or rotor contact areas 17 Check the strainer to make sure it is not clogged or damaged 18 Lubricate the gears with clean engine oil then attach the pump cover to the body and tighten the bolts evenly and securely 14 22a Removing the inner rotor
274. ed disconnect the struts on both sides by unscrewing the mounting screws Where applicable pull out the retaining pin or spring and remove the strut from the ball see illustrations 13 Mark the position of the hinge arms on the tailgate with a pencil 14 Unscrew the bolts and withdraw the tailgate from the hinge arms On 5 Series models it will be necessary to use an Allen key or bit see illustration 15 Refitting is the reverse of removal but make sure that the previously made marks are correctly aligned Check that the tailgate closes centrally between the rear pillars and enters the lock correctly 14 11 Removing the wiring from the rear pillar 5 Series 14 12c Removing the retaining to disconnect the bottom of the tailgate support strut 5 Series 11 11 8 Bodywork and fittings 14 14 Unscrewing the hinge mounting bolts 5 Series 15 Latch lock cylinder and handles removal refitting and adjustment 1 Remove the trim panel s and on the door the plastic shield see Section 12 Latch 2 Disconnect the operating rods from the latch see illustration 3 Remove the latch retaining screws 4 Detach the latch assembly and withdraw it 5 Refitting is the reverse of removal Lock cylinder 6 Detach the linkage 7 Use a screwdriver to slide the retaining clip off and withdraw the lock cylinder 8 Refitting is the reverse of removal 3 ASSEMBLY CYLIN
275. ed for clarity 8 Check the fuel system pressure See Section 3 9 If these checks do not locate the problem take the vehicle to a BMW dealer who will be able to read the fault codes stored in the ECU using special equipment 16 Airflow meter check removal and refitting Check L J etronic systems 1 Remove the duct from the intake end of the airflow meter Carefully open and close the sensor flap see illustration and check for binding The flap can bend during a backfire and cause incorrect resistance readings The flap will bind and stick in a partially open position causing the engine to run rich and Stall when it returns to idle 2 Disconnect the electrical connector from the airflow meter 3 Using an ohmmeter check the resistance access to the ECU on Motronic systems left hand drive model shown 16 3 Connect an ohmmeter to terminals 7 and 8 of the airflow meter and check fora smooth change in resistance as the vane door of the airflow meter is slowly opened and closed between terminals 7 and 8 see illustration The resistance should increase steadily without any flat spots as the sensor flap is Slowly moved from the fully closed position to the fully open position 4 Also check the intake air temperature sensor inside the airflow meter Using an ohmmeter probe terminals 8 and 9 see illustration 16 3 and check for the proper resistance The resistance should be 2200 to 2
276. ed on the left hand side of the engine compartment see illustration 2 Remove as much fluid as you can from the reservoir with a syringe 3 Place rags under the line fittings and prepare caps or plastic bags to cover the ends of the lines once they are disconnected Caution Brake fluid will damage paint Cover all body parts and be careful not to spill fluid during this procedure 4 Loosen the union nuts at the ends of the brake lines where they enter the master cylinder To prevent rounding off the flats on these nuts a split ring brake spanner which wraps around the nut should be used 5 Pull the brake lines away from the master cylinder slightly and plug the ends to prevent dirt contamination and further fluid loss 6 Disconnect any electrical connectors at the master cylinder then remove the nuts 7 1 To remove the master cylinder unplug the electrical connector top arrow disconnect the brake fluid hydraulic line fittings lower right arrow other fitting not visible in this photo and remove the two master cylinder mounting nuts lower left arrow other nut not visible in this photo 5 Series master cylinder shown 3 Series similar Braking system 9 9 6 14 When you get everything back together this is how it should look attaching the master cylinder to the brake servo Pull the master cylinder off the studs and lift it out of the engine compartment Again be careful not to spill
277. ed plugs listed above If spark plugs of any other type are to be fitted refer to their manufacturer s spark plug gap recommendations Brakes Disc brake pad thickness minimum 2 0 mm Drum brake shoe lining thickness 2 0 mm Wiper blades Windscreen SE DC Champion X 5103 3 Series passenger side from 1991 Champion X 5103 20 inch or Champion X 5303 21 inch 5 Series E28 old shape Champion X 4503 5 Series E34 Champion type not available Tailgate occi PETITUM Champion X 4503 onc rr Champion type not available Servicing Specifications 15 Tyre pressures cold bars psi Front Rear 3 Series E30 BEG 1 9 28 2 1 30 316i sr TETEE TEE ETENEE EEE EEEE SOET EOE TEE TET 2 0 29 2 1 30 E eee ee 2 0 29 2 2 32 1 8 26 1 9 28 1 9 28 2 0 29 2 2 32 2 3133 5 Series E28 old shape MIEM rrcerDTT 2 0 29 2 0 29 uei uq us dedu SEND dst d M 2 2 32 2 2 32 Doane 2 3 33 2 5 36 5 Series E34 new shape
278. ed to be fully run in Chapter 2 Part A 2 1 In car engine repair procedures Camshaft removal inspection and refitting See Chapter 2B Compression CHECK saan sau aam ni See Chapter 2B Crankshaft rear oil seal renewal 16 Cylinder head removal and refitting 12 Cylinder head dismantling and inspection See Chapter 2B Drivebelt check adjustment and renewal See Chapter 1 Engine removal and refitting See Chapter 2B Engine mountings check and renewal 17 Engine oil and filter change See Chapter 1 Engine overhaul general information See Chapter 2B Exhaust manifold removal and refitting 6 Flywheel driveplate removal and refitting 15 Front oil seals renewal 11 General Information 1 Intake manifold removal and refitting 5 Degrees of difficulty Easy Suitable for 2 Fairy easy suitable lt Fairly difficult novice with little DS for beginner with expenence some expenence 5 DIY mechanic Specifications General Displacement 3 series E30 body style 3161 1983 to 1991 occ tec eens ERGO earl 316 1983 to 1988 and 318i 1983 to 1987 HN GEARS
279. eed for renewal Note If any parts are to be renewed check with your local BMW dealer parts department to be sure compatible parts are used On M20 engines later sprockets tensioner rollers and timing belts are marked Z 127 Renewal of the timing belt on M20 engines will mean that the later belt tensioner should also be fitted if not already done 14 Inspect the idler roller and on M20 engines the tension spring Rotate the tensioner roller to be sure it rotates freely with no noise or play Note When fitting a new timing belt it is recommended that a new tensioner be fitted also Refitting 15 On the M20 engine refit the idler tensioner spring so that the timing belt can be fitted loosely 16 Refit the sprockets using a reversal of the removal procedure tighten the retaining bolts to the specified torque On the M40 engine turn the camshaft sprocket clockwise as far as possible within the location groove then tighten the retaining bolt to an initial torque of 1 to 3 Nm at this stage 17 If you are refitting the old belt make sure the mark made to indicate belt direction of rotation is pointing the right way the belt Should rotate in a clockwise direction as you face the front of the engine 18 Refit the timing belt placing the belt under the crankshaft sprocket first to get by z Pd T 10 21 On the M20 engine after the belt has been installed correctly around all sprockets and the tens
280. eels spongy when depressed Unable to select gears Clutch slips engine speed increases with no increase in vehicle speed Grabbing chattering as clutch is engaged Noise in clutch area Clutch pedal stays on floor High pedal effort Fault Finding Manual transmission Vibration Noisy in neutral with engine running Noisy in one particular gear Noisy in all gears Slips out of gear Leaks lubricant Automatic transmission Fluid leakage Transmission fluid brown or has a burned smell General shift mechanism problems Transmission will not kickdown with accelerator pedal pressed to the floor Engine will start in gears other than Park or Neutral Transmission slips shifts roughly is noisy or has no drive in forward or reverse gears Brakes Vehicle pulls to one side during braking Noise high pitched squeal when the brakes are applied Brake vibration pedal pulsates Excessive pedal effort required to stop vehicle Excessive brake pedal travel Dragging brakes Grabbing or uneven braking action Brake pedal feels spongy when depressed Brake pedal travels to the floor with little resistance Handbrake does not hold Suspension and steering Vehicle pulls to one side Abnormal or excessive tyre wear Wheel makes a thumping noise Shimmy
281. eft headlight wiper Wash wipe interval control unit Key to electric window system wiring diagram Description Plug for rear section to driver s door 6 pin Plug for rear section to center section 27 pin Plug for window control and central lock wire to driver s door 13 pin Plug for window control and central lock wire to special equipment plug Window switch rear left Window switch rear left Window switch rear right Plug for left rear door wire to window motor rear left Plug for right door wire to window motor rear right Window motor rear left Window motor rear right Plug for window control and central lock wire to left rear door Plug for window contro and central lock wire to right rear door 7 pin Power safety switch Child safety switch Window motor front left Window motor front right Plug for driver s door wire to window motor front left Plug for passengers door wire to window motor of passenger s door Relay Plug for window control and central lock wire to passenger s door 13 pin Window switch front left Window switch rear right Window switch front right Wiring diagrams 12 23 dT A G kag 48 1 uo 18 c 13 492 18 yg s F Ard AMA JT A 98 Pue lt yuo a 9 oe nnno A Ag Ald que 9 718 4 2 12 e N AIM _ e 49 19 ue 1 51 uJ9 L 1 5 dg8 c 18
282. elain insulator indicating the spark plug should not be used 14 4b To change the gap bend the earth electrode only as indicated by the arrows and be very careful not to crack or chip the porcelain insulator surrounding the centre electrode 1 18 a ae 14 5 When removing the spark plug HT leads pull only on the connector 5 With the engine cool remove the HT lead from one spark plug Do this by grabbing the connector at the end of the wire not the lead itself see illustration Sometimes it is necessary to use a twisting motion while the connector and HT lead are pulled free 6 If compressed air is available use it to blow any dirt or foreign material away from the spark plug area A common bicycle pump will also work The idea here is to eliminate the possibility of debris falling into the cylinder as the spark plug is removed 7 Place the spark plug socket over the plug and remove it from the engine by turning it anti clockwise see illustration 8 Compare the spark plug with those shown in the accompanying photos to get an indication of the overall running condition of the engine 9 Apply a little copper based anti seize compound to the threads of the new spark plug Locate the plug into the head screwing it in with your fingers until it no longer turns then tighten it with the socket If available use a torque wrench to tighten the plug to ensure that it is seated correctly The correct torque figure
283. elative ease are in addition to an engine hoist a heavy duty trolley jack complete sets of spanners and sockets as described in the front of this manual wooden blocks and plenty of rags and cleaning solvent for mopping up spilled oil coolant and fuel If the hoist must be hired make sure that you arrange for it in advance and perform all of the operations possible without it beforehand This will save you money and time Plan for the vehicle to be out of use for quite a while A machine shop will be required to perform some of the work which the do it yourselfer can t accomplish without special equipment These establishments often have a busy schedule so it would be a good idea to consult them before removing the engine in order to accurately estimate the amount of time required to rebuild or repair components that may need work Always be extremely careful when removing and refitting the engine Serious injury can result from careless actions Plan ahead take your time and a job of this nature although major can be accomplished successfully Warning The air conditioning system is under high pressure Do not loosen any fittings or remove any components until after the system has been discharged by a qualified engineer Always wear eye protection when disconnecting air conditioning system fittings Caution If removing the M40 engine it is important not to turn the engine upside down for longer than 10 minutes since it
284. elative to the sealing surface the component should be renewed Protect the lips of the seal from any surface which may damage them in the course of fitting Use tape or a conical sleeve where possible Lubricate the seal lips with oil before fitting and on dual lipped seals fill the space between the lips with grease Unless otherwise stated oil seals must be fitted with their sealing lips toward the lubricant to be sealed Use a tubular drift or block of wood of the appropriate size to install the seal and if the seal housing is shouldered drive the seal down to the shoulder If the seal housing is unshouldered the seal should be fitted with its face flush with the housing top face unless otherwise instructed Screw threads and fastenings Seized nuts bolts and screws are quite a common occurrence where corrosion has set in and the use of penetrating oil or releasing fluid will often overcome this problem if the offending item is soaked for a while before attempting to release it The use of an impact driver may also provide a means of releasing such stubborn fastening devices when used in conjunction with the appropriate screwdriver bit or socket If none of these methods works it may be necessary to resort to the careful application of heat or the use of a hacksaw or nut splitter device Studs are usually removed by locking two nuts together on the threaded part and then using a spanner on the lower nut to unscrew
285. elt If not done the belt tensioner will be too loose and damage could result 26 On the M20 engine loosen the tensioner roller bolts then tighten them to the torque listed in this Chapter s Specifications 27 On the M40 engine loosen the tensioner roller retaining nut and re adjust the tension of the timing belt as described in paragraph 23 On completion tighten the tensioner roller retaining nut then fully tighten the camshaft Sprocket bolt if previously loosened see illustration 28 Verify that the timing marks are still perfectly aligned If not remove and refit the timing belt 29 The remainder of refitting is the reverse of removal 11 Front oil seals renewal Note Oil seals are fitted with their sealing lips facing inwards towards the engine M10 and M30 timing chain engines Camshaft front seal M30 engines only 1 Remove the upper timing chain cover only see Section 7 10 27 Tightening the camshaft sprocket retaining bolt on the M40 engine 2 Support the cover on two blocks of wood and drive out the seal from behind with a hammer and screwdriver Be very careful not to damage the seal bore in the process 3 Coat the outside diameter and lip of the new seal with multi purpose grease and drive the seal into the cover with a hammer and a socket slightly smaller in diameter than the outside diameter of the seal 4 The remainder of refitting is the reverse of removal Crankshaft front
286. em The crankcase blow by vapours are routed directly to the air cleaner or air collector with crankcase pressure behind them The vapour is not purged with fresh air on most models or 5 2 PCV hose being removed from the valve cover 5 3 It s a good idea to check for excess residue from the crankcase vapours circulating in the hoses and ports this can eventually clog the system and cause a pressure increase in the engine block filtered with a flame trap like most conventional systems There are no conventional PCV valves fitted on these systems just a hose see illustration 3 The main components of the PCV system are the hoses that connect the valve cover to the throttle body or air cleaner If abnormal Operating conditions Such as piston ring problems arise the system is designed to allow excessive amounts of blow by gases to flow back through the crankcase vent tube into the intake system to be consumed by normal combustion Note Since these models don t use a filtering element it s a good idea to check the PCV system passageways for clogging from sludge and combustion residue see illustration 6 Evaporative emissions control EVAP system General description Note This system is normally only fitted to those vehicles equipped with a catalytic converter 1 When the engine isn t running the fuel in the fuel tank evaporates to some extent creating fuel vapour The evaporative emissions contro
287. emove the bolts then separate it from 14 32 Using a large socket and the crankshaft pulley bolt to pull the oil seal into the housing M40 engine 15 4 Using socket and ratchet remove the eight bolts that hold the flywheel driveplate to the crankshaft flange prevent the flywheel driveplate from turning by locking the ring gear with a lever the crankshaft flange see illustration Be careful the flywheel is heavy 5 To refit the flywheel driveplate on the crankshaft use a liquid thread locking compound on the bolts and tighten them gradually using a criss cross pattern to the torque listed in this Chapter s Specifications 6 The remainder of refitting is the reverse of removal 16 Crankshaft rear oil seal renewal Why 1 Remove the flywheel or driveplate see Section 15 2 Remove the bolts and or nuts attaching the seal retainer to the engine block Be sure to remove the two bolts from underneath connecting the rear of the sump to the bottom of the seal retainer see illustration 3 Run a Sharp thin knife between the sump gasket and the seal retainer cutting the retainer free from the gasket Be very careful not to damage the gasket and keep it clean SO you Can re use it 4 Break the seal retainer to block gasket seal by tapping the retainer with a plastic mallet or block of wood and hammer Do not prise between the retainer and the engine block as damage to the gasket sealing surfaces will resul
288. emperature sender unit near the fuel pressure regulator 4 Information sensors Note Refer to Chapters 4 5 for additional information on the location and diagnosis of the information sensors that are not covered in this Section Coolant temperature sensor General description 1 The coolant temperature sensor see illustration is a thermistor a resistor which varies its resistance value in accordance with temperature changes The change in the resistance value regulates the amount of voltage that can pass through the sensor At low temperatures the sensor s resistance is high As the sensor temperature increases its resistance will decrease Any failure in this sensor circuit will in most cases be due to a loose or shorted out wire if no wiring problems are evident check the sensor as described below Check 2 To check the sensor first check its resistance see illustration when it is completely cold typically 2100 to 2900 ohms Next start the engine and warm it up until it reaches operating temperature The resistance should be lower typically 270 to 400 ohms Note restricted access to the coolant temperature sensor makes it difficult to attach electrical probes to the terminals remove the sensor as described below and perform the tests in a container of heated water to simulate the conditions Warning Wait until the engine is completely cool before beginning this procedure Renewal
289. en We recommend the purchase of combination Spanners ring one end open ended the other although more expensive than open ended ones they do give the advantages of both types of spanner C Combination spanners Metric 8 9 10 11 12 13 14 15 16 17 19 21 22 24 amp 26 mm Adjustable spanner 35 mm jaw approx Transmission drain plug key Allen type Set of feeler gauges Spark plug spanner with rubber insert Spark plug gap adjustment tool Brake bleed nipple spanner Screwdrivers Flat blade approx 100 mm long x 6 mm dia Cross blade approx 100 mm long x 6 mm dia Combination pliers Hacksaw junior Tyre pump Tyre pressure gauge Oil can Oil filter removal tool Fine emery cloth Wire brush small Funnel medium size LILILIEJEJ EJ EJ LILIELIEJEJ EJ EJ EJ E Tools and Working Facilities Repair and overhaul tool kit These tools are virtually essential for anyone undertaking any major repairs to a motor vehicle and are additional to those given in the Maintenance and minor repair list Included in this list is a comprehensive set of Sockets Although these are expensive they will be found invaluable as they are so versatile particularly if various drives are included in the set We recommend the half inch square drive type as this can be used with most proprietary torque wrenches If you cannot afford a socket set even bought piecemeal then inexpensive tubular box spanners a
290. ensor flap On early Motronic systems probe terminals 7 and 9 On later Motronic systems probe terminals 7 and 12 The resistance should increase steadily without any flat spots as the sensor flap is slowly moved from the fully closed position to the fully open position Note Early Motronic systems are distinguishable by the 35 pin ECU electrical connector later Motronic systems use a 55 pin connector 8 If the resistance readings are incorrect check the wiring harness Removal and refitting all systems 9 Disconnect the electrical connector from the airflow meter 10 Remove the air cleaner assembly see Section 8 11 Remove the nuts see illustrations and lift the airflow meter from the engine compartment or from the air cleaner assembly 12 Refitting is the reverse of removal 16 7b Unplug the connector connect th ohmmeter probes to terminals 7 and 9 early Motronic systems and check for a smooth change in resistance as the door on the airflow meter is slowly opened and closed 4 16 Fuel exhaust systems 16 11 Push the tab and remove the air duct from inside the air cleaner assembly 17 Throttle body check removal and refitting WU Check 1 Detach the air intake duct from the throttle body see Section 8 and move the duct out of the way 2 Have an assistant depress the throttle pedal while you watch the throttle valve Check that the throttle valve moves smoothly when t
291. epaired by the BMW dealer 3 Electronic control unit ECU BN removal and refitting X AY Removal 1 The Electronic Control Unit ECU is located either inside the passenger compartment under the right hand side of the facia panel on 3 Series models or in the engine compartment on the right hand side on 5 Series models see Chapter 4 2 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 First remove the access cover on models with the ECU on the right hand side of the engine compartment see Chapter 4 4 If the ECU is located inside the vehicle remove the access cover on the right hand side 5 Unplug the electrical connectors from the 6 Remove the retaining bolts from the ECU bracket 7 Carefully remove the ECU Note Avoid static electricity damage to the ECU by wearing rubber gloves and do not touch the connector pins Refitting 8 Refitting is a reversal of removal 6 2 Engine management and emission control systems 4 1 The coolant temperature sensor arrowed is usually located next to the t
292. er 1 Clutch slipping Chapter 8 Fuel filter clogged and or impurities in the fuel system Chapter 1 Emission control system not functioning properly Chapter 6 Low or uneven cylinder compression pressures Chapter 2 Battery will not hold charge Alternator drivebelt defective or not adjusted properly Chapter 1 Electrolyte level low Chapter 1 Battery terminals loose or corroded Chapter 1 Alternator not charging properly Chapter 5 Loose broken or faulty wiring in the charging circuit Chapter 5 Short in vehicle wiring Chapters 5 and 12 Internally defective battery Chapters 1 and 5 Ignition no charge warning light bulb blown on some early models Chapter 5 Fault Finding Engine stalls Idle speed incorrect Chapter 1 Fuel filter clogged and or water and impurities in the fuel system Chapter 1 Distributor components damp or damaged Chapter 5 Faulty emissions system components Chapter 6 Faulty or incorrectly gapped spark plugs Chapter 1 Faulty spark plug HT leads Chapter 1 Vacuum leak in the fuel injection system intake manifold or vacuum hoses Chapter 4 Engine backfires Emissions system not functioning properly Chapter 6 Ignition timing incorrect Chapter 5 Faulty secondary ignition system cracked spark plug insulator faulty plug HT leads distributor cap and or rotor Chapters 1 and 5 Fuel injection system
293. er attempt to bypass the use of any special tool when the procedure described specifies its use Not only is there a very great risk of personal injury but expensive damage could be caused to the components involved Environmental considerations When disposing of used engine oil brake fluid antifreeze etc give due consideration to any detrimental environmental effects Do not for instance pour any of the above liquids down drains into the general sewage system or onto the ground to soak away Many local council refuse tips provide a facility for waste oil disposal as do some garages If none of these facilities are available consult your local Environmental Health Department or the National Rivers Authority for further advice With the universal tightening up of legis lation regarding the emission of environmen tally harmful substances from motor vehicles most vehicles have tamperproof devices fitted to the main adjustment points of the fuel system These devices are primarily designed to prevent unqualified persons from adjusting the fuel air mixture with the chance of a consequent increase in toxic emissions If such devices are found during servicing or overhaul they should wherever possible be renewed or refitted in accordance with the manufacturers requirements current legislation Note It is antisocial and illegal to dump oil down the drain To find the location of your local oil recycling bank cal
294. er drier surface the refrigerant charge is low Recharging the system should be carried out by a qualified refrigeration engineer 13 Air conditioning compressor removal and refitting gt Warning Due to the potential A dangers associated with the system you are strongly advised to have any work on the air conditioning system carried out by a BMW dealer or air conditioning specialist At the very least DO NOT dismantle any part of the system hoses compressor line fittings etc until after the system has been discharged by a qualified engineer Refer to the precautions given at the start of Section 12 Note If a new compressor is fitted the receiver drier see Section 16 should also be renewed Removal 1 Have the air conditioning discharged see Warning above 2 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 Disconnect the compressor clutch wiring harness 4 Remove the drivebelt see Chapter 1 5 Disconnect the refrigerant lines from the rear of the compressor Plug the open fittings to prevent entry of dirt and moisture 6 Unbolt the compressor from the mounting system Li i g
295. er motor assembly You can check the motor by following the procedure described in Sec tion 9 Refitting 6 Refitting is the reverse of removal Cooling heating and air conditioning systems 3 9 15 Air conditioning condenser removal and refitting N EN x Warning Due to the potential dangers associated with the system you are strongly advised to have any work on the air conditioning system carried out by a BMW dealer or air conditioning specialist At the very least DO NOT dismantle any part of the system hoses compressor line fittings etc until after the system has been discharged by a qualified engineer Refer to the precautions given at the start of Section 12 Note If a new condenser is fitted the receiver drier see Section 16 should also be renewed Removal 1 Have the air conditioning discharged see Warning above 2 Remove the radiator see Section 4 except on new shape E34 5 series models On the latter remove the front bumper see Chap ter 11 3 Remove the radiator grille see Chapter 11 4 Unbolt the auxiliary fan from the air conditioning condenser mounting brackets 5 Disconnect the refrigerant lines from the condenser 6 Remove the mounting bolts from the condenser brackets 7 Lift the condenser out of the vehicle and plug the lines to keep dirt and moisture out 8 If the original condenser is being refitted Store it with the line fittings uppermost to prevent oil
296. er to move the beam left or right 7 With main beam on the bright spots on the wall should be exactly on the vertical lines and just below the horizontal line Note It may not be possible to position the headlight aim exactly for both main and dipped beams If a compromise must be made keep in mind that the dipped beam is most used and will have the greatest effect on driver safety 8 Have the headlights adjusted by a dealer service department or qualified garage at the earliest opportunity 14 Headlight housing removal and refitting Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable ki 15 3b models with high mounted centre brake lights the self earthing holder is accessible from the luggage area pull the holder out 14 4 Remove the screws arrowed and detach the headlight housing 2 Remove the side grille see Chapter 11 then remove the rear cover s where necessary 3 Unplug the headlight sealed beam type or remove the bulb halogen bulb type 4 Remove the sc
297. erial off the main bearing journals and or the bearing faces Use your fingernail or the edge of a credit card don t nick or scratch the bearing faces Final crankshaft refitting 18 Carefully lift the crankshaft out of the engine 19 Clean the bearing faces in the block then apply a thin uniform layer of molybdenum disulphide moly grease or engine oil to each of the bearing surfaces Be sure to coat the thrust faces as well as the journal face of the thrust bearing 20 Make sure the crankshaft journals are clean then lay the crankshaft back in place in the block 21 Clean the faces of the bearings in the caps then apply engine oil to them 22 Refit the caps in their respective positions with the arrows pointing towards the front of the engine 23 Refit the bolts finger tight 24 Lightly tap the ends of the crankshaft forward and backward with a lead or brass hammer to line up the main bearing and crankshaft thrust surfaces 25 Tighten the bearing cap bolts to the specified torque working from the centre outwards On M10 M20 and M30 engines tighten the bolts in three stages to the final torque leaving out the thrust bearing cap bolts at this stage On M40 engines tighten all of the bolts in the two stages given in the Specifications 26 On M10 M20 and M30 engines tighten the thrust bearing cap bolts to the torque listed in this Chapter s Specifications 27 On manual transmission models fit a new pilot beari
298. ers have begun using R 134a a non CFC substance that is considered less harmful to the ozone in the upper atmosphere Rocker arm A lever arm that rocks on a shaft or pivots on a stud In an overhead valve engine the rocker arm converts the upward movement of the pushrod into a downward movement to open a valve Rotor In a distributor the rotating device inside the cap that connects the centre electrode and the outer terminals as it turns distributing the high voltage from the coil secondary winding to the proper spark plug Also that part of an alternator which rotates inside the stator Also the rotating assembly of a turbocharger including the compressor wheel shaft and turbine wheel Runout The amount of wobble in and out movement of a gear or wheel as it s rotated The amount a shaft rotates out of true The out of round condition of a rotating part 5 Sealant liquid or paste used to prevent leakage at a joint Sometimes used in conjunction with a gasket Sealed beam lamp An older headlight design which integrates the reflector lens and filaments into a hermetically sealed one piece unit When a filament burns out or the lens cracks the entire unit is simply replaced Serpentine drivebelt A single long wide accessory drivebelt that s used on some newer vehicles to drive all the accessories instead of a series of smaller shorter belts Serpentine drivebelts are usually tensioned by an automatic tensioner
299. ert it into the cable conduit 10 4a To detach the handbrake cable from the handbrake actuator on models with rear disc brakes pull on the outer cam and disconnect it from the inner cam 10 6 Pull the cable out of its conduit before you refit the new cable be sure to lubricate it with multi purpose grease 9 12 Braking system and push it through until the forward end comes out at the handbrake lever 8 Insert the cable conduit through the backplate and attach the rear end of the cable to the handbrake lever rear drum models or the actuator rear disc models Make sure you don t kink the cable while connecting it 9 Refit the cable conduit to the clips on the back of the trailing arm 10 On rear drum models refit the brake shoes and drum see Section 6 On rear disc models refit the handbrake shoes and actuator see Section 12 and the rear brake disc see Section 5 11 Lower the vehicle and refit the adjusting nut at the handbrake lever Adjust the handbrake cable see Section 11 and refit the handbrake lever boot 11 Handbrake adjustment Rear drum brake models Note Adjustment of the handbrake cable s on models with rear drum brakes should only be necessary when you renew a cable or detach if from the rear brake assembly for some reason Failure of the handbrake system to hold the vehicle usually indicates worn brake shoes faulty self adjusting mechanism 1 Raise the rear of the veh
300. ery itself is defective the alternator drivebelt is loose see Chapter 1 the alternator brushes are worn dirty or disconnected see Section 17 the voltage regulator is malfunctioning see Section 16 or the diodes stator coil or rotor coil are defective Repairing or renewing the diodes stator coil or rotor coil is beyond the scope of the home mechanic Either renew 5 10 Engine electrical systems a in 15 2 Depending how many accessories the vehicle has sometimes it s easier to remove the alternator from the brackets first and then turn it sideways to gain access to the connections arrowed on the rear of the alternator body the alternator complete or take it to an automotive electrician who may be able to overhaul it Note On models up to 1986 a blown ignition no charge warning light bulb will prevent the alternator from charging After 1987 a resistor is wired in parallel with the warning light in order to allow current to bypass the light in the event of a broken circuit blown warning light 15 Alternator removal and refitting Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to p
301. es in BMWs They may be able to repair the head 10 Valves servicing N 1 Examine the valves as described in Sec tion 9 paragraphs 13 and 14 Renew any valve that shows signs of wear or damage 2 If the valve appears satisfactory at this stage measure the valve stem diameter at several points using a micrometer see illustration 9 13 Any significant difference in the readings obtained indicates wear of the valve stem Should any of these conditions be apparent the valve s must be renewed 3 Ifthe valves are in satisfactory condition they should be ground lapped into their respective seats to ensure a gas tight seal If the seat is only lightly pitted or if it has been re cut fine grinding compound should be used to produce the required finish Coarse valve grinding compound should not normally be used unless a seat is badly burned or deeply pitted If this is the case the cylinder head and valves should be inspected by an expert to decide whether seat re cutting or even the renewal of the valve or seat insert is required 4 Valve grinding is carried out as follows Place the cylinder head upside down on a bench with a block of wood at each end to give clearance for the valve stems 5 Smear a trace of the appropriate grade of valve grinding compound on the seat face and press a suction grinding tool onto the valve head With a semi rotary action grind the valve head to its seat lifting the valve occasionally to redi
302. es out of the bleed screw opening Tighten the bleed screw 18 Refit the radiator cap and run the engine until the thermostat opens the upper radiator hose will become hot Slowly loosen the bleed screw until no bubbles emerge then tighten the screw 19 Repeat the procedure until the air is bled from the system 30 Fuel filter renewal Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Don t work ina garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand 1 On fuel injection engines depressurise the fuel system see Chapter 4 2 The fuel filter is located in the engine compartment on the bulkhead or under the vehicle adjacent to the fuel tank 3 Because on some models the filter is located adjacent to the starter motor fuel could leak onto the electrical connections For Safety reasons therefore disconnect the battery negative cable before beginning work Caution If the radio in your vehicle is equipped with an anti A theft system make sure you have the correct activation code before disconnecting the battery 1925 30 5
303. ess the retaining tab in and slide the blade assembly down the wiper arm see illustration 6 If you wish to renew the blade rubbers separately detach the end of the rubber from the wiper blade frame then slide the rubber out of the frame see illustration 7 Compare the new rubber with the old for length design etc 8 Slide the new rubber into place and insert the end in the wiper blade frame to lock it in place 9 Refit the blade assembly on the arm then wet the glass and check for proper operation Every 24 000 miles or 2 years whichever comes first 28 Automatic transmission fluid EN and filter change X 1 At the specified intervals the transmission fluid should be drained and renewed Since the fluid will remain hot long after driving perform this procedure only after the engine has cooled down completely 2 Before beginning work purchase the specified transmission fluid see Lubricants and fluids at the beginning of this Chapter and a new filter 3 Other tools necessary for this job include axle stands or ramps to support the vehicle in a raised position a drain pan capable of holding at least 4 5 litres and newspapers and clean rags 4 Raise the vehicle and support it securely 5 Loosen the dipstick tube collar then detach the dipstick tube and let the fluid drain see illustrations 6 Remove the transmission sump mounting bolts and brackets see illustration 1 24 28 5a Unscrew
304. essary use the bolts as levers to remove the caps Try not to drop the bearing Shells if they come out with the caps 6 Carefully lift the crankshaft out of the engine It may be a good idea to have an assistant available since the crankshaft is quite heavy see illustration With the bearing shells in place in the engine block and main bearing caps return the caps to their respective locations on the engine block and tighten the bolts finger tight 14 Intermediate shaft removal and inspection Note The intermediate shaft is used on the M20 engine only The shaft rotates in the engine block parallel to the crankshaft It is driven by the timing belt and its only purpose is to drive the oil pump 1 Remove the timing belt see Chapter 2A 2 With the belt removed unbolt the gear from the intermediate shaft and unbolt the front cover 3 Remove the oil pump driveshaft see Chapter 2A 4 The shaft is held in the cylinder block by a retaining plate with two bolts Remove the bolts and pull the shaft forwards and out of the block 5 Look for any signs of abnormal wear on the bearing surfaces or the gear at the back end of the shaft which drives the oil pump shaft If the bearing surfaces in the engine block show wear they ll have to be attended to by a machine shop 15 Engine block cleaning Caution core plugs be A difficult or impossible to retrieve if they re driven into the block coolan
305. essed manual transmission 2 Make sure that the battery is charged and that all cables both at the battery and starter solenoid terminals are clean and secure 3 If the starter motor spins but the engine is not cranking the overrun clutch in the starter motor is slipping and the starter motor must be renewed 4 If when the switch is actuated the starter motor does not operate at all but the solenoid Clicks then the problem lies either in the battery the main solenoid contacts or the starter motor itself or the engine is seized 5 f the solenoid plunger cannot be heard when the switch is actuated the battery is faulty the switch is defective the fusible link is burned out the circuit is open or the solenoid itself is defective 6 To check the solenoid connect a jumper lead between the battery and the ignition switch wire terminal the small terminal on the solenoid If the starter motor now operates the solenoid is OK and the problem is in the ignition switch starter inhibitor switch automatic transmission models clutch switch some manual transmission models or the wiring 7 f the starter motor still does not operate remove the starter solenoid assembly for dismantling testing and repair 8 If the starter motor cranks the engine at an abnormally slow speed first make sure that the battery is charged and that all terminal connections are tight If the engine is partially seized or has the wrong
306. etronic fuel injection Models with Motronic fuel injection Ignition coil Primary resistance TCI system Motronic SYSTEMI ssns nacio d Y E eal E m Cu cl cC ee wee n Secondary resistance TCI system SYSTEM Gui ago edet suivie ded dea ees dU dac a aed Distributor models with TCI system Air gap Pick up coil impulse generator resistance Ignition timing models with TCI system Vacuum line disconnected at distributor 316 with M10 B18 318i with M 10 B 18 engine 320i with M 20 B 20 engine 518 with M 10 B 18 CNOING ea e 4 nica cae Ce e 518i with M 10 B 18 engine 525i with M 30 B25 engine except distributor 25 302 009 PM 525i with M30 B25 engine distributor 237 302 033 528i with 30 28 engine Transistorised Coil Ignition TCI system Ignition functions controlled by Motronic system 0 82 ohms 0 50 ohms 8250 ohms 5000 to 6000 ohms 0 3 mm to 0 7 mm 900 to 1200 ohms 259 BTDC at 2500 rpm 2900 rpm from 9 83 309 BTDC at 3000 rpm 239 BTDC at 5000 50 rpm 259 BTDC at 2900 50 rpm 309 BTDC at 3000 50 rpm 229 BTDC at 1800 50 rpm 229 BTDC at 2150 50 rpm 229 BTDC at 2150 50 rpm 5 2 Engine electrical systems 1 General information The engine electrical systems include all ignition charging and starting components Because of their engine related functions these
307. ever new shoes are fitted Turn the adjuster wheel so that the assembly is at its shortest position ready for refitting 9 Disconnect the handbrake cable from the handbrake lever and remove the rear shoe see illustration 10 Refitting is basically the reverse of removal but note the following points 11 Apply a smear of high temperature brake grease to the backing plate see illustration Be careful not to get grease onto the 6 11 Before you fit the new shoes apply some high temperature brake grease to the friction surfaces where the inner edge of the shoe slides on the brake backing plate when you refit the automatic adjuster mechanism make sure each end engages properly with its respective notch in the brake shoe 6 13a Refit the automatic adjuster lever first make sure it s properly engaged with the notch in the front end of the adjuster mechanism friction surfaces of the brake shoes or drums 12 Make sure the adjuster assembly is properly engaged with its respective notch in the handbrake lever 13 When refitting the automatic adjustment mechanism fit the lever on the shoe first see illustration then hook the lower end of the spring onto the lever and the upper end into its hole in the front shoe see illustration 14 When you re done the brake assembly should look like this see illustration Now proceed to the other brake 15 When you re done with both brakes refit the brake drums
308. ewal 1 Remove the track rod ends see Sec tion 17 2 Cut the boot clamps at both ends of the old boots and slide off the boots 3 While the boots are removed inspect the Seals in the end of the steering gear If they re 17 6 Measure the length of the track rod and record your measurement or paint an alignment mark on the threads to ensure the track rod end is refitted in the same position then loosen the clamp bolt arrowed 17 7 Using a puller to separate the track rod end from the steering arm leaking renew the steering gear See Sec tion 19 4 Slide the new boots into place and fit new boot clamps 5 Refit the track rod ends See Section 17 19 Rack and pinion steering gear 3 Series removal and refitting Removal 1 Loosen but do not remove the wheel bolts raise the vehicle and support it securely on axle stands Remove the front wheels 2 Mark the lower universal joint on the Steering shaft and the pinion shaft to ensure proper alignment when they re reassembled Remove the nut and bolt that attach the lower end of the universal joint shaft to the steering gear pinion shaft Loosen the bolt and nut at the upper end of the universal joint shaft Slide the universal joint shaft up a little disengage it from the pinion shaft and remove it Inspect the universal joints and the rubber coupling for wear If any of them are worn or defective renew the universal joint sha
309. f the rack so the rack moves right or left in the housing when the pinion is turned The movement of the rack is transmitted through the track rods and track rod ends to the steering arms which are an integral part of the strut housings On 5 Series models the upper part of the steering system is identical to a 3 Series Instead of a rack and pinion set up however these models use power assisted recirculating ball steering box which steers the front wheels via a steering linkage consisting of a Pitman arm an idler arm a centre track rod a pair of inner track rods and two track rod ends a X b E 15 14d When you refit the spacer make sure it s centred on the inner race of the bearing before tightening the nut 17 2 Loosen the nut on the track rod balljoint stud For preference use a balljoint separator otherwise give the steering arm a few light blows with a hammer to release the balljoint stud Remove the nut and separate the balljoint stud from the steering arm Where power assistance is fitted hydraulic pressure provided by an engine driven pump delivers power steering fluid to the rack and pinion steering gear or the recirculating ball Steering box this enhances steering response and reduces steering effort Aside from maintaining the proper level of power steering fluid in the system and checking the tension of the drivebelt see Chapter 1 where applicable the steering system requires
310. facia opening See illustration 5 For access to the cluster components release the catches or remove the screws and separate the two halves see illustration Refitting 6 Refitting is the reverse of removal 11 Service Indicator SI board general information All models that have service indicator lights are equipped with a Service Indicator 51 board located in the instrument cluster This board turns the lights on at the proper mileage intervals The lights can only be turned off using a special tool which plugs into the engine check connector see Chapter 1 The 10 5 Turn the plastic knobs to release the back of the cluster some models use screws B d i L 11 2 These batteries arrowed power the Service Indicator SI board SI board is a self contained computer which includes a chip and batteries The rechargeable 51 board nickel cadmium nicad batteries maintain power to the computer memory in the event of a power drop such as during starting or complete power loss such as a dead or disconnected battery see illustration This assures power so the computer can continue to keep track of mileage and turn the lights on at the proper interval The batteries have a life of approximately six years at which time they must be replaced with new ones Also since they are recharged by the engine charging system they can run down prematurely if power is cut off for some reason such as a blown f
311. far enough to clear the end of the control arm 3 Series or the steering arm 5 Series 13 Support the weight of the strut and remove the three mounting nuts at the top of the strut located inside the engine compartment see illustration and remove the strut 14 Remove the strut assembly If a new shock absorber strut cartridge is being fitted see Section 6 Refitting 15 Refitting is the reverse of removal On 3 Series models be sure to use new self locking nuts on the control arm balljoint the track rod end balljoint and the strut upper mountings On 5 Series models make sure the tang in the steering arm is mated with the notch in the strut housing see illustration BMW recommends using a thread locking compound on the steering arm mounting bolts On all models tighten the fasteners to the torques listed in this Chapter s Specifi cations 16 When you re done drive the vehicle to a dealer service department or qualified garage and have the wheel alignment checked and if necessary adjusted 5 15 On 5 Series models make sure the tang in the steering arm is mated with the notch in the strut housing arrowed 6 Strut shock absorber coil N spring renewal 5 A Note This section applies to all front strut assemblies and on 5 Series models the rear coil over shock absorber assemblies 1 Ifthe struts shock absorbers or coil springs exhibit the telltale signs of wear leaking fluid loss of damping capa
312. fitting 3 Refitting is the reverse of removal 18 Exterior mirror removal and refitting Removal 1 If it is required to renew the mirror glass only insert a small screwdriver through the hole in the bottom of the exterior mirror and carefully lever clockwise the plastic holder on the rear of the glass ie move the bottom of the screwdriver to the right This will release the glass which can then be withdrawn If electric mirrors are fitted it will be necessary to disconnect the wiring before completely removing the glass 2 To remove the complete mirror prise off the cover panel and or the tweeter speaker where applicable 3 Unplug the electrical connector 4 Remove the retaining screws and lift the mirror off Refitting 5 Refitting is the reverse of removal 19 3 Use a Phillips screwdriver to remove the upper column shroud screws 19 Steering column shrouds removal and refitting Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Remove the steering wheel Chapter 10 3 Remove
313. flow expressed as amps and break the Circuit Fusible link A circuit protection device consisting of a conductor surrounded by heat resistant insulation The conductor is Smaller than the wire it protects so it acts as the weakest link in the circuit Unlike a blown fuse a failed fusible link must frequently be cut from the wire for replacement G Gap The distance the spark must travel in jumping from the centre electrode to the side Adjusting spark plug gap electrode in a spark plug Also refers to the spacing between the points in a contact breaker assembly in a conventional points type ignition or to the distance between the reluctor or rotor and the pickup coil in an electronic ignition Gasket Any thin soft material usually cork cardboard asbestos or soft metal installed between two metal surfaces to ensure a good seal For instance the cylinder head gasket seals the joint between the block and the cylinder head Gasket Gauge An instrument panel display used to monitor engine conditions A gauge with a movable pointer on a dial or a fixed scale is an analogue gauge A gauge with a numerical readout is called a digital gauge H Halfshaft rotating shaft that transmits power from the final drive unit to a drive wheel usually when referring to a live rear axle Harmonic balancer 4A device designed to reduce torsion or twisting vibration in the crankshaft May be incorporated in the crankshaft p
314. fluid as this is done Discard the old O ring See illustration between the master cylinder and the servo unit Warning The O ring should A always be renewed A faulty O ring can cause a vacuum leak which can reduce braking performance and cause an erratic idle Bleeding procedure 7 Before fitting a new or overhauled master cylinder it should be bled on the bench Because it will be necessary to apply pressure to the master cylinder piston and at the same time control flow from the brake line outlets it is recommended that the master cylinder be mounted in a vice Use a vice with protected jaws and don t clamp the vice too tightly or the master cylinder body might crack 8 Insert threaded plugs into the brake line outlet holes Tighten them down so that there will be no air leakage past them but not so tight that they cannot be easily loosened 9 Fill the reservoir with brake fluid of the recommended type see Lubricants fluids and capacities in Chapter 1 10 Remove one plug and push the piston assembly into the master cylinder bore to AE 1223 254 7 6 Always renew the O ring 1 groove arrowed between the master cylinder and the brake servo 9 10 Braking system expel the air from the master cylinder A large Phillips screwdriver can be used to push on the piston assembly 11 To prevent air from being drawn back into the master cylinder the plug must be refitted and tighte
315. for a blockage If there is no blockage renew the fuel pressure regulator 10 the pressure doesn t fluctuate as described in paragraph 7 connect a vacuum 18 5 Carefully watch the fuel pressure gauge as vacuum is applied fuel pressure should decrease as vacuum increases P 18 15 Remove the two bolts arrowed and remove the fuel pressure regulator from the fuel rail gauge to the pressure regulator vacuum hose and check for vacuum engine idling 11 If there is vacuum present renew the fuel pressure regulator 12 If there isn t any reading on the gauge check the hose and its port for a leak or a restriction Renewal 13 Depressurise the fuel system see Sec tion 2 14 Detach the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 15 Detach the vacuum hose and fuel return hose from the pressure regulator then unscrew the mounting bolts see illustration 16 Remove the pressure regulator 17 Refitting is the reverse of removal Be sure to use a new O ring Coat the O ring with a light film of engine oil prior
316. for the language resetting procedure 1 Disconnect the battery negative cable 15 4b then remove the bulb from the housing Windscreen wiper motor 2 Remove the covers and nuts then detach the wiper arms see illustrations 3 Prise out the retaining clips and detach the cowl grille for access to the wiper assembly 4 Remove the screws or nuts and detach the wiper cover located the engine compartment bulkhead 5 Unplug the electrical connector and detach the wiper linkage 6 Mark the relationship of the wiper shaft to the linkage Detach the wiper link from the motor Shaft by prising carefully with a screwdriver 7 Remove the three retaining bolts and remove the wiper motor from the vehicle 8 Refitting is the reverse of removal When fitting the motor if necessary plug in the 15 5 After removing the instrument cluster see Section 10 turn the bulbholder anti clockwise to remove the bulb connector and run the motor briefly until it is in the neutral wipers parked position Tailgate wiper motor 9 On 3 Series models remove the cover and nut then detach the wiper arm see illustration On 5 Series models open the rear window away from the tailgate 10 As applicable remove the trim panel s then disconnect the washer tube and the wiring plug 11 Unscrew the mounting nuts and withdraw the wiper motor see illustrations On 5 Series models the wiper blade and pivot mechanism may be removed from
317. from the fuel tank Check for loose connections deteriorated hoses crimped lines and other damage Repair or renew damaged sections as necessary see Chapter 4 22 Cooling system check BN x 1 Many major engine failures be attributed to cooling system problems If the vehicle has automatic transmission the engine cooling system also plays an important Every 12 000 miles role in prolonging transmission life because it cools the transmission fluid 2 The engine should be cold for the cooling system check so perform the following procedure before the vehicle is driven for the day or after it has been switched off for at least three hours 3 Remove the radiator cap doing so slowly and taking adequate precautions against scalding if the engine is at all warm Clean the cap thoroughly inside and out with clean water Also clean the filler neck on the radiator The presence of rust or corrosion in the filler neck means the coolant should be changed see Section 29 The coolant inside the radiator should be relatively clean and Clear If it s rust coloured drain the system and refill with new coolant 4 Carefully check the radiator hoses and the smaller diameter heater hoses Inspect each coolant hose along its entire length renewing any hose which is cracked swollen or deteriorated see illustration Cracks will show up better if the hose is squeezed Pay close attention to hose clamps that secure the hose
318. ft 3 On power steering models using a large 10 10 14 Suspension and steering systems 19 6 Rack and pinion steering gear mounting bolts arrowed 3 Series models self locking nuts not visible in this photo syringe or hand pump empty the power steering fluid reservoir 4 On power steering models remove the banjo bolts and disconnect the power steering pressure and return lines from the steering gear Place a container under the lines to catch spilled fluid Plug the lines to prevent excessive fluid 1055 contamination Discard the sealing washers new ones should be used when reassembling 5 Disconnect the track rod ends from the steering arms see Section 17 6 Remove the nuts and bolts from the steering gear mounting brackets see illustration Discard the old nuts 7 Withdraw the assembly from beneath the vehicle Take care not to damage the steering gear boots Refitting 8 Refitting is the reverse of removal Make sure the marks you made on the lower universal joint and the pinion shaft are aligned before you tighten the clamping bolts for the upper and lower universal joints Use new self locking nuts on the steering rack 20 4 To remove an outer track rod remove this nut arrowed from the end of the centre track rod and use a balljoint separator to separate the balljoint stud from the centre track rod if you re renewing the inner track rod end mark the threads with paint before l
