Bmw3 Series

M3, 3181, 3231, 3251, 3281Sedan, Coupe and Convertible

1992, 1993, 1994, 1995, 1996,1997, 1998

Bentley, PublishersCambridge, Massachusetts

B-1 ROBERT BENTLEY, INC. I AUTOMOTIVE PUBLISHERS

Information that makes

1734 Massachusetts Avenuethe differenceoCambridge,MA 02138 USA

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WARNING-Important Safety Notice

Technical Contact InformationWe value your feedback . Technical comments andsuggestions are helpful to us . Please send yourcomments andthoughtsto Bentley Publisherse-mail : tech .bmw@rb.comFrom time to time, updates may be made to thismanual . A listing of updates can be found on the web

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Do not use this manual unless you arefamiliarwith basic automotive repair procedures and safe workshop practices. This manualillustrates the workshop procedures required for most service work . It is not a substitutefor fui¡ and up-to-date information from thevehicie manufacturer orfor propertraining as an automotive technician . Note that it is not possible for us to anticipate al¡ of thewaysorconditions under which vehicles may be serviced or to provide cautions as to all of the possible hazards that may result.The vehicie manufacturer will continue to issue service information updates and parts retrofits after the editorial closing of thismanual . Some of those updates and retrofits will apply to procedures and specifications in this manual . We regretthat we cannotsupply updates to purchasers of this manual .We have endeavored to ensure the accuracy of the information in this manual . Please note, however, that considering the vastquantity and the complexity ofthe service information involved, we cannotwarrant the accuracy orcompleteness ofthe informationcontained in this manual .FORTHESE REASONS,NEITHERTHE PUBLISHER NORTHE AUTHOR MAKESANYWARRANTIES, EXPRESSOR IMPLIED,THATTHE INFORMATION INTHISBOOK ISFREEOFERRORSOR OMISSIONS,ANDWE EXPRESSLY DISCLAIMTHEIMPLIEDWARRANTIES OF MERCHANTABILITYANDOF FITNESSFOR A PARTICULAR PURPOSE, EVEN IF THE PUBLISHER OR AUTHOR NAVE BEEN ADVISED OF A PARTICULAR PURPOSE, AND EVEN IF APARTICULAR PURPOSE IS INDICATED IN THE MANUAL . THE PUBLISHER AND AUTHOR ALSO DISCLAIM ALL LIABILITY FOR DIRECT, INDIRECT,INCIDENTAL OR CONSEQUENTIAL DAMAGESTHAT RESULT FROM ANYUSEOFTHE EXAMPLES, INSTRUCTIONS OR OTHERINFORMATION IN THISBOOK.IN NO EVENT SHALL OUR LIABILITYWHETHER INTORT, CONTRACTOR OTHERWISEEXCEEDTHE COST OFTHIS MANUAL.

Your common sense and goodjudgment arecrucial to safe and successful service work. Read procedures through before startingthem . Think about whether the condition of your car, your leve¡ of mechanical skill, or your leve¡ of reading comprehension mightresult in orcontribute in some way to an occurrence which might cause you injury, damage your car, or result in an unsafe repair.lf you have doubts for these or other reasons about your ability to perform safe repair work on your car, have the work done at anauthorized BMW dealer or other qualified shop .Part numbers listed in this manual are for identification purposes only, not for ordering . Always check with your authorized BMWdealer to verify part numbers and availability before beginning service work that may requíre new parts .Before attempting any work on your BMW, read the wamings and cautions on pages vi¡ and vi¡¡, and any waming or caution thataccompanies a procedure in the service manual . Review the warnings and cautions on pages vi¡ and viü each time you prepare towork on your BMW.Special tools required to perform certain service operations areidentified in the manual and are recommendedforuse. Use of toolsother than those recommended in this service manual may be detrimental to the car's safe operation as well as the safety of theperson servicing the car .

Copies of this manual may be purchased from most automotive accessories and parts dealers specializing in BMW automobiles, fromselected booksellers, or directly from the publisher by mail .The publisher encourages comments from the reader of this manual . These communications have been and will be carefully considered inthe preparation of this and other manuals . Please write to Robert Bentley, Inc ., Publishers at the address listed on the top of this page .This manual was published by Robert Bentley, Inc ., Publishers . BMW has not reviewed and does not vouch forthe accuracy of the technicalspecifications and procedures described in this manual.Library of Congress Cataloging-in-Publication DataBMW 3 Series Service Manual M3, 318i, 323i, 3251, 328i, Sedan, Coupe and Convertible:

1992, 1993, 1994, 1995, 1996, 1997, 1998 .p . cm .