319. g their associated valve springs 11 For the remaining rocker arms that are still compressing their valve springs BMW recommends using a special forked tool to compress the rocker arms against the valve springs and therefore take the valve spring tension off the camshaft lobe If the tool is not available insert a standard screwdriver into the gap above the adjuster eccentric at the valve end tip of each rocker arm Using the 8 8 Check the rocker arm to shaft radial clearance by setting up a dial indicator as shown and trying to rotate the rocker arm against the shaft DO NOT slide the rocker arm along the shaft 8 6 Remove the cover from the rear of the cylinder head be sure to note the locations of any washers gaskets and seals while you are removing the cover screwdrivers prise the rocker arms against the valve springs and hold them in place as the camshaft is removed see the next paragraph At least one assistant will be necessary for this operation since three or four valve springs usually need compressing If no assistance is available you could try retaining the screwdrivers that are compressing the valve springs to the bench with lengths of sturdy wire Warning Be sure the wire is A securely attached to the bench and screwdrivers or the screwdrivers could fly off the cylinder head possibly causing injury 12 When all the rocker arms are no longer contacting the camshaft lobes slowly and carefully p
320. g is not correct check the oxygen sensor heater relay see Chapter 12 If the information is not available check the owner s handbook for the exact location of the oxygen sensor heater relay The relay should receive battery voltage 17 If the oxygen sensor fails any of these tests renew it Renewal Note Because it is fitted in the exhaust manifold converter or pipe which contracts when cool the oxygen sensor may be very difficult to loosen when the engine is cold Rather than risk damage to the sensor Engine management and emission control systems 6 3 4 12b These oxygen sensor terminal designations are for the harness side only Use the corresponding terminals on the sensor side for the testing procedures there are three different four wire oxygen sensor connectors available don t get them mixed up assuming you are planning to re use it in another manifold or pipe start and run the engine for a minute or two then switch it off Be careful not to burn yourself during the following procedure 18 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for t
321. g the movement of the body It should stop moving and come to rest in a level position with one or two bounces 3 If the vehicle continues to move up and down or if it fails to return to its original position a worn or weak strut or shock absorber is probably the reason 4 Repeat the above check at each of the three remaining corners of the vehicle 5 Raise the vehicle and support it on axle Stands 6 Check the struts shock absorbers for evidence of fluid leakage A light film of fluid is 23 2 Check the exhaust system rubber mountings for cracks 1922 24 10 Inspect the balljoint boots for tears arrowed no cause for concern Make sure that any fluid noted is from the struts shocks and not from any other source If leakage is noted renew the struts or shock absorbers in axle pairs or as a full set 7 Check the struts shock absorbers to be Sure that they are securely mounted and undamaged Check the upper mountings for damage and wear If damage or wear is noted renew the struts or shock absorbers 8 If the struts or shock absorbers must be renewed refer to Chapter 10 for the procedure Always renew both units on the Same axle or the safety of the vehicle may be compromised If possible renew all four as a Set Steering and suspension check 9 Inspect the steering system components for damage and distortion Look for leaks and damaged seals boots and fittings 10 Clean the lower end of the steering knuck
322. ge At this stage the dent should be Surrounded by a ring of bare metal which in turn should be encircled by the finely feathered edge of the good paintwork Rinse the repair area with clean water until all of the dust produced by the rubbing down operation has gone Spray the whole area with a light coat of primer this will show up any imperfections in the surface of the filler Repair these imperfections with fresh filler paste or bodystopper and once more smooth the Surface with abrasive paper Repeat this Spray and repair procedure until you are Satisfied that the surface of the filler and the feathered edge of the paintwork are perfect Clean the repair area with clean water and allow to dry fully TET If bodystopper is used it can be mixed with cellulose HiNT thinners to form a really thin paste which is ideal for filling small holes The repair area is now ready for final spraying Paint spraying must be carried out in a warm dry windless and dust free atmosphere This condition can be created artificially if you have access to a large indoor working area but if you are forced to work in the open you will have to pick your day very carefully If you are working indoors dousing the floor in the work area with water will help to settle the dust which would otherwise be in the atmosphere If the repair area is confined to one body panel mask off the surrounding panels this will help to minimise the
323. ght diode for burglar alarm Plug for boot light Boot light Door contact switch front left Door contact switch front right Door contact switch rear left Door contact switch rear right Boot lid contact Bonnet contact Rear window heater Plug centre section to wire for on board computer burglar alarm Horn Plug for light diode Description Diode Plug burglar alarm wire to central lock connecting wire Chime left of steering column Connection for chime Plug centre section to LE Jetronic wire harness Ignition switch Remote control switch for on board computer Plug on board computer to outside temperature sensor wire Plug outside temperature sensor wire to outside tempera ture sensor Outside temperature sensor lower front panel Plug extra heater wire to automatic aerial Parked car heating electronic control unit on parked car heater underneath right seat Connection for electronic control unit Relay for parked car heater on heater Plug on board computer wire to extra heater wire Plug centre section to instrument cluster Connection for instrument cluster On board computer electronic control unit right of instrument cluster Connection for on board computer Connection for instrument cluster Il Instrument cluster Plug rear section to instrument cluster Plug digital clock wire to instrument cluster Plug extra wire to heater wire Plug heater wire to fuel pump wire Connection for
324. good condition secure and legible with letters and numbers correctly spaced spacing at A should be twice that at B The VIN plate and or homologation plate must be legible MOT Test Checks Electrical equipment C Switch on the ignition and check the operation of the horn Check the windscreen washers and wipers examining the wiper blades renew damaged or perished blades Also check the operation of the stop lights C Inspect both front brake flexible hoses for cracks or deterioration of the rubber Turn the steering from lock to lock and ensure that the hoses do not contact the wheel tyre or any part of the steering or suspension mechanism With the brake pedal firmly depressed check the hoses for bulges or leaks under pressure Check the operation of the sidelights and number plate lights The lenses and reflectors must be secure clean and undamaged Check the operation and alignment of the headlights The headlight reflectors must not be tarnished and the lenses must be undamaged C Switch on the ignition and check the operation of the direction indicators including the instrument panel tell tale and the hazard warning lights Operation of the sidelights and stop lights must not affect the indicators if it does the cause is usually a bad earth at the rear light cluster Check the operation of the rear foglight s including the warning light on the instrument panel or
325. h an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Detach the breather hose from the valve cover 3 On M20 engines unbolt and remove the intake manifold support bracket and if applicable the bracket for the engine sensors or idle air stabiliser it will probably be necessary to disconnect the electrical connectors from the sensors and stabiliser 4 On M30 engines disconnect the electrical connector for the airflow sensor Unclip the electrical harness moving it out of the way 5 Where necessary on M30 engines remove the hoses and fittings from the intake air hose then loosen the clamp and separate the hose from the throttle body Unscrew the mounting nuts for the air cleaner housing and remove the housing together with the air hose and airflow sensor 6 Remove the valve cover retaining nuts and washers see illustrations Where necessary disconnect the spark plug lead clip or cover 4 7a Removing the valve cover on the M40 engine 4 6a Valve cover bolt locations arrowed on M10 four cylinder engines from the stud s and set it aside It will usually not be necessary to disconnect the leads from the spark plugs 7 Remove the valve cover and gasket
326. h spots on the bearing which will lead to failure 21 Engine overhaul reassembly sequence 1 Before beginning engine reassembly make Sure you have all the necessary new parts gaskets and seals as well as the following items on hand Common hand tools A torque wrench Piston ring refitting tool Piston ring compressor Vibration damper refitting tool Short lengths of rubber or plastic hose to fit over connecting rod bolts where applicable Plastigage Feeler gauges A fine tooth file New engine oil Engine assembly oil or disulphide moly grease Gasket sealant Thread locking compound 2 In order to save time and avoid problems engine reassembly should be done in the following general order molybdenum 22 4 With the ring square in the cylinder measure the end gap with a feeler gauge Piston rings Crankshaft and main bearings Piston connecting rod assemblies Oil pump Sump Cylinder head assembly Timing belt or chain and tensioner assemblies Water pump Timing belt or chain covers Intake and exhaust manifolds Valve cover Engine rear plate Flywheel driveplate 22 Piston rings refitting WU 1 Before fitting the new piston rings the ring end gaps must be checked It s assumed that the piston ring side clearance has been checked and verified see Section 18 2 Lay out the piston connecting rod assemblies and the new ring sets so that the ring sets will be matched with the sa
327. hapter 10 Worn control arm bushings or tie rod ends Chapter 10 Loose anti roll bar Chapter 10 Loose wheel bolts Loose suspension mounting bolts Chapter 10 Fault Finding rer 1s Wandering or poor steering stability Mismatched or uneven tyres Chapter 10 Lack of lubrication at balljoints and tie rod ends Chapter 1 Worn shock absorbers Chapter 10 Loose anti roll bar Chapter 10 Broken or sagging springs Chapter 10 Front or rear wheel alignment incorrect Chapter 10 Erratic steering when braking Wheel bearings worn Chapter 1 Broken or sagging springs Chapter 10 Leaking wheel cylinder rear drum brake models or caliper Chapter 9 Warped discs Chapter 9 Excessive pitching and or rolling around corners or during braking Loose anti roll bar Chapter 10 Worn shock absorbers or mountings Chapter 10 Broken or sagging springs Chapter 10 Overloaded vehicle Suspension bottoms Overloaded vehicle Worn shock absorbers Chapter 10 Broken or sagging springs or incorrect springs fitted Chapter 10 Unevenly worn tyres Front wheel or rear wheel alignment incorrect Chapter 10 _ Worn shock absorbers Chapter 10 Wheel bearings worn Chapter 10 Excessive tyre o
328. hapter 11 for access to these Screws 2 There are several methods of adjusting the headlights The simplest method requires a blank wall or garage door 25 feet in front of the vehicle and a level floor 3 Position masking tape vertically on the wall to mark the vehicle centreline and the centreline of both headlights Note It may be easier to position the tape on the wall with the vehicle parked only a few inches away and then move the vehicle back the required distance when all marks have been made 4 Make a horizontal line on the wall to mark the centreline of all headlights 5 Move the vehicle back so that it is 25 feet away from the marked wall keep the front end of the vehicle square to the wall Adjustment Should be made with the vehicle sitting level the fuel tank half full and with no unusually heavy loads in the vehicle 6 Switch on the dipped beam The bright Spots on the wall should be two inches below the horizontal line and two inches to the left of the headlight vertical lines Adjustment is made by turning the adjusting screw to raise or lower the beam The other adjusting screw an 15 3a tail light bulbs on later 5 Series models are in self earthing holders which can be simply pulled out of the housing the bulb is then removed from the holder 13 1 The headlight adjustment screws arrowed are accessible from the back of the headlight on 3 Series models Should be used in the same mann
329. hat connect the front of the sump to the bottom of the front cover see illustration 7 14 20 Run a sharp thin knife between the sump gasket and the front cover cutting the cover free from the gasket Be very careful not to damage the gasket and keep it clean so you can re use it 21 Break the front cover to block gasket seal by tapping the cover with a rubber mallet or block of wood and hammer Do not prise between the cover and the engine block as damage to the gasket sealing surfaces will result P 11 14 Fitting new camshaft oil seal the M40 engine note the adhesive tape around the end of the camshaft to protect the seal 22 Using a scraper remove all traces of old gasket material from the sealing surfaces of the covers and engine block Caution Be very careful not to scratch or gouge the delicate aluminium surfaces Also do not damage the sump gasket and keep it clean Gasket removal solvents are available at motor factors and may prove helpful After all gasket material has been removed the gasket surfaces can be degreased by wiping them with a rag dampened with a suitable solvent 23 Support the cover on two blocks of wood and drive out the seals from behind with a hammer and screwdriver Be very careful not to damage the seal bores in the process 24 Coat the outside diameters and lips of the new seals with multi purpose grease and drive the seals into the cover with a hammer and a socket
330. having the equipment to depressurise the system safely Never disconnect air conditioning hoses or components until the system has been depressurised General 1 High temperatures under the bonnet can cause deterioration of the rubber and plastic hoses used for various systems Periodic inspection should be made for cracks loose clamps material hardening and leaks 2 Information specific to the cooling system can be found in Section 22 while the braking system is covered in Section 26 3 Most but not all hoses are secured with clamps Where clamps are used check to be sure they haven t lost their tension allowing the hose to leak If clamps aren t used make sure the hose has not expanded and or hardened where it slips over the fitting allowing it to leak Vacuum hoses 4 105 quite common for vacuum hoses especially those in the emissions system to be colour coded or identified by coloured 1 14 Stripes moulded into them Various systems require hoses with different wall thicknesses collapse resistance and temperature resistance When fitting new hoses be sure the new ones are made of the same material 5 Often the only effective way to check a hose is to remove it completely from the vehicle If more than one hose Is removed be sure to label the hoses and fittings to ensure correct refitting 6 When checking vacuum hoses be sure to include any plastic T fittings in the check Inspect the connections for cracks w
331. he disc see illustration If severe vibration has been noticed during application of the brakes the discs may be warped excessive run out If the vehicle is equipped with the Anti lock Braking System ABS do not confuse vibration caused by warped discs with normal Operation of the ABS It is quite normal for some vibration to be felt through the pedal when the system is working 4 To check disc run out place a dial indicator at a point about 13 mm from the outer edge of the disc see illustration Set the indicator to zero and rotate the disc The indicator reading should not exceed the specified 5 5 The disc thickness can be checked with a micrometer 5 6b and remove the disc from the hub H 5 4a To check disc run out mount a dial indicator as shown and rotate the disc allowable run out limit If it does and if the run out is not due to wheel bearing wear the disc should be renewed or if possible refinished by a specialist Note It is recommended that the discs be resurfaced regardless of the dial indicator reading as this will impart a smooth finish and ensure a perfectly flat surface eliminating any vibration felt through the brake pedal or other undesirable symptoms related to questionable discs At the very least if you elect not to have the discs resurfaced remove the glazing from the surface with emery cloth or sandpaper using a swirling motion see illustration 5 It is absolutely crit
332. he language resetting procedure 19 Raise and support the vehicle 20 Disconnect the electrical connector from the sensor 21 Carefully unscrew the sensor Caution Excessive force may damage the threads 22 A high temperature anti seize compound must be used on the threads of the sensor to facilitate future removal The threads of new sensors will already be coated with this compound but if an old sensor is removed and refitted recoat the threads 4 28 The TPS on L J etronic systems is located under the intake manifold terminals arrowed 23 Refit the sensor and tighten it securely 24 Reconnect the electrical connector of the pigtail lead to the main engine wiring harness 25 Lower the vehicle and reconnect the battery Oxygen Sensor Heated power sensor type output signal supply 12V Unheated single wire black wire Not applicable Heated terminal 1 terminals three wire 3 and 2 Heated terminal 2 terminals four wire 4 and 3 Throttle Position Sensor TPS General description 26 The Throttle Position Sensor TPS is located on the end of the throttle shaft on the throttle body By monitoring the output voltage from the TPS the ECU can determine fuel delivery based on throttle valve angle driver demand In this system the TPS acts as a switch rather than a potentiometer One set of throttle valve switch contacts is closed continuity only at idle A second set of contact
333. he edges of the boot compartment with pads or cloths to protect the painted surfaces when the lid is removed 2 Disconnect any cables or electrical connectors attached to the boot lid that would interfere with removal 3 Make alignment marks around the hinge bolts see illustration 4 Have an assistant support the lid then remove the lid to hinge bolts on both sides and lift it off 13 7 The door lock striker position can be adjusted after loosening the screws arrowed 14 3 Mark around the hinge bolts so you can refit the boot lid in its original location unscrew or loosen the boot lid to hinge bolts to remove or adjust it 5 Refitting is the reverse of removal Align the lid to hinge bolts with the marks made during removal 6 After refitting close the lid and make sure it s in proper alignment with the surrounding panels Fore and aft and side to side adjustments are controlled by the position of the hinge bolts in the slots To make an adjustment loosen the hinge bolts reposition the lid and retighten the bolts 7 The height of the lid in relation to the surrounding body panels when closed can be changed by loosening the lock and or striker bolts repositioning the striker and or lock and tightening the bolts see illustrations Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the informatio
334. he particular procedure you re performing or because of the close proximity of two otherwise unrelated components to one another For example if the vehicle is raised for chassis lubrication you should inspect the exhaust suspension steering and fuel Weekly checks 4 Fluid level checks Note The following are fluid level checks to be done on a 250 mile or weekly basis Additional fluid level checks can be found in Specific maintenance procedures which follow Regardless of intervals be alert to fluid leaks under the vehicle which would indicate a fault to be corrected immediately 1 Fluids are an essential part of the lubrication cooling brake and windscreen washer systems Because the fluids gradually become depleted and or contaminated during normal operation of the vehicle they must be periodically replenished See Lubricants and fluids at the beginning of this Chapter before adding fluid to any of the following components Note The vehicle must be on level ground when any fluid levels are checked Routine Maintenance systems while you re under the vehicle When the wheels are removed for other work it makes good sense to check the brakes since the wheels are already removed Finally let s suppose you have to borrow a torque wrench Even if you only need it to tighten the spark plugs you might as well check the torque of as many critical nuts and bolts as time allows The first step in this mainte
335. he throttle body mounting nuts upper and bolts lower and detach the throttle body from the air intake plenum see illustration 12 Cover the air intake plenum opening with a clean cloth to prevent dust or dirt from entering while the throttle body is removed 13 Refitting is the reverse of removal Be sure to tighten the throttle body mounting nuts to the torque listed in this Chapter s Specifica tions and adjust the throttle cable see Section 9 on completion 18 Fuel pressure regulator check and renewal Why Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Don t work ina garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure
336. he throttle is moved from closed idle position to fully open wide open throttle 3 If the throttle valve is not working properly renew the throttle body unit Warning Wait until the engine is A completely cool before beginning this procedure Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal and refitting 4 Detach the battery negative cable 5 Detach the air intake duct from the throttle body and place to one side 6 Detach the accelerator cable from the throttle body See Section 9 7 Detach the cruise control cable if applicable 8 Clearly label all electrical connectors throttle position sensor cold start injector idle air stabiliser etc then unplug them 9 Clearly label all vacuum hoses then detach them 10 Unscrew the radiator or expansion tank cap to relieve any residual pressure in the cooling system then refit it Clamp shut the coolant hoses then loosen the hose clamps and detach the hoses Be prepared for some coolant leakage 16 11b Remove the nuts arrowed from the air cleaner housing and detach the airflow meter 11 Remove t
337. he transmission to engine bolts and tighten them securely Caution DO NOT use the bolts to force the transmission and engine together 34 Refit the remaining components in the reverse order of removal 35 Add coolant oil power steering and transmission fluid as needed 36 Run the engine and check for leaks and proper operation of all accessories then refit the bonnet and test drive the vehicle 37 Where necessary have the air conditioning system recharged and leak tested 6 Engine overhaul alternatives The do it yourselfer is faced with a number of options when performing an engine overhaul The decision to renew the engine block piston connecting rod assemblies and crankshaft depends on a number of factors with the number one consideration being the condition of the block Other considerations are cost access to machine shop facilities parts availability time required to complete the project and the extent of prior mechanical experience on the part of the do it yourselfer Some of the alternatives include Individual parts f the inspection procedures reveal that the engine block and most engine components are in re usable condition purchasing individual parts may be the most economical alternative The block crankshaft and piston connecting rod assemblies should all be inspected carefully Even if the block shows little wear the cylinder bores should be surface honed Crankshaft kit A crankshaft kit
338. he vacuum advance adjusts ignition timing to compensate for changes in engine load Motronic ignition system This system also known as Digital Motor Electronics DME incorporates all ignition and fuel injection functions into one central control unit or ECU computer The ignition timing is based on inputs the ECU receives for engine load engine speed coolant temperature and intake air temperature The only function the distributor performs is the distribution of the high voltage signal to the individual spark plugs The distributor is attached directly to the cylinder head There is no mechanical spark advance system used on these systems Ignition timing is electronically controlled and is not adjustable on Motronic systems During starting a crankshaft position sensor reference sensor relays the crankshaft position to the ECU and an initial baseline ignition point is determined Once the engine is running the ignition timing is continually changing based on the various input signals to the ECU Engine speed is signalled by a Speed sensor Early Motronic systems have the position reference sensor and the speed sensor mounted on the bellhousing over the flywheel on the left hand side Later Motronic systems have a single sensor pulse sensor mounted over the crankshaft pulley This sensor functions as a speed sensor as well as a position reference sensor Refer to Sec tion 12 for checking and renewing the ignition sens
339. he wiring harness on or near the steering column Access is gained by removing the Steering column shrouds see illustration 2 When the flasher unit is functioning properly a regular clicking noise can be heard from it when the indicators or hazard flashers are switched on If the direction indicators fail side or the other and the flasher unit does not make its characteristic clicking sound a faulty direction indicator bulb is indicated 3 If both direction indicators fail to blink the problem may be due to a blown fuse a faulty flasher unit a broken switch or a loose or open connection If a quick check of the fusebox 5 1 direction indicator hazard warning flasher unit is located on the steering column on most models squeeze the tabs to detach it indicates that the direction indicator and or hazard fuse has blown check the wiring for a short circuit before fitting a new fuse 4 Make sure that the new unit is identical to the original Compare the old one to the new one before fitting it 5 Refitting is the reverse of removal 6 Steering column switches removal and refitting Warning Some later models equipped with an airbag or Supplemental Restraint System SRS To avoid possible damage to this system the manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other specialist because of the special too
340. here a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand Check In vehicle check 1 Using a mechanic s stethoscope available at most car accessory shops check for a clicking sound at each of the injectors while the engine is idling see illustration 15 7 TT NaN If you don t have mechanic s stethoscope a HiNT screwdriver can be used to check for a clicking sound at the injectors Place the tip of the screwdriver against the injector and press your ear against the handle 2 The injectors should make a steady clicking sound if they are operating properly 3 Increase the engine speed above 3500 rpm The frequency of the clicking sound should rise with engine speed 4 If an injector isn t functioning not clicking purchase a special injector test light a car accessory shop or fuel injection specialist may be able to help and connect it to the injector electrical connector Start the engine and make sure the light flashes If it does the injector is receiving the proper voltage so the injector itself must be faulty 5 Unplug each injector connector and check 20 8 Remove the bolts arrowed and separate the fuel rail and injectors from the intake manifold the
341. hey do become stained which can be more apparent on light coloured upholstery use a little liquid detergent and a soft nail brush to scour the grime out of the grain of the material Do not forget to keep the headlining clean in the same way as the upholstery When using liquid cleaners inside the vehicle do not over wet the surfaces being cleaned Excessive damp could get into the seams and padded interior causing stains offensive odours or even rot TET If the inside of the vehicle gets wet accidentally it is HiNT worthwhile taking some trouble to dry it out properly particularly where carpets are involved Do not leave oil or electric heaters inside the vehicle for this purpose 5 Bodywork repair minor damage Note For more detailed information about bodywork repair Haynes Publishing produce a book by Lindsay Porter called The Car Bodywork Repair Manual This incorporates information on such aspects as rust treatment painting and glass fibre repairs as well as details on more ambitious repairs involving welding and panel beating Repairs of minor scratches in bodywork If the scratch is very superficial and does not penetrate to the metal of the bodywork repair is very simple Lightly rub the area of the scratch with a paintwork renovator or a very fine cutting paste to remove loose paint from the scratch and to clear the surrounding bodywork of wax polish Rinse the area with clean water
342. hich could cause leakage 7 A small piece of vacuum hose can be used as a stethoscope to detect vacuum leaks Hold one end of the hose to your ear and probe around vacuum hoses and fittings listening for the hissing sound characteristic of a vacuum leak Warning When probing with the vacuum hose stethoscope be careful not to touch moving engine components such as the drivebelt cooling fan etc Fuel hoses Warning There are certain precautions which must be taken when servicing or inspecting fuel system components Work in a well ventilated area and do not allow open flames cigarettes appliance pilot lights etc or bare light bulbs near the work area Mop up any spills immediately and do not store fuel soaked rags where they could ignite If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand 8 The fuel hoses are usually under pressure so if any fuel hoses are to be disconnected be prepared to catch spilled fuel Warning On vehicles equipped with fuel injection you must depressurise the fuel system before servicing the fuel hoses Refer to Chapter 4 for details SMALL CRACKS CREASE ALWAYS CHECK the underside of the belt GLAZED 11 3 Here are some of the more common problems associated with drivebelts check the belts very carefully to prevent an untimely bre
343. hicle supported only by a hydraulic or scissors type jack always use axle stands 5 f you haven t changed the oil on this vehicle before get under it and locate the drain plug and the oil filter Note that on some engines the oil filter is located on the top left hand side of the engine The exhaust components will be hot as you work so note how they are routed to avoid touching them 6 Being careful not to touch the hot exhaust components position a drain pan under the plug in the bottom of the engine 7 Clean the area around the plug then remove the plug see illustration It s a good idea to wear a rubber glove while unscrewing the plug the final few turns to avoid being scalded by hot oil Hold the drain plug against 6 7 Using a ring spanner to remove the oil drain plug 6 16 Lubricate the oil filter sealing ring with clean engine oil before refitting the filter on the engine the threads as you unscrew it then pull it away from the drain hole suddenly This will place your arm out of the way of the hot oil as well as reducing the chances of dropping the drain plug into the drain pan 8 It may be necessary to move the drain pan slightly as oil flow slows to a trickle Inspect the old oil for the presence of metal particles which could give early warning of engine wear 9 After all the oil has drained wipe off the drain plug with a clean rag Any small metal particles clinging to the plug would immediately co
344. hin 8 to 12 degrees of fully open If the readings are incorrect adjust the TPS 30 If all the resistance readings are correct and the TPS is properly adjusted check for power 5 volts at the sensor and if necessary trace any wiring circuit problems between the sensor and ECU see Chapter 12 Adjustment 31 If the adjustment is not as specified paragraphs 28 to 30 loosen the screws on the TPS and rotate the sensor into the correct adjustment Follow the procedure for checking the TPS given above and tighten the screws when the setting is correct 32 Recheck the TPS once more if the readings are correct reconnect the TPS harness connector Early 535i models with automatic transmission Check 33 First test the continuity of the TPS Follow paragraphs 28 to 30 and check for continuity 34 Next test the idle position switch see illustration Unplug the electrical connector in the idle position switch harness and IDLE POSITION SWITCH ADJUSTING MOUNTING SCREWS FOR SWITCH ADJUSTING MOUNTING SCREWS FOR SENSOR THROTTLE POSITION SENSOR 4 34 Idle position switch and TPS on early 535i models with automatic transmission connect an ohmmeter to terminals 1 and 2 There should be continuity Open the throttle slightly and measure the resistance There should now be no continuity 35 Check for the correct voltage signals from the TPS with the throttle closed and the ignition on Probe the back of the TPS connector
345. hing the fuel injector s or carburettor Chapters 1 and 4 Damaged fuel injection system speed sensors Chapter 5 Faulty fuel injection relays Chapter 5 Oil puddle under engine Oil sump gasket and or sump drain plug seal leaking Chapter 2 Oil pressure sender unit leaking Chapter 2 Valve cover gaskets leaking Chapter 2 Engine oil seals leaking Chapter 2 Engine idles erratically Vacuum leakage Chapter 4 Air filter element clogged Chapter 1 Fuel pump not delivering sufficient fuel to the fuel injection system or carburettor Chapter 4 Leaking head gasket Chapter 2 Timing belt chain and or sprockets worn Chapter 2 Camshaft lobes worn Chapter 2 Faulty charcoal canister where fitted Chapter 6 Engine misses at idle speed Spark plugs worn or incorrectly gapped Chapter 1 Faulty spark plug HT leads Chapter 1 Vacuum leaks Chapter 1 Incorrect ignition timing Chapter 5 Uneven or low compression Chapter 2 Faulty charcoal canister where fitted Chapter 6 Engine misses throughout driving speed range Fuel filter clogged and or impurities in the fuel system Chapter 1 Low fuel output at the injectors or partially blocked carburettor jets Chapter 4 Faulty or incorrec
346. hop for advice before making a purchase Care and maintenance of tools Having purchased a reasonable tool kit it is necessary to keep the tools in a clean and serviceable condition After use always wipe off any dirt grease and metal particles using a clean dry cloth before putting the tools away Never leave them lying around after they have been used A simple tool rack on the garage or workshop wall for items such as screwdrivers and pliers is a good idea Store all normal spanners and sockets in a metal box Any measuring instruments gauges meters etc must be carefully stored where they cannot be damaged or become rusty Take a little care when tools are used Hammer heads inevitably become marked and screwdrivers lose the keen edge on their blades from time to time A little timely attention with emery cloth or a file will soon restore items like this to a good serviceable finish Working facilities Not to be forgotten when discussing tools Stud extractor set is the workshop itself If anything more than routine maintenance is to be carried out some form of suitable working area becomes essential It is appreciated that many an owner mechanic is forced by circumstances to remove an engine or similar item without the benefit of a garage or workshop Having done this any repairs should always be done under the cover of a roof Wherever possible any dismantling should be done on a clean flat workbench or ta
347. hose from the coolant recovery reservoir Drain the reservoir and flush it with clean water then reconnect the hose Refilling 10 Tighten the radiator drain plug or reconnect the radiator bottom hose Refit and tighten the cylinder block drain plug Four cylinder engines 11 Slowly add new coolant a 4096 6096 mixture of antifreeze to water to the radiator until it is full Add coolant to the reservoir up to the lower mark 12 Leave the radiator cap off and run the engine in a well ventilated area until the thermostat opens coolant will begin flowing through the radiator and the upper radiator hose will become hot 13 Turn the engine off and let it cool Add more coolant mixture to bring the coolant level back up to the lip on the radiator filler neck On the M40 engine unscrew the bleed screw from the top of the radiator and add coolant until it comes out of the bleed screw hole Refit and tighten the bleed screw 14 Squeeze the upper radiator hose to expel air then add more coolant mixture if necessary Refit the radiator cap 15 Start the engine allow it to reach normal operating temperature and check for leaks Every 24 000 miles ru 2 29 16 The bleed screw arrowed is located on the thermostat housing six cylinder models Six cylinder engines 16 Loosen the bleed screw in the thermostat housing see illustration 17 Fill the radiator with a 40 60 solution of antifreeze and water until it com
348. i theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Detach the battery negative cable 2 Raise the vehicle and support it securely on axle stands 3 Clearly label the wires from the terminals on 20 4b Withdrawing the starter motor from the M40 engine the starter motor and solenoid then disconnect them Note On some models it may be necessary to remove the air cleaner see Chapter 4 coolant expansion tank see Chapter 3 and the heater hoses to gain access to the top of the starter Carefully label any hoses or components that need to be removed from the engine compartment to avoid confusion when reassembling 4 Unscrew the mounting bolts and detach the Starter see illustrations Refitting 5 Refitting is the reverse of removal 21 Starter solenoid removal and refitting Removal Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrume
349. ia 11 Carburettor removal and refitting Removal 1 Remove the air cleaner as described in Section 8 2 Disconnect the accelerator cable from the carburettor with reference to Section 9 3 On automatic transmission models disconnect the kickdown cable 4 Disconnect the wiring from the carburettor noting the location of each wire 5 Remove the screw and disconnect the earth cable from the throttle positioner bracket see illustration 6 Disconnect the vacuum hoses noting that the hose with the white tracer is located on the white plastic T piece and the distributor vacuum hoses are located on the side of the carburettor see illustration 7 On the 2 4 carburettor disconnect and plug the coolant hoses from the TM thermal starter valve 8 Disconnect the fuel supply hose see illustration 11 8 Disconnect the fuel supply hose arrowed 11 9 Unscrew the four bolts arrowed and lift the carburettor from the intake manifold 9 Unscrew the four bolts and lift the carburettor from the insulating flange on the intake manifold see illustration 10 If necessary unscrew the nuts and remove the insulating flange from the intake manifold see illustration Refitting 11 Refitting is a reversal of removal but clean the mating faces thoroughly The insulating flange may be re used if it s in good condition Adjust the accelerator cable with reference to Section 9 and the kickdown cable where a
350. ical that the disc not be machined to a thickness less than that specified The minimum wear or discard thickness is stamped into the hub of the disc The disc thickness can be checked with a micrometer see illustration Removal 6 Remove the disc retaining screw see illustration and remove the disc from the hub see illustration If the disc is stuck to the hub spray a generous amount of penetrating oil onto the area between the hub and the disc see illustration and allow a few minutes for it to loosen the rust between the two components If a rear disc still sticks insert a thin flat bladed screwdriver through the hub flange rotate the starwheel on the handbrake 5 If the disc is stuck to the hub spray some penetrating oil onto the area between the hub and the disc and give the oil a few minutes to separate the two parts i 3 20 9 4 1 1 ET 1 XU j a k m i 4 p 4 Wu c D D i 3 i TA 5 6d Ifa rear disc still sticks to the hub insert a thin flat bladed screwdriver through the hub flange rotate the starwheel on the handbrake adjusting screw and contract the handbrake shoes disc removed for clarity adjusting screw and contract the handbrake shoes see illustration TET If the front disc is stuck on some discs it is possible to HINT thread two or three bolts into the holes provided a
351. icle and place it securely on axle stands 2 Fully release the handbrake lever then apply the brakes firmly several times with the footbrake pedal 3 Pull the handbrake lever up five clicks 4 Tighten or loosen the adjusting nuts by equal amounts until the rear brake shoes just begin to drag on the brake drum You should feel the same amount of resistance at both wheels when you rotate them 5 Release the handbrake lever and verify that the wheels rotate freely If they don t re adjust them Rear disc brake models Note The handbrake system is not self adjusting on models with rear disc brakes The handbrake therefore requires periodic adjustment to compensate for wear It should also be adjusted anytime either cable brake disc or handbrake assembly is renewed or removed for some reason 6 Slowly apply the handbrake and count the number of clicks at the lever If the lever can be pulled up further than the eighth click adjust the handbrake cable as follows 7 Peel back the handbrake lever boot and loosen the cable adjusting nut see illustration 10 1 On some models it may be necessary to remove the centre console completely for access 8 Loosen a single bolt in each rear wheel Raise the vehicle and place it securely on axle Stands 9 Remove the bolt you loosened in each rear wheel Turn the wheel until using a torch you can see the adjuster starwheel through the bolt hole 10 Turn the adjuster clockwise
352. icle is still under warranty To be sure of obtaining the correct parts it will be necessary to give the storeman the full Vehicle Identification Number and if possible to take the old parts along for positive identification Many parts are available under a factory exchange scheme any parts returned should always be clean It obviously makes good sense to go straight to the specialists on your vehicle for this type of part as they are best equipped to supply you Other garages and accessory shops These are often very good places to buy materials and components needed for the maintenance of your vehicle eg oil filters spark plugs bulbs drivebelts oils and greases touch up paint filler paste etc They also sell general accessories usually have convenient opening hours charge lower prices and can often be found not far from home Motor factors Good factors will stock all the more important components which wear out comparatively quickly eg exhaust systems brake pads seals and hydraulic parts clutch components bearing shells pistons valves etc Motor factors will often provide new or reconditioned components on a part exchange basis this can save a considerable amount of money Vehicle identification numbers Modifications are a continuing and unpublicised process in vehicle manufacture quite apart from major model changes Spare parts manuals and lists are compiled upon a numerical basis the appropri
353. ied out FROM THE DRIVER S SEAT Handbrake C Test the operation of the handbrake Excessive travel too many clicks indicates incorrect brake or cable adjustment Check that the handbrake cannot be released by tapping the lever sideways Check the security of the lever mountings Footbrake C Depress the brake pedal and check that it does not creep down to the floor indicating a master cylinder fault Release the pedal wait a few seconds then depress it again If the pedal travels nearly to the floor before firm resistance is felt brake adjustment or repair is necessary If the pedal feels spongy there is air in the hydraulic system which must be removed by bleeding 2 Checks carried out WITH THE VEHICLE ON THE GROUND TURN Check that the brake pedal is secure and in good condition Check also for signs of fluid leaks on the pedal floor or carpets which would indicate failed seals in the brake master cylinder Check the servo unit when applicable by Operating the brake pedal several times then keeping the pedal depressed and starting the engine As the engine starts the pedal will move down slightly If not the vacuum hose or the servo itself may be faulty Steering wheel and column Examine the steering wheel for fractures or looseness of the hub spokes or rim Move the steering wheel from side to side and then up and down Check that the steering wheel is not loose on the colum
354. iemens Telefunken and the earth to the vehicle body Continuity should exist 5 Using an ohmmeter check for continuity between connector terminal 4 Bosch or 3 Siemens Telefunken and terminal 15 of the ignition coil Continuity should exist 6 If the readings are incorrect repair the wiring harness Impulse generator signal 7 f the ignition control unit is receiving 10 2b Check for voltage at terminals 6 and battery voltage check the A C signal voltage 4 on the control unit electrical connector on the control unit electrical connector coming from the impulse generator to the Bosch system shown Siemens Telefunken system shown control unit Engine electrical systems 5 7 10 8 Back probe the ignition control unit connector and check for signal voltage on terminals 5 and 6 Bosch system shown It is very helpful to use angled probes 8 Use a digital voltmeter for the following tests a On Bosch systems connect the positive probe to connector terminal 5 and the negative probe to terminal 6 see illustration b On Siemens Telefunken systems connect the positive probe to terminal of the smaller connector and the negative probe to terminal 9 Have an assistant crank the engine over and check that there is 1 to 2 volts A C present If there is no voltage check the wiring harness between the impulse generator in the distributor and the control unit If the harness is OK check the impuls
355. ighten the cylinder head bolts in the sequence shown to the torque listed in this Chapter s Specifications see illustrations Note that on some engines the final stage of tightening takes place after the engine has been run 31 The remainder of refitting is the reverse of removal Set the valve clearances on M10 M20 and M30 engines see Chapter 1 before refitting the valve cover check them again after the engine is warmed up Run the engine and check for leaks cylinder head bolts see 12 28 Lowering the cylinder head onto the block M40 engine 12 29 Inserting a cylinder head bolt M40 engine 12 30a Cylinder head bolt TIGHTENING sequence for M10 four cylinder engines 9 000 07 12 30b Cylinder head bolt TIGHTENING sequence for M20 six cylinder engines 12 30c Cylinder head bolt TIG HTENING sequence for M30 six cylinder engines 12 30d Cylinder head bolt TIGHTENING sequence for M40 four cylinder engines bolts M40 engine 13 Sump removal and refitting EN ES 1 Drain the engine oil see Chapter 1 2 Raise the front of the vehicle and place it securely on axle stands 3 Remove the splash shields from under the engine 4 Where applicable disconnect the hoses attached to the sump and move them to one side see illustration 5 Where applicable disconnect the oil level sensor electrical connector see illustration 6 Where applicable remove the cast aluminium inspection cover tha
356. in the journal or if it s nicked or scratched see illustration the new seal may leak when the engine is reassembled In some cases a machine shop may be able to repair the journal by pressing on a thin sleeve If repair isn t feasible a new or different crankshaft should be fitted 9 Examine the main and big end bearing shells see Section 20 20 Main and connecting big end bearings inspection Whi 1 Even though the main and connecting big end bearings should be renewed during the engine overhaul the old bearings should be retained for close examination as they may reveal valuable information about the condition of the engine see illustration 2 Bearing failure occurs because of lack of lubrication the presence of dirt or other foreign particles overloading the engine and corrosion Regardless of the cause of bearing failure it must be corrected before the engine is reassembled to prevent it from happening again 20 1 Typical bearing failures A Scratched by dirt debris embedded into bearing material B Lack of oil overlay wiped out C Improper seating bright polished sections D Tapered journal overlay gone from entire Surface E Radius ride F Fatigue failure craters or pockets 2B 2B 18 General engine overhaul procedures 3 When examining the bearings remove them from the engine block the main bearing caps the connecting rods and the rod caps and lay them out on a clean surface in the sa
357. in the switch Footbrake Examine the master cylinder brake pipes and servo unit for leaks loose mountings corrosion or other damage Bk E DAL z E C The fluid reservoir must be secure and the fluid level must be between the upper A and lower B markings Steering and suspension Have your assistant turn the steering wheel from side to side slightly up to the point where the steering gear just begins to transmit this movement to the roadwheels Check for excessive free play between the steering wheel and the steering gear indicating wear or insecurity of the steering column joints the column to steering gear coupling or the steering gear itself Have your assistant turn the steering wheel more vigorously in each direction so that the roadwheels just begin to turn As this is done examine all the steering joints linkages fittings and attachments Renew component that shows signs of wear or damage On vehicles with power steering check the security and condition of the steering pump drivebelt and hoses Check that the vehicle is standing level and at approximately the correct ride height Shock absorbers Depress each corner of the vehicle in turn then release it The vehicle should rise and then settle in its normal position If the vehicle continues to rise and fall the shock absorber is defective A shock absorber which has seized will also cause the vehicle to fail
358. ing belt A toothed belt which drives the camshaft Serious engine damage may result if it breaks in service Timing chain chain which drives the camshaft Toe in The amount the front wheels are closer together at the front than at the rear On rear wheel drive vehicles a slight amount of toe in is usually specified to keep the front wheels running parallel on the road by offsetting other forces that tend to spread the wheels apart Toe out The amount the front wheels are closer together at the rear than at the front On front wheel drive vehicles a slight amount of toe out is usually specified Tools For full information on choosing and using tools refer to the Haynes Automotive Tools Manual Tracer A stripe of a second colour applied to a wire insulator to distinguish that wire from another one with the same colour insulator Tune up process of accurate and careful adjustments and parts replacement to obtain the best possible engine performance Turbocharger centrifugal device driven by exhaust gases that pressurises the intake air Normally used to increase the power output from a given engine displacement but can also be used primarily to reduce exhaust emissions as on VW s Umwelt Diesel engine U Universal joint or U joint A double pivoted connection for transmitting power from a driving to a driven shaft through an angle A U joint consists of two Y shaped yokes and a cross shaped member called the spide
359. ing removal installation tool Three legged hub and bearing puller Micrometer set Vernier calipers Dial test indicator and magnetic stand Compression testing gauge Clutch plate alignment set Brake shoe steady spring cup removal tool Impact screwdriver Micrometer and or vernier calipers see illustrations C Dial gauge see illustration Universal electrical multi meter Cylinder compression gauge see illustration Clutch plate alignment set see illustration Brake shoe steady spring cup removal tool see illustration Bush and bearing removal installation set see illustration Stud extractors see illustration Tap and die set see illustration C Lifting tackle Trolley jack Buying tools For practically all tools a tool factor is the best source since he will have a very comprehensive range compared with the average garage or accessory shop Having said that accessory shops often offer excellent quality tools at discount prices so it pays to shop around Remember you don t have to buy the most expensive items on the shelf but it is always advisable to steer clear of the very cheap tools There are plenty of good tools around at Bush and bearing removal installation set Tools and Working Facilities reasonable prices but always aim to purchase items which meet the relevant national safety standards If in doubt ask the proprietor or manager of the s
360. inkage check and lubrication 1 The throttle linkage should be checked and lubricated periodically to ensure its proper operation 2 Check the linkage to make sure it isn t binding 3 Inspect the linkage joints for looseness and the connections for corrosion and damage renewing parts as necessary see illustration 4 Lubricate the connections with spray lubricant or lithium based grease 20 Air filter renewal Carburettor engines 1 Release the spring clips then unscrew the centre nut and lift off the cover 2 Remove the air filter element and wipe clean the air cleaner body and cover 3 Fit the new air filter element then refit the cover using a reversal of the removal procedure Fuel injection engines 4 Loosen the clamp on the air intake duct and detach the duct see illustration 20 6b and lift the air filter element out uem x 20 5 Use a screwdriver to detach the air cleaner cover clips 5 Release the air cleaner cover retaining clips see illustration 6 Rotate the cover up lift it off and lift the element out noting which way round it is fitted see illustrations 7 Wipe the inside of the air cleaner housing with a clean cloth then fit the new element If the element is marked TOP be sure the marked side faces up 8 Refit the cover and secure the clips 9 Connect the air duct and tighten the clamp SCrew 21 Fuel system check Warning Fuel is extre
361. int While the engine is being overhauled other components such as the distributor starter and alternator can be rebuilt as well The end result should be a like new engine that will give many thousands of trouble free miles Note Critical cooling system components such as the hoses drivebelts thermostat and water pump MUST be renewed when an engine is overhauled The radiator should be checked carefully to ensure that it isn t clogged or leaking see Chapters 1 or 3 Also we don t recommend overhauling the oil pump always fit a new one when an engine is rebuilt Before beginning the engine overhaul read through the entire procedure to familiarise yourself with the scope and requirements of the job Overhauling an engine isn t difficult if you follow all of the instructions carefully have the necessary tools and equipment and pay close attention to all specifications however it is time consuming Plan on the vehicle being tied up for a minimum of two weeks especially if parts must be taken to an automotive machine shop for repair or recon ditioning Check on availability of parts and make sure that any necessary special tools and equipment are obtained in advance Most work can be done with typical hand tools although a number of precision measuring tools are required for inspecting parts to determine if they must be replaced Often an automotive machine shop will handle the inspection of parts and offer advice concerni
362. into the pan then refit the drain plug and tighten it securely 7 Refer to Section 17 and fill the differential with lubricant 8 Refit the filler level plug and tighten it securely 9 Lower the vehicle Check for leaks at the drain plug after the first few miles of driving Every 24 000 miles 1 33 2 Inspect the hoses arrowed at the top of the evaporative emissions charcoal canister for damage 33 Evaporative emissions control EVAP system check 1 The function of the evaporative emissions control system is to draw fuel vapours from the tank and fuel system store them in a charcoal canister and then burn them during normal engine operation This system is normally only fitted to those vehicles equipped with a catalytic converter 2 The most common symptom of a fault in the evaporative emissions system is a strong fuel odour in the engine compartment If a fuel odour is detected inspect the charcoal canister and system hoses for cracks The canister is located in the front corner of the engine compartment on most models see illustration 3 Refer to Chapter 6 for more information on the evaporative emissions system 34 Service indicator light resetting Service indicator lights 1 All models covered in this manual are equipped with various service indicator lights on the facia which automatically go on when the mileage interval is reached These lights can only be turned off by using a s
363. ion window to inspect the brake pads the pad lining which rubs against the disc can also be inspected by looking through each end of the caliper d Brake pedal pulsates normal if ABS is working e Brake fluid leaks usually on the inner side of the tyre or wheel 3 If any of these conditions are noted inspect the brake system immediately Brake lines and hoses Note Steel brake pipes are used throughout the brake system with the exception of flexible reinforced hoses at the front wheels and as connectors at the rear axle Periodic inspection of all these lines is very important 4 Park the vehicle on level ground and switch off the engine Remove the wheel covers Loosen but do not remove the bolts on all four wheels 5 Raise the vehicle and support it securely on axle stands 6 Remove the wheels see J acking and towing at the front of this book or refer to your owner s handbook if necessary 7 Check all brake lines and hoses for cracks chafing of the outer cover leaks blisters and distortion Check the brake hoses at front and rear of the vehicle for softening cracks bulging or wear from rubbing on other components Check all threaded fittings for leaks and make sure the brake hose mounting bolts and clips are secure 8 If leaks or damage are discovered they must be repaired immediately Refer to Chapter 9 for detailed brake system repair procedures Disc brakes 9 If it hasn t already been
364. ioner pulley lightly apply pressure to the tensioner to be sure the tensioner isn t stuck and has full movement against the timing belt In car engine repair procedures 2A 11 10 12b Removing the crankshaft pulley bolt M40 engine the housing Guide the belt around the other Sprocket s 19 Finally place idler tensioner rollers 20 On the M20 engine loosen the tensioner bolts and allow the spring tension to be applied to the belt 21 On the M20 engine lightly apply pressure behind the tensioner to be sure spring pressure is being applied to the belt see illustration Don t tighten the bolts while applying pressure lightly tighten the bolts only after releasing the tensioner 22 On the M40 engine unbolt and remove the valve cover then use the special tool to hold the camshaft in the TDC position see paragraph 11 23 On the M40 engine loosen the tensioner roller retaining nut and use an Allen key to rotate the roller anti clockwise until the timing belt is tensioned correctly The 90 twist method of checking the tension of the timing belt is not accurate enough for this engine and it is strongly recommended that the special BMW tensioning tool is obtained if at all possible apply 32 2 graduations on the tool see illustration A reasonably accurate alternative can be made using an Allen key and a spring balance see illustration Make sure that the spring balance is positioned as shown since the tensioner r
365. ions If the hold pressure is less than specified a Checkthe system for fuel leaks Repair any leaks found and recheck the fuel pressure b Checkthe fuel pump pressure see below C Check the fuel pressure regulator see Section 18 d Check the injectors see Section 20 Fuel pump pressure check Warning For this test a fuel pressure gauge with a bleed valve will be needed in order to relieve the high fuel pressure safely After the test is completed the normal procedure for depressurising will not work because the gauge is connected directly to the fuel pump P T 3 11 and connect the gauge between the fuel feed line and the fuel rail using a tee piece fitting 19 Depressurise the fuel system See Sec tion 2 20 Detach the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 21 Detach the fuel feed hose from the fuel rail and attach a fuel pressure gauge directly to the hose Note If the tee fitting is still connected to the gauge be sure to plug the open end 22 Reconnect the battery 23 Using a jumper wire bridge the te
366. ire you will see arcing or a small spark at the damaged area If arcing is noticed make a note to obtain new HT leads then allow the engine to cool 3 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti A theft system make sure you have the correct activation code before disconnecting the battery 15 11 On later models loosen the screws and detach the distributor cap up so you can inspect the inside Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 4 The HT leads should be inspected one ata time to prevent mixing up the firing order which is essential for proper engine operation 5 Disconnect the HT lead from the spark plug Do not pull on the lead itself only on the connector 6 Inspect inside the connector for corrosion which will look like a white crusty powder Push the HT lead and connector back onto the end of the spark plug It should be a tight fit on the plug end If it is not remove the lead and use pliers to carefully crimp the metal terminal inside the connector until it fits securely on the end of the spark plug 7 Using a clean rag wipe the entire length of the HT lead to remove any built up dirt and grease Once the lead is clean check for burns cracks and other damage Do not bend the lead excessively since the conductor might break 8 D
367. ired when changing the engine oil and filter 1 Drain It should be fairly shallow in depth but wide enough to prevent spills 2 Rubber gloves When removing the drain plug and filter you will get oil on your hands the gloves will prevent burns 3 Socket bar Sometimes the oil drain plug is tight and a long bar is needed to loosen it The correct size ring spanner may work just as well 4 Socket To be used with the bar or a ratchet must be the correct size to fit the drain plug six point preferred 5 Filter spanner This is a metal band type spanner which requires clearance around the filter to be effective This tool is not required on all engines 6 Filter spanner This type fits on the bottom of the filter and can be turned with a ratchet or breaker bar different size spanners are available for different types of filters This tool is not required on all engines 2 Start the engine and allow it to reach normal operating temperature oil and sludge will flow more easily when warm If new oil a filter or tools are needed use the vehicle to go and get them thus warming up the engine oil at the same time 3 Park on a level surface and switch off the engine when it s warmed up Remove the oil filler cap from the valve cover 4 Access to the oil drain plug and filter will be improved if the vehicle can be lifted on a hoist driven onto ramps or supported by axle stands Warning DO NOT work under a A ve
368. irling motion diameter of the drum is cast into the drum 98 Braking system 6 4b then unhook it from the rear shoe and remove it 6 4a Unhook the lower return spring from the front shoe 6 6a Remove the front shoe hold down spring 6 5b then unhook it from the rear shoe and remove it 4 Unhook and remove the lower return spring see illustrations 5 Unhook and remove the upper return spring see illustrations 6 Remove the front and rear brake shoe hold down springs see illustrations 7 Remove the front shoe see illustration 8 Remove the adjuster assembly see illustration Clean the adjuster and make Sure that the adjuster wheel moves freely on the threads It is recommended that the thermo clip the spring clip next to the 6 7 Remove the front shoe automatic adjuster lever and spring as an assembly then remove the lever and spring and set them aside for attachment to the new shoe 6 9 To disconnect the handbrake cable from the handbrake lever pull on the plug at the end of the cable and detach the cable from the bracket on the upper end of the lever diagonal cutting pliers are being used here because they grip the cable well but care must be taken not to nick the cable 6 8 Remove the automatic adjuster assembly 6 5a Unhook the upper return spring from the front shoe 6 6b and the rear shoe hold down spring adjuster wheel be renewed when
369. is available from the British Library Box 1504 751 45 Uppsala Sweden Chapter 1 1 1 Routine maintenance and servicing Contents Alt Mer saapi rrai E ro REO EORR A 20 Automatic transmission fluid and filter change 28 Automatic transmission fluid level check 8 Battery check maintenance and charging 13 Brake system check Cx ees 26 Cooling system draining flushing and refilling 29 System CHECK d s 22 Differential lubricant change 32 Differential lubricant level check 1 Driveshaft galter check 25 Drivebelt check adjustment and 11 Engine idle speed and CO level check and adjustment 12 Engine oil and filter 6 Engine timing belt renewal 35 ExhausEt SUStaI CHECK 23 Evaporative Emissions Control EVAP system check 33 Fluid level checks ced ees Coe ech a dad 4 Fuel filter renewal 30 Degrees of difficulty Fairly easy Suitable for beginner with some expenence Easy Suitable for novice with little expenence A x x
370. is not part of the Motronic ignition system Speed and position sensors Check 1 Locate the two electrical connectors for the sensors see illustrations The grey connector is for the position sensor and the white connector is for the speed sensor 2 Using an ohmmeter check the resistance between terminal 1 yellow wire and terminal 2 black wire on the sensor side of each connector The resistance should be 860 to 1 060 ohms 3 Also check the resistance between terminal 3 and either terminal 1 or terminal 2 The resistance should be approximately 100 000 ohms 4 If the reading s are incorrect renew the sensor s Renewal 5 Remove the sensor mounting screw s 12 5 Location of the position sensor B and speed sensor D on the bellhousing on all Motronic systems do not interchange the sensors the engine will not start using an Allen key where necessary and pull the sensor s from the sockets Disconnect the wiring from one sensor at a time be sure the connectors are not interchanged when fitting new sensors The bellhousing is marked with a B for the position sensor grey connector and D for the speed sensor black connector see illustration Note It is a good idea to check the condition of the raised pin on the flywheel while the sensors are out of the sockets Turn the engine by hand as necessary to bring the pin into view 6 Tighten the sensor mounting screw s securely but be careful not to over
371. is type of repair A wide flexible plastic or nylon applicator will be found invaluable for imparting a smooth and well contoured finish to the surface of the filler Mix up a little filler on a clean piece of card or board measure the hardener carefully follow the maker s instructions on the pack otherwise the filler will set too rapidly or too Slowly Using the applicator apply the filler paste to the prepared area draw the applicator across the surface of the filler to achieve the correct contour and to level the Surface AS soon as a contour that approximates to the correct one is achieved Stop working the paste if you carry on too long the paste will become sticky and begin to pick up on the applicator Continue to add thin layers of filler paste at 20 minute intervals until the level of the filler is just proud of the surrounding bodywork Once the filler has hardened the excess can be removed using a metal plane or file From then on progressively finer grades of abrasive paper should be used starting with a 40 grade production paper and finishing with a 400 grade wet and dry paper Always wrap the abrasive paper around a flat rubber cork or wooden block otherwise the surface of the filler will not be completely flat During the smoothing of the filler surface the wet and dry paper should be periodically rinsed in water This will ensure that a very smooth finish is imparted to the filler at the final sta
372. isconnect the HT lead from the distributor Again pull only on the connector Check for corrosion and a tight fit in the same manner as the spark plug end Renew the HT lead in the distributor if necessary 9 Check the remaining spark plug HT leads making sure they are securely fastened at the distributor and spark plug when the check is complete 10 If new spark plug HT leads are required purchase a set for your specific engine model Lead sets are available pre cut with the connectors already fitted Remove and renew the HT leads one at a time to avoid mix ups in the firing order 11 Loosen the screws or detach the clips and remove the distributor cap see illustration Remove the screws if applicable and pull the rotor off the shaft see illustration Check the distributor cap and rotor for wear Look for cracks carbon tracks and worn burned or loose contacts see illustrations Renew the and rotor if defects are found It is common practice to fit a new cap and rotor whenever new spark plug HT leads are fitted When fitting a new cap remove the HT leads from the old cap one at a time and attach 15 11b Use an Allen key to remove the screws then lift the rotor off the shaft later models BROKEN TOWER w CRACK CARBON TRACK CHARRED OR ERODED TERMINALS CARBON TRACK WORN OR DAMAGED ROTOR BUTTON 15 11 Shown here are some of the common defects to look for when inspecting the distributor cap if in
373. ise control system repair should be left to a dealer service department However it is possible for the home mechanic to make simple checks of the wiring and vacuum connections for minor faults which can be easily repaired These include a Inspect the cruise control actuating switches for broken wires and loose connections b Check the cruise control fuse The cruise control system is operated by vacuum so it s critical that all vacuum Switches hoses and connections are secure Check the hoses in the engine compartment for loose connections cracks or obvious vacuum leaks 20 Central locking system description and check central door locking system operates the door lock actuators mounted in each door The system consists of the switches actuators and associated wiring Diagnosis is limited to simple checks of the wiring connections and actuators for minor faults which can be easily repaired These include a Check the system fuse and or circuit breaker where applicable b Check the switch wires for damage and loose connections Check the switches for continuity c Remove the door trim panel s and check the actuator wiring connections to see if they re loose or damaged Inspect the actuator rods to make sure they aren t bent damaged The actuator be checked by applying battery power momentarily A discernible click indicates that the solenoid is operating properly 21 Electric
374. ith no broken or loose terminals WS White Y Yellow VI Violet W White 12 12 10 Wiring diagrams 1 1 gt 2 5 VI TO INSTRUMENT CLUSTER D 4 0 RT SEE SHEET 4 OF 4 2 5 GN 1 15u 24 F6 F12 TO STOP LIGHT SWITCH SEE SHEET 3 OF 4 0 5 VIGR TO CHECK CONTROL SEE SHEET 3 OF 4 3 1 5 RTWS 30s 1 5 VIGR 2 5 SWGE SMA 570 NIIA 07 i F18 ur o g 5 T A SALY ST Com 28 QE AND ST amp j9N9 S 39N9 S I yg 4 09 4 e CO D e m i Q 9 SAN9 S O 0 19 0 9 ot Qo nS i ge TO INSTRUMENT CLUSTER e ji TO REG INSTRUMENT amp T T SEE SHEET 4 OF 4 LIGHT SWITCH O F19 SEE SHEET 2 OF 4 5 w w TO CHECK CONTROL 2 p m SEE SHEET 3 OF 4 m i m TRIL NUMBER TO DIM DIP RELAY PLRTE LIGHT SWITCH SEE SHEET 2 OF 4 SEE SHEET 3 OF 4 TO INSTRUMENT CLUSTER SEE SHEET 4 OF 4 TO MIRROR SWITCH SEE SHEET 3 OF 4 S GNSW i AS8 5 1418 lt iua 1518 KEY ITEMS 7 REVERSING LIGHT LEFT REVERSING LIGHT RIGHT BATTERY ALTERNATOR TWO TONE HORN DIRECTION INDICATOR RIGHT FRONT DIRECTION iNDICATOR RIGHT RERR DIRECTION INDICATOR LEFT REAR DIRECTION INDICATOR LEFT FRONT 10 HORN RELAY 12 RELAY FOR HEATER BLOWER HEATED REAR W
375. itting is the reverse of removal Caution If the radio in your vehicle is equipped with an anti 10 Instrument cluster removal and refitting Caution The instrument cluster and components are very susceptible to damage from static electricity Make sure you are earthed and have discharged 1 10 4 Push on the levers to detach the cluster electrical connectors any static electricity by touching an object such as a metal water pipe before touching the cluster or components Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 As necessary remove the steering column Shrouds and lower trim panel see Chap ter 11 3 Remove the screws holding the cluster to the facia see illustration Note the location of the lower screws to ensure they are refitted in the same place On 3 Series models the length of the two lower inner screws must not exceed 9 5 mm 4 Tilt the top of the cluster back reach behind it and detach the electrical connectors by pressing on the levers then lift the cluster out of the
376. k for leaks 4 If the water pump shaft bearings fail there may be a howling sound at the front of the engine while it s running Shaft wear can be felt if the water pump pulley is rocked up and down with the drivebelt removed Don t mistake drivebelt slippage which causes a squealing sound for water pump bearing failure Alternator bearing failure can also cause a howling sound but after removing the drivebelt s it should be easy enough to tell which component is responsible 7 Water pump removal and refitting Warning Wait until the engine is A completely cool before beginning this procedure 5 29 Removing the water pump pulley M40 engine Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Drain the cooling system see Chapter 1 If the coolant is relatively new or in good condition save it and re use it 3 Remove the cooling fan shroud Section 5 4 Remove the drivebelts see Chapter 1 5 Where applicable loosen the clamps and detach the hoses from the water pump If they re stuck grasp each hose near the end with a pair of water pump pliers and gently twist it to break the
377. ker arms Note There is more than one style of clip The wire type clips see illustration are fitted one each side of the rocker arm the spring steel type goes over the rocker arm and clips onto either side of it 8 Before removing the rocker arm shafts measure the rocker arm radial clearance using a dial indicator and compare your measurement to the Specifications at the j 8 7 Remove the retaining clips from the rocker arms the wire type clip is shown here 8 4 To check camshaft endfloat mount a dial indicator so that its stem is in line with the camshaft and just touching the camshaft at the front beginning of this Chapter Without sliding the rocker arm along the shaft try to rotate the rocker arm against the shaft in each direction see illustration The total movement measured at the camshaft end of the rocker arm is the radial clearance If the clearance is excessive either the rocker arm bush rocker arm shaft or both will need to be renewed 9 Remove the rubber retaining plugs or the threaded plugs at the front of the cylinder head as applicable There is a plug in front of each rocker shaft Caution If your engine has welded in retaining plugs at the front of the rocker shafts take the cylinder head to a machine shop for plug removal to avoid possible damage to the cylinder head or the rocker arm shafts 10 Rotate the camshaft until the most rocker arms possible are loose not compressin
378. kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand 1 Always disconnect the battery negative cable and on fuel injection models depressurise the fuel system as described in Section 2 before servicing fuel lines or fittings 2 The fuel feed return and vapour lines extend from the fuel tank to the engine compartment The lines are secured to the underbody with clip and screw assemblies 4 22b Fuel level sender unit terminal designations on later Motronic systems check the sender unit resistance across terminals 1 and 3 of the connector 1 Fuel level sender unit earth 2 Warning light 3 Sender unit 4 Fuel pump earth 5 Fuel pump These lines must be occasionally inspected for leaks kinks and dents See illustration 3 If evidence of dirt is found in the system or fuel filter during dismantling the lines should be disconnected and blown out On fuel injection models check the fuel strainer on the in tank fuel pump for damage and deterioration 4 Because fuel lines used on fuel injection vehicles are under high pressure they require Special consideration If renewal of a rigid fuel line or emission line is called for use welded steel tubing meeting BMW specification or its equivalent Don t use plastic copper or aluminium tubing to renew steel tubing These materials cannot withstand normal vehicle vibration 5 When renewing fuel hoses be sure to use only hoses of original eq
379. l system see illustration stores these fuel vapours a charcoal canister When the engine is cruising the purge control valve is opened slightly and a small amount of fuel vapour is drawn into the intake manifold and burned When the engine is starting cold or idling the purge valve prevents any vapours from entering the intake manifold and causing excessively rich fuel mixture 2 Two types of purge valve are used electrically operated or vacuum operated To find out which type is on your vehicle follow the hose from the charcoal canister until you locate the purge valve Some are located on the intake manifold and others near the charcoal canister Look for either an electrical connector or vacuum lines to the purge valve Engine management and emission control systems 6 5 THROTTLE BUTTERFLY THREE WAY CATALYST OXYGEN SENSOR q DISTRIBUTOR Ui VACUUM ADVANCE LINE CHARCOAL CANISTER FUEL TANK 6 1 Diagram of the EVAP system on the M10 engine others similar 3 A faulty EVAP system will only affect engine driveability when the engine is warm The EVAP system is not usually the cause of difficult cold starting or any other cold running problems Check Vacuum operated purge valve 4 Remove the vacuum lines from the purge valve and blow into the larger valve port It Should be closed and not pass any air Note Some models have a thermo vacuum valve that delays canister purging until the
380. l brake line see illustration If the nut is stuck soak it with penetrating oil After the hose is disconnected from the metal line remove the spring clip from the bracket and detach the hose from the bracket 4 To detach the flexible hose from the caliper 9 14 Braking system connection To disconnect it use one spanner to hold the hex shaped fitting on the end of the flexible hose lower right arrow and loosen the threaded fitting on the metal line with a split ring brake spanner upper right arrow then remove the spring clip left arrow Simply unscrew it Plug the open fitting in the caliper if the hose is removed for any length of time to prevent dirt ingress 5 Refitting is the reverse of the removal procedure Make sure the brackets are in good condition and the locknuts are securely tightened Renew the spring clips if they don t fit tightly 6 Carefully check to make sure the Suspension and steering components do not make contact with the hoses Have an assistant turn the steering wheel from lock to lock during inspection 7 Bleed the brake system as described in Section 16 Metal brake line renewal 8 When renewing brake lines use genuine parts only preferably from a BMW dealer 9 Genuine BMW brake lines are supplied straight You ll need a pipe bending tool to bend them to the proper shape 10 First remove the line you intend to renew lay it on a clean workbench and measure it caref
381. l information 16 Steering wheel removal and refitting 24 Strut or shock absorber coil spring 6 Suspension and steering checks Track rod ends removal and refitting Tyre and tyre pressure checks See Chapter 1 Treron ded aas See Chapter 1 Wheel alignment general information 26 Wheels and tyres general information Difficult suitable for Very difficult suitable for expert mechanic DIY or professional See Chapter 1 175 70x14 175 70x14 195 65x14 175 70x14 195 65x14 195 65x14 200 60x356 205 55x15 175x14 175x14 175x14 195 70x14 195 70x14 220 55x390 195 65x15 195 65x15 225 60x15 195 65x15 205 65x15 225 65x15 205 65x15 225 60x15 225 60x15 240 45x415 See Chapter 1 Specifications 10 10 2 Suspension and steering systems Torque wrench settings Nm Front suspension Strut damper rod nut Torque wrench settings Nm Rear suspension Rear shock absorber 3 Series Rod with external hexagon 65 Shock absorber to upper mounting bracket 12 to 15 Rod with internal hexagon 44 Shock absorber to trailing arm 71 to 85 Strut cartridge threaded 130 Rear shock absorber 5 Series Strut upper mounting NUS 22 Lower mounting
382. l often be necessary to use some sort of lever to move the accessory while the belt is adjusted If this must be done to gain the proper leverage be very careful not to damage the component being moved or the part being prised against Renewal 9 To renew a belt follow the instructions above for adjustment but remove the belt from the pulleys 10 In some cases you will have to remove more than one belt because of their arrangement on the front of the engine Because of this and the fact that belts will tend to fail at the same time it is wise to renew all belts together Mark each belt and its appropriate pulley groove so all renewed belts can be fitted in their proper positions 11 itis a good idea to take the old belts with you when buying new ones in order to make a direct comparison for length width and design 12 Recheck the tension of new belts after a few hundred miles 12 Engine idle speed and CO N level check and adjustment amp x Note The engine should be at normal Operating temperature with correct ignition timing and valve clearances where adjustable The air filter should be in good condition and all electrical components including the air conditioning where fitted Should be switched off Every 6000 miles 12 5 Mixture adjustment screw 2 on the 2B4 carburettor Carburettor 1 Connect a tachometer and exhaust gas analyser CO meter to the engine 2 Start the engine and allow it to id
383. l this number free Engine Engine will not rotate when attempting to start Engine rotates but will not start Engine hard to start when cold Engine hard to start when hot Starter motor noisy or excessively rough in engagement Engine starts but stops immediately Oil puddle under engine Engine idles erratically Engine misses at idle speed Engine misses throughout driving speed range Engine misfires on acceleration Engine surges while holding accelerator steady Engine stalls Engine lacks power Engine backfires Pinking or Knocking engine sounds when accelerating or driving uphill Engine runs with oil pressure light on Engine runs on after switching off Engine electrical system _ Battery will not hold charge _ Ignition no charge warning light fails to go out Ignition no charge warning light fails to come on when key is turned Fuel system L L Excessive fuel consumption Fuel leakage and or fuel odour Cooling system Overheating Overcooling External coolant leakage Internal coolant leakage Coolant loss Poor coolant circulation Clutch P edal travels to floor no pressure or very little resistance Fluid in area of master cylinder dust cover and on pedal Fluid on slave cylinder Pedal f
384. lastic container and a length of clear plastic or vinyl tubing to fit over the bleed screws Alternatively a one man bleeding kit can be used A one man kit usually contains a tube or bottle with a one way valve incorporated in this way the pedal can be pumped as normal but air is not drawn back into the system when the pedal is released If a one man kit is used follow the instructions provided with it similarly with pressure bleeding kits In any case you will also need a Supply of new brake fluid of the recommended type and a spanner for the bleed screw 8 Beginning at the right rear wheel loosen the bleed screw slightly then tighten it to a point where it is tight but can still be loosened quickly and easily 9 Place one end of the tubing over the bleed nipple and submerge the other end in brake fluid in the container see illustration 10 Have the assistant pump the brakes a few times then hold the pedal firmly depressed Note If the vehicle is equipped with ABS have the assistant pump the pedal at least 12 times 11 While the pedal is held depressed open the bleed screw just enough to allow a flow of fluid to leave the caliper or wheel cylinder Your assistant should press the brake pedal Smoothly to the floor and hold it there Watch for air bubbles coming out of the submerged end of the tube When the fluid flow slows after a couple of seconds close the screw and have your assistant release the pe
385. le 3 Check that the idle speed is as given in the Specifications Adjustment of the idle speed is only possible on the 2B4 carburettor Turn the carburettor idle speed adjustment screw until the engine idles at the correct speed see illustration 4 f the idle speed is low on the 2BE carburettor and all wiring to the carburettor is in good condition it is possible to connect a resistance into the control circuit This should be carried out by your BMW dealer 5 Check that the CO reading is as given in the Specifications If not turn the carburettor idle mixture adjustment screw until the mixture is correct see illustration L J etronic 6 Connect a tachometer and CO meter to the engine BMW technicians use a special CO tester with a probe connected into the exhaust manifold but the normal type of tester which locates in the exhaust tailpipe can be used instead Note however that on models with a catalytic converter meaningful CO readings will not be obtained at the tailpipe 7 Start the engine and allow it to idle 8 Check that the idle speed is as given in Specifications If not remove the tamperproof cap from the throttle housing and turn the idle adjustment screw until the speed is correct 9 Check that the CO reading is as given in the Specifications The mixture control screw is located on the airflow meter and a special 1 15 12 12 Removing the tamperproof plug from the airflow meter tool BMW number
386. le Have an assistant grasp the lower edge of the tyre and move the wheel in and out while you look for movement at the Steering knuckle to axle arm balljoints Inspect the balljoint boots for tears see illustration If there is any movement or the boots are torn or leaking the balljoint s must be renewed 11 Grasp each front tyre at the front and rear edges push in at the front pull out at the rear and feel for play in the steering linkage If any free play is noted check the steering gear mountings and the track rod balljoints for looseness If the steering gear mountings are loose tighten them If the track rods are loose the balljoints may be worn check to make sure the nuts are tight Additional steering and suspension system information can be found in Chapter 10 25 Driveshaft gaiter check EN EN a 1 The driveshaft gaiters are very important because they prevent dirt water and foreign material from entering and damaging the constant velocity CV joints External oil and grease contamination can cause the gaiter Every 12 000 miles 25 2 Gently probe the driveshaft boots to check for cracks material to deteriorate prematurely so it s a good idea to wash the gaiters with soap and water 2 Inspect the gaiters for tears and cracks as well as for loose clamps see illustration If there is any evidence of cracks or leaking lubricant the gaiter must be renewed see Chapter 8 26 Brake system
387. le is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable Sealed beam type 2 Remove the grille see Chapter 11 3 Remove the headlight retainer screws taking care not to disturb the adjustment Screws 4 Remove the retainer and pull the headlight out enough to allow the connector to be unplugged 5 Remove the headlight 6 To refit the headlight plug the connector in place the headlight in position and refit the retainer and screws Tighten the screws securely 12 10 Disconnecting the wire from the rear of the headlight bulb Body electrical systems 12 5 12 9 Twist and release the headlight inner cover 7 Refit the grille Connect the battery negative cable Halogen bulb type Warning Halogen gas filled bulbs A are under pressure and may shatter if the surface is scratched or the bulb is dropped Wear eye protection and handle the bulbs carefully grasping only the base whenever possible Do not touch the surface of the bulb with your fingers because the oil from your skin could cause it to overheat and fail prematurely TYNAN If you do touch the he
388. lf should be inspected 2 With the vehicle raised and supported on 12 7a Remove the lower shoe return spring diagonal cutting pliers are being used here because they grip the spring well but care must be taken not to cut or nick the spring axle stands remove the rear wheels 3 On rear brake drum models refer to Chapter 1 checking the thickness of the brake shoes is routine maintenance procedure 4 On rear disc brake models remove the rear discs as outlined in Section 5 Support the caliper assemblies with a coat hanger or heavy wire do not disconnect the brake line from the caliper 5 With the disc removed the handbrake components are visible and can be inspected for wear and damage The linings should last the life of the vehicle However they can wear down if the handbrake system has been improperly adjusted or if the handbrake is regularly used to stop the vehicle There is no minimum thickness specification for the handbrake shoes but as a rule of thumb if the shoe material is less than 1 5 mm thick you should renew them Also check the Springs and adjuster mechanism and inspect the drum for deep scratches and other damage Removal and refitting Note The following procedure applies only to models with rear disc brakes The handbrake system on models with rear drum brakes is an integral part of the rear brake assembly see Section 6 6 Loosen the rear wheel bolts raise the rear of the vehicle and place
389. librated spark tester available at most car accessory shops Note There are two different types of spark testers Be sure to specify electronic breakerless ignition Connect the clip on the Engine electrical systems 5 3 6 1 To use a spark tester simply disconnect a spark plug HT lead clip the tester to a convenient earth like a valve cover bolt or nut and operate the starter if there is enough power to fire the plug sparks will be visible between the electrode tip and the tester body tester to an earth point such as a metal bracket see illustration 2 If you are unable to obtain a calibrated spark tester remove the spark plug HT lead from one of the spark plugs Using an insulated tool hold the lead about a quarter inch from the engine block make sure the gap is not more than a quarter inch or damage may be caused to the electronic components 3 Crank the engine and observe the tip of the tester or spark plug HT lead to see if a spark occurs If bright blue well defined sparks occur sufficient voltage is reaching the plugs to fire the engine However the plugs themselves may be fouled so remove and check them as described in Chapter 1 4 If there s no spark check another HT lead in the same manner A few sparks followed by no spark is the same condition as no spark at all 5 f no spark occurs remove the distributor cap and check the cap and rotor as described in Chapter 1 If moisture is present
390. ll work although the wedge type tends to tear the balljoint boots Sometimes you can also jar a balljoint taper pin free from its eye by striking opposite sides of the eye simultaneously with two large hammers but the space available to do this is limited and the balljoint stud sometimes 20 7 To unbolt the idler arm from the subframe crossmember remove this nut arrowed sticks to the eye because of rust and dirt There is also a risk of damaging the component being struck 4 To remove the outer track rods disconnect the track rod ends from the steering arms see Section 17 Remove the nut that attaches the balljoint on the inner end of each outer track rod to the centre track rod see illustration Using a balljoint separator disconnect the outer track rods from the centre track rod If you re renewing the balljoint at either end of the outer track rods paint or scribe alignment marks on the threads to mark their respective positions as a guide to adjustment during reassembly see illustration 17 3 5 To remove the centre track rod remove the nuts that attach the centre track rod balljoints to the Pitman arm and the idler arm and use a balljoint separator to disconnect the balljoints from the two arms 6 To remove the Pitman arm you ll have to remove the steering box first see Section 21 Look for match marks between the sector shaft and arm If there aren t any scribe a mark across the bottom face of both part
391. lly inspect the entire length of each battery cable for damage cracked or burned insulation and corrosion Poor battery cable connections can cause Starting problems and decreased engine performance Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 3 3a Always detach the cable from the battery negative terminal first then detach the positive cable to remove the hold down assembly remove the nuts arrowed or single bolt 2 Check the cable to terminal connections at the ends of the cables for cracks loose wire Strands and corrosion The presence of white fluffy deposits under the insulation at the cable terminal connection is a sign that the cable is corroded and should be cleaned or renewed Check the terminals for distortion missing mounting bolts and corrosion Renewal 3 When removing the cables always disconnect the negative cable first and connect it up last This reduces the risk of accidental short circuits Even if only a new positive cable is being fitted be sure to disconnect the negative cable from the battery first see Chapter 1 for further inf
392. locating the source of the leak Remember that some leaks may only occur while the engine is running Sump oll Oil from filter Gearbox oil Engine oil may leak from the drain plug _ or from the base of the oil filter Gearbox oil can leak from the seals at the inboard ends of the driveshafts Antifreeze Brake fluid Power steering fluid Leaking antifreeze often leaves a crystalline A leak occurring ata wheel is almost Power steering fluid may leak from the pipe deposit like this certainly brake fluid connectors on the steering rack
393. ls and techniques required There is a risk of injury if the airbag is accidentally triggered Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable remove the steering wheel see Chapter 10 and steering column shrouds see Chapter 11 Direction indicator headlight switch 2 Where necessary remove the switch mounting screws Depress the tabs and pull the switch out of the steering column mounting see illustration 3 Trace the switch wires down the steering column to the electrical connector and unplug them see illustration 4 Refitting is the reverse of removal EM F ian m 1 6 2 Squeeze the tabs to release the switch from the mounting Wiper washer switch 5 Where necessary remove the switch mounting screws 6 Depress the release clip and detach the switch from the steering column mounting see illustration Trace the switch wiring down the steering column to the electrical connector and unplug it 7 Refitting is the reverse of removal Cruise control switch 8 Remove the wiper washer switch 9 Where necessary rem
394. lse generator see illustration Slide the feeler gauge up 11 2 Use a brass feeler gauge to check the air gap be sure the gauge rubs lightly against the trigger wheel as well as the locating pin for the correct adjustment 5 8 Engine electrical systems 12 1 Location of the position sensor grey connector A and the speed sensor black connector B on Motronic systems early models and down you should feel a slight drag on the feeler gauge as it is moved if the gap is correct The gap must be as given in this Chapter s Specifications 3 To adjust the gap itis necessary to remove the impulse generator and the baseplate assembly from the distributor see illus tration 10 1 4 Follow paragraphs 17 to 24 in Section 10 and loosen the screws that retain the impulse generator to the baseplate assembly 5 Carefully insert the feeler gauge and tighten the screws 6 Refit the assembly back into the distributor and recheck the adjustment 12 7a On later 3 Series models the pulse sensor connector arrowed is located next to the 20 pin diagnostic connector 12 1b Location of the position sensor grey connector A and the speed sensor black connector B on Motronic systems later models 12 Ignition sensors Motronic EN system check and renewal Note Some models are equipped with a TDC sensor mounted on the front of the engine This sensor is strictly for the BMW service test unit and
395. lt check adjustment and renewal ES X Check 1 The drivebelts sometimes called V belts or simply fan belts are located at the front of the engine and play an important role in the overall operation of the vehicle and its BELT DEFLECTION STRAIGHT EDGE 22 MAKE SURE RULER 15 PERPENDICULAR TO STRAIGHT EDGE 11 4 Measuring drivebelt deflection with a straightedge and ruler components Due to their function and material make up the belts are prone to failure after a period of time and should be inspected and adjusted periodically to prevent major engine damage 2 The number of belts used on a particular vehicle depends on the accessories fitted Drivebelts are used to turn the alternator power steering pump water pump and air conditioning compressor Depending on the pulley arrangement a single belt may be used to drive more than one of these components 3 With the engine switched off open the bonnet and locate the various belts at the front of the engine Using your fingers and a torch if necessary move along the belts checking for cracks and separation of the belt plies Also check for fraying and glazing which gives the belt a shiny appearance see illustration Both sides of the belts should be inspected which means you will have to twist each belt to check the underside 4 The tension of each belt is checked by pushing firmly with your thumb and seeing how much the belt moves deflect
396. lter housing an airflow meter a throttle body the intake manifold and the associated ducting The airflow meter is an information gathering device for the ECU These models are equipped with the vane type airflow meter A potentiometer measures intake airflow and a temperature sensor measures intake air temperature This information helps the ECU determine the amount of fuel to be injected by the injectors injection duration The throttle plate inside the throttle body is controlled by the driver As the throttle plate opens the amount of air that can pass through the System increases so the potentiometer opens further and the ECU signals the injectors to increase the amount of fuel delivered to the intake ports Electronic control system The computer control system controls the fuel system and other systems by means of an Electronic Control Unit ECU The ECU receives signals from a number of information sensors which monitor such variables as intake air volume intake air temperature coolant temperature engine rpm acceleration deceleration and exhaust oxygen content These signals help the ECU determine the injection duration necessary for the optimum air fuel ratio These sensors and their corresponding ECU controlled output actuators are located throughout the engine compartment For further information regarding the ECU and its relationship to the engine electrical systems and ignition system refer to Chapters 5 and
397. lts If the gasket protrudes above the cover to block joint or bunches up at the cover to sump joint trim the gasket so it fits correctly Note 2 After applying RTV type sealant reassembly must be completed in about 10 minutes so the RTV won t prematurely harden 21 Refit the upper timing chain cover in the same way as the lower cover If the gasket protrudes beyond the top of the cover and the engine block trim off the excess with a razor blade 22 Refitting is otherwise the reverse of removal 2 2 8 In car engine repair procedures 8 Timing chain and EN sprockets removal A inspection and refitting X Note This procedure applies to M10 and M30 engines Caution Once the engine is set at TDC do not rotate the camshaft or crankshaft until the timing chain is reinstalled If the crankshaft or camshaft is rotated with the timing chain removed the valves could hit the pistons causing expensive internal engine damage Removal 1 Position the No 1 cylinder at Top Dead Centre TDC on the compression stroke see Section 3 2 Remove the valve cover see Section 4 Double check that the No 1 cylinder is at TDC on the compression stroke by making sure the No 1 cylinder rocker arms are loose not compressing their valve springs 3 Remove the upper timing chain cover see Section 7 Note the location of the camshaft timing marks which should now be aligned On four cylinder M10 engines there s usually
398. lug the fan wire harness 3 To test the fan motor unplug the electrical connector at the motor and use jumper wires to connect the fan directly to the battery If the fan doesn t work when connected directly to the battery the motor is proved faulty and must be renewed If the fan works there s a good chance the switch is malfunctioning To more accurately diagnose the problem follow the steps that apply to your model Note Spin the auxiliary fan motor by hand to check that the motor or fan isn t binding Make sure however that the engine is sufficiently cool that there is no danger of the fan cutting in on its own when this is done 4 To test the low speed and high speed circuits disconnect the electrical connector from one of the fan switches and bridge the terminals of the switch s electrical connector with a short piece of wire The fan should run at low or high speed depending on which switch has been disconnected On some models the ignition must be on before the fan will run 5 Repeat the test at the other switch so that both high and low speeds are tested 6 If the low speed and high speed circuits are OK but there has been a problem with the fan not operating correctly in service renew the switch or switches To remove a switch drain the coolant below the level of the switch see Chapter 1 then unscrew the switch and screw in the new one Refill the system with coolant 7 the switches are satisfactory
399. ly operated solenoid valves If a problem develops within the system an ABS warning light will glow on the dashboard Sometimes a visual inspection of the ABS system can help you locate the problem Carefully inspect the ABS wiring harness Pay particularly close attention to the harness and connections near each wheel Look for signs of chafing and other damage caused by incorrectly routed wires If a wheel sensor harness is damaged the sensor should be renewed the harness and sensor are integral Warning DO NOT try to repair an ABS wiring harness The ABS system is sensitive to even the smallest changes in resistance Repairing the harness could alter resistance values and cause the system to malfunction If the ABS wiring harness is damaged in any way it must be renewed Caution Make sure the ignition is turned off before unplugging or re making any electrical connections Diagnosis and repair If the dashboard warning light comes on and stays on while the vehicle is in operation the ABS system requires attention Although special electronic ABS diagnostic testing tools are necessary to properly diagnose the system you can perform a few preliminary checks before taking the vehicle to a dealer service department a Check the brake fluid level in the reservoir b Verify that the electronic control unit connectors are securely connected C Checkthe electrical connectors at the hydraulic control unit d Che
400. m 59 977 to 59 983 mm 59 971 to 59 976 mm 0 030 to 0 070 mm 0 020 to 0 046 mm 47 975 to 47 991 mm 44 975 to 44 991 mm 0 041 mm 0 030 to 0 070 mm 0 020 to 0 055 mm 0 010 to 0 052 mm 89 00 to 89 01 mm 80 00 to 80 01 mm 84 00 to 84 01 mm 86 00 to 86 01 mm 86 00 to 86 01 mm 89 00 to 89 01 mm 92 00 to 92 01 mm 92 00 to 92 01 mm 84 000 to 84 014 mm 84 000 to 84 014 mm Pistons and piston rings Piston diameter standard 542555 Sd orent d t depre eS 20 engines BAU segues ee ee eee eee eee 30 engines B30M M40 engines Facto ecco a eee oe eae oe dibus eee ees Factory Stage ca dau aie eiin eis takie Piston to cylinder wall clearance New M10 and M30 engines M20 and M40 engines Service limit Except B25 engine amp 5 B25 engine Piston ring end gap M10 engine TOO COMPIESSION NNO auae ereer ek ed Second compression NING 225255403554 oad gre abb ex EO e O eaea rer TU M20 engine AROS Raye des add ole dr ede d 9 997 EUR a edo 0 328 9 EI d M30 engine TOD COIBGDIeSSIOH GING 254 a acd o atl dc di dae c adc eae eae wad second compression NING des cic tc do dn aco saccis OUTING es es a hn don od wee ea amp GERNE OR rad M40 engine Top compressiofi NNO a aii
401. m the radiator Cooling heating and air conditioning systems 3 3 m 3 20a Removing the elbow from the cylinder head M40 engine bottom hose from the elbow on the front of the cylinder head 20 Unbolt the elbow from the cylinder head Note the fitted position of the thermostat then remove it see illustrations Remove the rubber O ring a new one will be needed for reassembly 21 Locate the thermostat in the cylinder head in the same position as noted during removal arrow pointing upwards 22 Press a new O ring in the groove and locate the elbow on the cylinder head Tighten the bolts 23 Connect the bottom hose to the elbow and tighten the hose clamp 24 Refit the upper timing belt cover and cooling fan All models 25 Refill the cooling system see Chapter 1 26 Connectthe battery negative cable 27 Start the engine and allow it to reach normal operating temperature then check for leaks and proper thermostat operation as described earlier in this Section 4 Radiator removal and refitting Warning Wait until the engine is A completely cool before beginning this procedure 4 3b Bottom hose connection to the radiator P z 3 206 Removing the thermosta M40 engine Note If the radiator is being removed because it is leaking note that minor leaks can often be repaired without removing the radiator using a radiator sealant Caution If the radio in your
402. mage to nearby components 5 f the positive terminal and cable clamp on your vehicle s battery is equipped with a rubber protector make sure that it s not torn or damaged It should completely cover the terminal 6 The external condition of the battery should be checked periodically Look for damage Such as a cracked case 7 Check the tightness of the battery cable clamps to ensure good electrical connections Check the entire length of each cable looking for cracked or abraded insulation and frayed conductors 8 If corrosion visible as white fluffy deposits is evident remove the cables from the terminals clean them with a battery brush and reconnect them see illustrations Corrosion can be kept to a minimum by fitting specially treated washers available at car accessory shops or by applying a layer of petroleum jelly or suitable grease to the mc I Ko i 13 8b Removing a cable from the battery post with a spanner sometimes special battery pliers are required for this procedure if corrosion has caused deterioration of the nut always remove the earth cable first and connect it last corrosion must be removed the inside of the clamp is tapered to match the taper on the post so don t remove too much material terminals and cable clamps after they are assembled 9 Make sure that the battery carrier is in good condition and that the hold down clamp bolt is tight If the battery is removed see Chap
403. malfunctioning Chapter 4 Injector s leaking or carburettor automatic choke faulty Chap ter 4 Distributor rotor carbon tracked Chapter 5 complex and never overlook the obvious Anyone can run the fuel tank dry or leave the lights on overnight so don t assume that you are exempt from such oversights Finally always establish a clear idea of why a problem has occurred and take steps to ensure that it doesn t happen again If the electrical system fails because of a poor connection check all other connections the system to make sure that they don t fail as well If a particular fuse continues to blow find out why don t just renew one fuse after another Remember failure of a small component can often be indicative of potential failure or incorrect functioning of a more important component or system Engine hard to start when hot Air filter element clogged Chapter 1 Fuel not reaching the fuel injection system or carburettor Chap ter 4 Corroded battery connections especially earth negative connection Chapter 1 Starter motor noisy or excessively rough in engagement Pinion or flywheel gear teeth worn or broken Chapter 5 Starter motor mounting bolts loose or missing Chapter 5 Engine starts but stops immediately Loose or faulty electrical connections at distributor coil or alternator Chapter 5 Insufficient fuel reac
404. manifold to downpipe flange M40 engine Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 2 f you re removing the lower timing chain cover the upper cover can be removed separately remove the cooling fan and fan Shroud the radiator and the fan drivebelt pulley see Chapter 3 3 On the M10 engine only remove the water pump see Chapter 3 4 On engines where the distributor cap is mounted directly to the timing chain cover remove the cap rotor and the black plastic cover beneath the rotor see Chapter 1 5 On the M30 engine fitted with the L Jetronic fuel system remove the distributor from the upper timing cover see Chapter 5 6 Remove the valve cover see Section 4 7 f you ll be removing the lower timing chain cover on the M30 engine remove the crankshaft pulley from the vibration damper hub Hold the pulley stationary with a socket on the centre bolt and remove the pulley bolts with another socket See illustration 8 If you ll be removing the lower timing chain 1 E 1 7 Pie E ni EX L E E m E ES oT 7 4 1 6 7 Removing the exhaust manifold to downpipe gasket M40
405. mble more serious malfunctions 2 Make sure the battery is fully charged as the control unit and sensors depend on an accurate supply voltage in order to properly meter the fuel 3 Check the air filter element a dirty or partially blocked filter will severely impede performance and economy see Chapter 1 4 If a blown fuse is found renew it and see if it blows again If it does search for an earthed wire in the harness related to the system 5 Check the air intake duct from the airflow meter to the intake manifold for leaks Intake air leaks can cause a variety of problems Also check the condition of the vacuum hoses connected to the intake manifold 6 Remove the air intake duct from the throttle body and check for dirt carbon and other residue build up If it s dirty clean it with carburettor cleaner and a toothbrush 7 With the engine running place screwdriver or a stethoscope against each injector one at a time and listen for a clicking sound indicating operation see illustration 15 7 Use a stethoscope or screwdriver to determine if the injectors are working properly they should make a steady clicking sound that rises and falls with engine speed changes 16 1 Check for binding of the flap in the airflow meter as it nears closing position or wide open position Any hesitation or binding will cause erratic idle conditions rich fuel mixture or poor acceleration and throttle response airflow meter remov
406. me general position as their location in the engine This will enable you to match any bearing problems with the corresponding crankshaft journal 4 Dirt and other foreign particles get into the engine in a variety of ways It may be left in the engine during assembly or it may pass through filters or the crankcase ventilation P CV system It may get into the oil and from there into the bearings Metal chips from machining operations and normal engine wear are often present Abrasives are sometimes left in engine components after recondi tioning especially when parts are not thoroughly cleaned using the proper cleaning methods Whatever the source these foreign objects often end up embedded in the soft bearing material and are easily recognised Large particles will not embed in the bearing and will score or gouge the bearing and journal The best prevention for this cause of bearing failure is to clean all parts thoroughly and to keep everything spotlessly clean during engine assembly Frequent and regular engine oil and filter changes are also recommended 5 Lack of lubrication lubrication breakdown has a number of interrelated causes Excessive heat which thins the oil overloading which squeezes the oil from the bearing face and oil leakage or throw off from excessive bearing clearances worn oil pump or high engine speeds all contribute to lubrication breakdown Blocked oil passages which usually are the re
407. me of air indicates acceleration while a small volume of air indicates deceleration or idle Refer to Chapter 4 for all the diagnostic checks and renewal procedures for the airflow meter Ignition timing sensors 41 Ignition timing is electronically controlled on Motronic systems and is not adjustable During starting a crankshaft position sensor relays the crankshaft position to the ECU and an initial baseline ignition point is determined Once the engine is running the ignition point is continually changing based on the various input signals to the ECU Engine speed is Signalled by a speed sensor Early Motronic systems have the reference sensor and the Speed sensor mounted on the bellhousing over the flywheel Later Motronic systems have a single sensor pulse sensor mounted over the crankshaft pulley This sensor functions aS a speed sensor as well as a position sensor Refer to Chapter 5 for more information Note Some models equipped with a TDC sensor mounted on the front of the engine This sensor is strictly for the BMW service test unit and it is not part of the Motronic ignition system 5 Positive crankcase ventilation PCV system 1 The Positive Crankcase Ventilation P CV system see illustration reduces hydrocarbon emissions by scavenging crankcase vapours It does this by circulating blow by gases and then re routing them to the intake manifold by way of the air cleaner 2 This PCV system is a sealed syst
408. me piston and cylinder during the end gap measurement and engine assembly 3 Insert the top ring into the first cylinder and Square it up with the cylinder walls by pushing it in with the top of the piston see illustration The ring should be near the bottom of the cylinder at the lower limit of ring travel 4 To measure the end gap slip feeler gauges between the ends of the ring until a gauge equal to the gap width is found see illustration The feeler gauge should slide between the ring ends with a slight amount of drag Compare the measurement to this Chapter s Specifications If the gap is larger or smaller than specified double check to make sure you have the Correct rings before proceeding 5 f the gap is too small it must be enlarged or the ring ends may come in contact with each other during engine operation which can cause serious damage to the engine The end gap can be increased by filing the ring ends very carefully with a fine file Mount the 22 5 If the end gap is too small clamp a file in a vice and file the ring ends from the outside in only to enlarge the gap slightly 22 9a Refitting the spacer expander in the oil control ring groove file in a vice equipped with soft jaws slip the ring over the file with the ends contacting the file face and slowly move the ring to remove material from the ends When performing this operation file only from the outside in see illustration 6 Excess end g
409. mely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Don t work ina garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present Work in a well ventilated area If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand Mop up spills immediately but do not store fuel soaked rags where they could ignite 1 If you smell fuel while driving or after the vehicle has been sitting in the sun inspect the fuel system immediately 2 Remove the fuel filler cap and inspect it for damage and corrosion The gasket should have an unbroken sealing imprint If the gasket is damaged or corroded fit a new cap 3 Inspect the fuel feed and return lines for cracks Make sure that the connections between the fuel lines and the carburettor or fuel injection system and between the fuel lines and the in line fuel filter are tight Warning On fuel injection models the fuel system must be depressurised before servicing fuel system components as outlined in Chapter 4 ALWAYS CHECK hose for chafed or burned areas that may cause an untimely and costly failure SOFT hose indicates inside deterioration This deterioration can contaminate the cooling system a
410. mospheres atm Bars Kilopascals kPa Kilograms force per square centimetre kgf cm kg cm Pascals Pa Pounds force per square inch psi Ibf in Ib in Millimetres of mercury mmHg Inches of water inH5O Inches of water 0 Pounds force per square inch psi Ibf in Ib in Kilograms force centimetre kgf cm kg cm Newton metres Nm Pounds force feet Ibf ft Ib ft Kilograms force metres kgf m kg m Newton metres Nm Kilograms force metres kgf m kg m Watts W Kilometres per hour km hr kph Kilometres per litre km l x 0 0394 3 281 0 621 0 061 1 76 0 88 0 833 1 057 0 22 0 833 0 264 x KK KK X X 0 035 x 2 205 0 225 9 81 14 223 14 696 145 0 145 98 1 0 01 68 947 1 333 2 491 1 868 27 68 X X x x 0 868 8 85 12 7 233 0 738 9 804 0 0013 0 621 2 825 Inches Feet ft Miles Cubic inches cu in in Imperial pints Imp pt Imperial quarts Imp qt Imperial quarts Imp qt US quarts US 40 Imperial gallons Imp gal Imperial gallons Imp gal US gallons US gal Ounces oz Pounds Ib Ounces force ozf oz Pounds force lbf Ib Newtons N Pounds force per square inch psi Ibf in Ib in Pounds force per square inch psi Ibf in Ib in Pounds force per square inch psi Ibf in Ib in Pounds force per square inch psi Ibf
411. moval and refitting 9 TIT 12 SedEtDOlLCliBCK arae aea worn id ad et e s ed wap door s a ptr nra ah 16 Seats removal and refitting 20 T 17 Steering column shrouds removal and refitting 19 T G 18 Upholstery and carpets maintenance 4 Very difficult suitable for expert DIY or professional on vehicles with wax based underbody protective coating or the coating will be removed Such vehicles should be inspected annually preferably just prior to Winter when the underbody should be washed down and any damage to the wax coating repaired Ideally a completely fresh coat should be applied It would also be worth considering the use of such wax based protection for injection into door panels sills box sections etc as an additional safeguard against rust damage where such protection is not provided by the vehicle manufacturer After washing paintwork wipe off with a chamois leather to give an unspotted clear finish A coat of clear protective wax polish will give added protection against chemical pollutants in the air If the paintwork sheen has dulled or oxidised use a cleaner polisher combination to restore the brilliance of the shine This requires a little effort but such dulling is usually caused because regular washing has been neglected Care needs to be taken with metallic paintwork as special non a
412. mper advance specified advance BTDC in degrees 6 With the ignition off loosen the distributor clamp nut just enough to allow the distributor to pivot without any slipping where 7 9b Flywheel OZ timing mark 7 Make sure the timing light wires are routed away from the drivebelts and fan then start the engine 8 Raise the engine rpm to the specified speed and then point the flashing timing light at the timing marks be very careful of moving engine components 9 The mark on the flywheel or vibration damper will appear stationary If it s aligned with the specified point on the bellhousing or engine front cover the ignition timing is correct see illustrations 10 If the marks aren t aligned adjustment is required Turn the distributor very slowly until the marks are aligned taking care not to touch the HT leads 11 Tighten the nut on the distributor clamp and recheck the timing 12 Switch off the engine and remove the timing light and tachometer Reconnect the vacuum hose where applicable 8 Distributor removal and refitting TCI system Removal 1 After carefully marking them for position remove the coil HT lead and spark plug HT leads from the distributor cap see Chapter 1 2 Remove No 1 spark plug the one nearest you when you are standing in front of the engine 3 Manually rotate the engine to Top Dead Centre TDC on the compression stroke for No 1 piston see Chapter 2A 4 Ca
413. mperature sensor see Chapter 6 Section 4 Check fuel pressure see Section 3 Check EVAP system see Chapter 6 Section 6 Check ignition timing see Chapter 5 Check vacuum advance system Have the ECU tested at a dealer service department or other specialist Test the idle air stabiliser valve see Section 21 Corrective action Test fuel injectors Check for clogged injector lines Renew faulty injectors see Section 20 Test fuel system pressure see Section 3 Test fuel pressure regulator see Section 18 Inspect fuel lines and fuel injectors for leaks see Chapter 4 Tune up engine see Chapter 1 Check the distributor cap rotor HT leads and spark plugs and renew any faulty components Inspect the airflow meter for damage see Section 16 Inspect all vacuum lines air ducts and oil filler and dipstick seals Corrective action Check the idle air stabiliser valve see Section 21 Check the idle air stabiliser relay and wiring circuit see Chapter 12 Check vacuum advance system and electronic vacuum advance relay Have the idle speed control unit checked by a dealer Note With this system when faults occur the ECU stores a fault code in its memory These codes can only be read by a BMW dealer as specialised equipment is required It may save time to have at least the initial fault diagnosis carried out by a dealer Lack of power Probable cause Coolant temperature sensor faulty or wire to sensor broken Fuel pressure incor
414. must be renewed Refitting 6 Fit the shock absorbers in the reverse order of removal but don t tighten the mounting bolts and nuts yet 7 Bounce the rear of the vehicle a couple of times to settle the bushings then tighten the nuts and bolts to the torque values listed in this Chapter s Specifications 10 Rear coil springs 3 Series N removal and refitting 5 Note Although coil springs don t always wear out simultaneously renew both left and right springs at the same time to prevent handling peculiarities or abnormal ride quality Removal 1 Loosen the wheel bolts Chock the front wheels then raise the rear of the vehicle and Suspension and steering systems 10 9 i 4 gt A 11 2 Remove the shock absorber lower mounting bolt arrowed Support it securely on axle stands Make sure the stands don t interfere with the rear Suspension when it s lowered and raised during this procedure Remove the wheels 2 Disconnect the mountings and brackets which support the rear portion of the exhaust system and temporarily lower the exhaust system see Chapter 4 Lower the exhaust system only enough to lower the suspension and remove the springs Suspend the exhaust with a piece of wire 3 Support the differential with a trolley jack then remove the differential rear mounting bolt Push the differential down and wedge it into this lowered position with a block of wood This reduces the drive angle preventing d
415. n Use only low pressure such as that produced by a foot pump to ease the piston out of its bore Warning Be careful not to place your fingers between the piston and the caliper as the piston may come out with some force If you re working on a front caliper of a 3 Series model remove the dust boot 6 Inspect the mating surfaces of the piston and caliper bore wall If there is any scoring rust pitting or bright areas renew the complete caliper unit 7 If these components are in good condition remove the piston seal from the caliper bore using a wooden or plastic tool see illustration Metal tools may damage the cylinder bore 8 Remove the caliper guide pins or bolts and remove the rubber dust boots 9 Wash all the components using methylated spirit or brake system cleaner 10 Using the correct overhaul kit for your vehicle reassemble the caliper as follows 11 Dip the new rubber seal in clean brake fluid and refit it in the lower groove in the caliper bore making sure it isn t twisted 12 On all calipers except the front calipers of 3 Series models coat the walls of the caliper 15 Plug 16 Caliper bracket 17 Cable clamp 18 Piston seal piston dust boot and circlip 19 Guide bush repair kit 20 Brake pads bore and the piston with clean brake fluid and refit the piston at this time Do not force the piston into the bore but make sure that it is squarely in place then apply firm but not excessive pressure to
416. n indicating wear or a loose retaining nut Continue moving the steering wheel as before but also turn it slightly from left to right C Check that the steering wheel is not loose on the column and that there is no abnormal 3 Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO d Checks carried out on YOUR VEHICLE S EXHAUST EMISSION SYSTEM movement of the steering wheel indicating wear in the column support bearings or couplings Windscreen and mirrors The windscreen must be free of cracks or other significant damage within the driver s field of view Small stone chips are acceptable Rear view mirrors must be secure intact and capable of being adjusted REF REFe2 Note The following checks are applicable to all seat belts front and rear Examine the webbing of all the belts including rear belts if fitted for cuts serious fraying or deterioration Fasten and unfasten each belt to check the buckles If applicable check the retracting mechanism Check the security of all seat belt mountings accessible from inside the vehicle The front seats themselves must be securely attached and the backrests must lock in the upright position Doors Both front doors must be able to be opened and closed from outside and inside and must latch securely when closed 2 Checks carried out WITH THE VEHICLE ON THE GROUND Vehicle identification Number plates must be in
417. n fasteners that are subjected to high temperatures such as exhaust manifold bolts and nuts Anti seize compound Asbestos A natural fibrous mineral with great heat resistance commonly used in the composition of brake friction materials Asbestos is a health hazard and the dust created by brake systems should never be inhaled or ingested Axle A shaft on which a wheel revolves or which revolves with a wheel Also a solid beam that connects the two wheels at one end of the vehicle An axle which also transmits power to the wheels is known as a live axle Axle assembly Axleshaft single rotating shaft on either side of the differential which delivers power from the final drive assembly to the drive wheels Also called a driveshaft or a halfshaft Ball bearing An anti friction bearing consisting of a hardened inner and outer race with hardened steel balls between two races Bearing Bearing The curved surface on a shaft or in a bore or the part assembled into either that permits relative motion between them with minimum wear and friction Big end bearing The bearing in the end of the connecting rod that s attached to the crankshaft Bleed nipple valve on a brake wheel cylinder caliper or other hydraulic component that is opened to purge the hydraulic system of air Also called a bleed screw Brake bleeding Brake bleeding Procedure for removing air from lines of a hydraulic brake system
418. n for about 30 minutes 3 Immediately after driving the vehicle park it on a level surface apply the handbrake and start the engine While the engine is idling depress the brake pedal and move the Every 6000 miles 8 6 With the fluid hot the level should be kept between the two dipstick notches preferably near the upper one selector lever through all the gear ranges beginning and ending in Park 4 The automatic transmission dipstick tube is located in the left rear corner of the engine compartment 5 With the engine still idling pull the dipstick out of the tube see illustration wipe it off with a clean rag push it all the way back into the tube and withdraw it again then note the fluid level 6 The level should be between the two marks see illustration If the level is low add the specified automatic transmission fluid through the dipstick tube use a clean funnel preferably equipped with a fine mesh filter to prevent spills Caution Be careful not to A introduce dirt into the transmission when topping up 7 Add just enough of the recommended fluid to fill the transmission to the proper level It takes about half a litre to raise the level from the low mark to the high mark when the fluid is hot so add the fluid a little at a time and keep checking the level until it s correct 8 The condition of the fluid should also be checked along with the level If the fluid is black or a dark reddish brown col
419. n on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Tailgate 8 Disconnect the battery negative cable 9 Open the tailgate and cover the rear edge of the roof with pads or cloths to protect the painted surfaces when the tailgate is 14 12a Removing the tailgate strut spring Clip 3 Series 14 7a Loosen the lock bolts arrowed and move the lock to adjust the boot lid closing position removed On 5 Series models the window may be removed separately by disconnecting the wiring and unscrewing the mounting screws have an assistant hold the window while the screws are being loosened see illustration 10 Remove the trim from the inside of the tailgate Also where necessary on 5 Series models remove the edge covers for access to the strut mountings 11 Disconnect the wiring loom and the washer tubing On some models it will be necessary to pull the wiring loom out of the rear pillar and then disconnect the plug see illustration 12 While an assistant holds the tailgate open 14 9 Tailgate window mounting screws 5 Series 14 12b Strut mounting on the tailgate 5 Series Bodywork and fittings 11 7 pi NT a i Ei E j i 14 7b Adjust the boot lid lock striker after loosening the bolts arrow
420. n the telescoping gauge is at the correct point will be developed over time so work slowly and repeat the check until you re satisfied the bore measurement is accurate scored or if they re out of round or tapered beyond the limits given in this Chapter s Specifications have the engine block rebored and honed at a machine shop If a rebore is done oversize pistons and rings will be required 12 If the cylinders are in reasonably good condition and not worn to the outside of the limits and if the piston to cylinder clearances can be maintained properly then they don t have to be rebored Honing see Section 17 and a new set of piston rings is all that s necessary 17 Cylinder honing 1 Prior to engine reassembly the cylinder bores must be honed so the new piston rings will seat correctly and provide the best possible combustion chamber seal Note If you don t have the tools or don t want to tackle the honing operation most machine shops will do it for a reasonable fee 2 Before honing the cylinders refit the main bearing caps and tighten the bolts to the torque listed in this Chapter s Specifications 3 Two types of cylinder hones are commonly available the flex hone or bottle brush Wh E 17 4 A bottle brush hone will produce better results if you ve never honed cylinders before a 16 4 gauge is then measured with micrometer to determine the bore si
421. n the flow of electricity to and from the battery 12 12 2 Body electrical systems Finding a short circuit One method of finding a short circuit is to remove the fuse and connect a test light or voltmeter in its place There should be no voltage present in the circuit Move the electrical connectors from side to side while watching the test light If the bulb goes on there is a short to earth somewhere in that area probably where the insulation has been rubbed through The same test can be performed on each component in a circuit even a switch Earth check Perform a earth check to see whether a component is properly earthed passing current back via the vehicle body Disconnect the battery and connect one lead of a self powered test light often known as a continuity tester to a known good earth Connect the other lead to the wire or earth connection being tested The bulb should light indicating a good earth connection If not dismantle the connection and clean all relevant parts thoroughly When re making the connection use serrated shakeproof washers if possible and tighten all bolts etc securely Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language a
422. n the jack head to serve as a cushion 3 Remove the shock absorber mounting bolt see illustration lower 9 3 Remove the shock absorber lower mounting bolt arrowed 9 4 Shock absorber upper mounting nuts arrowed late model convertible shown On other early models upper nuts are accessible from the luggage compartment on later models they re behind the back of the rear seat up under the parcel shelf 4 some models working inside the boot you can remove the trim to access the upper mounting nuts on later models you ll have to remove the rear seat back to get at the upper mounting nuts On Touring Estate models remove the side backrest and rear seat belt reels and unscrew the centring shell on the wheel arch On Convertibles simply remove the top from the recessed well behind the passenger compartment and remove the Small rubber access cover As you remove the mounting nuts see illustration have an assistant support the shock absorber from below so it doesn t fall out 5 Look for oil leaking past the seal in the top of the shock absorber body Inspect the rubber bushings in the shock absorber eye If they re cracked dried or torn renew them To test the shock absorber grasp the shock absorber body firmly with one hand and push the damper rod in and out with the other The strokes should be smooth and firm If the rod goes in and out too easily or unevenly the shock absorber is defective and
423. nance programme is to prepare yourself before the actual work begins Read through all the procedures you re planning to do then gather up all the parts and tools needed If it looks like you might run into problems during a particular job seek advice from a mechanic or an experienced do it yourselfer 3 Engine tune up general information The term tune up is used in this manual to represent a combination of individual operations rather than one specific procedure If from the time the vehicle is new the routine maintenance schedule is followed closely and frequent checks are made of fluid levels and high wear items as suggested throughout this manual the engine will be kept in relatively good running condition and the need for additional work will be minimised More likely than not however there will be times when the engine is running poorly due to a lack of regular maintenance This is even more likely if a used vehicle which has not received regular and frequent maintenance checks is purchased In such cases an engine tune up will be needed outside of the regular maintenance intervals Engine oil 2 Engine oil is checked with a dipstick which is located on the side of the engine refer to the underbonnet illustrations in this Chapter for dipstick location The dipstick extends through a metal tube down into the sump 3 The engine oil should be checked before the vehicle has been driven or at least 15 minu
424. nd tighten them Alternate between the bolts turning them a couple of turns at a time until the disc is free Refitting 7 Ensure that the disc is completely clean before refitting If penetrating oil was used to remove the disc make sure that no trace of this is present Place the disc on the hub and refit the disc retaining screw Tighten the screw securely 8 Refit the caliper mounting bracket if removed brake pads and caliper see Sections 3 and 4 Tighten all fasteners to the torques listed in this Chapter s Specifications 9 Refit the wheel then lower the vehicle to the ground Depress the brake pedal a few times to bring the brake pads into contact with the disc 10 Adjust the handbrake shoes if necessary Section 11 11 Check the operation of the brakes carefully before returning the vehicle to normal service 6 Drum brake shoes renewal A A Warning Brake shoes must be renewed on both wheels at the same time never renew the shoes on only one wheel Also the dust created by the brake system may contain asbestos which is harmful to your health Never blow it out with compressed air and don t inhale any of it Always wear an approved filtering mask when servicing the brake system Do not under any 6 2a Removing the drum retaining screw circumstances use petroleum based solvents to clean brake parts Use brake system cleaner only Caution Whenever the brake shoes are renewed ne
425. nd cause particles to clog the radiator HARDENED hose can fail at any time Tightening hose clamps will not seal the connection or stop leaks SWOLLEN hose or oil soaked ends indicate danger and possible failure from oil or grease contamination Squeeze the hose to locate cracks and breaks that cause leaks 22 4 Hoses like drivebelts have a habit of failing at the worst possible time to prevent the inconvenience of a blown radiator or heater hose inspect them carefully as shown here 4 Since some components of the fuel system the fuel tank and some of the fuel feed and return lines for example are underneath the vehicle they can be inspected more easily with the vehicle raised on a hoist If that s not possible raise the vehicle and support it on axle stands or ramps 5 With the vehicle raised and safely supported inspect the fuel tank and filler neck for punctures cracks or other damage The connection between the filler neck and the tank is particularly critical Sometimes a rubber filler neck will leak because of loose clamps or deteriorated rubber Inspect all fuel tank mounting brackets and straps to be sure the tank is securely attached to the vehicle Warning Do not under any circumstances try to repair a fuel tank except rubber components A welding torch or any naked flame can easily cause fuel vapours inside the tank to explode 6 Carefully check all flexible hoses and metal lines leading away
426. nd air conditioning systems Fuel and exhaust systems Engine electrical systems Engine management and emission control systems Transmission Manual transmission Automatic transmission Clutch and driveline Brakes Braking system Suspension Suspension and steering systems Body Equipment Bodywork and fittings Electrical Body electrical systems Wiring Diagrams REFERENCE MOT Test Checks Checks carried out from the driver s seat Checks carried out with the vehicle on the ground Checks carried out with the vehicle raised Checks carried out on your vehicle s exhaust emission system Tools and Working Facilities General Repair Procedures Fault Finding Conversion factors Automotive chemicals and lubricants Buying spare parts and vehicle identification numbers Glossary of Technical Terms Index Contents Page 2A 1 Page 2Bel Page 3 1 Page 4 1 Page 5 1 Page 6 1 Page 7 1 Page 7Bel Page 8 1 Page 9 1 Page 10 1 Page 1121 Page 12 1 Page 12 10 Page Page Page Page Page Page Page Page Page Page Page Page REFel REFe2 REFe3 REFe4 REFe5 REF 8 REF 9 REF 17 REF 18 REF 19 20 REFe25 o4 Introduction Introduction to the BMW 3 and 5 Series The E30 3 Series range first became available in the UK in March 1983 and continued in production until April 1991 when the revised E36 3 Series range not covered by this manual was introduced Convertible and Touring Esta
427. nd refitting procedures Precautions 7 The catalytic converter is a reliable and Simple device which needs no maintenance in itself but there are some facts of which an owner should be aware if the converter is to function properly for its full service life a DO NOT use leaded eg UK 4 star petrol in a car equipped with a catalytic converter the lead will coat the precious metals reducing their converting efficiency and will eventually destroy the converter b Always keep the ignition and fuel systems well maintained in accordance with the manufacturer s schedule as given in Chapter 1 In particular ensure that the air cleaner filter element the fuel filter where fitted and the spark plugs are renewed at the correct interval If the intake air fuel mixture is allowed to become too rich due to neglect unburned fuel will enter the catalytic converter overheating the element and eventually destroying the converter c If the engine develops a misfire do not drive the car at all or at least as little as possible until the fault is cured the misfire will allow unburned fuel to enter the converter which will result in its overheating as noted above d DO NOT push or tow start the car this will soak the catalytic converter in unburned fuel causing it to overheat when the engine does start see b or c above e DO NOT switch off the ignition at high engine speeds ie do not blip the throt
428. nd the fuel pressure regulator is located at the top of the thermostat housing B 3 15 M20 and M30 engine models after the housing and thermostat have been removed take the O ring out of the housing and clean the recess in the housing to be sure of a good seal upon reassembly 12 If the outer surface of the fitting that mates with the hose is deteriorated corroded pitted etc it may be damaged further by hose removal If it is a new thermostat housing cover will be required 13 Remove the bolts and detach the housing cover If the cover is stuck tap it with a soft faced hammer to jar it loose Be prepared for some coolant to spill as the gasket seal is broken 14 Note how it s fitted then remove the thermostat 15 Stuff a rag into the engine opening then remove all traces of old gasket material if the gasket is paper type Otherwise remove the rubber O ring see illustration and sealant from the housing and cover with a gasket scraper Remove the rag from the opening and clean the gasket mating surfaces 16 Fit the new thermostat and gasket in the housing Make sure the correct end faces out the spring end is normally directed towards the engine 17 Refit the cover and bolts Tighten the bolts to the torque listed in this Chapter s Specifications 40 engines 18 Remove the cooling fan and timing belt upper cover 19 Unscrew the hose clamp and detach the 4 3a Disconnecting the top hose fro
429. ndicates excessive wear which must be corrected The piston connecting rod assemblies should be taken to a machine shop for attention 13 If the pistons must be removed from the connecting rods for any reason they should be taken to a machine shop When this is done have the connecting rods checked for bend and twist since most machine shops have special equipment for this purpose Note Unless new pistons and or connecting rods must be fitted do not dismantle the pistons and connecting rods 14 Check the connecting rods for cracks and other damage Temporarily remove the rod caps lift out the old bearing shells wipe the rod and cap bearing surfaces clean and inspect them for nicks gouges and scratches After checking the rods fit new bearing shells slip the caps into place and tighten the nuts finger tight 19 Crankshaft inspection 1 Remove all burrs from the crankshaft oil holes with a stone file or scraper see illustration 19 6 Measure the diameter of each crankshaft journal at several points to detect taper and out of round conditions General engine overhaul procedures 2 17 19 2 Use a wire or stiff plastic bristle brush to clean the oil passages in the crankshaft 2 Clean the crankshaft with solvent and dry it with compressed air if available Be sure to clean the oil holes with a stiff brush see illustration and flush them with solvent 3 Check the main and connecting big end bearing j
430. ndicates that coolant is leaking into the combustion chamber and or the crankcase Again the cause must be corrected or the problem may persist in the rebuilt engine 10 Measure the piston ring side clearance by laying a new piston ring in each ring groove and slipping a feeler gauge in beside it see illustration Check the clearance at three or four locations around each groove Be sure to use the correct ring for each groove they are different If the side clearance is greater than the figure listed in this Chapter s Specifi cations new pistons will have to be used 11 Check the piston to bore clearance by measuring the bore see Section 16 and the piston diameter Make sure the pistons and bores are correctly matched Measure the piston across the skirt at 90 to and in line with the gudgeon pin see illustration Any difference between these two measurements indicates that the piston is no longer perfectly round Subtract the piston diameter from the bore diameter to obtain the clearance If it s greater than specified the block will have to be rebored and new pistons and rings fitted 18 11 Measure the piston diameter at a 90 degree angle to the gudgeon pin at the same height as the gudgeon pin 19 1 oil holes should be chamfered so sharp edges don t gouge or scratch the new bearings 12 Check the piston to rod clearance by twisting the piston and rod in opposite directions Any noticeable play i
431. ne BMW 320i Saloon E30 Introduction BMW 518i E28 0 6 Safety First Working on your car can be dangerous This page shows just some of the potential risks and hazards with the aim of creating a Safety conscious attitude General hazards Scalding Don t remove the radiator or expansion tank cap while the engine is hot Engine oil automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running Burning Beware of burns from the exhaust system and from any part of the engine Brake discs and drums can also be extremely hot immediately after use Crushing When working under or near ei a raised vehicle d EN SM always ZENG ay supplement the Gs jack with axle EAM stands or use drive on ramps Never venture under a car which is only supported by a jack Take care if loosening or tightening high torque nuts when the vehicle is on stands Initial loosening and final tightening should be done with the wheels on the ground Fire Fuel is highly flammable fuel vapour is explosive Don t let fuel spill onto a hot engine Do not smoke or allow naked lights including pilot lights anywhere near a vehicle being worked on Also beware of creating sparks electrically or by use of tools Fuel vapour is heavier than air so don t work on the fuel system with the vehicle over an inspection pit
432. ne It may take a few moments for the fuel system to build up pressure but the engine should start without a great deal of effort Note If backfiring occurs through the throttle body or carburettor check the valve timing check that the timing chain belt has been correctly fitted the firing order check the fitted order of the Spark plug HT leads and the ignition timing 5 After the engine starts it should be allowed to warm up to normal operating temperature While the engine is warming up make a thorough check for fuel oil and coolant leaks 6 Shut the engine off and recheck the engine oil and coolant levels 7 Drive the vehicle to an area with minimum traffic accelerate at full throttle from 30 to 50 mph then lift off the throttle completely and allow the vehicle to slow to 30 mph with the throttle closed Repeat the procedure 10 or 12 times This will load the piston rings and cause them to seat properly against the cylinder walls Check again for oil and coolant leaks 8 Drive the vehicle gently for the first 500 miles no sustained high speeds and keep a constant check on the oil level It is not unusual for an engine to use oil during the running in period 9 At approximately 500 to 600 miles change the oil and filter 10 For the next few hundred miles drive the vehicle normally don t nurse it but don t abuse it either 11 After 2000 miles change the oil and filter again The engine may now be consider
433. ne repair procedures 6 Exhaust manifold removal and refitting Warning Make sure the engine is A completely cool before beginning work on the exhaust system Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 On models where the air cleaner is on the exhaust manifold side of the engine remove the air cleaner housing assembly and or airflow sensor to provide sufficient working area see Chapter 4 if necessary TW Remove the windscreen washer reservoir from the HiNT right hand side of the engine compartment to give more working room 3 Unplug the leads and set the spark plug lead harness aside See Chapter 1 4 Clearly label then disconnect or remove all wires hoses fittings etc that are in the way Be sure to disconnect the oxygen sensor where fitted 5 Raise the vehicle and support it securely on axle stands Working from under the vehicle separate the exhaust downpipe from the manifold Use penetrating oil on the fasteners to ease removal see illustrations 6 Remove the axle stands and lower the vehicle Working from the ends of the manifold toward the centre loosen the retaining nut
434. ned down before releasing the pressure on the piston assembly 12 Repeat the procedure until brake fluid free of air bubbles is expelled from the brake line outlet hole Repeat the procedure with the other outlet hole and plug Be sure to keep the master cylinder reservoir filled with brake fluid to prevent the introduction of air into the system 13 High pressure is not involved in the bench bleeding procedure so the plugs described above need not be refitted each time the piston is released if wished Instead before releasing the piston simply put your finger tightly over the hole to keep air from being drawn back into the master cylinder Wait several seconds for brake fluid to be drawn from the reservoir into the piston bore then depress the piston again removing your finger as brake fluid is expelled Be sure to put your finger back over the hole each time before releasing the piston and when the bleeding procedure is complete for that outlet refit the plug and tighten it up before going on to the other port Refitting 14 Refit the master cylinder together with a new O ring over the studs on the brake servo and tighten the mounting nuts only finger tight at this time 15 Thread the brake line fittings into the master cylinder Since the master cylinder is Still a bit loose it can be moved slightly in order for the fittings to thread in easily Do not Strip the threads as the fittings are tightened 16 Tighten the brake
435. ng big end bearing oil clearance jb EOD REMITTI LT M20 and M30 engines WAG ULIS cue Engine block Cylinder bore diameter standard M IO BIS CHOING 3 toed 2 9 3E EXC Que die s deae bt M20 B20 engi ai e doe ea or edo em d AR de de dear ded arde dcr 1139 BZS ENJING iiaeia Seba ded AER dc de dra d dese ioa dca 5139 5258 GOING 4 dd ded SEDI M30 B 30M ChOING iussi agens qe ees 139 834 BOBO d M30 B33M 255252 Ee TCR debe MA40 B 10 CHGING gt betes Eur Roc dr OR e ec d 35 4 455 Xsackoa fd u ore eee aede d Cylinder out of round limit maximum M20 B20 engine M20 B25 60E RC OD All ONE CHGINGS 4 2 2 9 079 RE YR Ra Cylinder taper maximum M20 B20 20 25 engines All other engines 0 033 to 0 076 mm 0 02 to 0 13 mm 0 2 mm maximum 0 03 to 0 18 mm 0 065 to 0 150 mm 0 015 to 0 051 mm 0 085 to 0 174 mm 0 080 to 0 163 mm 54 98 to 54 99 mm 54 97 to 54 98 mm 59 98 to 59 99 mm 59 97 to 59 98 mm 59 984 to 59 990 m
436. ng compressor and remove the retainer the spring and the spring seat if used 23 Pull the valve out of the head then remove the oil seal from the guide 8 21 A small plastic bag with an appropriate label can be used to store the valve components so they can be kept together and refitted in the original position 8 19 Compartmentalised box to hold the hydraulic tappets M40 engine 2B If the valve binds in the guide won t pull through push it back into the head and deburr the area around the collet groove with a fine file or whetstone compress a valve spring 2B 10 General engine overhaul procedures 24 Repeat the procedure for the remaining valves Remember to keep all the parts for each valve together so they can be refitted in the same locations 25 Once the valves and related components have been removed and stored in an organised manner the head should be thoroughly cleaned and inspected If a complete engine overhaul is being done finish the engine dismantling procedures before beginning the cylinder head cleaning and inspection process 9 Cylinder head and components cleaning and inspection 1 Thorough cleaning of the cylinder head s and related valve train components followed by a detailed inspection will enable you to decide how much valve service work must be done during the engine overhaul Note If the engine was severely overheated the cylinder head is probably warpe
437. ng in the end of the crankshaft see Chapter 8 25 4 Drive the new seal into the retainer with a wooden block or a section of pipe if you have one large enough make sure the seal enters the retainer bore squarely 28 Rotate the crankshaft a number of times by hand to check for any obvious binding 29 The final step is to check the crankshaft endfloat with a feeler gauge or a dial indicator as described in Section 13 The endfloat should be correct providing the crankshaft thrust faces aren t worn or damaged and new bearings have been fitted 30 Fit the new seal then bolt the housing to the block see Section 25 25 Crankshaft rear oil seal BN refitting A 1 crankshaft must be fitted first and the main bearing caps bolted in place The new seal should then be fitted in the retainer and the retainer bolted to the block 2 Before refitting the crankshaft check the seal contact surface very carefully for scratches and nicks that could damage the new seal lip and cause oil leaks If the crankshaft is damaged the only alternative is a new or different crankshaft unless a machine shop can suggest a means of repair 3 The old seal can be removed from the housing with a hammer and punch by driving it out from the back side See illustration Be Sure to note how far it s recessed into the housing bore before removing it the new seal will have to be recessed an equal amount Be very careful not to scratch or
438. ng procedure 2 Battery emergency jump starting Refer to the J ump starting procedure at the front of this manual 3 Battery removal and refitting Note Depending on the model the battery may be located in the engine compartment in the rear luggage compartment or under the rear seat Consult your owners handbook for the location of the battery if not already known to you Caution If the radio in your A vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 Detach the cable from the positive terminal 3 Remove the battery hold down bracket see illustrations and lift out the battery Be careful it s heavy Do not tilt the battery to any extent while it is being removed and Store it upright 4 While the battery is out inspect the carrier tray for corrosion see Chapter 1 5 f you are renewing the battery make sure that you get one that s identical with the Same dimensions amperage rating cold cranking rating etc 6 Refitting is the reverse of removal 4 Battery cables check and renewal 1 Periodica
439. ng reconditioning and renewal Note Always wait until the engine has been completely disassembled and all components especially the engine block have been inspected before deciding what service and repair operations must be performed by an automotive machine shop Since the block s condition will be the major factor to consider when determining whether to overhaul the original engine or buy a rebuilt one never purchase parts or have machine work done on other components until the block has been thoroughly inspected As a general rule time is the primary cost of an overhaul so it doesn t pay to refit worn or substandard parts As a final note to ensure maximum life and minimum trouble from a rebuilt engine everything must be assembled with care in a spotlessly clean environment 3 Compression check 1 A compression check will tell you what mechanical condition the upper end pistons rings valves head gaskets of your engine is in Specifically it can tell you if the compression is down due to leakage caused by worn piston rings defective valves and seats or a blown head gasket Note The engine must be at normal operating temperature and the battery must be fully charged for this check 2 Begin by cleaning the area around the spark plugs before you remove them compressed air should be used if available b Li EY 3 5 As a safety precaution before performing a compression check remove the cover and the m
440. ning the bolts The tabs are no longer available from the manufacturer and do not have to be used on refitting 5 Remove the lower timing chain cover see Section 7 6 Unscrew and remove the four camshaft sprocket bolts then disengage the chain from the crankshaft sprocket and carefully remove the chain and camshaft sprocket from the engine It may be necessary to gently prise the camshaft sprocket loose from the camshaft with a screwdriver Inspection Timing sprockets 7 Examine the teeth on both the crankshaft sprocket and the camshaft sprocket for wear Each tooth forms an inverted V If worn the side of each tooth under tension will be slightly concave in shape when compared with the other side of the tooth i e one side of the inverted V will be concave when compared with the other giving the teeth a hooked appearance If the teeth appear to be worn the sprockets must be renewed Note The crankshaft sprocket is a press fit on the crankshaft and can be removed with a jaw type puller after the Woodruff key and oil pump are removed see Section 14 However BMW recommends the new sprocket be pressed onto the crankshaft after being heated to 80 C 175 F on the M10 engine or to 200 C 390 F on the M30 engine For this reason if the crankshaft sprocket requires renewal we recommend removing the crankshaft see Part B of this Chapter and taking it to an engineering works to have the old sprocket pressed off and a new
441. niversal joint shaft for wear If it s stiff or worn renew it 9 Remove the banjo bolts and disconnect the hydraulic pressure line and the return line from the box see illustration Plug the ends of the lines to prevent fluid loss and contamination Discard the sealing washers new ones should be used when reassembling 10 Remove the steering box retaining bolts see illustrations and remove the steering box 11 If it s necessary to detach the Pitman arm from the box sector shaft to have the box serviced or to switch the arm to a new or Suspension and steering systems 10 15 21 9 Disconnect the power steering pressure line fitting right arrow and the return line fitting left arrow Note that the return line fitting banjo bolt is larger than the bolt for the pressure line fitting left hand drive shown rebuilt unit make a match mark across the two for correct reassembly Remove the Pitman arm retaining nut and washer Use a puller to withdraw the arm if necessary Refitting 12 Refit the Pitman arm by aligning the match marks made during removal then tighten the nut to the torque listed in this Chapter s Specifications 13 When fitted the Pitman arm must not have any measurable endfloat within 100 from the neutral position If play exists have the following parts checked a Sector shaft and bearings for wear b Thrust washer and adjuster bolt head for Wear Ball nut and worm shaft for we
442. no maintenance However on high mileage vehicles the track rod end balljoints the universal joints on either end of the universal joint shaft and the rubber coupling between the steering column and the universal joint shaft will wear develop excessive play and cause the steering to feel somewhat loose At this point you ll have to renew these items they can t be serviced Before you conclude that the steering system needs work however always check the tyres see Section 25 and tyre pressures see Chapter 1 Also inspect the bearings in the strut upper mounts see Section 5 the front hub bearings see Section 8 and other suspension parts which may also be contributing to an imprecise steering feel 17 Track rod ends removal and refitting WIV 1 Loosen but do not remove the wheel bolts then raise the front of the vehicle and secure it on axle stands Remove the front wheel 3 Series models 2 Loosen the nut on the track rod balljoint stud and free the balljoint stud from the steering arm using a balljoint separator In the absence of a separator tool try giving the steering arm a few light blows with a hammer see illustration Remove the nut and separate the balljoint stud from the steering arm Suspension and steering systems 10 13 all 17 3 Loosen the clamp bolt arrowed that locks the track rod end to the inner track rod Paint an alignment mark on the threads to ensure the track
443. nt panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 Remove the starter motor See Section 20 3 Disconnect the cable from the solenoid to the starter motor terminal 4 Remove the screws which secure the solenoid to the starter motor 5 Detach the solenoid from the starter body 6 Remove the plunger and plunger spring Refitting 7 Refitting is the reverse of removal 441 Chapter 4 Fuel and exhaust systems Contents Accelerator cable check adjustment and renewal 9 Air cleaner assembly removal and refitting 8 Air filter See Chapter 1 Airflow meter check removal and refitting 16 Carburettor cleaning and 12 Carburettor general information 10 Carburettor removal and refitting Cold start injector and thermotime switch CNECKANG TeDneWal 24 24 3 9 309 19 Engine idle speed check and adjustment See Chapter 1 Exhaust system See Chapter 1 Exhaust system servicing general information 22 Fuel filter renewal See Chapter 1 Fuel injection system check 15 Fuel injection system depressurising Degrees of difficulty Easy Suitable for EN
444. ntaminate the new oil 10 Refit the plug and tighten it securely Use a new washer if necessary 11 Move the drain pan into position under the oil filter Canister type oil filter 12 Loosen the spin off type oil filter by turning it anti clockwise with a filter spanner Any standard filter spanner will work 13 Sometimes the spin off type oil filter is screwed so tightly that it can t be easily loosened If it is punch a metal bar or long screwdriver directly through it and use itas a T bar to turn the filter Be prepared for oil to spurt out of the canister as it s punctured 14 Once the filter is loose use your hands to unscrew it from the block J ust as the filter is detached from the block immediately tilt the open end up to prevent oil inside the filter from spilling out 15 Using a clean rag wipe off the mounting surface on the block Also make sure that none of the old sealing ring remains stuck to the mounting surface It can be removed with a scraper if necessary 16 Compare the old filter with the new one to make sure they are the same type Smear some engine oil on the rubber sealing ring of the new filter and screw it into place see illustration Overtightening the filter will damage the sealing ring so don t use a filter spanner Most filter manufacturers recommend tightening the filter by hand only Normally they should be tightened three quarters of a turn after the sealing ring contacts the
445. nufacturers may require different approaches Do not mix up the top and middle rings as they have different cross sections 12 Make sure the identification mark is facing the top of the piston then slip the ring into the middle groove on the piston see illus tration 18 2 Don t expand the ring any more than necessary to slide it over the piston Use a proper ring fitting tool if available with care old feeler gauges can be used to prevent the rings dropping into empty grooves General engine overhaul procedures 2B 19 22 9b DO NOT use a piston ring refitting tool when refitting the oil ring side rails 13 Refit the top ring in the same manner Make sure the mark is facing upwards Be careful not to confuse the top and middle rings 14 Repeat the procedure for the remaining pistons and rings 23 Intermediate shaft refitting 5 x A 1 Clean the intermediate shaft bearing surfaces and the pressed in bearing sleeves in the cylinder block 2 Lubricate the shaft and slide it into the block 3 Refit the two bolts that hold the retaining plate to the block 4 The remainder of the parts are fitted in the reverse order of removal 24 Crankshaft refitting and main bearing oil clearance check 1 Crankshaft refitting is the first major step in engine reassembly It s assumed at this point that the engine block and crankshaft have been cleaned inspected and repaired or reconditioned 2 Position the
446. o make sure it s tight 1 10 leak down very slowly If a slow puncture persists check the valve stem core to make Sure it is tight See illustration Examine the tread for an object that may have embedded itself in the tyre or for a previous repair that may have begun to leak If a puncture is Suspected it can be easily verified by Spraying a solution of soapy water onto the puncture see illustration The soapy solution will bubble if there is a leak Unless the puncture is unusually large a tyre Specialist can usually repair the tyre 5 Carefully inspect the inner sidewall of each tyre for evidence of brake fluid leakage If you see any inspect the brakes immediately 6 Correct air pressure adds miles to the life Span of the tyres improves fuel economy and enhances overall ride quality A tyre pressure gauge is essential TET Keep an accurate gauge the glove compartment The HiNT pressure gauges attached to the nozzles of air hoses at service stations are often inaccurate 7 Always check the tyre pressures when the tyres are cold ie before driving the vehicle Weekly Checks 5 4b If the valve core is tight raise the vehicle and spray a soapy water solution onto the tread as the tyre is turned slowly leaks will cause small bubbles to appear Checking the pressures when the tyres are warm or hot will result in higher readings due to heat expansion On no account should air be let out of the tyres
447. obes vary more than about 0 08 mm or if the camshaft is exhibiting any signs of wear renew the camshaft 24 Inspect the camshaft bearing surfaces in the cylinder head for scoring and other damage If the bearing surfaces are scored or damaged you ll normally have to renew the cylinder head since the bearings are simply a machined surface in the cylinder head Note A machine shop particularly one that specialises in BMWs or dealer service department may be able to provide an alternative to fitting a new cylinder head if the only problem with the head is mildly scored camshaft bearing surfaces 25 Using a micrometer measure the journals on the camshaft and record the measurements see illustration Using a telescoping gauge or inside micrometer 9 25 Measure each camshaft bearing journal and its corresponding bearing diameter in the cylinder head then subtract the journal diameter from the bearing inside diameter to obtain the oil clearance measure the camshaft bearing diameters in the cylinder head on the M40 engine refit the bearing caps first Subtract the camshaft journal measurement from its corresponding bearing inside diameter to obtain the oil clearance Compare the oil clearance to what s listed in this Chapter s Specifications If it s not within tolerance a new camshaft and or cylinder head will be required Note Before fitting a new cylinder head check with a machine shop particularly one that specialis
448. ode before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure WP 2 1b Removing the fuel pump fuse on 5 Series models pi Fuel and exhaust systems 4 3 3 Fuel pump fuel pressure check Whi Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Also don t work in a garage where a natural gas type appliance with a pilot light is present Carburettor engines 1 To test the fuel pump it will be necessary to connect a suitable pressure gauge between the fuel pump outlet and the carburettor Supply pipe For this particular test the fuel return valve which is normally connected in the fuel line from the fuel pump to the carburettor must be bypassed 2 With the engine running at idle speed the pump pressure should be between 0 1 and 0 3 bars 3 Should a pressure gauge not be available a Simpler but less accurate method of testing the fuel pump is as follows 4 Disconnect the outlet hose from the fuel pump 5 Disconnect the LT lead from the coil to prevent the engine firing then turn the engine over on the starter Well defined spurts of
449. of aluminium and are quite soft 12 Clean the sump with solvent and dry it thoroughly Check the gasket sealing surfaces for distortion Clean any residue from the 13 6a Remove the four inspection cover bolts arrowed and 13 76 Removing the oil dipstick tube bracket mounting bolt 13 5 If applicable disconnect the oil level sensor connector at the left side of the engine down near the power steering pump mounting bracket gasket sealing surfaces on the sump and engine with a rag dampened with a suitable solvent 13 Before refitting the sump apply a little RTV type gasket sealant to the area where the front and rear covers join the cylinder block Lay anew sump gasket in place on the block If necessary apply more sealant to hold the gasket in place 14 Carefully position the sump in place do not disturb the gasket and refit the bolts Start with the bolts closest to the centre of the Sump and tighten them to the torque listed in this Chapter s Specifications using a criss cross pattern Do not overtighten them or leakage may occur 13 9 Remove the bolts holding the sump to the engine block and front cover as shown here on a six cylinder engine 2A 2 16 In car engine repair procedures 15 The remainder of refitting is the reverse of removal Fit a new gasket to the lower sump section on models with the M40 engine 16 On completion refill the engine with oil Chapter 1 Run the engine an
450. of water will dilute the antifreeze In order to maintain the proper ratio of antifreeze and water always top up the coolant level with the correct mixture 11 If the coolant level drops consistently there must be a leak in the system Inspect the radiator hoses filler cap drain plugs and water pump see Section 29 If no leaks are noted have the expansion tank cap or radiator cap pressure tested by a BMW dealer 12 If you have to remove the cap wait until the engine has cooled completely then wrap a thick cloth around the cap and turn it to the first stop If coolant or steam escapes let the engine cool down longer then remove the Cap 13 Check the condition of the coolant as well It should be relatively clear If it s brown or rust coloured the system should be drained flushed and refilled Even if the coolant appears to be normal the corrosion 4 9d Adding antifreeze mixture 4 15 Adding hydraulic fluid to the clutch fluid reservoir inhibitors wear out so it must be renewed at the specified intervals Brake and clutch fluid Warning Brake fluid can harm your eyes and damage painted surfaces so use extreme caution when handling or pouring it Do not use brake fluid that has been standing open or is more than one year old Brake fluid absorbs moisture from the air which can cause a dangerous loss of brake effectiveness Use only the specified type of brake fluid Mixing different types such as DOT 3
451. ol cables 5 Disconnect the cables marking them for accurate refitting 6 Disconnect the electrical connector 7 Remove the lever assembly 8 Each lever assembly can be removed separately 5 Series models 9 Remove the centre console see Chap ter 11 10 Remove the radio see Chapter 12 then pull the knobs off the heater air conditioning control levers 11 Remove the trim bezel and pull the control unit from the dash This will allow you to disconnect the control cables from the lever assembly 9 6 Lift out the assembly and disconnect the electrical connection from the blower motor 3 8 Cooling heating and air conditioning systems 12 Disconnect the cables from the clips securing them to the lever assembly marking them for accurate refitting 13 Disconnect the electrical connection from the control assembly 14 Remove the screws attaching the bezel to the control assembly and remove the control assembly Refitting 15 Refitting is the reverse of the removal procedure 11 Heater matrix removal and refitting Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 Drain the cooling system see Chap
452. oles face inwards the large oil holes face down toward the valve guides 9 Lubricate the camshaft journals and lobes 11 6 With the retainer fitted compress the valve spring and refit the collets as shown see illustration then carefully insert it into the cylinder head rotating it as you go so the camshaft lobes will clear the rocker arms It will also be necessary to compress the rocker arms against the valve springs as described in Section 8 so they ll clear the camshaft lobes Be very careful not to scratch or gouge the camshaft bearing surfaces in the cylinder head M4O engines 10 Lubricate the bores for the hydraulic tappets in the cylinder head then insert the tappets in their original positions 11 Locate the thrust discs and cam followers on the valves and pivot posts in their original positions 12 Lubricate the bearing surfaces of the camshaft in the cylinder head 13 Locate the camshaft in the cylinder head so that the valves of No 1 cylinder are both open and the valves of No 4 cylinder are rocking exhaust closing and inlet opening No 1 cylinder is at the timing belt end 14 Lubricate the bearing surfaces in the bearing caps then locate them in their correct positions and insert the retaining bolts Progressively tighten the bolts to the specified torque 15 Fit a new oil seal to the camshaft front bearing cap see Chapter 2A Section 11 All engines 16 Refit the oil supply tube to the to
453. oller is on an eccentric and different readings will be obtained otherwise The spring balance should be connected 85 mm along the Allen key and a force of 2 0 kg 4 4 Ib should be the belt over the aah T E 10 23a Using the special BMW tool to check the tension of the timing belt on the M40 engine 10 12c Removing the crankshaft sprocket from the front of the crankshaft 2 10 13 Inspect the timing belt carefully for cracking as shown here Rubber exposed Rounded belt side Se e an Xj Separation Flank worn On load side Tooth missing ite canvas i fiber expose 7 esi 10 23b Using a spring balance and Allen key to adjust the tension of the timing belt on the M40 engine Dimension A 2 85 mm 2 12 In car engine repair procedures applied Tighten the retaining nut to the specified torque to hold the tensioner in its correct position Note It is important that the timing belt is tensioned correctly If the belt is over tightened it will howl and there is the possibility of it being damaged If the belt is too slack it may jump on the sprockets 24 Check to make sure the camshaft and crankshaft timing marks are still aligned see illustrations 10 5a and 10 5b 25 Turn the crankshaft clockwise through two complete revolutions Remove the camshaft positioning tool from the M40 engine first Caution This is necessary to stretch the new b
454. olts Sidus d uitae beet 30 SLE Ek E E Os Angle tighten an additional 90 DLAC E eee eee Angle tighten an additional 90 M30 six cylinder engine up to and including 1987 model year 60 Stage 2 wait 15 minutes Angle tighten an additional 33 Stage 3 engine at normal operating temperature Angle tighten an additional 33 30 six cylinder engine from 1988 model year noc P P 60 stage Wait 20 80 Stage 3 engine at normal operating temperature Angle tighten an additional 35 M40 four cylinder engine cleus pce E ee ne ee ee 30 cop Angle tighten an additional 90 rd dep qd eie OE EN RES Angle tighten an additional 90 Intake manifold to cylinder head bolts Ma DOC esaer 22 15 MODO m 10 Exhaust manifold to cylinder head nuts ELO THE 552251550 ban bee ee eee eo ne 10 tS ee ee eee 15 Flywheel driveplate bolts Manual transmisso a xac oh dc 94820404084 i EANA eae 105 Automatic transmission _
455. omatic choke 2B4 16 Check that the automatic choke cover and housing alignment marks are clearly visible if not make new marks 17 Remove the three screws and withdraw the metal ring see illustration 18 Remove the plastic cover at the same time disengaging the bi metal spring from the control lever see illustration 19 Fit a rubber band to the bottom of the control lever Push the pulldown lever to the right and use a 4 2 mm diameter drill to check the distance between the lower edge of the choke valve and the wall of the carburettor 12 19 Fit a rubber band 2 to the bottom of the control lever then push the pulldown lever to the right and use a 4 2 mm diameter drill 1 to check the distance between the lower edge of the choke valve and the wall of the carburettor Fuel and exhaust systems 4 13 12 17 Remove the three screws and withdraw the metal ring see illustration Alternatively apply vacuum to the pulldown unit to move the lever 20 If adjustment is necessary turn the screw on the end of the pulldown unit see illustration 21 Refit the cover in reverse order making sure that the alignment marks are in line Throttle positioner 2B4 22 With the throttle in the idle position check that the length of the spring on the throttle positioner is 23 0 1 0 mm If not adjust the nut as required 23 With no vacuum applied engine stopped check that the control travel measured between the stop sc
456. ompartment Check carefully to make Sure everything is disconnected 26 Remove the flywheel driveplate and where applicable the engine rear plate and mount the engine on an engine stand see illustration Do not turn the M40 engine upside down see Caution in Section 4 Refitting 27 Check the engine and transmission mountings If they re worn or damaged renew them 28 Refit the flywheel or driveplate see Chapter 2A If you re working on a manual transmission vehicle refit the clutch and pressure plate see Chapter 7A Now is a good time to fit a new clutch 29 f the torque converter came out with the engine during removal carefully refit the converter into the transmission before the engine is lowered into the vehicle 30 Carefully lower the engine into the engine compartment make sure the engine mountings line up 31 If you re working on an automatic transmission vehicle guide the torque converter onto the crankshaft following the procedure outlined in Chapter 7B 32 If you re working on a manual transmission vehicle apply a dab of high melting point grease to the input shaft and guide it into the clutch and crankshaft pilot bearing until the bellhousing is flush with the engine block Do not allow the weight of the engine to hang on the input shaft TNA 1 may be necessary to rock the engine slightly or to turn the crankshaft to allow the input shaft splines to mate with the clutch plate 33 Refit t
457. omy and driveability A new thermostat is normally an inexpensive component anyway 4 If the upper radiator hose is hot it means that the coolant is flowing and the thermostat is at least partly open Consult the Fault finding Section at the rear of this manual for cooling system diagnosis Renewal All models 5 Disconnect the negative cable from the battery Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 6 Drain the cooling system see Chapter 1 If the coolant is relatively new or in good condition save it and re use it M10 engines 7 The thermostat is located in the bottom hose First remove the cooling fan 8 Note the fitted position of the thermostat then unscrew the hose clamps and withdraw the thermostat from the hose connections see illustration 9 Refit the thermostat to hose connections and tighten the hose clamps 10 Refit the cooling fan M20 and M30 engines 11 Loosen the hose clamp see illustration then detach the hose s from the thermostat cover 3 11 On M20 and M30 engine models loosen the hose clamp A and disconnect the hose from the thermostat housing cover note that the coolant temperature sender unit barely visible behi
458. on If necessary unscrew the stud from the cylinder block 14 8 Removing the timing belt tensioner M40 engine 14 2 On M10 and M30 engines remove the three bolts that hold the driven gear to the oil pump and remove the gear 14 36 On M10 and M30 engines the oil pump is bolted to the front and centre of the engine block 9 Unscrew and remove the crankshaft hub bolt while holding the crankshaft stationary The bolt is tightened to a very high torque and it will be necessary to prevent the crankshaft turning Ideally a metal bar should be bolted to the sprocket or the starter motor may be removed and the flywheel held using a wide bladed screwdriver Beware of possible damage to surrounding components if it is necessary to improvise some method of immobilising the crankshaft 10 Remove the sprocket and spacer noting that the shoulder on the spacer faces inwards 11 Unscrew the bolts and remove the stabilising and guide rollers from the front end cover see illustrations 14 11a Removing the stabilising roller from the front end cover M40 engine 14 3a On M20 engines the oil pump is bolted across the engine block from side to side towards the front of the engine m 14 4 If necessary on the M20 engine remove the plug and oil pump driveshaft from the engine Inspect the driveshaft gear as well as this intermediate shaft gear in the engine block arrow
459. on areas of leakage are a Transmission sump Chapters 1 and 7B b Filler pipe Chapter 7B C Transmission fluid cooler lines Chapter 7B d Speedometer sensor Chapter 7B Transmission fluid brown or has a burned smell Transmission fluid burned fluid should be changed May indicate transmission internal fault Chapters 1 and 7B Transmission will not kickdown with accelerator pedal pressed to the floor Kickdown cable out of adjustment Chapter 7B Fault Finding rer 13 Noisy in all gears Insufficient lubricant Chapter 1 Damaged or worn bearings Worn or damaged input gear shaft and or output gear shaft Slips out of gear Worn or incorrectly adjusted linkage Chapter 7A Transmission to engine mounting bolts loose Chapter 74A Shift linkage binding Chapter 7 Worn shift fork Chapter 7 Leaks lubricant Excessive amount of lubricant in transmission Chapters 1 and 7A Loose or broken input shaft bearing retainer Chapter 7 Input shaft bearing retainer O ring and or lip seal damaged Chapter 7A General shift mechanism problems Chapter 7B deals with checking and adjusting the shift linkage on automatic transmissions Common problems which may be attributed to poorly adjusted linkage are a Engine starting in gears other than Park or Neutral b Indicator on sele
460. oosening the clamp bolt and nut mounting bolts and new sealing washers on the hydraulic line fittings Tighten the mounting bolts the track rod end nuts and the universal joint shaft clamping bolts to the torque values listed in this Chapter s Specifi cations 9 Lower the vehicle to the ground 10 On power steering models fill the reservoir with the recommended fluid see Chapter 1 and bleed the power steering System see Section 23 11 it s good idea to have the front wheel alignment checked by a dealer service department or qualified garage 20 Steering linkage 5 Series N inspection removal and N refitting X Inspection 1 Raise the vehicle and place it securely on axle stands 2 Firmly grasp each front tyre at the top and bottom then at the front and rear and check for play in the steering linkage by rocking the tyre back and forth There should be little or no play in any of the linkage balljoints Inspect the Pitman arm the idler arm the centre track rod the inner track rods the track rod ends and the steering arms for any obvious damage Try forcing the linkage parts in opposite directions from one another There should be no play between any of them If any of the parts are bent or damaged in any way or if any of the balljoints are worn renew the parts concerned Removal 3 Before dismantling the steering linkage obtain a suitable balljoint separator A two jaw puller or a wedge type tool wi
461. or 2 Engine oil drain plug 3 Front suspension control arm left hand side 4 Front anti roll bar 5 Clutch slave cylinder 6 Transmission 7 Exhaust downpipe 8 Front suspension control arm right hand side Typical rear underside components 1 Exhaust system 2 Differential fill check plug 3 Driveshaft boot 4 Fuel tank filler tube 5 Differential drain plug 6 Rear brake 7 Rear shock absorber 1 Introduction This Chapter is designed to help the home mechanic maintain his or her vehicle with the goals of maximum performance economy Safety and reliability in mind Included is a master maintenance schedule followed by procedures dealing specifically with each item on the schedule Visual checks adjustments component renewal and other helpful items are included Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of various components Servicing the vehicle in accordance with the mileage time maintenance schedule and the step by step procedures will result in a planned maintenance programme that should produce a long and reliable service life Keep in mind that itis a comprehensive plan so maintaining some items but not others at specified intervals will not produce the same results 2 Routine maintenance As you service the vehicle you will discover that many of the procedures can and should be grouped together because of the nature of t
462. or 4and DOT 5 can cause brake failure 14 The brake master cylinder is mounted at the left rear corner of the engine compartment The clutch fluid reservoir manual transmission models is mounted on the right hand side 15 To check the clutch fluid level observe the level through the translucent reservoir The level should be at or near the step moulded into the reservoir If the level is low remove the reservoir cap to add the specified fluid see illustration 16 The brake fluid level is checked by looking through the plastic reservoir mounted on the master cylinder see illustration The fluid level should be between the MAX and MIN lines on the reservoir If the fluid level is low first wipe the top of the reservoir and the cap with a clean rag to prevent contamination of the system as the cap is unscrewed Top up with the recommended brake fluid but do not overfill 17 While the reservoir cap is off check the master cylinder reservoir for contamination If rust deposits dirt particles or water droplets are present the system should be drained and refilled 18 After filling the reservoir to the proper level make sure the cap is seated correctly to prevent fluid leakage and or contamination 19 The fluid level in the master cylinder will drop slightly as the disc brake pads wear There is no need to top up to compensate for this fall provided that the level stays above the MIN line the level will rise again when new pads a
463. or 90A A stamped serial number on the rear of the alternator will identify the type and amperage rating Perform the charging system checks see Section 14 to diagnose any problems with the alternator The voltage regulator and the alternator brushes are mounted as a single assembly On Bosch alternators this unit can be removed from the alternator see Section 16 and the components serviced individually The alternator on all models is mounted on the left front of the engine and utilises a V belt and pulley drive system Drivebelt tension and battery servicing are the two primary maintenance requirements for these systems See Chapter 1 for the procedures regarding engine drivebelt checking and battery servicing The ignition no charge warning light should come on when the ignition key is turned to Start then go off immediately the engine starts If it remains on there is a malfunction in the charging system see Section 14 Some vehicles are also equipped with a voltmeter If the voltmeter indicates abnormally high or low voltage check the charging system see Section 14 Note On models up to 1986 a blown ignition no charge warning light will prevent the alternator from charging After 1987 a resistor is wired in parallel with the warning light in order to allow current to bypass the light in the event of a broken circuit blown warning light Precautions Be very careful when making electrical circuit connection
464. or carburettor malfunctioning Chapter 4 Vacuum leak at fuel injector s intake manifold or vacuum hoses Chapter 4 Valve clearances incorrect Chapter 1 or valve s sticking or damaged Chapter 2 Pinking or knocking engine sounds when accelerating or driving uphill Incorrect grade of fuel Ignition timing incorrect Chapter 5 Fuel injection system or carburettor in need of adjustment Chap ter 4 Damaged spark plugs or HT leads or incorrect type fitted Chapter 1 Worn or damaged distributor components Chapter 5 Faulty emission system Chapter 6 Vacuum leak Chapter 4 Engine runs with oil pressure light on Caution Stop the engine immediately if the oil pressure light comes on and establish the cause Running the engine while the oil pressure is low can cause severe damage Low oil level Chapter 1 Idle speed too low Chapter 1 Short circuit in wiring Chapter 12 Faulty oil pressure sender unit Chapter 2 Worn engine bearings and or oil pump Chapter 2 Engine runs on after switching off Idle speed too high Chapter 1 Excessive engine operating temperature Chapter 3 Incorrect fuel octane grade Spark plugs defective or incorrect grade Chapter 1 Ignition no charge warning light fails to
465. ormation regarding battery cable removal 4 Disconnect the old cables from the battery then trace each of them to their opposite ends and detach them from the starter solenoid and earth terminals Note the routing of each cable to ensure correct refitting 5 f the old cables are to be renewed take them with you when buying new cables It is vitally important that you renew the cables with identical parts Cables have character istics that make them easy to identify positive cables are usually red larger in cross section and have a larger diameter battery post clamp earth cables are usually black smaller in cross section and have a slightly smaller diameter clamp for the negative post 6 Clean the threads of the solenoid or earth connection with a wire brush to remove rust and corrosion TNA ca Apply a light coat of battery terminal corrosion inhibitor or petroleum jelly to the terminal threads to prevent future corrosion 7 Attach the cable to the solenoid or earth connection and tighten the mounting nut bolt securely 8 Before connecting a new cable to the battery make sure that it reaches the battery post without having to be stretched 9 Connectthe positive cable first followed by the negative cable gt _ gt 3 3b The battery is mounted under the rear seat on some models 5 Ignition system general information and precautions The ignition system includes the ignition Switch the battery the di
466. ors Note Some models are equipped with a TDC sensor mounted on the front of the engine This sensor is strictly for the BMW service test unit and it is not part of the Motronic ignition system Precautions Certain precautions must be observed when working on a transistorised ignition System a Do not disconnect the battery cables when the engine is running b Make sure the ignition control unit TCI ignition system is always well earthed see Section 10 C Keep water away from the distributor and HT leads d Ifa tachometer is to be connected to the engine always connect the tachometer positive lead to the ignition coil negative terminal and never to the distributor Do not allow the coil terminals to be earthed as the impulse generator or coil could be damaged f Do notleave the ignition switch on for more than ten minutes with the engine off or if the engine will not start 6 Ignition system check BN N A Warning Because of the high voltage generated by the ignition system extreme care should be taken whenever an operation is performed involving ignition components This not only includes the impulse generator electronic ignition coil distributor and spark plug HT leads but related components such as spark plug connectors tachometer and other test equipment 1 If the engine turns over but will not start disconnect the spark plug HT lead from any spark plug and attach it to a ca
467. our or if it smells burned it should be changed see Section 28 If you are in doubt about its condition purchase some new fluid and compare the two for colour and smell 9 Tyre rotation 1 tyres be rotated at the specified intervals or whenever uneven wear is noticed However bear in mind that if rotation succeeds in making all the tyres wear evenly you will eventually have to renew all four at once Since the vehicle will be raised and the wheels removed anyway check the brakes also see Section 26 Note Even if you don t rotate the tyres at least check the wheel bolt tightness 2 It is recommended that the tyres be rotated 1 13 FRONT 9 2 The tyre rotation pattern for these models in a specific pattern see illustration so that their direction of rotation remains the same 3 Refer to the information in J acking and towing at the front of this manual for the proper procedure to follow when raising the vehicle and changing a tyre 4 The vehicle must be raised on a hoist or supported on axle stands to get all four tyres off the ground Make sure the vehicle is safely supported 5 After the rotation procedure is finished check and adjust the tyre pressures as necessary and be sure to check the wheel bolt tightness 10 Underbonnet hose check BN and renewal A x Warning Renewal of air conditioning hoses must be left to a dealer service department or air conditioning specialist
468. ournals for uneven wear scoring pits and cracks 4 Rub a copper coin across each journal several times see illustration If a journal picks up copper from the coin it s too rough and must be reground 5 Check the rest of the crankshaft for cracks and other damage If necessary have a machine shop inspect the crankshaft 6 Using a micrometer measure the diameter of the main and connecting rod journals and compare the results to this Chapter s Specifi cations see illustration By measuring the diameter at a number of points around each journal s circumference you ll be able to determine whether or not the journal is out of round Take the measurement at each end of the journal near the crank webs to determine if the journal is tapered 7 If the crankshaft journals are damaged tapered out of round or worn beyond the limits given in the Specifications have the crankshaft reground by a machine shop Be sure to use the correct size bearing shells if the crankshaft is reconditioned 8 Check the oil seal journals at each end of 19 8 If the seals have worn grooves in the crankshaft journals or if the seal contact surfaces are nicked or scratched the new seals will leak y 19 4 Rubbing penny lengthways each journal will reveal its condition if copper rubs off and is embedded in the crankshaft the journals should be reground the crankshaft for wear and damage If the seal has worn a groove
469. ournals with a Clean lint free cloth 8 Check or clean the oil holes in the crankshaft as any dirt here can go only one way Straight through the new bearings 9 Once you re certain the crankshaft is clean carefully lay it in position in the main bearings 10 Before the crankshaft can be permanently fitted the main bearing oil clearance must be checked 11 Cut several pieces of the appropriate size Plastigage they must be slightly shorter than the width of the main bearings and place one piece on each crankshaft main bearing journal parallel with the crankshaft centreline see illustration 12 Clean the faces of the bearings in the caps and refit the caps in their respective T a m E L 2 1 p a 1 24 11 Lay the Plastigage strips the main bearing journals parallel to the crankshaft centreline 2B 2B 20 General engine overhaul procedures 24 15 Compare the width of the crushed Plastigage to the scale on the envelope to determine the main bearing oil clearance always take the measurement at the widest point of the Plastigage be sure to use the correct scale standard and metric ones are included positions don t mix them up with the arrows pointing towards the front of the engine Don t disturb the Plastigage 13 Starting with the centre main bearing and working out toward the ends progressively tighten the main bearing cap bolts to the torque listed in this Ch
470. ove the switch mounting screw Squeeze the release tabs and withdraw the switch from the mounting see illustration 10 Disconnect the switch electrical connector from the harness at the base of the steering column 11 Refitting is the reverse of removal 7 Ignition switch removal and refitting Warning Some later models equipped with an airbag or Supplemental Restraint System SRS To avoid possible damage to this system the manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other specialist because of the special 6 6 Squeeze the wiper washer switch tabs and pull it directly out of the mounting Body electrical systems 12 3 6 3 Follow the wiring down the steering column to the connector tools and techniques required There is a risk of injury if the airbag is accidentally triggered Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Remove the steering wheel see Chap ter 10 3 Remove the steering column
471. p of the cylinder head together with new seals then tighten the bolts to the specified torque 17 The cylinder head may now be refitted see Chapter 2A 12 Pistons connecting rods EN removal 5 Note Before removing the piston connecting rod assemblies remove the cylinder head and the sump On M10 M20 and M30 engines only remove the oil pump Refer to the appropriate Sections in Chapter 2A 1 Use your fingernail to feel if a ridge has formed at the upper limit of ring travel about 6 mm down from the top of each cylinder If 12 1 ridge reamer is required to remove the ridge from the top of each cylinder do this before removing the pistons carbon deposits or cylinder wear have produced ridges they must be completely removed with a special tool called a ridge reamer see illustration Follow manufacturer s instructions provided with the tool Failure to remove the ridges before attempting to remove the piston connecting rod assemblies may result in piston ring breakage 2 After the cylinder ridges have been removed turn the engine upside down so the crankshaft is facing up 3 Before the connecting rods are removed check the side play with feeler gauges Slide them between the first connecting rod and crankshaft web until no play is apparent see illustration The side play is equal to the thickness of the feeler gauge s If the side play exceeds the service limit new connecting rods will be req
472. p timing light is preferred Generally the power leads for the timing light are attached to the battery terminals and the pick up lead is attached to the No 1 spark plug HT lead The No 1 spark plug is the one at the front of the engine Caution If an inductive pick up timing light isn t available don t puncture the spark plug HT lead to attach the timing light pick up lead Instead use an adapter between the spark plug and HT lead If the insulation on the HT lead is damaged the secondary voltage will jump to earth at the damaged point and the engine will misfire Note On some models a TDC transmitter is fitted for checking the ignition system However a special BMW tester must be connected to the diagnostic socket to use it so unless the special tester is available a conventional timing light should be used The ignition timing mark may be on the vibration damper but if not normally the TDC mark will be If the timing light is of the adjustable delay type then the ignition timing may be determined by zeroing the adjustment then turning the adjustment until the TDC marks are aligned and then reading off the amount of advance from the timing light If a standard timing light is being used make a mark on the vibration damper in accordance with the specified advance using the following formula to calculate the distance from the TDC mark to the timing mark Distance 2Pr x advance 360 23 142 radius of vibration da
473. paste or molybdenum disulphide moly grease then lightly drive on the seal with a socket or piece of tubing 114b molybdenum disulphide moly grease or clean engine oil to each valve stem and refit the first valve 4 Lubricate the lip of the valve guide seal carefully slide it over the tip of the valve then Slide it all the way down the stem to the guide Using a hammer and a deep socket or seal fitting tool gently tap the seal into place until it s completely seated on the guide see illustrations Don t twist or distort a seal during fitting or it won t seal properly against the valve stem Note On some engines the seals for intake and exhaust valves are different don t mix them up 5 Drop the spring seat or shim s over the valve guide and set the valve spring and retainer in place 6 Compress the spring with a valve spring compressor and carefully refit the collets in the upper groove then slowly release the compressor and make sure the collets seat properly see illustration Apply a small dab of grease to each collet to hold it in place if necessary 7 Repeat paragraphs 3 to 6 for each of the valves Be sure to return the components to their original locations don t mix them up M10 M20 and M30 engines 8 Refit the rocker arms and shafts by reversing the dismantling sequence Be sure to refit the rocker shafts in the correct orientation The guide plate notches and the small oil h
474. pecial tool which plugs into the service connector located in the engine compartment 2 Although the service light resetting tool can be obtained from a dealer reasonably priced alternatives may also be available from aftermarket sources When obtaining a tool it is important to know the vehicle year and model and whether the service connector has 15 or 20 pins see illustrations Once the proper tool is obtained it is a simple matter to plug it into the service connector and following the tool manufacturer s instructions reset the service lights Note The brake warning light will not automatically reset if the sensor on the brake pad or its wiring is 34 2a The earlier 15 pin connector arrowed is mounted near the front of the engine The 20 pin connector used on later models is located in the left rear corner of the engine compartment 34 2b An aftermarket service light resetting tool such as this one can be plugged into the service connector and used to reset the service lights damaged because it is worn through it must be repaired first 3 The service lights are controlled by the Service Indicator SI board in the instrument cluster which is powered by rechargeable batteries Should these batteries fail problems will develop in the SI board Symptoms of failed batteries include the inability to reset the service lights and malfunctions affecting the tachometer temperature gauge and radio operation Refe
475. ped with an Anti lock Braking System ABS All models are manufactured to fine limits and live up to the BMW reputation of quality workmanship Although many of the models covered by this manual appear complex at first sight they should present no problems to the home mechanic Note for UK readers The greater part of this manual was originally written in the USA Some of the photographs used are of American market models but the procedures given are fully applicable to right hand drive models or have been amended where necessary Acknowledgements Thanks are due to Champion Spark Plug who supplied the illustrations showing spark plug conditions Thanks are also due to S ykes Pickavant Limited who provided some of the workshop tools and to all those people at Sparkford who helped in the production of this manual Technical writers who contributed to this project include Robert Maddox Mark Ryan and Mike Stubblefield We take great pride in the accuracy of information given in this manual but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us No liability can be accepted by the authors or publishers for loss damage or injury caused by any errors in or omissions from the information given Project vehicles The main project vehicle used in the preparation of this manual for the UK market was a 1988 BMW 318i with an M40 B18 engi
476. plate faulty Chapter 8 Incorrect size master or slave cylinder fitted Chapter 8 Manual transmission Vibration Damaged propeller shaft Chapter 8 Out of round tyres Chapter 1 Tyre out of balance Chapters 1 and 10 Worn propeller shaft universal joint Chapter 8 Noisy in neutral with engine running Worn clutch release bearing Chapter 8 Worn transmission input shaft bearing Chapter 7A Noisy in one particular gear Damaged or worn constant mesh gears Damaged or worn synchronisers Automatic transmission Note Due to the complexity of the automatic transmission it is difficult for the home mechanic to properly diagnose and service this unit For problems other than the following the vehicle should be taken to a dealer or transmission specialist Fluid leakage Automatic transmission fluid is a deep red colour Fluid leaks should not be confused with engine oil which can easily be blown by airflow onto the transmission To pinpoint a leak first remove all built up dirt and grime from the transmission housing with degreasing agents and or by steam cleaning Then drive the vehicle at low speed so airflow will not blow the leak far from its source Raise the vehicle and determine where the leak is coming from Comm
477. point in the cylinder that each piston reaches as it travels up and down when the crankshaft turns Each piston reaches TDC on the compression stroke and again on the exhaust Stroke but TDC generally refers to piston position on the compression stroke 2 Positioning the piston at TDC is an essential part of many procedures such as timing belt or chain removal and distributor removal 3 Before beginning this procedure be sure to place the transmission in Neutral and apply the handbrake or chock the rear wheels Also disable the ignition system by detaching the coil wire from the centre terminal of the distributor cap and earthing it on the engine block with a jumper wire Remove the spark plugs see Chapter 1 4 In order to bring any piston to TDC the crankshaft must be turned using one of the methods outlined below When looking at the front of the engine normal crankshaft rotation is Clockwise a The preferred method is to turn the crankshaft with a socket and ratchet attached to the bolt threaded into the front of the crankshaft A remote starter switch which may save some time can also be used Follow the instructions included with the switch Once the piston is close to TDC use a socket and ratchet as described in the previous paragraph c If an assistant is available to turn the ignition switch to the Start position in Short bursts you can get the piston close to TDC without a remote starter swi
478. ppears on the instrument panel display refer to page 0 7 for the language resetting procedure Continuity check A continuity check determines if there are any breaks in a circuit if it is conducting electricity properly With the circuit off no power in the circuit a self powered continuity tester can be used to check the circuit Connect the test leads to both ends of the circuit and if the test light comes on the circuit is passing current properly If the light doesn t come on there is a break somewhere in the circuit The same procedure can be used to test a switch by connecting the continuity tester to the power in and power out sides of the switch With the switch turned on the test light should come on Finding an open circuit When diagnosing for possible open Circuits it is often difficult to locate them by sight because oxidation or terminal misalignment are hidden by the connectors Intermittent problems are often caused by oxidised or loose connections Merely wiggling an electrical connector may correct the open circuit condition albeit temporarily Dismantle the connector and spray with a water dispersant aerosol On simpler connectors it may be possible to carefully 3 1 The fusebox is located in the engine compartment under a cover the box also includes several relays bend the connector pins inside to improve the metal to metal contact don t damage the connector in the process however
479. pplicable with reference to Chapter 7B 12 4 Using an Allen key to remove the carburettor cover centre bolt 12 6b View of the underside of the cover E d 11 10 Carburettor insulating flange on the intake manifold can be removed if necessary 12 Carburettor cleaning and adjustment Note This Section describes the procedure for the 2B4 carburettor The procedure for the 2BE carburettor is similar Cleaning 1 Obtain a complete set of gaskets and seals for the carburettor 2 Wash clean the exterior surfaces of the carburettor 12 5 Prise the link arrowed from the choke valve plastic lever 12 6c View of the carburettor main body with the cover removed Fuel and exhaust systems 4 11 12 3 Using a screwdriver to disconnect the accelerator pump linkage arrowed 3 Using a screwdriver prise the accelerator pump linkage from the primary throttle arm see illustration 4 Unscrew the bolts securing the cover to the main body An Allen key is necessary to remove the centre bolt see illustration 5 Prise the link from the choke valve plastic lever see illustration 6 Lift the cover from the main body and remove the gasket see illustrations 7 Remove the screw securing the throttle positioner bracket to the throttle housing see illustration 8 Disconnect the vacuum unit pullrod from the secondary throttle lever see illustration 12 6a Lifting the cover from the
480. procedure 4 Remove the tank drain plug see illustration and drain the fuel into an approved fuel container If no drain plug is fitted it should be possible to syphon the fuel out not by mouth otherwise the fuel will have to be drained during the removal operation 5 Unplug the fuel pump sender unit electrical connector as applicable and detach the fuel feed return and vapour hoses see Section 4 Where applicable remove the rear seat cushion for access 6 Remove the fuel illustration 7 Detach the fuel filler neck and breather hoses 8 Raise and support the vehicle On some models it will also be necessary to remove the exhaust system and propeller shaft 9 Support the tank with a trolley jack tank shield see 6 4 Remove the tank drain plug arrowed and drain the fuel into a suitable container 4 8 Fuel and exhaust systems Haal xh a 6 6 Exploded view of the fuel tank assembly on later 5 Series models Position a block of wood between the jack head and the fuel tank to protect the tank 10 Remove the mounting bolts at the corners of the fuel tank and unbolt the retaining straps see illustrations Pivot the straps down until they re hanging out of the way 11 Lower the tank just enough so you can see the top and make sure you have detached everything Finish lowering the tank and remove it from the vehicle 12 Refitting is the reverse of removal 6 10a Remove the fuel tank mounting bol
481. procket then loop it over the camshaft sprocket and guiding the chain between the chain guide and tensioner rail refit the camshaft sprocket on the camshaft Make sure the camshaft timing marks are aligned 15 The remainder of refitting is the reverse of removal Be sure to tighten the fasteners to the correct torques see this Chapter s Speci fications 9 Timing belt covers removal and refitting Note This procedure applies to M20 and M40 engines Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 Remove the fan clutch and fan shroud see Chapter 3 3 On the M20 engine remove the radiator see Chapter 3 4 Remove the fan drivebelt pulley 9 6a Unbolt the distributor cap M40 engine 9 9a Remove the upper timing belt cover first then the lower cover M20 engine 1 Upper timing belt cover 2 Lower timing belt cover 5 f applicable disconnect the reference sensor wiring harness which runs across the front of the timing belt cover and set it aside 6 If the distributor cap is mounted directly to the upper timing belt cover remove the cap rotor and the black plastic cover beneath the
482. ps and bearing shells in their respective connecting rods and refit the cap nuts bolts finger tight Leaving the old bearing shells in place until reassembly will help prevent the connecting big end bearing surfaces from being accidentally nicked or gouged 10 Don t separate the pistons from the connecting rods see Section 18 13 Crankshaft removal Note crankshaft can be removed only after the engine has been removed from the vehicle It s assumed that the flywheel or driveplate vibration damper timing chain or belt sump oil pump and piston connecting rod assemblies have already been removed The rear main oil seal housing must be unbolted and separated from the block before proceeding with crankshaft removal 1 Before the crankshaft is removed check the endfloat Mount a dial indicator with the stem in line with the crankshaft and touching the nose of the crankshaft or one of its webs see illustration 2 Push the crankshaft all the way to the rear 12 6 To prevent damage to the crankshaft journals and cylinder walls slip sections of rubber or plastic hose over the rod bolts before removing the pistons 12 4 Mark the big end bearing caps in order from the front of the engine to the rear one mark for the front cap two for the second one and so on and zero the dial indicator Next prise the crankshaft to the front as far as possible and check the reading on the dial indicator The distance tha
483. r aU 17 5 The cylinder hone should leave a smooth crosshatch pattern with the lines intersecting at approximately a 60 angle 2B 2 16 General engine overhaul procedures P Ei dp 18 2 Removing the compression rings with a ring expander note the mark arrowed facing up 7 Wipe the oil out of the cylinder and repeat the procedure for the remaining cylinders 8 After the honing job is complete chamfer the top edges of the cylinder bores with a Small file so the rings won t catch when the pistons are refitted Be very careful not to nick the cylinder walls with the end of the file 9 The entire engine block must be washed again very thoroughly with warm soapy water to remove all traces of the abrasive grit produced during the honing operation Note The bores can be considered clean when a lint free white cloth dampened with clean engine oil used to wipe them out doesn t pick up any more honing residue which will show up as grey areas on the cloth Be sure to run a brush through all oil holes and galleries and flush them with running water 10 After rinsing dry the block and apply a coat of light rust preventive oil to all machined surfaces Wrap the block in a plastic bag to keep it clean and set it aside until reassembly 18 Pistons connecting rods inspection 1 Before the inspection process be carried out the piston connecting rod assemblies must be cleaned and
484. r V Valve device through which the flow of liquid gas vacuum or loose material in bulk may be started stopped or regulated by a movable part that opens shuts or partially obstructs one or more ports or passageways A valve is also the movable part of such a device Valve clearance The clearance between the valve tip the end of the valve stem and the rocker arm or tappet The valve clearance is measured when the valve is closed Vernier caliper precision measuring instrument that measures inside and outside dimensions Not quite as accurate as a micrometer but more convenient Viscosity The thickness of a liquid or its resistance to flow Volt A unit for expressing electrical pressure in a circuit One volt that will produce a current of one ampere through a resistance of one ohm W Welding Various processes used to join metal items by heating the areas to be joined to a molten state and fusing them together For more information refer to the Haynes Automotive Welding Manual Wiring diagram drawing portraying the components and wires in a vehicle s electrical system using standardised symbols For more information refer to the Haynes Automotive Electrical and Electronic S ystems Manual Note References throughout this index relate to number A ABS 9 2 Accelerator cable 4 9 Acknowledgements 0 4 Aerial 12 4 Air bags 0 5 Air cleaner 4 8 Air conditioning
485. r Disconnect the pressure line from the pump 4 If you need to remove the pulley from the pump push on the power steering pump drivebelt by hand to increase the tension and unscrew the pulley nuts or bolts 5 Loosen the power steering pump drivebelt tensioner bolt and remove the drivebelt see Chapter 1 6 Remove the bolts mounting see illustrations and detach the power steering pump niie 22 6a Typical 3 Series power steering pump adjusting bolt arrowed 10 10 16 Suspension and steering systems Refitting 7 Refitting is the reverse of removal Tighten the nuts and bolts securely Adjust the drivebelt tension see Chapter 1 8 Top up the fluid level in the reservoir see Chapter 1 and bleed the system see Sec tion 23 23 Power steering system bleeding 1 To bleed the power steering system begin by checking the power steering fluid level and adding fluid if necessary see Chapter 1 2 Raise and support the front of the vehicle on axle stands 3 Turn the steering wheel from lock to lock several times Recheck the fluid level and top up if necessary 4 Start the engine and run it at 1000 rpm or less Turn the steering wheel from lock to lock again three or four times and recheck the fluid level one more time Note On 5 24 3 After removing the steering wheel nut mark the relationship of the steering wheel to the steering shaft arrowed to ensure proper alignment
486. r to Chapter 12 for more information on the 51 board Every 60 000 miles 35 Engine timing belt renewal EN x A Note This is not included in the manufacturer s maintenance schedule but is strongly recommended as a precaution against the timing belt failing in service If the timing belt fails while the engine is running extensive engine damage could be caused Refer to Chapter 2A Section 10 12 1 Chapter 12 Body electrical systems Contents BUID renewal m pues dre soe anaes 15 Heated rear window check and repair 17 Central locking system description and 20 Ignition switch removal refitting 7 Cruise control system description and check 19 Instrument cluster removal and refitting 10 Direction indicator hazard warning flasher check and renewal 5 8 Electric windows description and check 21 Radio aerial removal and refitting 9 Electrical system fault finding general information 2 Relays general information 4 Fuses general information 3 Service Indicator SI board general information 11 General INMOMNAUON s 5555555 m hee e ed bad XC Roa RC 1
487. r rear calipers although slightly different in size they re identical in design to the front brake calipers used on 5 Series models Note 2 Some models may have different numbers and types of anti squeal shims and other hardware than what is shown in this Chapter It S best to note how the hardware is fitted on the vehicle before dismantling so you can duplicate it on reassembly 3 5c Hold the guide pins while loosening the caliper mounting bolts 3 Series 3 5f On 5 Series models unplug the electrical connector for the brake pad wear sensor 9 4 Braking system 3 5g Remove the plugs for the brake caliper mounting bolts then remove the bolts 5 Series 3 5j Remove the caliper and inner brake pad 5 Series x a 3 5m Remove the outer brake pad to fit the new pads reverse the removal procedure 6 Be sure to inspect the wear sensor s left front wheel only or left front and right rear wheel If they re OK transfer them from the old pads to the new ones if they re worn by abrasion fit new sensors on the new pads 7 To fit the new pads reverse the removal procedure When refitting the caliper be sure to tighten the mounting bolts to the torque listed in this Chapter s Specifications Warning Check and if necessary renew the mounting bolts on 3 Series models whenever they are removed If in doubt use new bolts 8 After the job is completed firmly depress the brake pedal a few
488. r the same diameter as the outer race see illustration Don t apply force to the inner race Make sure the bearing is fully seated against the back of the bore Refit the circlip making sure it s fully seated into its groove b BMW dealers use special tools Part Nos 23 1 1300 33 4 080 and 33 4 020 to pull the stub axle into the bearing because the smooth portion between the splined portion of the stub axle and the flange is a press fit and knocks out the wheel bearing inner race during refitting of the stub axle However you can refit the stub axle without these tools using the old inner race and a piece of pipe 13 mm long by 38 mm inside diameter see 15 14b You can fabricate your own spacer tool from a piece of 13 mm long 38 mm inside diameter pipe left you ll also need to use the old inner race right 15 13b then drive the bearing out of the housing with a large socket or a suitable piece of pipe illustration First insert the stub axle through the new bearing until the threaded portion protrudes from the inner race Refit the nut and tighten it until the splined portion of the stub axle shaft bottoms against the nut You ll need to hold the stub axle flange with a lever or a large screwdriver while tightening the nut see illustration Remove the nut refit your piece of pipe centred on the inner race and refit the nut see illustration Tighten the nut again until it bottoms against the splines
489. r this check Preferably the engine should have been switched off for several hours Disable the ignition system by detaching the coil wire from the centre terminal of the distributor cap and earthing it on the engine block with a jumper wire Pull back the rubber boot from the thermotime switch see illustration and probe the black yellow wire connector terminal with a voltmeter 5 Have an assistant switch on the ignition and operate the starter The voltmeter should register a voltage signal the moment the starter engages This signal should last approximately 6 to 10 seconds depending on the temperature of the engine da 19 4 Check for a voltage signal on the black yellow wire of the thermotime switch when the ignition is on 4 18 Fuel and exhaust systems 19 6 Check the resistance of the thermotime switch with the engine coolant temperature below 30 There should be continuity 6 If the voltage is correct unplug the electrical connector and using an ohmmeter check for continuity between the terminals of the thermotime switch see illustration Continuity should exist 7 Reconnect the coil lead start the engine and warm it up above 419C When the engine is warm there should be no continuity between the terminals If there is the switch is faulty and must be renewed Note On 5 Series models there are several types of thermotime switch Each one is stamped with an opening temperature and maximum d
490. r wheel run out Chapter 10 Worn balljoints Chapter 10 Excessive tyre wear on outside edge Tyre pressures incorrect Chapter 1 Excessive cornering speed Wheel alignment incorrect excessive toe in Chapter 10 Suspension components damaged Chapter 10 Excessive tyre wear on inside edge Tyre pressures incorrect Chapter 1 _ Wheel alignment incorrect excessive toe out Chapter 10 Loose or damaged steering components Chapter 10 Tyre tread worn in one place Tyres out of balance Damaged or buckled wheel Inspect and renew if necessary Defective tyre Chapter 1 Excessive play or looseness in steering system Wheel bearing s worn Chapter 10 Tie rod end loose or worn Chapter 10 Steering gear mountings loose Chapter 10 Rattling or clicking noise in steering gear Insufficient or incorrect lubricant in rack and pinion assembly Chapter 10 Steering gear mountings loose Chapter 10 REF Length distance Inches in 25 4 Feet ft 0 305 Miles 1 609 Volume capacity Cubic inches cu in in 16 387 Imperial pints Imp pt x 0 568 Imperial quarts Imp qt 1 137 Imperial quarts Imp qt x 1 201 US quarts US qt x 0
491. ral information BN x Several electrical accessories the vehicle use relays to transmit the electrical signal to the component If the relay is defective that 4 2 Engine compartment relays component will not operate properly Relays are electrically operated switches which are often used in circuits drawing high levels of Current or where more complex switching arrangements are required The various relays are grouped together for convenience in several locations under the dash and in the engine compartment see accompanying illustration illus tration 3 1 If a faulty relay is suspected it can be removed and tested by a dealer or qualified automotive electrician No overhaul is possible Like fuses defective relays must be replaced with the correct type some relays look identical but perform very different functions 5 Direction indicator hazard warning flasher unit check and renewal A Warning Some later models equipped with an airbag or Supplemental Restraint System SRS To avoid possible damage to this system the manufacturer recommends that on airbag equipped models the following procedure should be left to a dealer service department or other specialist because of the special tools and techniques required There is a risk of injury if the airbag is accidentally triggered 1 The direction indicator hazard flasher unit is a small canister or box shaped unit located in t
492. ration 2 Disconnect the earth cable and windscreen washer hose from the bonnet 3 Detach the bonnet hinge rod clip and 9 10 Detach the centre grille valance by reaching under each headlight and pressing on the release lever 10 3a Use needle nose pliers to pull off the hinge pin clip 10 3b pull the hinge out while supporting the bonnet remove the pin see illustrations Be sure to support the bonnet while doing this 4 Have an assistant hold onto the bonnet on one side while you hold the other side 5 Remove the bonnet to hinge assembly bolts on your side of the bonnet then hold your side of the bonnet while your assistant removes the bonnet to hinge bolts on the other side 6 Remove the bonnet Place it somewhere safe where it will not be knocked over with rags to protect the paintwork where it rests on the ground or against a wall 7 Refitting is the reverse of removal 5 Series models 8 Open the bonnet On some later models it may be necessary to prise out the plastic clips and remove the insulation pad for access to 10 9 Pull off the clip with needle nose pliers 10 17 Loosen the bolts arrowed and raise or lower the catch to adjust the bonnet height AT 10 8a Use a small screwdriver to prise out the clip pin then the bonnet light connector and windscreen washer hoses see illustrations Having done this disconnect the wires and hoses 9 Detach th
493. rchase will prove a considerable expense offsetting some of the savings made by doing it yourself However provided that the tools purchased meet the relevant national Safety standards and are of good quality they will last for many years and prove an extremely worthwhile investment To help the average owner to decide which tools are needed to carry out the various tasks detailed in this manual we have compiled three lists of tools under the following headings Maintenance and minor repair Repair and overhaul and Special Newcomers to practical mechanics should start off with the Maintenance and minor repair tool kit and confine themselves to the simpler jobs around the vehicle Then as confidence and experience grow more difficult tasks can be undertaken with extra tools being purchased as and when they are needed In this way a Maintenance and minor repair tool kit can be built up into a Repair and overhaul tool kit over a considerable period of time without any major cash outlays The experienced do it yourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Special category when it is felt that the expense is justified by the amount of use to which these tools will be put Maintenance and minor repair tool kit The tools given in this list should be considered aS a minimum requirement if routine maintenance servicing and minor repair operations are to be undertak
494. re a useful alternative The tools in this list will occasionally need to be supplemented by tools from the Special list Sockets or box spanners to cover range in previous list Reversible ratchet drive for use with sockets see illustration Extension piece 250 mm for use with sockets Universal joint for use with sockets Torque wrench for use with sockets Self locking grips Ball pein hammer Soft faced mallet plastic aluminium or rubber Screwdrivers Flat blade long amp sturdy short chubby and narrow electrician s types Cross blade Long amp sturdy and short chubby types Pliers Long nosed Side cutters electrician s Circlip internal and external Cold chisel 25 mm Scriber Scraper Centre punch Pin punch Hacksaw Brake hose clamp Brake clutch bleeding kit Selection of twist drills L OHOOO L Sockets and reversible ratchet drive Steel rule straight edge C Allen keys inc splined Torx type see illustrations Selection of files Wire brush Axle stands J ack strong trolley or hydraulic type Light with extension lead Special tools The tools in this list are those which are not used regularly are expensive to buy or which need to be used in accordance with their manufacturers instructions Unless relatively difficult mechanical jobs are undertaken frequently it will not b
495. re fitted A very low level may indicate Weekly Checks 4 16 The brake fluid level should be kept above the MIN mark on the translucent reservoir unscrew the cap to add fluid worn brake pads Check for wear See Sec tion 26 20 If the brake fluid level drops consistently check the entire system for leaks immediately Examine all brake lines hoses and connections along with the calipers wheel cylinders and master cylinder see Sec tion 26 21 When checking the fluid level if you discover one or both reservoirs empty or nearly empty the brake or clutch hydraulic system should be checked for leaks and bled see Chapters 8 and 9 Windscreen washer fluid 22 Fluid for the windscreen washer system is Stored in a plastic reservoir in the engine compartment see illustration 23 In milder climates plain water can be used in the reservoir but it should be kept no more than two thirds full to allow for expansion if the water freezes In colder climates use windscreen washer system antifreeze available at any car accessory shop to lower the freezing point of the fluid This comes in concentrated or pre mixed form If you purchase concentrated antifreeze mix the antifreeze with water in accordance with the manufacturer s directions on the container Caution Do not use cooling A system antifreeze it will damage the vehicle s paint 5 2 Use tyre tread depth indicator to monitor tyre wear they
496. re with the engine at its normal operating temperature Compare your readings to the oil pressures listed in this Chapter s Specifications If the readings are Significantly below these and if the oil and oil filter are in good condition the crankshaft bearings and or the oil pump are probably worn out On M10 and M30 engines the oil pressure sender unit is located high on the left rear of the cylinder head On M20 engines the sender unit is threaded into the side of the engine block below the oil filter On M40 engines the sender unit is threaded into the rear of the oil filter housing Loss of power rough running knocking or metallic engine noises excessive valve train noise and high fuel consumption may also point to the need for an overhaul especially if they re all present at the same time If a complete tune up doesn t remedy the situation major mechanical work is the only solution An engine overhaul involves restoring the internal parts to the specifications of a new engine During an overhaul new piston rings are fitted and the cylinder walls are reconditioned rebored and or honed If a rebore is done by an engineering works new oversize pistons will also be fitted The main bearings and connecting big end bearings are generally renewed and if necessary the crankshaft may be reground to restore the journals Generally the valves are serviced as well since they re usually in less than perfect condition at this po
497. reading should be between 400 and 500 mA Adjust the valve if the current reading is not as specified see paragraph 15 Note The idle air stabiliser current will fluctuate between 400 and 1100 mA if the engine is too cold if the coolant temperature sensor is faulty if the idle speed needs to be adjusted if there is an engine vacuum leak or if electrical accessories are on 14 If there is no current reading have the idle speed control unit diagnosed by a BMW dealer or other specialist Note The idle air stabiliser control unit located under the facia can develop an electrical connector problem that intermittently turns the valve on and off Check the connector very carefully before fitting any new parts Sometimes a new control unit will only fix the problem temporarily Adjustment 15 With the ignition switched off connect a tachometer in accordance with the equipment manufacturer s instructions 16 Make sure the ignition timing is correct see Chapter 5 17 Connect an ammeter to the valve see paragraph 13 18 With the engine running the current reading should be 450 to 470 mA at 850 to Fuel and exhaust systems 4 19 5 21 21 Check the idle air stabiliser valve resistance on the two outer terminals on later Motronic systems it should be about 40 ohms 900 rpm manual transmission or 460 to 480 mA at 850 to 900 rpm automatic transmission 19 If the control current is not correct turn the a
498. reased by wiping them with a rag dampened with a suitable solvent Refitting 18 Renew the front oil seals see Section 11 It s not wise to take a chance on an old seal since renewal with the covers removed is very easy Be sure to apply a little oil to the front oil seal lips 19 Apply a film of RTV type gasket sealant to the surface of the sump gasket that mates with the lower timing chain cover Apply extra beads of RTV sealant to the edges where the gasket meets the engine block Note If the sump gasket is damaged instead of fitting a whole new gasket you might try trimming the front portion of the gasket off at the point where it meets the engine block then trim off the front portion of a new sump gasket so it s exactly the same size Cover the exposed inside area of the sump with a rag then clean all traces of old gasket material off the area where the gasket was removed Attach the new gasket piece to the sump with contact cement type gasket adhesive then apply RTV type sealant as described at the beginning of this paragraph 20 Coat both sides of the new gasket with RTV type gasket sealant then attach the lower timing chain cover to the front of the engine Refit the bolts and tighten them evenly to the torque listed in this Chapter s Specifications Work from bolt to bolt in a Criss cross pattern to be sure they re tightened evenly Note 1 Tighten the lower cover to block bolts first then tighten the sump to cover bo
499. rect Throttle plate not opening fully Corrective action Test coolant temperature sensor and wiring Repair wiring or renew sensor if faulty see Chapter 6 Check fuel pressure from main pump and transfer pump as applicable see Section 3 Check accelerator cable adjustment to make sure throttle is opening fully Adjust cable if necessary see Section 9 4 22 Fuel and exhaust systems Engine difficult to start or fails to start when cold Probable cause Cold start injector or thermotime switch faulty early Motronic system only Fuel pump not running Airflow meter flap door binding or stuck in open position Fuel pressure incorrect Intake air leaks Fuel injectors clogged or not operating Coolant temperature sensor faulty or wiring problem TPS throttle position sensor incorrectly adjusted Dirt or other contaminants in fuel Faulty ECU Crankshaft position signal missing Corrective action Test cold start injector and thermotime switch Renew faulty components see Section 19 Check fuel pump fuse and fuel pump relay see Sections 2 and 3 Inspect the airflow meter for damage see Section 16 Test system pressure see Section 3 Inspect all vacuum lines air ducts and oil filler and dipstick seals Check fuel injectors see Section 20 and wiring harness Test coolant temperature sensor see Chapter 6 Section 4 Check TPS adjustment see Chapter 6 Section 4 Check the fuel and drain the tank if necessary
500. red map and altering engine operation by controlling a number of different actuators Since special equipment is required most fault diagnosis and repair of the electronic control system is beyond the scope of the home mechanic Additional information and testing procedures for the emissions system components oxygen sensor coolant temperature sensor EVAP system etc is contained in Chapter 6 2 Fuelinjection system depressurising Warning Fuel is extremely A flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Also don t work in a garage where a natural gas type appliance with a pilot light is present 1 Remove the fuel pump fuse from the main fuse panel see illustrations Note Consult your owner s handbook for the exact location of the fuel pump fuse if the information is not stamped onto the fusebox cover 2 Start the engine and wait for it to stall S witch off the ignition 3 Remove the fuel filler cap to relieve the fuel tank pressure 4 The fuel system is now depressurised Note Place a rag around fuel lines before disconnecting to prevent any residual fuel from spilling onto the engine see illustration 5 Disconnect the battery negative cable before working on any part of the system Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation c
501. refit it Fit the new rubber dust boot and the retaining ring 13 On the front calipers of 3 Series models coat the piston with clean brake fluid and stretch the new dust boot over the bottom of the piston Hold the piston over the caliper bore and insert the rubber flange of the dust boot into the upper groove in the bore Start with the furthest side from you and work your way around towards the front until it is completely seated Push the piston into the caliper bore until it is bottomed in the bore then seat the top of the dust boot in the groove in the piston 14 Lubricate the sliding surfaces of the guide pins or bolts with silicone based grease usually supplied in the kit and push them into the caliper Refit the dust boots Refitting 15 Refit the caliper by reversing the removal procedure see Section 3 Waming Check and if necessary renew the mounting bolts on 3 Series models whenever they are removed If in doubt use new bolts Braking system 9 5 4 5 With the caliper padded to catch the piston use low pressure compressed air to force the piston out of its bore make sure your fingers are not between the piston and the caliper 16 If the hose was disconnected from the caliper bleed the brake system see Sec tion 16 5 Brake disc inspection removal and refitting Note This procedure applies to both the front and rear brake discs Brake discs should always be renewed or refinished in pai
502. refully mark the vacuum hoses if more than one is present on your distributor 5 Disconnect the vacuum hose s 6 Disconnect the primary circuit wires from the distributor 7 Mark the relationship of the rotor tip to the distributor housing see illustration Also mark the relationship of the distributor housing to the engine 8 7 Mark the relationship of the rotor to the distributor housing arrowed 8 Remove the hold down nut or bolt and clamp 9 Remove the distributor Note Do not rotate the engine with the distributor out Refitting 10 Before refitting the distributor make certain No 1 piston is still at TDC on the compression stroke 11 Insert the distributor into the engine with the adjusting clamp centred over the hold down hole Make allowance for the gear to turn as the distributor is inserted 12 Refit the hold down nut or bolt The marks previously made on the distributor housing and on the rotor and engine should line up before the nut or bolt is tightened 13 Refit the distributor cap 14 Connect the wiring for the distributor 15 Reconnect the spark plug HT leads 16 Reconnect the vacuum hoses as previously marked 17 Check the ignition timing see Section 7 Motronic system Removal 18 Remove the cover from the distributor see illustration and remove the distributor cap see Chapter 1 19 Using a small Allen key remove the three screws from the rotor see illustration 20 Remove the
503. removed from the engine for clarity hammer and screwdriver Be very careful not to damage the seal housing 12 On the M40 engine prise the seal out from the cylinder head using a screwdriver being careful not to damage the camshaft Surface or the seal bore 13 Coat the lip and outside diameter of the new seal with multi purpose grease 14 On the M40 engine wrap some adhesive tape around the end of the camshaft to protect the new seal from the location groove as it is being fitted see illustration 15 Carefully locate the new seal in position and press it in by hand initially so that it enters the bore Drive the new seal into the housing or cylinder head as applicable using a hammer and a socket with a diameter slightly smaller than the outside diameter of the seal On the M40 engine remove the adhesive tape from the end of the camshaft 16 On the M20 engine renew the O ring on the back of the seal housing and work the lip of the seal over the end of the camshaft Refit the screws and tighten them securely 17 The remainder of refitting is the reverse of removal Crankshaft and intermediate shaft front seals M20 engines 18 Remove the timing belt and crankshaft and intermediate shaft pulleys as applicable see Section 10 Note We recommend the timing belt be renewed any time it is removed 19 Remove the bolts and nuts securing the front cover to the engine block Be sure to remove the three bolts from underneath t
504. rers eg bumpers spoilers and in some cases major body panels rectification of more serious damage to such items has become a matter of either entrusting repair work to a specialist in this field or renewing complete components Repair of such damage by the DIY owner is not really feasible owing to the cost of the equipment and materials required for effecting such repairs The basic technique involves making a groove along the line of the crack in the plastic using a rotary burr in a power drill The damaged part is then welded Bodywork and fittings 11 3 back together using a hot air gun to heat up and fuse a plastic filler rod into the groove Any excess plastic is then removed and the area rubbed down to a smooth finish It is important that a filler rod of the correct plastic is used as body components can be made of a variety of different types eg polycarbonate ABS polypropylene Damage of a less serious nature abrasions minor cracks etc can be repaired by the DIY owner using a two part epoxy filler repair material Once mixed in equal proportions this is used in similar fashion to the bodywork filler used on metal panels The filler is usually cured in twenty to thirty minutes ready for sanding and painting If the owner is renewing a complete component himself or if he has repaired it with epoxy filler he will be left with the problem of finding a suitable paint for finishing which is compatible with the type
505. resistance of the injector see illustration Check your readings with the values listed in this Chapter s Specifications Renew any that do not give the correct resistance reading Volume test 6 Because a special injection checker is required to test injector volume this procedure is beyond the scope of the home mechanic Have the injector volume test performed by a BMW dealer or other specialist Renewal 7 Unplug the main electrical connector for the fuel injector wiring harness Remove the intake manifold see Chapter 2A 8 Detach the fuel hoses from the fuel rail and remove the fuel rail mounting bolts see illustration 9 Lift the fuel rail injector assembly from the intake manifold 10 Unplug the electrical connectors from the fuel injectors Detach the injectors from the fuel rail 11 Refitting is the reverse of removal Be sure to renew all O rings Coat the O rings with a light film of engine oil to prevent damage during refitting Pressurise the fuel system refit the fuel pump fuse and switch on the ignition and check for leaks before starting the engine 21 Idle air stabiliser valve check adjustment and renewal PT 1 The idle air stabiliser system works to maintain engine idle speed within a 200 rpm range regardless of varying engine loads at idle An electrically operated valve allows a Small amount of air to bypass the throttle plate to raise the idle speed whenever the idle speed drops below
506. rew and lever is 5 0 0 5 mm If necessary loosen the locknut and turn the diaphragm rod as required Tighten the locknut on completion 12 20 If adjustment is necessary turn the screw arrowed on the end of the pulldown unit 4 14 Fuel exhaust systems Throttle positioner 2BE 24 Special tools are required to carry out a comprehensive adjustment on the 2BE carburettor This work should therefore be left to a BMW dealer 13 Fuel injection general information The fuel injection system is composed of three basic sub systems fuel system air intake system and electronic control system Fuel system An electric fuel pump located inside the fuel tank or beside the fuel tank supplies fuel under constant pressure to the fuel rail which distributes fuel evenly to all injectors From the fuel rail fuel is injected into the intake ports just above the intake valves by the fuel injectors The amount of fuel supplied by the injectors is precisely controlled by an Electronic Control Unit ECU An additional injector known as the cold start injector L J etronic and early Motronic systems only supplies extra fuel into the intake manifold for starting A pressure regulator controls system pressure in relation to intake manifold vacuum A fuel filter between the fuel pump and the fuel rail filters the fuel to protect the components of the system Air intake system The air intake system consists of an air fi
507. rews and detach the housing see illustration Refitting 5 Refitting is the reverse of removal 15 Bulb renewal 1 The lenses of many lights are held in place by screws which makes it a simple procedure to gain access to the bulbs 2 On some lights the lenses are held in place by clips The lenses can be removed by using a small screwdriver to prise them off 3 Several bulbs are mounted in self earthing holders and are removed by pushing in and turning them anti clockwise see illustration The bulbs can then be removed see illustrations 4 The tail lights on 3 Series models are accessible after removing the housing then removing the bulbs see illustrations 5 To gain access to the facia lights the instrument cluster will have to be removed first see illustration then pull the bulb from the holder 15 3c Body electrical systems 12 7 light housing assembly is self earthing through the mounting screw loosen the plastic screw and pull the housing back 16 Windscreen tailgate wiper motor removal and refitting Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7
508. rminals of the fuel pump relay 24 Turn the ignition switch on to operate the fuel pump 25 Note the pressure reading on the gauge and compare the reading to the fuel pump pressure listed in this Chapter s Specifica tions 26 the indicated pressure is less than specified inspect the fuel line for leaks between the pump and gauge If no leaks are found renew the fuel pump 27 Turn the ignition off and wait five minutes Note the reading on the gauge and compare it to the fuel pump hold pressure listed in this Chapter s Specifications If the hold pressure is less than specified check the fuel lines between the pump and gauge for leaks If no leaks are found renew the fuel pump 28 Remove the jumper wire Relieve the fuel pressure by opening the bleed valve on the gauge and directing the fuel into a suitable container Remove the gauge and reconnect the fuel line Transfer pump pressure check 29 Depressurise the fuel system see Sec tion 2 30 Detach the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 31 Remove the transfer pump access pl
509. rnator is causing the problem First check the following items a Check the drivebelt tension and condition see Chapter 1 Renew the drivebelt if it s worn or deteriorated b Make sure the alternator mounting and adjustment bolts are tight c Inspect the alternator wiring harness and the connectors at the alternator and voltage regulator They must be in good condition and tight d Check the fuses e Start the engine and check the alternator for abnormal noises a shrieking or squealing sound indicates a worn bearing but could also be due to a Slipping drivebelt see a above Engine electrical systems 5 9 f Check the specific gravity of the battery electrolyte If it s low charge the battery doesn t apply to maintenance free batteries 0 Make sure the battery is fully charged one bad cell in a battery can cause overcharging by the alternator h Disconnect the battery cables negative first then positive Inspect the battery posts and the cable clamps for corrosion Clean them thoroughly if necessary see Chapter 1 Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the langu
510. rom the old control arm or thrust arm and re used in the new arm 4 Loosen the wheel bolts raise the vehicle and support it securely on axle stands Remove the wheel 5 f you re removing the control arm remove the three bolts from the steering arm see illustration and separate the strut assembly from the arm 6 Remove the nut and the through bolt that secure the control arm or thrust arm rear mounting see illustrations 7 Remove the nut from the balljoint see illustration Support the steering arm and separate the balljoint from the steering arm see illustrations Ideally you should use a purpose made balljoint separator tool for this job Using a hammer is OK if you re going to fit new parts anyway but is not recommended if you re planning to re use parts 4 7b You can separate the thrust arm balljoint from the steering arm with a puller 10 6 Suspension steering systems 4 7 but you may have to use hammer to knock the control arm balljoint stud loose from the steering arm because there s no room to use a puller A purpose made balljoint separator tool would be better Bush inspection and renewal 8 If the bush is cracked torn or otherwise deteriorated take the arm to a BMW dealer service department or an engineering works and have it pressed out and a new bush pressed in Bushes should always be renewed in pairs a new bush should be fitted in each arm and both bushes should have
511. rotor Refitting 21 Refitting is the reverse of removal 9 4c resistance between the primary terminals of the coil using an ohmmeter measure the 8 18 Remove three bolts arrowed from the distributor cap 9 Ignition coil check and renewal Caution Do not earth the coil as the coil and or impulse generator could be damaged Note On models equipped with the Motronic system a faulty ECU can cause the ignition coil to become damaged Be sure to test the ignition coil if the engine will not start and an ECU fault is suspected 1 Mark the wires and terminals for position then remove the primary circuit wires and the HT lead from the coil WU 9 4a Using an ohmmeter measure the resistance between the primary terminals of the ignition coil TCI system shown 9 5a Using an ohmmeter measure the secondary resistance of the coil TCI system Engine electrical systems 5 5 8 19 Remove the rotor screws arrowed with an Allen key and pull the rotor off the shaft 2 Remove the coil assembly from its mounting then clean the outer casing and check it for cracks and other damage 3 Inspect the coil primary terminals and the coil tower terminal for corrosion Clean them with a wire brush if any corrosion is found 4 Check the coil primary resistance by attaching ohmmeter to the primary terminals see illustrations Compare the measured resistance to the Specifications listed in this
512. rs both front or both rear discs even if only one is damaged or defective 4 7 Remove the piston seal from the caliper bore using a wooden or plastic tool metal tools may damage the cylinder bore 9 6 Braking system ae 5 2 Remove the caliper mounting bracket bolts arrowed and remove the bracket Inspection 1 Loosen the wheel bolts raise the vehicle and support it securely on axle stands Remove the wheel and refit three bolts to hold the disc in place If the rear brake disc is being worked on release the handbrake 2 Remove the brake caliper as outlined in Section 4 It is not necessary to disconnect the brake hose After removing the caliper Suspend it out of the way with a piece of wire Remove the caliper mounting bracket see illustration 3 Inspect the disc surface for scoring cracks or other damage Light scratches and shallow grooves are normal after use and are not usually detrimental to brake operation but deep scoring requires disc removal and 5 4b Using a swirling motion remove the glaze from the disc surface with sandpaper or emery cloth 5 6a Remove the disc retaining screw 5 3 The brake pads on this vehicle were obviously neglected as the backing plate cut deep grooves into the disc wear this severe means the disc must be renewed renewal or if possible refinishing by a specialist If a disc is cracked it must be renewed Be sure to check both sides of t
513. rt of Section 12 concerning the potential dangers associated with the air conditioning System 2 Antifreeze general information Warning Do not allow antifreeze to come in contact with your skin or painted surfaces of the vehicle Rinse off spills immediately with plenty of water If consumed antifreeze can be fatal children and pets are attracted by its sweet taste so wipe up garage floor and drip pan coolant spills immediately Keep antifreeze containers covered and repair leaks in your cooling system as soon as they are noticed The cooling system should be filled with a 60 40 water ethylene glycol based anti freeze solution which will prevent freezing down to approximately 27 C 17 F The antifreeze also raises the boiling point of the coolant and if of good quality provides protection against corrosion The cooling system should be drained flushed and refilled at the specified intervals see Chapter 1 Old or contaminated antifreeze solutions are likely to cause damage and encourage the formation of rust and scale in the system Use distilled water with the antifreeze if available or clean rainwater Tap water will do but not if the water in your area is at all hard Before adding antifreeze check all hose connections because antifreeze tends to search out and leak through very minute openings Engines don t normally consume coolant so if the level goes down find the cause and correc
514. rushes are retained either by set screws or by solder If you are not skilled at soldering it may be best to have an auto electrician fit the new brushes Note Be careful not to apply heat to the solder joint for more than 5 seconds If necessary use a heat sink to capture the excess heat This can be accomplished by clamping a pair of needle nose pliers next to the solder joint 6 On the screw type hold the assembly in place and refit the screws Tighten them evenly a little at a time so the holder isn t distorted 7 Refit the alternator regulator assembly to the Engine electrical systems 5 11 Brust eri ata 17 3 Check the brush length in the normal rest position spring uncoiled 8 Reconnect the battery negative cable Motorola alternator 9 Remove the alternator 10 The brushes are mounted under the regulator on the rear of the alternator see illustration 16 7 11 Remove the mounting screws and insulating washers and separate the voltage regulator and brush holder from the brush end housing 12 Measure the length of the brushes see illustration 17 3 If any brush is less then 6 0 mm long renew them all as a set 13 Make sure the brushes move smoothly in the holder 14 Refit the brush holder regulator Tighten the screws securely Make sure the brushes aren t earthed 15 Refitting is the reverse of removal 18 Starting system general information and precautions The sole function of the star
515. rvicing Maintenance schedule The following maintenance intervals are based on the assumption that the vehicle owner will be doing the maintenance or service work as opposed to having a dealer service department do the work Although the time mileage intervals are loosely based on factory rec ommendations most have been shortened to ensure for example that such items as lubricants and fluids are checked changed at intervals that promote maximum engine driveline service life Also subject to the preference of the individual owner interested in keeping his or her vehicle in peak condition at all times and with the vehicle s ultimate resale in mind many of the maintenance procedures may be performed more often than recommended in the following schedule We encourage such owner initiative When the vehicle is new it should be serviced initially by a factory authorised dealer service department to protect the factory warranty In many cases the initial maintenance check is done at no cost to the owner check with your dealer service department for more information Every 250 miles or weekly whichever comes first Check the engine oil level Section 4 Check the engine coolant level Section 4 Check the brake fluid level Section 4 Check the clutch fluid level Section 4 Check the washer fluid level Section 4 Check the tyres and tyre pressures Section 5 Every 6000 miles or
516. s Measure the deflection with a ruler see illustration A good rule of thumb is that the belt should deflect 6 mm if the distance from pulley centre to pulley centre is between 180 and 280 mm The belt should deflect 13 mm if the distance from pulley centre to pulley centre is between 300 and 400 mm Adjustment 5 f it is necessary to adjust the belt tension either to make the belt tighter or looser it is done by moving a belt driven accessory on its bracket When the same belt drives more than one accessory normally only one accessory is moved when making adjustment 6 For each component there will be an adjusting bolt and a pivot bolt Both bolts must be loosened slightly to enable you to move the component On some components the drivebelt tension can be adjusted by turning an adjusting bolt after loosening the lockbolt see illustration 7 After the two bolts have been loosened 11 6 Loosen the nut on the other end of the adjuster bolt arrowed and turn the bolt to increase or decrease tension on the drivebelt 12 3 Idle speed adjustment screw on the 2B4 carburettor shown with the carburettor removed move the component away from the engine to tighten the belt or towards the engine to loosen the belt Hold the accessory in position and check the belt tension If it is correct tighten the two bolts until just tight then recheck the tension If the tension is still correct tighten the bolts 8 It wil
517. s Remove the Pitman arm pinch bolt and nut then remove the arm with a puller 7 To unbolt the idler arm first remove the small cover bolted to the top of the subframe crossmember Put a spanner on the bolt and remove the nut recessed into the underside of the subframe crossmember see illustration Check the idler arm rubber bush for wear If it s damaged or worn renew it 8 Check each balljoint for excessive play or stiffness and for split or deteriorated rubber dust boots Renew all worn or damaged balljoints The inner and outer track rod ends on the outer track rods can be renewed individually if either balljoint on the centre track rod is damaged or worn you must renew the centre track rod Refitting 9 Refitting is the reverse of the removal procedure but observe the following points a Realign the match marks on the Pitman arm and the steering box sector shaft when reassembling them b If you re fitting new inner or outer track rod ends on the outer track rods position them so that the match marks made during dismantling are aligned and make sure they are equally spaced on each side C Position the track rod end balljoint studs on the outer track rods at an angle of 90 to each other d Make sure the left and right outer track rods are equal in length when they are fitted e Tighten all retaining bolts to the torque values listed in this Chapter s Specifi cations f When reassembly of the linkage is
518. s Section 27 Every 24 000 miles or 2 years whichever comes first All items listed above plus Change the automatic transmission fluid and filter Section 28 Drain flush and refill the cooling system Section 29 Renew the spark plugs Section 14 Check renew the spark plug HT leads Section 15 Renew the fuel filter Section 30 Change the manual transmission lubricant Section 31 Change the differential oil Section 32 Check the evaporative emissions system where applicable Section 33 Reset the service indicator lights Section 34 Renew brake fluid by bleeding see Chapter 9 Check the handbrake operation see Chapter 9 Every 60 000 miles Renew the timing belt Section 35 Maintenance and Servicing 1 5 Underbonnet view left hand side of a UK model 318i 1988 Radiator Intake manifold Idle control valve Accelerator cable Diagnostic service indicator resetting socket Fuse relay box Brake hydraulic fluid reservoir Airflow meter Air cleaner unit Radiator filler cap Radiator top hose Oil filter housing Underbonnet view right hand side of a UK model 318i 1988 1 Oil filler cap 2 Valve cover 3 Engine oil filler dipstick 4 Viscous cooling fan 5 Distributor cap cover 6 Bottom hose 7 Windscreen washer fluid reservoir 8 Ignition coil 9 Clutch hydraulic fluid reservoir 0 10 Battery 16 Maintenance and Servicing Front underbody view of a UK model 318i 1988 1 Radiat
519. s Before attempting to locate or define a problem with electrical test Difficult suitable for experienced DIY x Very difficult suitable for expert gt DIY or professional instruments use the wiring diagrams to decide where to make the necessary connections Voltage checks Perform a voltage check first when a circuit is not functioning properly Connect one lead of a circuit tester to either the negative battery terminal or a Known good earth Connect the other lead to a connector in the circuit being tested preferably nearest to the battery or fuse If the bulb of the tester lights up voltage is present which means that the part of the circuit between the connector and the battery is problem free Continue checking the rest of the circuit in the same fashion When you reach a point at which no voltage is present the problem lies between that point and the last test point with voltage Most of the time problems can be traced to a loose connection Note Keep in mind that some circuits receive voltage only when the ignition key is turned to a certain position Electrical fault diagnosis is simple if you keep in mind that all electrical circuits are basically electricity running from the battery through the wires switches relays fuses and fusible links to each electrical component light bulb motor etc and then to earth from where it is passed back to the battery Any electrical problem is an interruption i
520. s so it loosens by being turned clockwise as viewed from the front of the vehicle 28 Lift the fan clutch assembly and shroud if necessary out of the engine compartment 29 f necessary remove the four bolts attaching the pulley to the water pump hub The pulley can then be removed after removing the drivebelt s See illustration Cooling heating and air conditioning systems 3 5 yp m 5 27b to loosen the nut place a 32 mm open ended spanner on the nut and sharply strike the spanner A with a metal drift B and hammer this will loosen the nut and allow it to be turned easily so the fan can be removed 30 Carefully inspect the fan blades for damage and defects Renew it if necessary 31 At this point the fan may be unbolted from the clutch if necessary If the fan clutch is stored position it with the radiator side facing down 32 Refitting is the reverse of removal 6 Water pump check 1 A failure in the water pump can cause serious engine damage due to overheating 2 There are two ways to check the operation of the water pump while it s fitted on the engine If either of the following checks Suggest that the pump is defective a new one Should be fitted 3 Water pumps are equipped with weep or vent holes If a failure occurs in the pump seal coolant will leak from the hole In most cases you ll need a torch to find the hole on the water pump from underneath to chec
521. s so keep lighted tobacco and all other flames and sparks away from it The electrolyte inside the battery is actually dilute sulphuric acid which will cause injury if splashed on your skin or in your 13 1 Tools and materials required for battery maintenance I Face shield safety goggles When removing corrosion with a brush the acidic particles can easily fly up into your eyes 2 Baking soda A solution of baking soda and water can be used to neutralise corrosion 3 Petroleum jelly A layer of this on the battery posts will help prevent corrosion 4 Battery post cable cleaner This wire brush cleaning tool will remove all traces of corrosion from the battery posts and cable clamps 5 Treated felt washers Placing one of these on each post directly under the cable clamps will help prevent corrosion 6 Puller Sometimes the cable clamps are very difficult to pull off the posts even after the nut bolt has been completely loosened This tool pulls the clamp straight up and off the post without damage 7 Battery post cable cleaner Here is another cleaning tool which is a slightly different version of No 4 above but it does the same thing 8 Rubber gloves Another safety item to consider when servicing the battery remember that s acid inside the battery eyes It will also ruin clothes and painted surfaces When disconnecting the battery cables always detach the negative cable first and connect it last 1
522. s won t be necessary Normal piston wear appears as even vertical wear on the piston thrust surfaces 90 to the gudgeon pin bore and slight looseness of the top ring in its groove New piston rings however should always be used when an engine is rebuilt 7 Carefully inspect each piston for cracks around the skirt at the pin bosses and at the ring lands 8 Look for scoring and scuffing on the thrust faces of the skirt holes in the piston crown and burned areas at the edge of the crown If the skirt is scored or scuffed the engine may have been suffering from overheating and or abnormal combustion which caused excessively high operating temperatures The cooling and lubrication systems should be checked thoroughly A hole in the piston crown is an indication that abnormal combustion pre ignition was occurring Burned areas at the edge of the piston crown are usually evidence of spark knock detonation If any of the above 18 10 Check the ring side clearance with a feeler gauge at several points around the groove problems exist the causes must be corrected or the damage will occur again The causes may include intake air leaks incorrect fuel air mixture or incorrect ignition timing On later vehicles with high levels of exhaust emission control including catalytic converters the problem may be with the EGR exhaust gas recirculation system where applicable 9 Corrosion of the piston in the form of small pits i
523. s any free play renew the control arm the balljoints can t be renewed separately 3 Inspect the rubber bush If it s cracked dry torn or otherwise deteriorated renew it see below Bush renewal Note Rubber bushes should always be renewed in pairs Make sure both new bushes have the same markings indicating they re manufactured by the same firm 4 Remove the two bolts see illustration which attach the bush bracket to the underbody 5 Using a puller remove the bracket and 3 12 Remove the self locking nut from the balljoint stud protruding through the top of the subframe not shown in this photo but it s directly above the balljoint and separate the balljoint from the subframe Try not to damage the dust boot 2 4 Remove the bolts arrowed from the anti roll bar brackets to detach the anti roll bar from the subframe 3 Series model shown 5 series similar bush from the end of the control arm If the puller slips on the end of the control arm centre punch the control arm to give the puller bolt a place to seat 6 Note the orientation of the old bush This is exactly how the new bush should be orientated when it s fitted Press the old rubber bush out of the bracket or have it pressed out by an engineering works 7 Coat the end of the control arm with BMW s Special lubricant Part No 81 22 9 407 284 and press the new bush and bracket onto the arm or have it pressed on at an engineering works
524. s closes as the engine approaches full throttle Both sets of contacts are open no continuity between these positions A broken or loose TPS can cause intermittent bursts of fuel from the injector and an unstable idle because the ECU thinks the throttle is moving 27 All models except for early 535i models with automatic transmission combine the idle and full throttle switch a separate idle position switch indicates the closed throttle position while the TPS is used for the full throttle position On 535i models with automatic transmission the TPS is connected directly to the automatic transmission control unit With the throttle fully open the transmission control unit sends the full throttle signal to the Motronic control unit All models except early 535i with automatic transmission Check 28 Remove the electrical connector from the TPS and connect an ohmmeter to terminals 2 and 18 see illustrations Open the throttle 4 28b First check for continuity between terminals 2 and 18 with the throttle closed later Motronic system shown 6 4 Engine management and emission control systems 4 28 between terminals 3 and 18 as the throttle is opened slightly by hand Release the throttle slowly until it reaches 0 2 to 0 6 mm from the throttle stop There should be continuity 29 Check the resistance between terminals 3 and 18 as the throttle is opened There should be continuity when the throttle switch is wit
525. s gradually until they can be removed Again penetrating oil may prove helpful 7 Pull the manifold off the head then remove the old gaskets see illustrations Note Be very careful not to damage the oxygen sensor where fitted 6 7a Removing the exhaust manifold M40 engine 6 5a Remove the exhaust manifold nuts arrowed from the exhaust pipe M20 engine soaking the nuts with penetrating oil should make them easier to remove 8 Clean the gasket mating surfaces of the head and manifold and make sure the threads on the exhaust manifold studs are in good condition 9 Check for corrosion warping cracks and other damage Repair or renew the manifold as necessary 10 When refitting the manifold use new gaskets Tighten the manifold to head retaining nuts gradually starting at the centre and working out to the ends to the torque listed in this Chapter s Specifications Also tighten the downpipe to manifold nuts 11 The remaining steps are simply a reversal of the removal procedure 7 Timing chain covers removal and refitting Note 1 This procedure applies to M10 30 engines Note 2 The upper timing chain cover can be removed separately If you need to remove both the upper and lower covers special tools are required Read paragraphs 8 and 9 before beginning work Removal 1 Disconnect the battery negative cable 6 7b Removing the exhaust manifold gasket M40 engine 6 5b Exhaust
526. s original shape There is little point in trying to restore the original shape completely as the metal in the damaged area will have stretched on impact and cannot be reshaped fully to its original contour It is better to bring the level of the dent up to a point which is about 3 mm below the level of the surrounding bodywork In cases where the dent is very shallow anyway it is not worth trying to pull it out at all If the underside of the dent is accessible it can be hammered out gently from behind using a mallet with a wooden or plastic head Whilst doing this hold a suitable block of wood firmly against the outside of the panel to absorb the impact from the hammer blows and thus prevent a large area of the bodywork from being belled out Should the dent be in a section of the bodywork which has a double skin or some other factor making it inaccessible from behind a different technique is called for Drill several small holes through the metal inside the area particularly in the deeper section Then screw long self tapping screws into the holes just sufficiently for them to gain a good purchase in the metal Now the dent can be pulled out by pulling on the protruding heads of the screws with a pair of pliers The next stage of the repair is the removal of the paint from the damaged area and from an inch or so of the surrounding sound bodywork This is accomplished most easily by using a wire brush or abrasive pad on
527. s the reverse of removal Use thread locking compound on the mounting bolts nuts and be sure to tighten them securely This is a guide to getting your vehicle through the test Obviously it will not be possible to examine the vehicle to the same Standard as the professional MOT tester However working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test Where a testable component is in borderline condition the tester has discretion in deciding whether to pass or fail it The basis of such discretion is whether the tester would be happy for a close relative or friend to use the vehicle with the component in that condition If the vehicle presented is clean and evidently well cared for the tester may be more inclined to pass a borderline component than if the vehicle is scruffy and apparently neglected It has only been possible to summarise the test requirements here based on the regulations in force at the time of printing Test standards are becoming increasingly stringent although there are some exemptions for older vehicles For full details obtain a copy of the Haynes publication Pass the MOT available from stockists of Haynes manuals MOT Test Checks REF 1 An assistant will be needed to help carry out some of these checks The checks have been sub divided into four categories as follows 1 Checks carried out FROM THE DRIVER S SEAT 1 Checks carr
528. s to cooling system components Hose clamps can pinch and puncture hoses resulting in coolant leaks 5 Make sure all hose connections are tight A leak in the cooling system will usually show up as white or rust coloured deposits on the area adjoining the leak If wire type clamps are used on the hoses it may be a good idea to replace them with screw type clamps 6 Clean the front of the radiator and where applicable the air conditioning condenser with compressed air if available or a soft brush Remove all flies leaves etc embedded in the radiator fins Be extremely careful not to damage the cooling fins or to cut your fingers on them 7 f the coolant level has been dropping consistently and no leaks are detected have the radiator cap and cooling system pressure tested 23 Exhaust system check 1 The engine should be cold for this check so perform the following procedure before the vehicle is driven for the day or after it has been switched off for at least three hours Check the complete exhaust system from the engine to the end of the tailpipe Ideally the inspection should be done with the vehicle on a hoist to give unrestricted access If a hoist isn t available raise the vehicle and support it securely on axle stands or ramps 2 Check the exhaust pipes and connections for evidence of leaks severe corrosion and damage Make sure that all brackets and mountings are in good condition and that they are
529. s to the alternator and note the following a When reconnecting wires to the alternator from the battery be sure to note the polarity b Before using arc welding equipment to repair any part of the vehicle disconnect the wires from the battery terminals and from the alternator Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure C Never start the engine with a battery charger connected Always disconnect both battery cables before using a battery charger d Never disconnect cables from the battery or from the alternator while the engine is running e The alternator is turned by an engine drivebelt Serious injury could result if your hands hair or clothes become entangled in the belt with the engine running f Because the alternator is connected directly to the battery take care not to short out the main terminal to earth g Wrap a plastic bag over the alternator and secure it with rubber bands before steam cleaning the engine 14 Charging system check BN x lf a malfunction occurs in the charging circuit don t automatically assume that the alte
530. se Deposits on the undersides of the valve heads can also cause low compression Record the highest gauge reading obtained 8 Repeat the procedure for the remaining cylinders and compare the results to the compression listed in this Chapter s Specifi cations 9 f compression was low add some engine oil about three squirts from a plunger type oil can to each cylinder through the spark plug hole and repeat the test 10 If the compression increases after the oil is added the piston rings are definitely worn If the compression doesn t increase General engine overhaul procedures 2 5 significantly the leakage is occurring at the valves or head gasket Leakage past the valves may be caused by burned valve seats and or faces or warped cracked or bent valves 11 If two adjacent cylinders have equally low compression there s a strong possibility that the head gasket between them is blown The appearance of coolant in the combustion chambers or the crankcase would verify this condition 12 If one cylinder is 20 percent lower than the others and the engine has a slightly rough idle a worn exhaust lobe on the camshaft could be the cause 13 If the compression is unusually high the combustion chambers are probably coated with carbon deposits If that s the case the cylinder head should be removed and decarbonised 14 If compression is way down or varies greatly between cylinders it would be a good idea to have a leak
531. se of removal Note Before refitting the regulator check the condition of the slip rings see illustration Use a torch and check for any scoring or deep wear grooves Renew the alternator if necessary Motorola alternator 6 Remove the alternator from the engine compartment see Section 15 7 Remove the rear cover and diode carrier remove the voltage regulator mounting screws see illustration and lift the regulator off the alternator body 8 Refitting is the reverse of removal 17 Alternator brushes check and renewal Whi Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery 16 5 Use a torch to check the slip rings for scoring or deep grooves 16 7 Exploded view of the Motorola alternator Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable Bosch alternator 2 Remove the voltage regulator from the back of the alternator see Section 16 3 Measure the length of the brushes see illustration They should not be less than 6 0 mm If any are worn past this point renew them all as a set 4 Also check for excessively worn slip rings see illustration 16 5 5 The b
532. seal then pull it off If the hoses are deteriorated cut them off and refit new ones 6 Remove the fan and clutch assembly and the pulley at the end of the water pump shaft see Section 5 7 To remove the water pump follow the Specific steps that apply to your engine M10 engine 8 Unscrew the mounting bolts and remove the water pump see illustration see locations arrowed that hold the water pump to the block 3 6 Cooling heating and air conditioning systems 7 12 Water bolt locations on the M20 engine M20 engine 9 Remove the distributor cap and HT leads ignition rotor and dust shield see Chapter 1 10 Where applicable remove the timing sensor see Chapter 5 11 Remove the timing belt upper cover see Chapter 2A 12 Loosen all three water pump mounting bolts Remove the top and right hand side bolts but DON T remove the lower bolt see illustration 13 Rotate the pump downwards and remove the drivebelt tensioner spring and pin 14 Remove the final water pump bolt and remove the pump Caution Leave the tensioner bolt tight Be careful to not move the camshaft gear as damage can occur if the valves are moved M30 engine 15 Remove the engine lifting bracket 16 Remove the bolts that mount the water pump to the engine block 17 Remove the water pump and recover the gasket M4O engine 18 Unscrew the mounting bolts and remove the water pump If the pump is tight in the cylin
533. separate front and rear subframe assemblies Certain components are particularly vulnerable to accident damage and can be unbolted and repaired or renewed Among these parts are the body mouldings bumpers bonnet doors tailgate and all glass Only general body maintenance procedures and body panel repair procedures within the scope of the do it yourselfer are included in this Chapter 2 Bodywork and underframe maintenance The general condition of a vehicle s bodywork is the one thing that significantly affects its value Maintenance is easy but needs to be regular Neglect particularly after minor damage can lead quickly to further deterioration and costly repair bills It is important also to keep watch on those parts of the vehicle not immediately visible for instance the underside inside all the wheel Fairly easy suitable for beginner with some experience Fairly difficult ENS N suitable for competent X X DIY mechanic X arches and the lower part of the engine compartment The basic maintenance routine for the bodywork is washing preferably with a lot of water from a hose This will remove all the loose solids which may have stuck to the vehicle It is important to flush these off in such a way as to prevent grit from scratching the finish The wheel arches and underframe need washing in the same way to remove any accumulated mud which will retain moisture and tend to encourage rust Paradoxi
534. shafts for scoring excessive wear and other damage The areas where the 9 18 Look for signs of pitting discoloration or excessive wear on the ends of the rocker arms where they contact the camshaft and the valve stem tip General engine overhaul procedures 2B 11 rocker arms contact the shafts should be smooth If there is a visible ridge at the edge of where the rocker arm rides the shaft is probably worn excessively Cam followers and hydraulic tappets M40 engines 21 Check the cam followers where they contact the valve stems and pivot posts for wear scoring and pitting If there is excessive wear on both the followers and camshaft then a new camshaft complete with cam followers must be obtained 22 Similarly check the hydraulic tappets where they contact the bores in the cylinder head for wear scoring and pitting Occasionally a hydraulic tappet may be noisy and require renewal and this will have been noticed when the engine was running It is not easy to check a tappet for internal damage or wear once it has been removed if there is any doubt a complete set of new tappets should be fitted Camshaft 23 Inspect the camshaft journals the round bearing areas and lobes for scoring pitting flaking and excessive wear Using micrometer measure the height of each exhaust and intake lobe Compare the heights of all the exhaust lobes and intake lobes If the readings among the exhaust valve lobes or intake valve l
535. slightly smaller in diameter than the outside diameter of the seal 25 Apply a film of RTV type gasket sealant to the surface of the sump gasket that mates with the front cover Apply extra beads of RTV sealant to the edges where the gasket meets the engine block Note If the sump gasket is damaged instead of fitting a whole new gasket you might try trimming the front portion of the gasket off at the point where it meets the engine block then trim off the front portion of a new sump gasket so it s exactly the same size Cover the exposed inside area of the sump with a rag then clean all traces of old gasket material off the area where the gasket was removed Attach the new gasket piece to the sump with contact cement type gasket adhesive then apply RTV type sealant as described at the beginning of this paragraph 26 Coat both sides of the new gasket with RTV type gasket sealant then attach the front cover to the front of the engine carefully working the seals over the crankshaft and intermediate shaft Refit the bolts and tighten them evenly to the torque listed in this Chapter s Specifications Work from bolt to bolt in a criss cross pattern to be sure they re tightened evenly Note 1 Tighten the front cover to block bolts first then tighten the sump to cover bolts Note 2 After applying RTV type sealant reassembly must be completed in about 10 minutes so the RTV won t prematurely harden 27 The remainder of refitting is the
536. speed the drying process and to blow out all the oil holes and galleries Warning Wear eye protection when using compressed air 7 If the block isn t extremely dirty or sludged up you can do an adequate cleaning job with hot soapy water and a stiff brush Take plenty of time and do a thorough job Regardless of the cleaning method used be sure to clean all oil holes and galleries very thoroughly dry the block completely and coat all machined surfaces with light oil 8 The threaded holes in the block must be clean to ensure accurate torque readings P 15 8 All bolt holes in the block particularly the main bearing cap and head bolt holes should be cleaned and restored with a tap be sure to remove debris from the holes after this is done 13 6 Remove the crankshaft by lifting straight up Be very careful when removing the crankshaft it is very heavy during reassembly Run the proper size tap into each of the holes to remove rust corrosion thread sealant or sludge and to restore damaged threads see illustration If possible use compressed air to clear the holes of debris produced by this operation Be sure also that the holes are dry any oil or other fluid present could cause the block to be cracked by hydraulic pressure when the bolts are tightened Now is a good time to clean the threads on all bolts Note that BMW recommend that the cylinder head bolts and main bearing bolts are renewed as
537. ssion control system contains activated charcoal granules to trap vapours from the fuel system Canister Carburettor A device which mixes fuel with air in the proper proportions to provide a desired power output from a spark ignition internal combustion engine Carburettor Castellated Resembling the parapets along the top of a castle wall For example a castellated balljoint stud nut Castellated nut Castor In wheel alignment the backward or forward tilt of the steering axis Castor is positive when the steering axis is inclined rearward at the top Glossary of Technical Terms ar 2i Catalytic converter A silencer like device in the exhaust system which converts certain pollutants in the exhaust gases into less harmful substances Catalytic converter Circlip A ring shaped clip used to prevent endwise movement of cylindrical parts and shafts An internal circlip is installed in a groove in a housing an external circlip fits into a groove on the outside of a cylindrical piece such as a shaft Clearance The amount of space between two parts For example between a piston and a cylinder between a bearing and a journal etc Coil spring A spiral of elastic steel found in various sizes throughout a vehicle for example as a springing medium in the suspension and in the valve train Compression Reduction in volume and increase in pressure and temperature of a gas caused by squeezing it into a smaller sp
538. ssure see Section 3 Inspect fuel lines and fuel injectors for leaks Correct leaks as necessary Test coolant temperature sensor see Chapter 6 Section 4 Check fuel pressure see Section 3 Check EVAP system see Chapter 6 Section 6 Have the ECU tested at a dealer service department or other specialist Test the idle air stabiliser valve see Section 21 Check the oxygen sensor see Chapter 6 Section 4 Corrective action Test fuel injectors Check for clogged injector lines Renew faulty injectors see Section 20 Test fuel system pressure see Section 3 Test fuel pressure regulator see Section 18 Inspect fuel lines and fuel injectors for leaks see Chapter 4 Tune up engine see Chapter 1 Check the distributor cap rotor HT leads and spark plugs and renew any faulty components Inspect the airflow meter for damage see Section 16 Inspect all vacuum lines air ducts and oil filler and dipstick seals Check TPS adjustment see Chapter 6 Corrective action Check for worn or broken components kinked cable or other damage Renew faulty components Inspect throttle valve and adjust or renew as required Corrective action Check the idle air stabiliser valve see Section 21 Check the idle air stabiliser relay and wiring circuit see Chapter 12 Have the idle speed control unit checked by a dealer Corrective action Test and if necessary renew cold start injector see Section 19 Test the oxygen sensor see Chapter
539. stribute the grinding compound see illustration 10 5 Grinding in a valve do not grind in the valves any more than absolutely necessary or their seats will be prematurely sunk into the cylinder head 2B 2B 12 General engine overhaul procedures 11 4a Lubricate the valve guide seal and place it on the guide the valve should be in place too light spring placed under the valve head will greatly ease the valve grinding operation 6 If coarse grinding compound is being used work only until a dull matt even surface is produced on both the valve seat and the valve then wipe off the used compound and repeat the process with fine compound When a smooth unbroken ring of light grey matt finish is produced on both the valve and seat the grinding operation is complete Do not grind in the valves any further than absolutely necessary 7 When all the valves have been ground in carefully wash off all traces of grinding compound using paraffin or a suitable solvent before reassembly of the cylinder head 11 Cylinder head reassembly 1 Make sure the cylinder head is spotlessly clean before beginning reassembly 2 f the head was sent out for valve servicing the valves and related components will already be in place Begin the reassembly procedure with paragraph 8 3 Starting at one end of the head apply 11 9 Lubricate the camshaft bearing journals and lobes with engine assembly
540. stributor the primary low voltage low tension or secondary high voltage high tension or HT wiring circuits the spark plugs and the spark plug leads Models fitted with a carburettor or L J etronic fuel injection are equipped with Transistorised Coil Ignition TCI system Models fitted with the Motronic fuel injection system have the ignition system incorporated within the Motronic system Digital Motor Electronics or DME Transistorised Coil Ignition TCI system This system is has four major components the impulse generator the ignition control unit the coil and the spark plugs The impulse generator provides a timing signal for the ignition system Equivalent to cam actuated breaker points in a standard distributor the impulse generator creates an A C voltage signal every time the trigger wheel tabs pass the impulse generator tabs When the ignition control unit capacitive discharge unit receives the voltage signal it triggers a spark discharge from the coil by interrupting the primary coil circuit The ignition dwell coil charging time is adjusted by the ignition control unit for the most intense spark Note The air gap distance between the impulse generator and trigger wheel tabs can be adjusted see Section 11 Ignition timing is mechanically adjusted see Section 7 A centrifugal advance unit that consists of spring loaded rotating weights advances ignition timing as engine speed increases T
541. sult of misaligned oil holes in a bearing shell will also oil starve a bearing and destroy it When lack of lubrication is the cause of bearing failure the bearing material is wiped or extruded from the steel backing of the bearing Temperatures may increase to the point where the steel backing turns blue from overheating 6 Driving habits can have a definite effect on bearing life Full throttle low speed operation labouring the engine puts very high loads on 22 3 When checking piston ring end gap the ring must be square in the cylinder bore this is done by pushing the ring down with the top of a piston as shown bearings which tends to squeeze out the oil film These loads cause the bearings to flex which produces fine cracks in the bearing face fatigue failure Eventually the bearing material will loosen in places and tear away from the steel backing Short trip driving leads to corrosion of bearings because insufficient engine heat is produced to drive off the condensation and corrosive gases These products collect in the engine oil forming acid and sludge As the oil is carried to the engine bearings the acid attacks and corrodes the bearing material 7 Incorrect bearing refitting during engine assembly will lead to bearing failure as well Tight fitting bearings leave insufficient bearing oil clearance and will result in oil starvation Dirt or foreign particles trapped behind a bearing shell result in hig
542. surised coolant recovery system On most models a white plastic expansion tank or coolant reservoir located in the engine compartment is connected by a hose to the radiator As the engine heats up during operation the expanding coolant fills the tank As the engine cools the coolant is automatically drawn back into the cooling system to maintain the correct level 9 The coolant level in the reservoir see illustrations should be checked regularly Add a 4096 6096 mixture of ethylene glycol based antifreeze to water see illustration Warning Do not remove the expansion tank cap or radiator cap to check the coolant level unless the engine is completely cold The level in the reservoir varies with the temperature of the engine When the engine is cold the coolant level should be im 4 9 Onsome 5 Series models the expansion tank coolant reservoir is located on the bulkhead 4 On some models the expansion tank coolant reservoir is mounted on the radiator make sure the level is kept at or near the FULL mark arrowed above the LOW mark on the reservoir Once the engine has warmed up the level should be at or near the FULL mark If it isn t allow the engine to cool then remove the cap from the reservoir 10 Drive the vehicle and recheck the coolant level If only a small amount of coolant is required to bring the system up to the proper level plain water can be used However repeated additions
543. t around the intake and exhaust ports near the spark plug areas and in close proximity to the exhaust valve guides A wax pellet type thermostat is located in line in the bottom hose on M10 engines in a housing near the front of the engine on M20 and M30 engines or behind an elbow under the timing belt upper cover on the front of the cylinder head on M40 engines During warm up the closed thermostat prevents coolant from circulating through the radiator As the engine nears normal operating temperature the thermostat opens and allows hot coolant to travel through the radiator where it s cooled before returning to the engine The pressure in the system raises the boiling point of the coolant and increases the cooling efficiency of the radiator The cooling system is sealed by a pressure type cap If the system pressure exceeds the cap pressure relief value the excess pressure in the system forces the spring loaded valve inside the cap off its seat and allows the coolant to escape through the overflow tube The pressure cap on four cylinder models is on the top of the radiator on six cylinder models it s on top of a translucent plastic expansion tank The cap pressure rating is moulded into the top of the cap The pressure rating is either 1 0 bar 14 psi or 1 2 bars 17 psi 3 2 Cooling heating and air conditioning systems Warning Do not remove the pressure cap from the radiator or expansion tank until the engin
544. t yg ug t H9 18 tc Aa TE ug c dg L H 22036 24 23 22 12 Typical electric window system wiring diagram 12 24 Wiring diagrams T g EES Meo T A 89 ug u9 1 Alt9 I A u9 o re g E 21371 de MeO GR BR GR e m Y AD 5 wih o BAON BON H Mua Mc an BR W Mad 3 WO EE a Ug 07 E 8 25 x E e oe o Cx I qe NN EN H ee E t 9 uo E sEI MW u y sH ua Jp Si d ifie 5 ug e ug 2 7 Lak ee qp 5 E Mage uo9 ud smn E 14 311 s REN ug 5 Xus apyg Typical heating and air conditioning system wiring diagram o a COs Key to air conditioning system wiring diagram Description Light for heater controls Light diode lil Light diode II Light diode Switch heater evaporator blower Plug heater control wire harness to centre wire harness 13 pin Plug front wire harness section to heater controls Fuse heater blower Fuse extra fan stage 1 Fuse ind lamp reversing lights tachometer and mirrors power distributor Temperature switch 91 C stage Temperature switch 99 C stage Il Switch air conditioner Water valve Evaporator
545. t 5 Using a scraper remove all traces of old gasket material from the sealing surfaces of the retainer and engine block Gasket removal solvents are available at car accessory shops and may prove helpful After all gasket material has been removed the gasket Surfaces can be degreased by wiping them with a rag dampened with a suitable solvent Caution Be very careful not to scratch or gouge the delicate aluminium surfaces Also do not damage the sump gasket and keep it clean 6 Support the retainer on two blocks of wood and drive out the seal from behind with a hammer and screwdriver see illustration In car engine repair procedures 2 19 16 2 Remove the six bolts from the rear of the block and the two from underneath at the sump Be very careful not to damage the seal bore in the process 7 Coat the outside diameter and lip of the new seal with multi purpose grease and drive the seal into the retainer with a hammer and a block of wood see illustration 8 Apply a film of RTV type gasket sealant to the surface of the sump gasket that mates with the seal retainer Apply extra beads of RTV Sealant to the edges where the gasket meets the engine block Note If the sump gasket is damaged instead of fitting a whole new gasket you might try trimming the rear portion of the gasket off at the point where it meets the engine block then trim off the rear portion of a new sump gasket so it s exactly the same size Cover the
546. t Also called a Lambda sensor P Phillips screw A type of screw head having a cross instead of a slot for a corresponding type of screwdriver Plastigage thin strip of plastic thread available in different sizes used for measuring clearances For example a strip of Plastigage is laid across a bearing journal The parts are assembled and dismantled the width of the crushed strip indicates the clearance between journal and bearing Plastigage Propeller shaft The long hollow tube with universal joints at both ends that carries power from the transmission to the differential on front engined rear wheel drive vehicles Proportioning valve hydraulic control valve which limits the amount of pressure to the rear brakes during panic stops to prevent wheel lock up R Rack and pinion steering A steering system with a pinion gear on the end of the steering shaft that mates with a rack think of a geared wheel opened up and laid flat When the steering wheel is turned the pinion turns moving the rack to the left or right This movement is transmitted through the track rods to the steering arms at the wheels Radiator liquid to air heat transfer device designed to reduce the temperature of the coolant in an internal combustion engine cooling system Refrigerant Any substance used as a heat transfer agent in an air conditioning system R 12 has been the principle refrigerant for many years recently however manufactur
547. t the distance that the crankshaft can move forward and back in the cylinder block Engine management system EMS A computer controlled system which manages the fuel injection and the ignition systems in an integrated fashion Exhaust manifold part with several passages through which exhaust gases leave the engine combustion chambers and enter the exhaust pipe Exhaust manifold Fan clutch A viscous fluid drive coupling device which permits variable engine fan Speeds in relation to engine speeds Feeler blade A thin strip or blade of hardened Steel ground to an exact thickness used to check or measure clearances between parts Feeler blade Firing order The order in which the engine cylinders fire or deliver their power strokes beginning with the number one cylinder Flywheel A heavy spinning wheel in which energy is absorbed and stored by means of momentum On cars the flywheel is attached to the crankshaft to smooth out firing impulses Free play The amount of travel before any action takes place The looseness in a linkage or an assembly of parts between the initial application of force actual movement For example the distance the brake pedal moves before the pistons in the master cylinder are actuated Fuse An electrical device which protects a circuit against accidental overload The typical fuse contains a soft piece of metal which is calibrated to melt at a predetermined current
548. t which removes dust and dirt from the air being drawn into the engine Air filter element The actual filter in an air Cleaner system usually manufactured from pleated paper and requiring renewal at regular intervals Air filter Allen key A hexagonal wrench which fits into a recessed hexagonal hole Alligator clip long nosed spring loaded metal clip with meshing teeth Used to make temporary electrical connections Alternator A component in the electrical system which converts mechanical energy from a drivebelt into electrical energy to charge the battery and to operate the starting system ignition system electrical accessories Alternator exploded view Ampere amp A unit of measurement for the flow of electric current One amp is the amount of current produced by one volt acting through a resistance of one ohm Anaerobic sealer substance used to prevent bolts and screws from loosening Anaerobic means that it does not require oxygen for activation The Loctite brand is widely used Antifreeze substance usually ethylene glycol mixed with water and added to a vehicle s cooling system to prevent freezing of the coolant in winter Antifreeze also contains chemicals to inhibit corrosion and the formation of rust and other deposits that would tend to clog the radiator and coolant passages and reduce cooling efficiency Anti seize compound coating that reduces the risk of seizing o
549. t covers the rear of the sump see illustrations 7 On models with the M40 engine unbolt and remove the lower sump section and remove the gasket this is necessary for access to the front mounting bolts Unscrew the mounting bolt and pull the oil dipstick tube from the sump see illustrations Check the condition of the O ring and renew it if necessary 8 On models with the M40 engine unscrew the engine mounting nuts on both sides then attach a suitable hoist and lift the engine sufficiently to allow the sump to be removed As a Safety precaution position axle stands or blocks of wood beneath the engine 9 Remove the bolts securing the sump to the 13 7a Main sump retaining bolts accessed after removal of the lower sump section on the M40 engine engine on bench for clarity In car engine repair procedures 2 15 13 4 If applicable remove the nut securing the power steering lines to the sump and move the lines to one side to allow you to get at the sump bolts engine block and front rear covers see illustration 10 Tap on the sump with a soft faced hammer to break the gasket seal and lower the sump from the engine 11 Using a gasket scraper scrape off all traces of the old gasket from the engine block the timing chain cover the rear main oil seal housing and the sump Be especially careful not to nick or gouge the gasket sealing Surfaces of the timing chain cover and the oil seal housing they are made
550. t engages with the pocket made for this purpose just behind the front wheel or forward of the rear wheel Engage the wheel brace handle and turn it clockwise until the wheel is raised off the ground Unscrew the bolts remove the wheel and fit the spare Refit the wheel bolts and tighten them finger tight Lower the vehicle by turning the wheel brace anti clockwise Remove the jack and tighten the bolts in a diagonal pattern to the torque listed in the Chapter 1 Specifications If a torque wrench is not available have the torque checked by a BMW dealer or tyre fitting specialist as soon as possible Refit the hubcap Towing Vehicles with manual transmission can be towed with all four wheels on the ground if necessary Automatic transmission equipped vehicles can only be towed with all four wheels on the ground providing that the speed does not exceed 35 mph and the distance is not over 50 miles otherwise transmission damage can result For preference regardless of transmission type the vehicle should be towed with the driven rear wheels off the ground Proper towing equipment specifically designed for the purpose should be used and should be attached to the main structural members of the vehicle not to the bumpers or bumper brackets Sling type towing equipment must not be used on these vehicles Safety is a major consideration while towing The handbrake should be released and the transmission should be in neutr
551. t it The antifreeze mixture should be maintained at its correct proportions adding too much antifreeze reduces the efficiency of the cooling system If necessary consult the mixture ratio chart on the antifreeze container before adding coolant Hydrometers are available at most car accessory shops to test the coolant Use antifreeze which meets the vehicle manufacturer s specifications 3 Thermostat check and renewal Warning Do not remove the radiator cap drain the coolant or renew the thermostat until the engine has cooled completely Check 1 Before assuming the thermostat is to blame for a cooling system problem check the coolant level drivebelt tension see Chapter 1 and temperature gauge or warning light operation 2 If the engine seems to be taking a long time to warm up based on heater output or temperature gauge operation the thermostat is probably stuck open Renew the thermostat 3 If the engine runs hot use your hand to check the temperature of the upper radiator hose If the hose isn t hot but the engine is the thermostat is probably stuck closed 3 8 On the M10 four cylinder engine the thermostat arrowed is connected in line in the radiator hose preventing the coolant inside the engine from circulating to the radiator Renew the thermostat Caution Don t drive the vehicle without a thermostat The engine Will be very slow to warm up in cold conditions resulting in poor fuel econ
552. t it moves is the endfloat If it s greater than the maximum endfloat listed in this Chapter s Specifications check the crankshaft thrust surfaces for wear If no wear is evident new main bearings should correct the endfloat 3 If a dial indicator isn t available feeler gauges can be used Identify the main bearing with the thrust flanges either side of it this is referred to as the thrust main bearing see Section 24 paragraph 6 Gently prise or push the crankshaft all the way to the front of the engine Slip feeler gauges between the crankshaft and the front face of the thrust main bearing to determine the clearance 4 Check the main bearing caps to see if they re marked to indicate their locations They should be numbered consecutively from the front of the engine to the rear If they aren t mark them with number stamping dies or a centre punch see illustration Main bearing caps generally have a cast in arrow which points to the front of the engine Loosen the main bearing cap bolts a quarter turn at a time each working from the outer ends towards the centre until they can be removed by hand Note if any stud bolts are used and make sure they re returned to their original locations when the crankshaft is refitted 13 1 Checking crankshaft endfloat with a dial indicator 2B 2B 14 General engine overhaul procedures 5 Gently tap the caps with a soft faced hammer then separate them from the engine block If nec
553. t passages 1 Remove the core plugs from the engine block To do this knock one side of each plug into the block with a hammer and punch grasp the other side by its edge with large pliers and pull it out 2 Using a gasket scraper remove all traces of gasket material from the engine block Be very careful not to nick or gouge the gasket sealing Surfaces 3 Remove the main bearing caps and separate the bearing shells from the caps and the engine block Tag the bearings indicating which cylinder they were removed from and whether they were in the cap or the block then set them aside 4 Remove all of the threaded oil gallery plugs from the block The plugs are usually very tight they may have to be drilled out and the 13 4 Use a centre punch or number stamping dies to mark the main bearing caps to ensure refitting in their original locations on the block make the punch marks near one of the bolt heads holes retapped Use new plugs when the engine is reassembled 5 f the engine is extremely dirty it should be taken to a machine shop to be steam cleaned 6 After the block is returned clean all oil holes and oil galleries one more time Brushes specifically designed for this purpose are available at most motor factors Flush the passages with warm water until the water runs clear dry the block thoroughly and wipe all machined surfaces with light rust preventive oil If you have access to compressed air use it to
554. t used after August 1986 and 4 596 for older vehicles From January 1996 a much tighter limit around 0 596 applies to catalyst equipped vehicles first used from August 1992 If the CO level cannot be reduced far enough to pass the test and the fuel and ignition systems are otherwise in good condition then the carburettor is badly worn or there is some problem in the fuel injection system or catalytic converter as applicable HC emissions With the CO emissions within limits HC emissions must be no more than 1200 ppm parts per million If the vehicle fails this test at idle it can be re tested at around 2000 rpm if the HC level is then 1200 ppm or less this Counts as a pass Excessive HC emissions can be caused by oil being burnt but they are more likely to be due to unburnt fuel Diesel models The only emission test applicable to Diesel engines is the measuring of exhaust smoke density The test involves accelerating the engine several times to its maximum unloaded speed Note It is of the utmost importance that the engine timing belt is in good condition before the test is carried out Excessive smoke can be caused by a dirty air cleaner element Otherwise professional advice may be needed to find the cause Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle For the owner who does not possess any their pu
555. tach all coolant hoses from the engine see Chapter 3 7 Remove the cooling fan shroud and radiator see Chapter 3 Note On the 40 engine it is only necessary to remove the cooling fan and shroud however prevent damage to the radiator by covering it with a piece of wood or cardboard 8 Remove the drivebelts see Chapter 1 9 Disconnect the fuel lines from the fuel rail see Chapter 4 Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand 10 Disconnect the accelerator cable see Chapter 4 and kickdown linkage speed control cable see Chapter 7B if applicable from the engine 11 Where fitted unbolt the power steering pump see Chapter 10 Leave the lines hoses attached and make sure the pump is kept in an upright position in the engine compartment use wire or rope to restrain it out of the way 12 On air conditioned models unbolt the compressor see Chapter 3 and set it aside or tie it up out of the way Do not disconnect the hoses 13 Drain the engine oil see Chap
556. tage output to determine the ratio of oxygen to fuel in the mixture The ECU alters the air fuel mixture ratio by controlling the pulse width open time of the fuel injectors A mixture ratio of 14 7 parts air to 1 part fuel is the ideal mixture ratio for minimising exhaust emissions thus allowing the catalytic converter to operate at maximum efficiency It is this ratio of 14 7 to 1 which the ECU and the oxygen sensor attempt to maintain at all times 7 The oxygen sensor produces no voltage when it is below its normal operating temperature of about 3209 C During this initial period before warm up the ECU operates in open loop mode ie without the information from the sensor 8 If the engine reaches normal operating temperature and or has been running for two or more minutes and if the oxygen sensor is producing a steady signal voltage below A i 60 e 4 6 The oxygen sensor arrowed is usually located in the exhaust pipe downstream from the exhaust manifold 0 45 volts at 1500 rpm or greater the ECU fault code memory will be activated 9 When there is a problem with the oxygen sensor or its circuit the ECU operates in the open loop mode that is it controls fuel delivery in accordance with a programmed default value instead of with feedback information from the oxygen sensor 10 The proper operation of the oxygen sensor depends on four conditions a Electrical The low voltages generated by
557. tands Remove the wheel bolts and the wheel 2 Using a hammer and chisel remove the dust cap from the centre of the wheel hub see illustration 3 Unstake the hub nut see illustration 4 Refit the wheel and lower the vehicle to the ground Loosen but do not remove the hub nut Warning Always loosen and tighten the hub nut with the vehicle on the ground The rb UELLE 8 8b If the inner race of the bearing sticks to the stub axle use a puller to get it off Suspension and steering systems 8 3 Using a chisel knock out the staked portion of the hub nut leverage needed to loosen the nut which is very tight could topple the vehicle off a lift or an axle stand 5 Raise the front of the vehicle support it securely on axle stands and remove the front wheel again 6 Remove the front brake caliper and mounting bracket see Chapter 9 There is no need to disconnect the brake hose Hang the caliper out of the way with a piece of wire 7 Remove the brake disc see Chapter 9 8 Remove the hub nut and pull the hub and bearing assembly off the stub axle You may have to tap it off if it s stuck see illustration If the inner race of the bearing remains on the stub axle it probably will remove the dust shield rubber boot behind the bearing and use a puller to remove the inner race see illustration Refitting 9 Fit a new dust shield 10 Push the new hub and bearing onto the stub axle If it s necess
558. tarter motor the alternator the distributor and the fuel system components can be removed for repair with the engine in place The cylinder head can be removed without removing the engine so this procedure is covered in this Part of Chapter 2 Camshaft rocker arm and valve component servicing is In car engine repair procedures 2A 3 most easily accomplished with the cylinder head removed these procedures are covered in Part B of this Chapter Note however that the camshaft on the 40 engine may be removed with the engine in the vehicle since it is retained by bearing caps In extreme cases caused by a lack of necessary equipment repair or renewal of piston rings pistons connecting rods and big end bearings is possible with the engine in the vehicle However this practice is not recommended because of the cleaning and preparation work that must be done to the components involved 3 Top Dead Centre TDC for gt gt No 1 piston locating X Note 1 The following procedure is based on the assumption that the distributor if applicable is correctly fitted If you are trying to locate TDC to refit the distributor correctly piston position must be determined by feeling for compression at the No 1 spark plug hole then aligning the ignition timing marks or inserting the timing tool in the flywheel as applicable Note 2 The No 1 cylinder is the one closest to the radiator 1 Top Dead Centre TDC is the highest
559. tch 3 8 Align the notch in the pulley with the notch on the timing plate then check to see if the distributor rotor is pointing to the No 1 cylinder if not the camshaft is 180 degrees out the crankshaft will have to be rotated 360 degrees Make sure your assistant is out of the vehicle away from the ignition switch then use a socket and ratchet as described in a to complete the procedure 5 Note the position of the terminal for the No 1 spark plug lead on the distributor cap If the terminal isn t marked follow the plug lead from the No 1 cylinder spark plug to the cap No 1 cylinder is nearest the radiator 6 Use a felt tip pen or chalk to make a mark directly below the No 1 terminal on the distributor body or timing cover 7 Detach the distributor cap and set it aside see Chapter 1 if necessary 8 Turn the crankshaft see paragraph 4 above until the timing marks located at the front of the engine are aligned see illustration The M40 engine does not have any timing marks at the front of the engine but instead has a timing hole in the flywheel which must be aligned with a hole in the rear flange of the cylinder block On this engine turn the crankshaft until the distributor rotor is approaching the No 1 TDC position then continue to turn the crankshaft until a suitable close fitting drill can be inserted through the hole in the cylinder block and into the flywheel 9 Look at the distributor rotor
560. te models were introduced for 1988 and these models have continued in E30 form to date The E28 5 Series models were introduced in October 1981 and were superseded in J une 1988 by the revised E34 5 Series range Touring versions of which became available from March 1992 Throughout this manual E28 models are also referred to as old shape while E34 models are designated new shape The models covered by this manual are equipped with single overhead cam in line four and six cylinder engines Early 316 and 518 models are fitted with carburettors but all other models are fitted with fuel injection systems Transmissions are a five speed manual or three or four speed automatic The transmission is mounted to the back of the engine and power is transmitted to the fully independent rear axle through a two piece propeller shaft The final drive unit is bolted solidly to a frame crossmember and drives the rear wheels through driveshafts equipped with inner and outer constant velocity joints The front suspension is of MacPherson strut type with the coil spring shock absorber unit making up the upper suspension link The rear suspension is made up of coil spring over shock absorber struts or coil springs and conventional shock absorbers depending on model The brakes are disc type at the front with either drums or discs at the rear depending on model Servo assistance is standard on all models Some later models are equip
561. tem components unless it is absolutely necessary 14 Remove the fan drivebelt and fan see Chapter 3 15 Remove the valve cover and gasket see Section 4 Remove the semi circular rubber seal from the front of the cylinder head where this is not incorporated in the valve cover gasket 16 Set No 1 piston at Top Dead Centre on the compression stroke see Section 3 17 Remove the timing chain or belt see Section 8 or 10 Note If you want to save time by not removing and refitting the timing belt or chain and re timing the engine you can unfasten the camshaft sprocket and suspend it out of the way with the belt or chain still attached by a piece of rope Be sure the rope keeps firm tension on the belt or chain so it won t become disengaged from any of the sprockets 18 Loosen the cylinder head bolts a quarter turn at a time each in the reverse of the tightening sequence shown see illustrations 12 30a 12 30b 12 30c or 12 304 Do not dismantle or remove the rocker arm assembly at this time on M10 M20 and M30 engines 19 Remove the cylinder head by lifting it straight up and off the engine block Do not prise between the cylinder head and the engine block as damage to the gasket sealing surfaces may result Instead use a blunt bar positioned in an intake port to gently prise the head loose 20 Remove remaining X external components from the head to allow for thorough cleaning and inspection See Chapter 2B for
562. temperature regulator Air conditioner control unit heater controls Plug extra fan motor on extra fan motor Relay extra fan stage ll on power distributor Relay extra fan stage on power distributor Switch high pressure pressostat drier Switch temperature 110 C only for 524 td Motor heater blower Motor evaporator blower Plug high pressure pressostat to electromagnetic coupling Evaporator temperature sensor in evaporator Heater temperature sensor in heater Inside temperature sensor lower trim panel left Electromagnetic coupling for compressor Motor extra fan Key to wiring diagram for heated seats Description Heating passenger s seat Seat heating connection passenger s side Seat heating switch passenger s side Plug for heated seat wire driver s side to special equipment plug 58K Plug for heated seat wire driver s side to passenger s side Plug for heated seat wire driver s side to special equipment plug 15E and 30SA4 Seat heating relay Seat heating switch driver s side Heating driver s seat Seat heating connection driver s side Wiring diagrams 12 25 12 12 26 Wiring diagrams 18 89 19 49 4 And t ed AN AIM T M A9 wW 87 85 30 8 9 8 49 c Ow T T Tt wo uno e i o 10 Typical heated seats wiring diagram
563. tems 6 12 EVAP system charcoal canister viewed from under the vehicle 316i model On some models it will be necessary to release the retaining clip see illustration 13 Visually examine the canister for leakage or damage 14 Renew the canister if you find evidence of damage or leakage 7 Catalytic converter EN ES General description 1 To reduce emissions of unburnt hydrocarbons HC carbon monoxide CO and oxides of nitrogen NOx the later vehicles covered by this manual are equipped with a catalytic converter see illustration The converter contains a ceramic honeycomb coated with precious metals which speed up the reaction between the pollutants listed previously and the oxygen in the exhaust gas The pollutants are oxidised to produce water H20 nitrogen and carbon dioxide CO2 Check 2 Visually examine the converter s for cracks or damage Make sure all nuts and bolts are tight 3 Inspect the insulation cover if applicable welded onto the converter it should not be loose Caution If an insulation cover is dented so that it touches the converter housing inside excessive heat may be transferred to the floor 4 Start the engine and run it at idle speed 5 Check for exhaust gas leakage from the converter flanges Check the body of each converter for holes 7 1 Typical catalytic converter M10 engine type shown others similar Component renewal 6 See Chapter 4 for removal a
564. ter 1 3 Remove the centre console see Chap ter 11 Spread an old blanket over the front carpeting this will prevent stains if any residual coolant spills Removal 3 Series models 4 Remove the left hand side heater ducting and set it aside 5 Remove the heater valve clamp 6 Remove the screws and detach the flange where the two coolant lines enter the heater matrix case Be careful some coolant may spill 7 Remove the two screws holding the heater matrix case to the heater main assembly 8 Slide the heater matrix out of the mounting Be careful not to spill any of the remaining coolant in the heater matrix when removing it 5 Series models 9 Disconnect the electrical connectors 10 Disconnect the straps holding the wiring to the case and set the wiring out of the way 11 Unfasten the cover fasteners 12 Remove the screws holding the cover in place then remove the cover 13 Disconnect all heater pipe connections attached to the heater matrix Be careful some coolant may spill 14 Lifting on the right side of the heater matrix first remove the heater matrix Refitting Note Always use new O rings when attaching the coolant lines to the heater matrix temperature sensor 15 Refitting is the reverse of removal Refill the cooling system see Chapter 1 then run the engine with the heater on and check for correct operation and leaks 12 Air conditioning system precautions and maintenance Pr
565. ter 1 and remove the filter Remove the engine splash guard from under the engine 14 Remove the starter motor see Chapter 5 5 26 Removing the engine rear plate M40 engine 15 Remove the alternator see Chapter 5 This is not essential on all models but it is a good idea in any case to avoid accidental damage 16 Unbolt the exhaust system from the engine see Chapter 4 17 If you re working on a vehicle with automatic transmission remove the torque converter to driveplate fasteners see Chapter 7B On the M40 engine unbolt the automatic transmission fluid coolant pipes from the sump 18 Support the transmission with a jack Position a block of wood between them to prevent damage to the transmission Special transmission jacks with safety chains are available use one if possible 19 Attach an engine sling or a length of chain to the lifting brackets on the engine If the brackets have been removed the chain can be bolted directly to the intake manifold studs but place a flat washer between the chain and the nut and tighten the nut all the way up to the chain to avoid the possibility of the studs bending 20 Roll the hoist into position and connect the sling to it Take up the slack in the sling or chain but don t lift the engine Warning DO NOT place any part of your body under the engine when it s supported only bya hoist or other lifting device 21 On M10 M20 and M30 engines remove the transmission re
566. ter 5 for the removal and refitting procedure make sure that no parts remain in the bottom of the carrier when it s refitted When refitting the hold down clamp don t overtighten the bolt 10 Corrosion on the carrier battery case and Surrounding areas can be removed with a solution of water and baking soda Apply the mixture with a small brush let it work then rinse it off with plenty of clean water 11 Any metal parts of the vehicle damaged by corrosion should be coated with a zinc based primer then painted 12 Additional information on the battery and jump starting can be found in Chapter 5 and the front of this manual Charging Note The manufacturer recommends the battery be removed from the vehicle for charging because the gas which escapes during this procedure can damage the paint or interior depending on the location of the battery Fast charging with the battery cables connected can result in damage to the electrical system 13 Remove all of the cell caps if applicable and cover the holes with a clean cloth to prevent spattering electrolyte Disconnect the 14 1 Tools required for changing spark plugs I Spark plug socket This will have special padding inside to protect the spark plug s porcelain insulator 2 Torque wrench Although not mandatory using this tool is the best way to ensure the plugs are tightened properly 3 Ratchet Standard hand tool to fit the spark plug socket 4 Extension
567. ternator see Sec tion 14 16 Voltage regulator renewal BN BS 1 The voltage regulator controls the charging system voltage by limiting the alternator output The regulator is a sealed unit and isn t adjustable 2 f the voltmeter indicates that the alternator is not charging or if the ignition no charge warning light comes the alternator battery drivebelt tension and electrical connections seem to be fine have the 16 4b The regulator can be withdrawn easily on Bosch alternators This type of regulator is integral with the brush assembly regulator checked by a dealer service department or electrical specialist 3 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Bosch alternator 4 The voltage regulator is mounted externally on the alternator housing To renew the regulator remove the mounting screws see illustration and lift it off the alternator see illustration Note Some Bosch alternators have an integral voltage regulator which is part of the brush assembly 5 Refitting is the rever
568. tes after the engine has been shut off 5 If the oil is checked immediately after driving the HiNT vehicle some of the oil will remain in the upper part of the engine resulting in an inaccurate reading on the dipstick 4 Pull the dipstick out of the tube and wipe all of the oil away from the end with a clean rag or paper towel Insert the clean dipstick all the way back into the tube and pull it out again Note the oil at the end of the dipstick At its highest point the oil should be between 1 The first step any tune up or diagnostic procedure to help correct a poor running engine is a cylinder compression check A compression check See Chapter 2B will help determine the condition of internal engine components and should be used as a guide for tune up and repair procedures If for instance a compression check indicates serious internal engine wear a conventional tune up will not improve the performance of the engine and would be a waste of time and money Because of its importance the compression check should be done by someone with the right equipment and the knowledge to use it properly The following procedures are those most often needed to bring a generally poor running engine back into a proper state of tune Minor tune up Check all engine related fluids Section 4 Check all underbonnet hoses Section 10 Check and adjust the drivebelts Sec tion 11 Clean inspect and test the b
569. the centre nut and lift off the cover see illustrations 3 Remove the air filter element and wipe clean the air cleaner body and cover see illustration 4 To remove the body first disconnect the inlet duct and warm air hose see illustration 5 Disconnect the vacuum line at the carburettor a o7 m 8 3 Remove the air cleaner element and wipe clean the body and cover 8 4 Air cleaner inlet duct 1 and warm air hose 2 8 7 Air cleaner mounting bracket nut arrowed 6 Unscrew the four nuts retaining the air cleaner to the carburettor and remove the metal ring see illustrations 7 Unscrew the nut from the mounting bracket see illustration 8 Lift the air cleaner from the carburettor and disconnect the crankcase ventilation hose see illustration If necessary prise the sealing ring from the bottom of the air cleaner 9 Refitting is a reversal of removal but align the arrow on the cover with the arrow on the inlet tube see illustration Fuel injection engines 10 Detach the air intake duct from the front side of the air cleaner the air cleaner assembly Motronic system shown and lift it off its mountings 8 6a Unscrew the four air cleaner to carburettor nuts 8 8 Disconnecting the crankcase ventilation hose from the air cleaner 11 Detach the duct between the air cleaner and the throttle body 12 Remove the air filter see Chapter 1
570. the radiator Use a drip tray to catch spilled fluid Plug the fluid cooler lines and fittings 7 Disconnect the coolant sensors located on the radiator see illustration The thermo Statically controlled switches for high and low speed operation of the auxiliary fan are located in the radiator tanks in various locations depending on engine and model 8 Remove the radiator mounting bolt s The mountings are either on the top or sides of the radiator see illustration 9 Carefully lift out the radiator from the bottom mountings taking care not to damage the cooling fins Don t spill coolant on the vehicle or scratch the paint 10 With the radiator removed it can be inspected for leaks and damage If it needs repair have a specialist perform the work as Special techniques are required 11 Flies and dirt can be removed from the radiator with compressed air and a soft brush Don t bend the cooling fins as this is done 12 Check the radiator mountings for deterioration and renew if necessary see illustration Refitting 13 Refitting is the reverse of the removal procedure 14 After refitting fill the cooling system with the proper mixture of antifreeze and water Refer to Chapter 1 if necessary 4 12 When the radiator is out the radiator mountings can be inspected check for signs of deterioration and renew them if needed 4 8 The radiator is bolted to the front panel at either the sides or the top of the
571. the correct lubricant type The manual transmissions on some later or high performance models are filled with automatic transmission fluid ATF Such transmissions normally carry a sticker to this effect near the filler level plug Refer to a BMW dealer if still in doubt 4 Refit the plug and tighten securely Check for leaks after the first few miles of driving 5 f regular topping up is required this can only be due to a leak which should be found and repaired before it becomes serious 17 Differential lubricant level BN check ws J 1 The differential has a filler level plug which must be removed to check the lubricant level If the vehicle is raised to gain access to the plug be sure to support it safely do not 17 2 Remove the differential filler level plug with an Allen key and make sure the lubricant is level with the bottom of the hole 1 19 crawl under the vehicle when it s supported only by the jack Note The vehicle should be level to give an accurate lubricant check 2 Remove the filler level plug from the differential see illustration Use an Allen key to unscrew the plug 3 Use your little finger as a dipstick to make sure the lubricant level is up to the bottom of the plug hole If not use a syringe or squeeze bottle to add the recommended lubricant until it just starts to run out of the hole 4 Refit the plug and tighten it securely 5 f regular topping up is required this can only be due to
572. the cover inverted tap out the float pivot pins remove the floats and lift out the two needle valves keeping all the components identified side for side see illustrations 13 Unscrew the bypass fuel jet from the secondary float chamber then similarly remove the jets from the cover keeping them all identified for location see illustrations 14 Clean all the components and blow all the internal channels clear using low air pressure 15 Reassembly is a reversal of dismantling but note the following points a Fitthe new gaskets and seals supplied in the repair kit b Before refitting the cover check that the choke linkage arm is correctly located in the lever see illustration C Check and if necessary adjust the float settings Invert the cover and check the at the same time disengaging the bi metal spring from the control lever l measure the distance between the contact face and the top of the float distance from the contact face without gasket to the top of the float making sure that the needle valve spring tensioned ball is not depressed see illustration Note that the dimension is different for the primary and secondary floats see Specifications If adjustment is necessary bend the float arm as required d Make sure that the seal is fitted to the top of the accelerator pump see illustration Adjustment Note Idle speed and mixture adjustments are covered in Chapter 1 Aut
573. the dipstick tube collar 7 Detach the sump from the transmission and lower it being careful not to spill the remaining fluid see illustration 8 Carefully clean the sump to transmission contact surface 9 Pour the fluid from the sump into a suitable container then clean the sump with solvent and dry it with compressed air Be sure to clean any metal filings from the magnet if applicable 10 Remove the filter from inside the transmission see illustrations 11 Fit the O ring and a new filter being sure to tighten the bolts securely 12 Make sure that the sump gasket contact surfaces are clean then fit the new gasket Offer the sump up to the transmission and refit the brackets and bolts Working around 28 7 Lower the sump from the transmission 28 10a Use a Torx key to remove the filter bolts Every 24 000 miles 28 5b Detach the tube and let the fluid drain the sump tighten each bolt a little at a time until the torque listed in this Chapter s Specifi cations is reached Don t overtighten the bolts Connect the dipstick tube and tighten the collar securely 13 Lower the vehicle and add the specified amount of fluid through the filler tube see Section 8 14 With the transmission in Park and the handbrake applied run the engine at fast idle but don t race it 15 Move the gear selector through each position and back to Park Check the fluid level 16 Check under the vehicle for leaks after
574. the floor Renewal Note The following paragraphs describe the procedure for fuel injection engines the procedure is similar on carburettor engines 7 Disconnect the battery negative cable 9 5 To adjust the accelerator cable free play hold nut B stationary and turn nut A fuel injection engine shown 4 4 10 Fuel exhaust systems 9 8 Push the rubber grommet from the rear and separate the cable from the bracket Caution If the radio in your A vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 8 Loosen the cable adjuster locknuts and detach the cable from its support bracket located on the intake manifold see illustration 9 Pinch the plastic retainer with a pair of needle nose pliers and push it out of the bracket see illustration 9 10b After the cable is off the throttle valve assembly remove the plastic retainer from the cable 11 5 Remove the screw and disconnect the carburettor earth cable arrowed 9 9 Pinch the plastic retainer and push it through the bracket recess on the throttle valve 10 Pull the cable down through the slot and away from the bracket se
575. the same manufacturer markings If you re fitting a new thrust arm bush make sure it s correctly orientated see illustration Refitting 9 Refitting is the reverse of removal Be sure to use new self locking nuts on the balljoint stud nut and the through bolt Don t forget to refit the washers on both sides of the through bolt If you re refitting the control arm be sure to use thread locking compound on the steering arm mounting bolts Don t tighten the through bolt to the final torque yet Note Thrust arms are marked L for the left side and R for the right side Be sure to check the marking before fitting a new arm 10 Support the control arm with a trolley jack and raise it to simulate normal ride height then tighten the through bolt to the torque listed in this Chapter s Specifications 5 8 To remove the brake splash shield remove these three bolts arrowed RUBBER THRUST 4 8 Correct orientation of the bush for the 5 Series thrust arm The arrow on the rubber bush is aligned with the mark on the arm and the centre of the bush is concentric with the bore Refit the wheel and tighten the wheel bolts to the torque listed in the Chapter 1 Specifi cations 11 Have the front end alignment checked at a dealer service department or qualified garage 5 Front strut assembly removal and refitting Why Removal Note Although strut assemblies don t always fail or wear out simultaneousl
576. the sensor depend upon good clean connections which should be checked whenever a malfunction of the sensor is suspected or indicated b Outside air supply The sensor is designed to allow air circulation to the internal portion of the sensor Whenever the sensor is disturbed make sure the air passages are not restricted c Proper operating temperature The ECU will not react to the sensor signal until the sensor reaches approximately 320 This factor must be taken into consideration when evaluating the performance of the sensor d Unleaded fuel The use of unleaded fuel is essential for proper operation of the sensor Make sure the fuel you are using is of this type 11 In addition to observing the above conditions special care must be taken whenever the sensor is serviced a The oxygen sensor has a permanently attached pigtail and electrical connector which should not be removed from the sensor Damage or removal of the pigtail or electrical connector can adversely affect operation of the sensor b Grease dirt and other contaminants should be kept away from the electrical connector and the louvered end of the sensor c Do not use cleaning solvents of any kind on the oxygen sensor d Do not drop or roughly handle the sensor e The silicone boot must be fitted in the correct position to prevent the boot from being melted and to allow the sensor to operate properly warmed 320 puts out a
577. tighten Pulse sensor later models Check 7 Locate the two electrical connectors for the sensor see illustrations Disconnect the electrical connector from the front 8 Using an ohmmeter check resistance between terminal 1 yellow wire and terminal 2 black wire on the sensor side of each connector see illustration The resistance should be 500 to 600 ohms 9 Ifthe reading is incorrect renew the sensor Renewal 10 Remove the pulse sensor mounting bolt using a 5 mm hex spanner see illustration 12 7b On later 5 Series models the pulse sensor connector arrowed located next to the valve cover 12 8 The resistance of the pulse sensor should be 500 to 600 ohms later models 12 10 The pulse sensor itself arrowed is located on the timing belt cover to one side of the pulley later models Sensor tip 74 0 04 0 05 inches Pulse wheel 12 11 The sensor tip should be set at 1 0 0 3 mm from the pulse wheel Withdraw the sensor from its bracket and remove it 11 When fitting the new sensor use a brass feeler gauge to position the tip of the sensor the correct distance from the pulse wheel see illustration 12 Tighten the mounting bolt but be careful not to overtighten it 13 Charging system general information and precautions There are two different types of alternator fitted on these models Bosch and Motorola Also there are three different amperage ratings available 65A 80A
578. ting of the single blower motor and the old shape 5 Series vent heat motor is described below The removal and refitting of the old shape 5 Series air conditioning blower motor is described in Section 14 of this Chapter Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure 1 Disconnect the battery negative cable 2 The blower motor is located behind the bulkhead under an access panel Remove the panel securing screws see illustrations 3 Disconnect or cut the plastic ties holding the wiring harness to the panel and move the wiring out of the way 4 Remove the panel 5 Unclip the blower housing retaining clip and the clip securing the blower motor see illustrations u 9 5a Unclip the retaining strap to remove the blower housing Cooling heating and air conditioning systems 3 7 9 2a To getto the heater blower motor the access panel must be removed a fastener from the front 6 Disconnect the wiring and remove the blower motor see illustration Testing 7 You can test the blower motor by applying battery voltage to the blower motor s terminals with fused jumper wires be sure the fan blades won t hit anything when they rot
579. ting on top of the cylinder head see illustrations Note It s important to renew the seals under the tube mounting bolts 4 8 2a Remove the oil tube from the top of the cylinder head M10 engine Be sure to note the location of all gaskets and washers for reassembly 2B 2 8 General engine overhaul procedures 8 2b Removing the oil tube from the camshaft bearing caps on the top of the cylinder head M40 engine M10 M20 and M30 engines 3 Adjust all valves to their maximum clearance by rotating the eccentric on the valve end of the rocker arm towards the centre of the head see Chapter 1 if necessary 4 Before removing the thrustplate measure the camshaft endfloat by mounting a dial indicator to the front end of the cylinder head with the probe resting on the camshaft see illustration Prise the camshaft back and forth in the cylinder head The reading is the camshaft endfloat Compare the reading to this Chapter s Specifications 5 Unbolt and remove the camshaft thrustplate Note There are two different locations for the thrustplate On M10 and M30 engines it is attached on the front of the cylinder head behind the timing gear flange On M20 and M40 engines the thrustplate is located inside the head by the rocker shafts at the forward end of the cylinder head 6 Remove the rear cover plate from the back of the cylinder head see illustration 7 Remove the retaining clips from each of the roc
580. ting system is to turn over the engine quickly enough to allow it to start The starting system consists of the battery the starter motor the starter solenoid the ignition switch and the wires connecting them The solenoid is mounted directly on the starter motor The starter solenoid motor assembly is fitted on the lower part of the engine next to the transmission bellhousing When the ignition key is turned to the Start position the starter solenoid is actuated through the starter control circuit The starter solenoid then connects the battery to the starter and moves the starter pinion into mesh with the flywheel ring gear The battery supplies the electrical energy to the starter motor which does the actual work of cranking the engine The starter motor on some manual transmission vehicles can only be operated when the clutch pedal is depressed On a vehicle equipped with automatic transmission the starter can only be operated 5 12 Engine electrical systems when the transmission selector lever is in Park or Neutral Always detach the battery negative cable before working on the starting system 19 Starter motor in vehicle check WU Note Before diagnosing starter problems make sure the battery is fully charged 1 If the starter motor does not turn at all when the switch is operated make sure that the gear lever is in Neutral or Park automatic transmission or where applicable that the clutch pedal is depr
581. tions other than these can lead to inaccurate test results Test the brakes at various speeds with both light and heavy pedal pressure The vehicle Should stop evenly without pulling to one side or the other Avoid locking the brakes because this slides the tyres and diminishes braking efficiency and control of the vehicle Tyres vehicle load and wheel alignment are factors which also affect X braking performance 2 Anti lock Braking system ABS general information The Anti lock Braking System is designed to maintain vehicle control directional stability and optimum deceleration under severe braking conditions on most road surfaces It does so by monitoring the rotational speed of each wheel and controlling the brake line pressure to each wheel during braking This prevents the wheels from locking up The ABS system has three main components the wheel speed sensors the electronic control unit and the hydraulic control unit The sensors one at each wheel since 1985 but at both front wheels and one at the rear differential on earlier models send a variable voltage signal to the control unit which monitors these signals compares them to its program information and determines whether a wheel is about to lock up When a wheel is about to lock up the control unit signals the hydraulic unit to reduce hydraulic pressure or not increase it further at that wheel s brake caliper Pressure modulation is handled by electrical
582. tle immediately before switching off the engine If the ignition is switched off at anything above idle speed unburned fuel will enter the very hot catalytic converter with the possible risk of its igniting on the element and damaging the converter DO NOT use fuel or engine oil additives these may contain substances harmful to the catalytic converter g DO NOT continue to use the car if the engine burns oil to the extent of leaving a visible trail of blue smoke the unburned carbon deposits will clog the converter passages and reduce its efficiency in severe cases the element will overheat h Remember that the catalytic converter operates at very high temperatures hence the heat shields on the car s underbody and the casing will become hot enough to ignite combustible materials which brush against it DO NOT therefore park the car in dry undergrowth or over long grass or piles of dead leaves Remember that the catalytic converter is FRAGILE do not strike it with tools during servicing work and take great care when working on the exhaust system Ensure that the converter is well clear of any jacks or other lifting gear used to raise the car and do not drive the car over rough ground road humps etc in such a way as to ground the exhaust system In some cases particularly when the car is new and or is used for stop start driving a sulphurous smell like that of rotten eggs may be notice
583. tly gapped spark plugs Chapter 1 Incorrect ignition timing Chapter 5 Cracked distributor cap disconnected distributor HT leads or damaged distributor components Chapter 1 Faulty spark plug HT leads Chapter 1 Faulty emission system components Chapter 6 Low or uneven cylinder compression pressures Chapter 2 Weak or faulty ignition system Chapter 5 Vacuum leak in fuel injection system intake manifold or vacuum hoses Chapter 4 Engine misfires on acceleration Spark plugs fouled Chapter 1 Fuel injection system or carburettor malfunctioning Chapter 4 Fuel filter clogged Chapters 1 and 4 Incorrect ignition timing Chapter 5 Intake manifold air leak Chapter 4 Engine surges while holding accelerator steady Intake air leak Chapter 4 Fuel pump faulty Chapter 4 Loose fuel injector harness connections Chapters 4 and 6 Defective ECU Chapter 5 Engine lacks power Engine electrical system Incorrect ignition timing Chapter 5 Excessive play in distributor shaft Chapter 5 Worn rotor distributor cap or HT leads Chapters 1 and 5 Faulty or incorrectly gapped spark plugs Chapter 1 Fuel injection system or carburettor malfunctioning Chapter 4 Faulty coil Chapter 5 Brakes binding Chapter 1 Automatic transmission fluid level incorrect Chapt
584. to 0 09 mm 0 03 to 0 072 mm 0 02 to 0 06 mm 0 04 to 0 08 mm 0 03 to 0 07 mm 0 02 to 0 05 mm 0 04 to 0 072 mm 0 03 to 0 062 mm 0 02 to 0 055 mm 0 02 to 0 20 mm 0 02 to 0 10 mm 0 02 to 0 10 mm Not measured Nm 20 Angle tighten an additional 50 2B 2B 4 General engine overhaul procedures Torque wrench settings continued Nm Connecting rod cap bolts nuts MIO ahd M30 enges acer dd dedic dedos nolo ics 4 55 M20 and M40 engines H A 20 25454 Angle tighten an additional 70 Camshaft bearing caps M40 10 Intermediate shaft sprocket to shaft bolt M20 engine 60 Oil supply tube bolt s normal and M8 banjo dra cibi m dened dads 10 MS edd ou ade Eia Rae 5 BMW recommend that the main bearing bolts are renewed as a matter of course 1 Generalinformation Included in this Part of Chapter 2 are the general overhaul procedures for the cylinder head and engine internal components The information ranges from advice concerning preparation for an overhaul and the purchase of new parts to detailed paragraph by paragraph procedures covering removal and refitting of internal components and the inspection of parts The following Sections have been written based on the assumption that the engine has been removed
585. to 17 25 to 29 22 to 24 31 See Chapter 1 cluster which comes on when the brake pads have worn down to the point at which they require renewal DO NOT ignore this reminder If you don t renew the pads shortly after the brake pad wear warning light comes on the brake discs will be damaged On some models the brake pad wear warning system also includes an early warning light that comes on only when the brake pedal is depressed letting you know in advance that the pads need to be renewed The wear sensor is attached to the brake pads The sensor is located at the left front wheel on some models there is another sensor at the right rear wheel The wear sensor is part of a closed circuit Once the pads wear down to the point at which they re flush with the sensor the disc grinds away the side of the sensor facing the disc Thus the wire inside the sensor is broken and the red light on the instrument panel comes on Always check the sensor s when renewing the pads If you change the pads before the warning light comes on the sensor s may still be good once the light has come on renew the sensor Service After completing any operation involving dismantling of any part of the brake system always test drive the vehicle to check for proper braking performance before resuming normal driving When testing the brakes try to select a clean dry road with no camber ie as flat as possible and with no other traffic Condi
586. to normal use 9 Hydraulic brake servo description removal and refitting Why Warning Brake fluid is poisonous It is also an effective paint stripper Refer to the warning at the start of Section 16 Description 1 On 5 Series E28 old shape models a hydraulic brake servo system is fitted The servo unit located between the brake pedal left hand drive or cross shaft lever right hand drive and the master cylinder is Operated by hydraulic pressure generated by the power steering pump When the engine is running the power steering pump supplies hydraulic pressure to a power flow regulator accumulator regulator accumulator stores and regulates the pressure to the hydraulic brake servo When you press the brake pedal the pressure in the servo helps actuate the master cylinder reducing pedal effort 2 The hydraulic brake servo cannot be overhauled if it fails a new one must be fitted Testing the system requires special tools so even fault diagnosis is beyond the scope of the home mechanic If the system fails take it to a dealer service department or other qualified garage for repairs Removal and refitting 3 With the engine off discharge the hydraulic accumulator by depressing the brake pedal 20 times or more 4 Remove the master cylinder see Section 7 5 Clean the area around the return and supply line fittings then disconnect them Plug the lines to prevent dirt from entering the system
587. to refitting 18 Check for fuel leaks after refitting the pressure regulator 19 Cold start injector and thermotime switch check and renewal WU Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Don t work ina garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform 19 1 Cold start injector electrical connector arrowed on the M10 engine Most cold start injectors are mounted in the intake manifold any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand Check Cold start injector 1 The engine coolant should be below 30 for this check Preferably the engine should have been switched off for several hours Disconnect the electrical connector from the cold start injector see illustration and move it aside away from the work area there will be fuel vapour present Remove the two screws holding the injector to the air intake plenum and take the injector out The fuel line must be left connected Wipe the injector nozzle Disable the ignition system by detaching the coil wire from the centre terminal of the distributor cap and earthing it on the engine block with a jumper wire Run
588. to spray the hub area with some penetrating oil and to gently tap on the hub area with a hammer 10 Unscrew the plug and remove the timing chain tensioner spring see illustration The tensioner plunger may come out with the Spring If not reach down into the hole where the tensioner spring was and remove the plunger To check the plunger for proper operation see Section 8 Caution The spring is under tension and this could cause the plug to be ejected from its hole with considerable force Hold the tensioner plug securely as it s being In car engine repair procedures 2 7 7 10 Unscrew the plug from the timing chain cover and remove the tensioner Spring and plunger unscrewed and release the spring tension slowly 11 On the M30 engine if you re removing the upper timing cover unbolt the thermostat cover and remove the thermostat see Chapter 3 12 On the M30 engine if you re removing the lower timing cover loosen the alternator mounting bolts and swing the alternator to one side Remove the front lower mounting bracket bolt and loosen the other bolts Also unbolt the power steering pump mounting bracket and move it to one side 13 Remove the bolts and nuts securing the upper timing chain cover to the engine block and remove the cover Draw a simple diagram showing the location of the bolts so they can be returned to the same holes from which they re removed Remove the upper timing chain co
589. tons connectng rods Valves servicing Difficult suitable for Very difficult Suitable for expert mechanic DIY or professional 10 to 11 bars 0 5 to 2 0 bars 4 bars or above typically 0 10 mm 0 03 mm Minimum cylinder head thickness do not resurface the head to a thickness less than listed M10 and M30 engines M20 engines WAG ONONE saa hw es ee ede d Valves Valve stem diameter standard M10 and M30 engines x sa dcc d Bear ied os be dedil PR a and M40 engine Intake poe conte eee Minimum valve margin width Intake EXHAUS KROES eee oe ecu me wd wee Valve stem maximum lateral movement see text Valve face angle Intake eee ey eee DS ee PE 128 6 mm 124 7 mm 140 55 mm 6 975 mm 2B 2B 2 General engine overhaul procedures Camshaft and rocker arms Camshaft bearing oil clearance Camshaft endfloat EO COINS aec raa i e qb COR m ac eoa p E cR ce qn Date t 20 EOD 5 D uxo d nad Dot dew d a RR 130 SNINE LR CR e que Xe MAG ENJING aeren curia an dar den d X cea ce a 3 9 4 a eae Rocker arm radial clearance Crankshaft Endfloat MIO and M30 engines
590. tool for holding the camshaft in the TDC position on M40 engines T we 10 9 When removing the timing belt on models with a two piece crankshaft hub it s a tight fit to remove it around the hub but it s a lot easier than removing the crankshaft hub assembly which is secured by a very tight bolt alignment mark on the camshaft sprocket and rear timing cover to ensure correct refitting 6 On the M20 engine loosen the two tensioner roller retaining bolts a little and push the tensioner towards the water pump see illustration With the timing belt tension relieved re tighten the retaining bolt 7 On the M40 engine loosen the tensioner retaining nut and use an Allen key to rotate the tensioner clockwise This will relieve the tension of the timing belt Tighten the retaining nut to hold the tensioner in its free position 8 If the same belt is to be refitted mark it with an arrow indicating direction of rotation Caution It is not advisable to refit a timing belt which has been removed unless it is virtually new On the M40 engine BMW recommend that the timing belt is renewed every time the tensioner roller is released 9 Remove the timing belt by slipping it off the rollers and the other sprockets see illustrations 10 If it s necessary to remove the camshaft or the intermediate shaft sprocket remove the sprocket bolt while holding the sprocket to prevent it from moving To hold the sprocket wrap
591. ts one arrowed 6 10b Remove the retaining strap bolts one arrowed and lower the fuel tank Ht NN 8 2b then remove the air cleaner cover centre nut and lift off the cover et gt 8 2a Release the air cleaner cover spring Clips 7 Fuel tank cleaning and repair general information 1 All repairs to the fuel tank or filler neck Should be carried out by a professional who has experience in this critical and potentially dangerous work Even after cleaning and flushing of the fuel system explosive fumes remain and ignite during repair of the tank 2 If the fuel tank is removed from the vehicle it should not be placed in an area where sparks or open flames could ignite the fumes coming out of the tank Be especially careful inside garages where a natural gas type appliance is located because the pilot light could cause an explosion 8 Aircleaner assembly removal and refitting 1 Detach the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Carburettor engines 2 Release the spring clips then unscrew
592. tune up 1 7 Engine electrical systems 5 1 et seq Engine electrical systems fault finding REF 11 Engine management and emission control systems 6 1 et seq Engine oil 1 3 1 7 1 11 Environmental considerations REF 8 Evaporative emissions control EVAP system 1 26 6 5 Evaporator 3 10 Exhaust emission checks REF 4 Exhaust manifold 2A 6 Exhaust system 1 21 420 REF 3 E Fan 3 4 3 5 Fault finding REF 9 et seq Fault finding automatic transmission 7B 2 REF 13 Fault finding braking system REF 14 Fault finding clutch REF 12 Fault finding cooling system REF e12 Fault finding electrical system 12 1 REF 11 Fault finding engine REF 10 Fault finding fuel system 4 21 REF 12 Fault finding manual transmission REF 13 Fault finding suspension and steering REF 15 Filling 1193 Final drive 8 2 8 10 8 11 Final drive oil 193 1919 1 26 Fire 0 5 Flexible coupling 8 7 Fluid level checks 1 7 Fluid seals 7B 5 Flywheel 2A 18 Fuel and exhaust systems 1920 4 1 et seq REF 4 Fuel system fault finding REFe12 Fuel filter 1 25 Fuel hoses 1 14 Fuel injection system 4 3 4 14 Fuel injection system fault finding 4 21 Fuel injectors 4 18 Fuel level sender unit 4 5 4 6 Fuel lines and fittings 4 7 Fuel pressure 4 3 Fuel pressure regulator 4 16 Fuel pump 493 14 4 5 Fuel tank
593. turned to their original locations in the cylinder head M4O engines Caution Keep the cylinder head upright until all of the hydraulic tappets have been removed If this precaution is not taken the oil may drain out of the tappets and render them unserviceable 16 Check that the camshaft bearing caps are numbered or identified for location 17 Progressively unscrew and remove the camshaft bearing cap retaining bolts then remove the caps see illustrations 18 Lift the camshaft from the top of the cylinder head and remove the oil seal from the timing end 19 Have ready a compartmentalised box filled with engine oil to receive the hydraulic tappets so that they are kept identified for their correct location see illustration Also have a further box ready to receive the cam followers 2 then lift out the hydraulic tappets 8 20 8 20a Remove the cam followers 20 Remove the cam followers and thrust discs then lift out the hydraulic tappets from their bores in the cylinder head see illustrations All engines 21 Before the valves are removed arrange to label and store them along with their related components so they can be kept separate and reinstalled in the same valve guides from which they re removed see illustration 22 Compress the springs on the first valve with a spring compressor and remove the collets see illustration Carefully release the valve spri
594. u can better understand the process Toe in is the turning in of the wheels The purpose of a toe specification is to ensure parallel rolling of the wheels In a vehicle with zero toe in the distance between the front edges of the wheels will be the same as the distance between the rear edges of the wheels The actual amount of toe in is normally very small On the front end toe in is controlled by the track rod end position on the track rod On the rear end toe in can only be adjusted by fitting special eccentric bushings in the trailing arm outer mounting Incorrect toe in will cause the tyres to wear improperly by making them scrub against the road surface Camber is the tilting of the wheels from vertical when viewed from one end of the vehicle When the wheels tilt out at the top the camber is said to be positive When the wheels tilt in at the top the camber is negative The amount of tilt is measured in degrees from vertical and this measurement is called the camber angle This angle affects the amount of tyre tread which contacts the road and compensates for changes in the suspension geometry when the vehicle is cornering or travelling over an undulating surface Castor is the tilting of the front steering axis from the vertical A tilt toward the rear at the top is positive castor a tilt toward the front is negative castor Castor is not adjustable on the vehicles covered by this manual 10
595. ud RC ER POE C Roe CR Second compression Oil ring B16 engine B18 engine Piston ring side clearance M 10 engine Top compression NO dies 0 tanh diio c cere d dec ac Second compression NING ua ses axes ritti EOS max 8 Fr 554 20 Second compression 0 ON UNG ae eae S E LIRE Ez oe De OR C OR o Sr M30 engine COMPIESSION NNO iuda ee X ne D E Ce P op Second compression NING EU Fre 40 Top COMPIESSION DIO 555520 d EC AR UR de de dica a oe Phe Second compression NING xu chc RR dada ee Yen Oil ring B16 engine B18 engine Torque wrench settings Main bearing cap to engine block bolts M10 M20 and M30 engines M40 engines sre ar TT General engine overhaul procedures 2 3 88 97 mm 79 98 mm 83 98 mm 88 970 mm 88 980 mm 91 972 mm 91 980 mm 83 985 mm 84 065 mm 0 02 to 0 05 mm 0 01 to 0 04 mm 0 30 to 0 70 mm 0 20 to 0 40 mm 0 25 to 0 50 mm 0 20 to 0 50 mm 0 20 to 0 45 mm 0 40 to 0 65 mm 0 30 to 0 60 mm 0 20 to 1 00 mm 0 20 to 1 00 mm 0 20 to 1 00 mm 0 40 to 1 40 mm 0 06
596. uel hose and clamps attach a fuel pressure gauge without disturbing normal fuel flow see illustration Warning Do not use a plastic tee fitting for this test It won t be able to withstand the fuel system pressure 12 Reconnect the battery 13 Bridge the terminals of the fuel pump relay using a jumper wire 14 Turn the ignition switch on 15 Note the fuel pressure and compare it with the pressure listed in this Chapter s Specifications 16 If the system fuel pressure is less than specified a Checkthe system for fuel leaks Repair any leaks found and recheck the fuel pressure 3 10 Disconnect the fuel feed line arrowed from the fuel rail L J etronic system shown 4 I 2 uu i _ m rg 4 L E j Fu 9 a EI 3 6c On all 1989 and later models remove the four bolts and the protective cover to gain access to the fuel pump relay and b Ifthere are no leaks fit a new fuel filter and recheck the fuel pressure C Ifthe pressure is still low check the fuel pump pressure see below and the fuel pressure regulator see Section 18 17 If the pressure is higher than specified check the fuel return line for an obstruction If the line is not obstructed renew the fuel pressure regulator 18 Turn the ignition off wait five minutes and look at the gauge Compare the reading with the system hold pressure listed in this Chapter s Specificat
597. ug 25225 1 Sump removal and refitting 13 Timing belt and sprockets removal inspection and refitting 10 Timing belt covers removal and 9 Timing chain and sprockets removal inspection and refitting 8 Timing chain covers removal and refitting 7 Top Dead Centre TDC for No 1 piston locating 3 Valve clearance check and adjustment Valve cover removal and refitting 4 Valves servicing Difficult suitable for 2 suitable for competent X experienced DIY gt Very difficult A suitable for expert gt EN mechanic DIY or professional 1596 cc M40 4 cylinder engine 1766 cc M 10 4 cylinder engine 1796 cc M40 4 cylinder engine 1990 cc M20 6 cylinder engine 2494 cc M20 6 cylinder engine 1766 cc M 10 4 cylinder engine 2494 cc M30 6 cylinder engine 2788 cc M30 6 cylinder engine 3430 cc M30 6 cylinder engine 3430 cc M30 6 cylinder engine 1796 M40 4 cylinder engine 1990 cc M20 6 cylinder engine 2494 cc M20 6 cylinder engine 2986 cc M30 6 cylinder engine 3430 cc M30 6 cylinder engine 0 5 to 2 0 bars 4 bars or above typically 0 12 mm to 0 20 mm 84 1 mm 2 2A 2 In car engine repair procedures Torque wrench settings Nm Timing chain tensioner plug
598. uipment standard 6 Fuel tank removal and refitting Warning Fuel is extremely A flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Also don t work in a garage where a natural gas type appliance with a pilot light is present When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand If you spill any fuel on your skin clean it off immediately with soap and water Note To avoid draining large amounts of fuel make sure the fuel tank is nearly empty if possible before beginning this procedure Why 1 Remove the fuel tank filler cap to relieve fuel tank pressure Fuel and exhaust systems 4 7 5 2 When checking the fuel lines don t overlook these short sections of fuel hose attached to the main fuel rail they re a common source of fuel leaks 2 On fuel injection models depressurise the fuel system See Section 2 3 Detach the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting
599. uired If new rods or a new crankshaft are fitted ensure that some side play is retained if not the rods will have to be machined to restore it consult a machine shop for advice if necessary Repeat the procedure for the remaining connecting rods 4 Check the connecting rods and caps for identification marks If they aren t plainly marked use a small centre punch to make the appropriate number of indentations see illustration on each rod and cap 1 2 3 etc depending on the cylinder they re associated with 5 Loosen each of the connecting rod cap nuts bolts a half turn at a time until they be removed by hand Remove the No 1 connecting rod cap and bearing shell Don t drop the bearing shell out of the cap 6 Where applicable slip a short length of plastic or rubber hose over each connecting rod cap stud to protect the crankshaft journal and cylinder wall as the piston is removed see illustration 7 Remove the bearing shell and push the connecting rod piston assembly out through the top of the engine Use a wooden hammer handle to push on the upper bearing surface in the connecting rod If resistance is felt double check to make sure that all of the ridge was removed from the cylinder General engine overhaul procedures 2 13 12 3 Check the connecting rod side play with a feeler gauge as shown 8 Repeat the procedure for the remaining cylinders 9 After removal reassemble the connecting rod ca
600. ull the camshaft out the front of the cylinder head It may be necessary to rotate the camshaft as it is removed Caution Be very careful not to scratch the camshaft bearing journals in the cylinder head as the camshaft is withdrawn 13 After removing the camshaft carefully remove the rocker arm shafts On models without threaded holes at the front of the Shafts drive them out from the rear of the cylinder head with a hammer and hardwood dowel that is slightly smaller in diameter than the rocker arm shaft see illustration For 8 13 Removing a rocker arm shaft from the front of the cylinder head the shaft must be either driven out from the rear of the head with a hardwood dowel or on models where the rocker shaft is threaded at the front pulled out from the front with a slide hammer type puller General engine overhaul procedures 2 9 8 17a Removing the camshaft bearing caps rocker shafts with a threaded front hole screw in a slide hammer to pull the shaft from the head 14 As each rocker arm shaft is slid out of the cylinder head the rocker arms will be released one by one 15 Drop each rocker arm into a labelled bag so they can be returned to their original locations on reassembly While you re removing the rocker arm shafts note their orientation The guide plate notches and the small oil holes face in the large oil holes face down toward the valve guides Also label the rocker shafts so they can be re
601. ull the old strut cartridge from the strut housing on all struts except gas charged units pour the old oil from the strut housing Spring should have been removed first Suspension and steering systems 10 7 6 3 Following the tool manufacturer s instructions fit the spring compressor to the spring and compress it sufficiently to relieve all pressure from the suspension support damper rod stationary with another spanner or an Allen key 5 Remove the nut the strut bearing the insulator and the large washer Check the bearing for smooth operation If it doesn t turn smoothly renew it Check the rubber insulator for cracking and general deterioration If there is any separation of the rubber renew the insulator 6 Lift off the spring retainer and the rubber ring at the top of the spring Check the rubber ring for cracking and hardness Renew it if necessary 7 Carefully lift the compressed spring from the assembly and set it in a safe place such as a steel cabinet Warning Never place your head near the end of the spring 8 Slide the protective tube and rubber bumper off the damper rod If either is damaged or worn renew it 9 If you re working on a front strut loosen and remove the threaded collar see illustration and pull the old strut cartridge from the strut housing Pour the old oil from the strut housing 10 On all struts except gas charged units fill the strut housing with 20 to 25 cc 3 Series
602. ulley Also known as a vibration damper Hone An abrasive tool for correcting small irregularities or differences in diameter in an engine cylinder brake cylinder etc Hydraulic tappet tappet that utilises hydraulic pressure from the engine s lubrication system to maintain zero clearance constant contact with both camshaft and valve stem Automatically adjusts to variation in valve stem length Hydraulic tappets also reduce valve noise Ignition timing The moment at which the spark plug fires usually expressed in the number of crankshaft degrees before the piston reaches the top of its stroke Inlet manifold tube or housing with passages through which flows the air fuel mixture carburettor vehicles and vehicles with throttle body injection or air only port fuel injected vehicles to the port openings in the cylinder head start Starting the engine of a vehicle with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery L Load Sensing Proportioning Valve LSPV A brake hydraulic system control valve that works like a proportioning valve but also takes into consideration the amount of weight carried by the rear axle Locknut A nut used to lock an adjustment nut or other threaded component in place For example a locknut is employed to keep the adjusting nut on the rocker arm in position Lockwasher A form of washer designed to prevent an attaching nut from
603. ully Obtain a new line of the same length and bend it to match the pattern of the old line Warning Do not crimp or damage the line No bend should have a smaller radius than 14 mm Make sure the protective coating on the new line is undamaged at the bends 11 When fitting the new line make sure it s well supported by the brackets that the routing matches the original and that there s plenty of clearance between movable components or those components which will become hot 12 After refitting check the master cylinder fluid level and add fluid as necessary Bleed the brake system as outlined in Section 16 and test the brakes carefully before driving the vehicle Be sure there are no leaks 16 Brake hydraulic system bleeding Warning Wear eye protection when bleeding the brake system If the fluid comes in contact with your eyes immediately rinse them with water and seek medical attention Most types of brake fluid are highly flammable and may ignite if spilled onto hot engine components for example In this respect brake fluid should be treated with as much care as if it were petrol When topping up or renewing the fluid always use the recommended type and ensure that it comes from a freshly opened sealed container Never re use old brake fluid bled from the system and don t top up with fluid which has been standing open for a long time as it is potentially dangerous to do so TET Brake
604. uration Renewal Cold start injector 8 Depressurise the fuel system see Sec tion 2 9 Disconnect the electrical connector from the cold start injector 10 Where applicable using a ring spanner or deep socket remove the fuel line fitting connected to the cold start injector On other models simply loosen the hose clamp and detach the hose from the injector 11 Remove the cold start injector securing bolts and remove the injector 12 Refitting is the reverse of removal Clean the mating surfaces and use a new gasket Thermotime switch Warning Wait until the engine is completely cool before beginning this procedure Also remove the cap from the expansion tank or radiator to relieve any residual pressure in the cooling system 13 Prepare the new thermotime switch for fitting by applying a light coat of thread sealant to the threads 14 Disconnect the electrical connector from the old thermotime switch 15 Using a deep socket or a ring spanner unscrew the switch Once the switch is removed coolant will start to leak out so insert the new switch as quickly as possible Tighten the switch securely and plug in the electrical connector fuel injectors 20 Fuel injectors check and renewal Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Don t work ina garage w
605. use a fault in the wiring or extended storage of the vehicle Excessive heat or cold can also shorten battery life with heat the greatest enemy Extreme heat can cause the batteries to actually split open allowing acid to drip into the instrument cluster Several instruments controlled by the SI board can be affected by low or discharged batteries Symptoms of low or dead SI board batteries can include inconsistent tachometer and temperature gauge readings background radio noise and the inability to turn the service lights off with the special tool Although only complete SI boards are available from the manufacturer batteries are available separately from aftermarket sources While it is possible for the home mechanic to renew the batteries they are soldered to the board so unless you are skilled at this and have the proper tools this job should be left to an experienced electronics technician Considerable savings can be realised by removing the instrument cluster see Section 10 and taking it to an electronics Specialist Caution the instrument cluster and components are very susceptible to damage from static electricity Make sure you are earthed and have discharged any static electricity by touching an object such as a metal water pipe before touching the cluster components 12 8 Removing the headlight rear outer cover 3 Series shown 12 Headlights bulb renewal Caution If the radio in your vehic
606. uses Motronic fuel injection system The Motronic system combines the fuel control of the L J etronic fuel injection system with the control of ignition timing idle speed and emissions into one control unit The fuel injection and idle speed control functions are similar to those used on the L J etronic system described above For more information on the Motronic system see Chapter 6 An oxygen sensor is mounted in the exhaust system on later models with a catalytic converter This sensor continually reads the oxygen content of the exhaust gas The information is used by the ECU to adjust the duration of injection making it possible to adjust the fuel mixture for optimum converter efficiency and minimum emissions 15 Fuel injection system check Warning Fuel is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area Don t work ina garage where a natural gas type appliance such as a water heater or clothes dryer with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher on hand 1 Check the earth wire connections Check all wiring harness connectors that are related to the system Loose connectors and poor earths can cause many problems that rese
607. ve the large circlip see illustration that holds the wheel bearing in the wheel bearing housing then drive out the bearing with a large socket or piece of pipe 5 Refitting is basically the reverse of removal bearing in mind the following points a Be extremely careful where you place the socket or piece of pipe when you drive the new bearing into the housing It Should be butted up against the outer race of the bearing Driving in the new bearing using the inner race will ruin the bearing b Refit the wheel and lower the vehicle to the ground before attempting to tighten the driveshaft nut to the torque listed in the Chapter 8 Specifications 15 11 Remove the drive flange with a puller 15 7 Prise out the lockplate that secures the drive flange nut once you ve prised out an edge of the lockplate pull it out with a pair of needle nose pliers 5 Series models 6 Chock the front wheels then raise the rear of the vehicle and support it securely on axle stands Disconnect the outer CV joint from the drive flange see Chapter 8 Support the outer end of the driveshaft with a piece of wire don t let it hang as this could damage the inner CV joint 7 Prise out the lockplate that secures the drive flange nut see illustration Once you ve prised out an edge of the lockplate pull it out with a pair of needle nose pliers 8 Lower the vehicle and unscrew the drive flange nut but don t remove it yet You ll need a long
608. ved for access to the pump 28 Refill the cooling system and check the drivebelt tension see Chapter 1 Run the engine and check for leaks 7 24 New outer gasket on the M40 e engine water pump 7 18b and remove the water pump M40 engine 8 Coolant temperature sender unit check and renewal A Warning Wait until the engine is completely cool before beginning this procedure 1 The coolant temperature indicator system is composed of a temperature gauge mounted in the instrument panel and a coolant temperature sender unit that s normally mounted on the thermostat housing see illustration 3 11 Some vehicles have more than one sender unit but only one is used for the temperature gauge On the 40 engine the sender unit is mounted on the left hand side of the cylinder head towards the rear 2 f the gauge reading is suspect first check the coolant level in the system Make sure the wiring between the gauge and the sending unit is secure and that all fuses are intact If the fuel gauge reading is suspect as well the problem is almost certainly in the instrument panel or its wiring 3 Before testing the circuit refer to the relevant wiring diagrams see Chapter 12 Where the sender unit simply earths out the circuit test by earthing the wire connected to the sending unit while the ignition is on but without the engine running for safety If the gauge now deflects to the end of the scale rene
609. vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Removal 1 Disconnect the battery negative cable 2 Drain the cooling system see Chapter 1 If the coolant is relatively new or in good condition save it and re use it 3 Loosen the hose clamps then detach the hoses from the radiator see illustrations If they re stuck grasp each hose near the end with a pair of water pump pliers twist gently to break the seal then pull off be careful not to distort or break the radiator outlets If the hoses are old or deteriorated cut them off and refit new ones 4 On M20 and M30 engines disconnect the reservoir hose from the radiator filler neck 5 Remove the screws or plastic fasteners that attach the shroud to the radiator and slide the shroud towards the engine see illustration On some engines it is possible to completely remove the shroud 6 If the vehicle has automatic transmission 4 5 Plastic fastener retaining the radiator shroud on some engines 3 3 4 Cooling heating and air conditioning systems 4 7 Sensors that Sorte the high and low speed operation of the auxiliary cooling fan are located in various places in the radiator tanks disconnect the fluid cooler lines from
610. venly to the torque stated in the Specifications On no account alter the thickness of the distance piece or the correct operation of the fuel pump will be upset Fuel pump fuel injection engines Note 1 The electric fuel pump is located inside the fuel tank on later models with the Motronic system or adjacent to the fuel tank on the L J etronic system The early models are also equipped with a transfer pump located in the fuel tank The transfer pump feeds the larger main pump which delivers the high pressure required for proper fuel system operation Note 2 The fuel level sender unit is located in the fuel tank with the transfer pump on early models or with the main fuel pump on later models 6 Depressurise the fuel system see Sec tion 2 and remove the fuel tank filler cap to relieve pressure in the tank 7 Disconnect the battery negative cable Caution If the radio in your vehicle is equipped with an anti theft system make sure you have the correct activation code before disconnecting the battery Refer to the information on page 0 7 at the front of this manual before detaching the cable Note If after connecting the battery the wrong language appears on the instrument panel display refer to page 0 7 for the language resetting procedure Externally mounted fuel pump 8 Raise and support the vehicle 9 Remove the two rubber boots that protect the fuel pump connectors and disconnect the wires from th
611. ver If it sticks to the engine block tap it gently with a rubber mallet or place a piece of wood against the cover and hit the wood with a hammer On the M30 engine fitted with the L Jetronic fuel system remove the distributor driveshaft 14 Remove the bolts and nuts attaching the lower timing chain cover to the engine block Be sure to remove the three bolts from underneath that connect the front of the sump to the bottom of the front cover see illustration Loosen the remaining sump bolts 15 Run a sharp thin knife between the sump gasket and lower timing chain cover cutting the cover free from the gasket Be very careful not to damage or dirty the gasket so you can re use it 16 Break the lower timing chain cover to block gasket seal by tapping the cover with a rubber mallet or with a hammer and block of wood Do not prise between the cover and the engine block as damage to the gasket sealing surfaces will result 17 Using a scraper remove all traces of old gasket material from the sealing surfaces of the covers and engine block Caution Be very careful not to scratch or gouge the delicate aluminium surfaces Also do not damage the sump gasket and keep it clean Gasket removal solvents are available at motor factors and may prove helpful After all gasket material has been 7 14 From underneath the vehicle remove the three bolts arrowed that connect the cover and the sump removed the gasket surfaces can be deg
612. viscosity oil in it it will crank slowly 9 Run the engine until normal operating temperature is reached then disconnect the coil HT lead from the distributor cap and earth it on the engine 10 Connect a voltmeter positive lead to the battery positive post and connect the negative lead to the negative post p ee 20 4 Working under the vehicle remove the starter lower mounting bolt and nut arrowed 11 Crank the engine and take the voltmeter readings as soon as a steady figure is indicated Do not allow the starter motor to turn for more than 10 seconds at a time A reading of 9 volts or more with the starter motor turning at normal cranking speed is normal If the reading is 9 volts or more but the cranking speed is slow the solenoid contacts are burned there is a bad connection or the starter motor itself is faulty If the reading is less than 9 volts and the cranking speed is slow the starter motor is faulty or the battery is responsible defective or discharged 20 Starter motor removal and refitting Note If the starter motor is defective it should be renewed or taken to an auto electrical Specialist for repair Overhaul of the starter motor is unlikely to be a practical proposition for the home mechanic even if Spare parts are available However the solenoid can be renewed separately see Section 21 Removal Caution If the radio in your vehicle is equipped with an ant
613. voir 4 Disconnect the electrical connector s from the receiver drier note that not all models have both the high and low pressure Switches see illustration 5 Disconnect the refrigerant lines from the receiver drier 6 Plug the open line fittings to prevent the entry of dirt and moisture 7 Remove the mounting screws and remove the receiver drier Refitting 8 If a new receiver drier is being fitted it may be necessary to add a quantity of refrigerant oil follow the instructions supplied with the new unit 9 Remove the old refrigerant line O rings and fit new ones This should be done regardless of whether a new receiver drier is being fitted 10 If a new receiver drier is being fitted unscrew the pressure switches and transfer them to the new unit before fitting see illustration 16 4 Not all models have both the high and low pressure switches 11 Lubricate the O rings with refrigerant oil before assembly Refitting 12 Refitting is the reverse of removal but be sure to lubricate the O rings with refrigerant oil before connecting the fittings 3 10 Cooling heating and air conditioning systems 13 Have the system evacuated recharged and leak tested by the qualified engineer who discharged it 17 Evaporator matrix removal and refitting Warning Due to the potential dangers associated with the system you are strongly advised to have any work on the air conditioning system carried out
614. vots and attachments Now grasp the wheel at the 12 o clock and 6 o clock positions and repeat the previous inspection Spin the wheel and check for roughness or tightness of the front wheel bearing If excess free play is suspected at a component pivot point this can be confirmed by using a large screwdriver or similar tool and levering between the mounting and the component attachment This will confirm whether the wear is in the pivot bush its retaining bolt or in the mounting itself the bolt holes can often become elongated Carry out all the above checks at the other front wheel and then at both rear wheels Springs and shock absorbers Examine the suspension struts when applicable for serious fluid leakage corrosion or damage to the casing Also check the security of the mounting points coil springs are fitted check that the spring ends locate in their seats and that the spring is not corroded cracked or broken If leaf springs are fitted check that all leaves are intact that the axle is securely attached to each spring and that there is no deterioration of the spring eye mountings bushes and shackles REF 3 The same general checks apply to vehicles fitted with other suspension types such as torsion bars hydraulic displacer units etc Ensure that all mountings and attachments are secure that there are no signs of excessive wear corrosion or damage and on hydrauli
615. w return and hold down springs and new automatic adjuster thermo clips should also be fitted Due to the continuous heating cooling cycle to which the springs are subjected they may lose their tension over a period of time allowing the shoes to drag on the drum and wear at a much faster rate than normal When fitting new brake shoes use only original equipment or high quality brand name parts Note 1 All four rear brake shoes must be renewed at the same time but to avoid mixing up parts work on only one brake assembly at a time Some rear brake components are different for left and right hand sides so don t mix them up Note 2 If the wheel cylinder is found to be leaking or otherwise defective renew it after removing the brake shoes This is simply a matter of disconnecting the hydraulic line and unbolting the cylinder from the backplate Attempting to overhaul a leaking cylinder is unlikely to be satisfactory even if spare parts are available 1 Chock the front wheels then loosen the rear wheel bolts raise the rear of the vehicle and place it securely on axle stands Remove the rear wheels and release the handbrake 2 Remove the drum retaining screw see illustration and remove the drum If the drum is stuck to the hub spray the area between the hub and the drum with penetrating oil see illustration If the drum still won t come off the shoes have probably worn ridges into the drum and will have to be retracted Insert
616. w the sender unit If the gauge does not respond satisfactorily the gauge or the wiring to the gauge is faulty Where the sender unit has two terminals test the circuit by checking the resistance of the unit No figures were available at the time of writing but typically readings of several hundred or several thousand ohms depending on temperature would be expected A reading of zero short circuit or infinity open circuit would indicate a faulty sender unit Caution Do not earth the wire for more than a second or two or damage to the gauge could occur 4 If a new sender unit is to be fitted make sure the engine is completely cool There will be some coolant loss when the unit is unscrewed so be prepared to catch it or have the new unit ready to fit immediately the old one is removed Disconnect the wiring then unscrew the old unit from the engine and fit the new one Use sealant on the threads Reconnect the wiring and check the coolant level on completion 9 Heater and air conditioning blower motor removal testing and refitting Removal Note The 3 Series models covered by this manual have always used a single blower motor for ventilation heating and air conditioning Old shape E28 5 Series models use two separate blower motors one for ventilation and heating and another for air conditioning New shape E34 5 Series models have a single blower motor like the 3 Series The removal and refit
617. walls must be perfectly clean the top edge of each cylinder must be chamfered and the crankshaft must be in place 2 Remove the cap from the end of No 1 connecting rod refer to the marks made during removal Remove the original bearing shells and wipe the bearing surfaces of the connecting rod and cap with a clean lint free cloth They must be kept spotlessly clean Connecting rod ene bearing oil clearance chec 3 Clean the back side of the new upper bearing shell then lay it in place in the connecting rod Make sure the tab on the bearing fits into the recess in the rod Don t hammer the bearing shell into place and be very careful not to nick or gouge the bearing face Don t lubricate the bearing at this time 4 Clean the back side of the other bearing shell and refit it in the rod cap Again make sure the tab on the bearing fits into the recess in the cap and don t apply any lubricant It s critically important that the mating surfaces of the bearing and connecting rod are perfectly 26 11 Drive the piston gently into the cylinder bore with the end of a wooden or plastic hammer handle General engine overhaul procedures 2B 21 Clean and oil free when they re assembled for this check 5 Position the piston ring gaps so they re staggered 120 from each other 6 Where applicable slip a section of plastic or rubber hose over each connecting rod cap bolt 7 Lubricate the piston and rings with clean engine oil and
618. window system BN description and check N A The electric window system operates the electric motors mounted in the doors which lower and raise the windows The system consists of the control switches the motors associated wiring Removal of the motors and regulators is described in Chapter 11 Diagnosis is usually limited to simple checks of the wiring connections and motors for minor faults which can be easily repaired These include a Check the electric window switches for broken wires and loose connections b Check the electric window fuse and or circuit breaker where applicable c Remove the door trim panel s and check the electric window motor wires to see if they re loose or damaged Inspect the window mechanisms for damage which window mechanisms regulators could cause binding Colour codes BK Black GE Yellow GY Grey R Red SW Black BL Blue GN Green OR Orange RS Pink TN Tan BR Brown GR Green or Grey PK Pink RT Red V Violet Body electrical systems 12 9 22 Wiring diagrams general information Since it isn t possible to include all wiring diagrams for every model year covered by this manual the following diagrams are those that are typical and most commonly needed Prior to checking any circuit check the fuses and circuit breakers to make sure they re in good condition Make sure the battery is fully charged and check the cable connections see Chapter 1 Make sure all connectors are clean w
619. with a hydrometer every hour during the last few hours of the charging cycle Hydrometers are available inexpensively from car accessory shops follow the instructions that come with the hydrometer Consider the battery charged when there s no change in the specific gravity reading for two hours and the electrolyte in the cells is gassing bubbling freely The specific gravity reading from each cell should be very close to the others If not the battery probably has a bad cell s and a new one should be fitted 16 Some maintenance free sealed batteries have built in hydrometers on the top indicating the state of charge by the colour displayed in the hydrometer window Normally a bright coloured hydrometer indicates a full charge and a dark hydrometer indicates the battery still needs charging Check the battery manufacturer s instructions to be sure you know what the colours mean 14 4a Spark plug manufacturers recommend using a wire type gauge when checking the gap if the wire does not slide between the electrodes with a slight drag adjustment is required Lele 17 Ifthe battery is sealed and has no built in hydrometer you can connect digital voltmeter across the battery terminals to check the charge A fully charged battery Should read 12 6 volts or higher 18 Further information on the battery and jump starting can be found in Chapter 5 and at the front of this manual 14 Spark plug check and renewal
620. with a voltmeter and check for voltage at terminal 3 black wire and earth There should be 5 volts present Also probe terminal 3 black wire and terminal 1 brown wire There should be 5 volts present here also 36 Check for voltage at terminal 2 yellow wire and terminal 1 brown wire and slowly open the throttle The voltage should increase steadily from 0 7 volts throttle closed to 4 8 volts throttle fully open Adjustment 37 First measure the stabilised voltage With the ignition on and the throttle closed measure the voltage between terminal 3 black wire and terminal 1 brown wire It should be about 5 volts 38 Next loosen the sensor mounting screws and connect the voltmeter to terminal 2 yellow wire and terminal 3 black wire With the throttle fully open rotate the switch until there is 0 20 to 0 24 volts less than the stabilised voltage Note You will need a digital voltmeter to measure these small changes in voltage 39 Recheck the TPS once more if the readings are correct reconnect the TPS electrical connector It is a good idea to lock the TPS screws with paint or thread locking compound 5 1 Diagram of the PCV system on the M20 engine others similar Airflow meter General description 40 The airflow meter is located on the air intake duct The airflow meter measures the amount of air entering the engine The ECU uses this information to control fuel delivery A large volu
621. working loose MacPherson strut A type of front suspension system devised by Earle MacPherson at Ford of England In its original form a simple lateral link with the anti roll bar creates the lower control arm A long strut an integral coil spring and shock absorber is mounted between the body and the steering knuckle Many modern so called MacPherson strut systems use a conventional lower A arm and don t rely on the anti roll bar for location Multimeter An electrical test instrument with the capability to measure voltage current and resistance NOx Oxides of Nitrogen A common toxic pollutant emitted by petrol and diesel engines at higher temperatures unit of electrical resistance One volt applied to a resistance of one ohm will produce a current of one amp Ohmmeter instrument for measuring electrical resistance O ring type of sealing ring made of a special rubber like material in use the O ring is compressed into a groove to provide the sealing action Glossary of Technical Terms ar Overhead cam ohc engine An engine with the camshaft s located on top of the cylinder head s Overhead valve ohv engine An engine with the valves located in the cylinder head but with the camshaft located in the engine block Oxygen sensor device installed in the engine exhaust manifold which senses the oxygen content in the exhaust and converts this information into an electric curren
622. y Accessory drivebelts Driveshaft Any shaft used to transmit motion Commonly used when referring to the axleshafts on a front wheel drive vehicle Driveshaft Drum brake type of brake using a drum shaped metal cylinder attached to the inner surface of the wheel When the brake pedal is pressed curved brake shoes with friction linings press against the inside of the drum to slow or stop the vehicle Drum brake assembly rere22 Glossary of Technical Terms EGR valve A valve used to introduce exhaust gases into the intake air stream EGR valve Electronic control unit ECU A computer which controls for instance ignition and fuel injection systems or an anti lock braking system For more information refer to the Haynes Automotive Electrical and Electronic Systems Manual Electronic Fuel Injection EFI A computer controlled fuel system that distributes fuel through an injector located in each intake port of the engine Emergency brake braking system independent of the main hydraulic system that can be used to slow or stop the vehicle if the primary brakes fail or to hold the vehicle stationary even though the brake pedal isn t depressed It usually consists of a hand lever that actuates either front or rear brakes mechanically through a series of cables and linkages Also known as a handbrake or parking brake Endfloat The amount of lengthwise movement between two parts As applied to a crankshaf
623. y 7 Checking the oil level is an important preventive maintenance step A consistently low oil level indicates oil leakage through damaged seals or defective gaskets or oil burning internal leakage past worn rings or valve guides The condition of the oil should also be noted If the oil looks milky in colour or has water droplets in it the cylinder head gasket may be blown or the head or block may be cracked The engine should be repaired immediately Whenever you check the oil level slide your thumb and index finger up the dipstick before wiping off the oil If you see small dirt or metal particles clinging to the dipstick the oil should be changed see Section 6 Engine coolant Warning Do not allow antifreeze to come in contact with your skin or with the vehicle 4 9b On other models the expansion tank coolant reservoir is located on the side of the engine compartment remove the cap to add coolant Weekly Checks 4 6b Topping up the engine oil paintwork Rinse off spills immediately with plenty of water Antifreeze is highly toxic if ingested Never leave antifreeze lying around in an open container or in puddles on the floor children and pets are attracted by its sweet smell and may drink it Check with local authorities about disposing of used antifreeze Local collection centres may exist to see that antifreeze is disposed of safely 8 All vehicles covered by this manual are equipped with a pres
624. y renew both left and right struts at the same time to prevent handling peculiarities or abnormal ride quality 1 Loosen but do not remove the front wheel bolts 2 Raise the front of the vehicle and support it on axle stands 3 Remove the front wheel 4 Detach all brake hoses and electrical wires attached to the strut housing 5 Disconnect the electrical connections for the ABS system if applicable 6 If you re removing the left strut disconnect 5 2 pest 2 1 x n F i r nm E 5 13 Support the weight of the strut and remove the three mounting nuts arrowed at the top of the strut 5 Series shown 3 Series similar the electrical connector for the brake pad Wear sensor 7 Remove the bolt securing the ABS wheel sensor if applicable Remove the brake disc see Chapter 9 8 Remove the brake splash shield see illustration 9 On 3 Series models disconnect the anti roll bar from its connecting link see Sec tion 2 On 5 Series models disconnect the anti roll bar link from the strut housing see Section 2 10 On 3 Series models disconnect the control arm balljoint from the steering knuckle see Section 3 and the track rod end from the Steering arm see Section 17 11 On 5 Series models disconnect the bolts that attach the steering arm to the strut housing see illustration 4 5 12 Pull out the lower end of the strut housing
625. y a left hand threaded nut located directly behind the fan 3 Series models 14 Remove the radiator grille assembly see Chapter 11 15 Unbolt and remove the fan bracket and shroud assembly from the radiator see Section 5 16 Remove the radiator see Section 4 17 Unbolt the air conditioning condenser mounting bolts where applicable Do not remove the condenser or disconnect any refrigerant lines from the condenser 18 Carefully pull the condenser back towards the engine slightly to gain access to lift the auxiliary fan 19 Disconnect the fan motor electrical connection and remove the auxiliary fan 20 Refitting is the reverse of removal 5 Series models 21 Remove the screws and trim panel in front of the radiator 22 Unbolt the fan assembly from the condenser mounting points 23 Disconnect the fan electrical connector 24 Remove the fan and housing from the car being careful not to damage the air conditioning condenser when applicable while removing the fan 25 Refitting is the reverse of removal Mechanical fan with viscous clutch 26 Disconnect the battery negative cable Remove the fan shroud mounting screws or plastic fasteners and detach the shroud see Section 4 27 Use a 32 mm open ended spanner to remove the fan clutch assembly Place the spanner on the large nut ahead of the pulley see illustrations and tap the end of the spanner to loosen the nut Caution The nut has left handed A thread
626. ylinder bores for scuffing and scoring 4 Measure the diameter of each cylinder at the top just under the wear ridge area centre and bottom of the cylinder bore parallel to the crankshaft axis see illustrations 5 Next measure each cylinder s diameter at the same three locations across the crankshaft axis Compare the results to this Chapter s Specifications 6 If the required precision measuring tools aren t available the piston to cylinder clearances can be obtained though not quite as accurately using feeler gauges 7 To check the clearance select a feeler gauge and slip it into the cylinder along with the matching piston The piston must be positioned exactly as it normally would be The feeler gauge must be between the piston and cylinder on one of the thrust faces 90 to the gudgeon pin bore 8 The piston should slip through the cylinder with the feeler gauge in place with moderate pressure 9 If it falls through or slides through easily the Clearance is excessive and a new piston will be required If the piston binds at the lower end of the cylinder and is loose toward the top the cylinder is tapered If tight spots are encountered as the piston feeler gauge is rotated in the cylinder the cylinder is out of round 10 Repeat the procedure for the remaining pistons and cylinders 11 If the cylinder walls are badly scuffed or General engine overhaul procedures 2B 15 16 4b The ability to feel whe
627. ystem pressure relative to intake manifold pressure 3 Series E30 316i with M40 B16 engine 318i with M10 B18 engine 318i with M40 B18 engine 320i with M20 B20 engine L J etronic 320i with M20 B20 engine Motronic 325i with M20 B25 engine 5 Series E28 old shape All models 5 Series E34 new shape 518i with M 40 B18 engine All other models Fuel system hold pressure Fuel pump maximum pressure Fuel pump hold pressure Transfer pump pressure Injectors Injector resistance Accelerator cable free play Torque wrench settings Carburettor mountings Fuel pump to cylinder head Throttle body nuts bolts 1 Generalinformation With the exception of early models 316 and 518 models all engines are equipped with electronic fuel injection Early 316 and 518 models are equipped with Solex carburettors The carburettor fitted is either a Solex 2B4 early models or 2BE later models The mechanical fuel pump 3 0 0 06 bars 2 5 to 3 0 bars 3 0 0 06 bars 2 5 to 3 0 bars 2 5 0 05 bars 3 0 0 05 bars 2 5 to 3 0 bars 3 0 0 06 bars 2 5 to 3 0 bars 2 1 bars 6 3 to 6 9 bars 5 5 bars 0 28 to 0 35 bars 14 5 to 17 5 ohms 1 0 mm is driven by an eccentric lobe on the camshaft Fuel injection models are equipped with either the L J etronic or the Motronic fuel injection system From 1988 fuel injection
628. ze type and the more traditional surfacing hone with spring loaded stones Both will do the job but for the less experienced mechanic the bottle brush hone will probably be easier to use You ll also need some paraffin or honing oil rags and an electric drill Proceed as follows 4 Mount the hone in the drill compress the stones and slip it into the first cylinder see illustration Be sure to wear safety goggles or a face shield 5 Lubricate the cylinder with plenty of honing oil turn on the drill and move the hone up and down in the cylinder at a pace that will produce a fine crosshatch pattern on the cylinder walls Ideally the crosshatch lines should intersect at approximately a 60 angle see illustration Be sure to use plenty of lubricant and don t take off any more material than is absolutely necessary to produce the desired finish Note Piston ring manufacturers may specify a smaller crosshatch angle than the traditional 60 read and follow any instructions included with the new rings 6 Don t withdraw the hone from the cylinder while it s running Instead shut off the drill and continue moving the hone up and down in the cylinder until it comes to a complete stop then compress the stones and withdraw the hone If you re using a bottle brush type hone stop the drill then turn the chuck in the normal direction of rotation while withdrawing the hone from the cylinder CROSSHATCH PATTERN d

BMW 3- & 5-Series Service and Repair Manual

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BMW 3- &amp; 5-Series Service and Repair Manual

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BMW 3- & 5-Series Service and Repair Manual