Includes index .ISBN 0-8376-0326-91 . BMW 3 Series automobile--Maintenance and repair--Handbooks, manuals,

etc . I . Robert Bentley, inc .TL215.13251356 1999629.28' 722--cic21

99-17179CIP

Bentley Stock No . B398Editorial closing 01/990302010099 1098765432The paper used in this publication is acid free and meets the requirements of the National Standard for Information Sciences-Permanence of Paper for Printed Library Materials .O©Copyright 1999 Robert Bentley, Inc .All rights reserved . All information contained in this manual is based on the information available to the publisher at the time of editorialclosing . The right is reserved to make changes at any time without notice . No part of this publication may be reproduced, stored in a retrievalsystem, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior writtenconsent of the publisher . This includes text, figures, and tables . All rights reserved under Berne and Pan-American Copyright conventions .Manufactured in the United States of America

General Data and

010 FundamentalsfortheDo-lt-YourselfOwner

Maintenance

020 Maintenance Program

Engine

Transmission

Suspension,Steering andBrakes

4 Body

100 Engine-General110

Engine Removal and Installation113

Cylinder Head Removaland Installation

116

Cylinder Head and Valvetrain117

Camshaft Timing Chain119

Lubrication System

200 Transmission-General210 Clutch230 Manual Transmission

510

Exterior Trim, Bumpers

520

Seats

Bo y Equipment

512 DoorWTdws

540

nrt513

InteriorTrim

541

Convertible Top515

Central Locking and Anti-Theft

600

Electrical System-General

620

Instruments

Electrical S

stem 610 Electrical Component Locations

630 Exterior Lighting611

Wipers and Washers

640

Heating and Air Conditioning6

612

Switches and Electrical Accessories

650

Radio

Equipment and

720 SeatBelts

Accessories

721 Airbag System (SRS)

Electrical WiringDiagrams

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vWarnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viiIndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . back of book

300

Suspension, Steering and

330

Rear SuspensionBrakes-General

331

Final Drive310

Front Suspension

340

Brakes320

Steering and Wheel Alignment

400 Body-General

411 Doors410

Fenders, Engine Hood

412

Trunk Lid

120

Ignition System121

Battery, Starter, Alternator130

Fue¡ Injection160

Fuel Tank and Fuel Pump170

Radiator and Cooling System180

Exhaust System

240

Automatic Transmission250

Gearshift Linkage260 Driveshaft

BMWSERVICEMANUUASBMW7 Series Service Manual: 1988-19947351, 735iL, 740i, 740iL, 750iLRobert Bentley ISBN 0-8376-0328-5BMW3 Series Service Manual : 1992-1998M3,3181,323i,325i,328i, Sedan, Coupe andConvertible Robert BentleyISBN 0-8376-0326-9

Glory Days : When Horsepower andBMWZ3 Service Manual : 1996-1998

Passion Ruled Detroit4-cylinder and 6-cylinder models

Jim Wangers ISBN 0-8376-0208-4Robert Bentley ISBN 0-8376-0327-7

Alfa RomeoOwner's BibleTMBMW3-Series Service Manual: 1984-1990

PatBraden with foreword by Don Black3181, 325, 325e(es), 325i(is), and 325i

ISBN 0-8376-0707-9Convertible Robert BentleyISBN 0-8376-0325-0

Ford F-Series Pickup Owner's BibleTMMoses Ludel ISBN 0-8376-0152-5

BMW5-Series Service Manual: 1989-19955251, 530i, 535i, 540i including TouringRobert Bentley ISBN 0-8376-0319-6BMW5-Series Service Manual: 1982-1988528e, 5331, 535i, 535is Robert BentleyISBN 0-8376-0318-8

ENTHUSIAST TITLESComplete Roundel 1969-1998:30 Years ofthe Magazine of theBMWCar Club ofAmerica (CD-ROM) ISBN 0-8376-0322-6

AFrench Kiss With Death: SteveMcQueen and the Making of Le MansMichael Keyser ISBN 0-8376-0234-3The Speed Merchants: AJourney ThroughThe World ofMotor Racing,1969-72Michael Keyser ISBN 0-8376-0232-7Mustang 5.0Technical Reference&Performance HandbookAl Kirschenbaum ISBN 0-8376-0210-6Maximum Boost: Designing, Testing, andInstalling Turbocharger SystemsCorky Bell ISBN 0-8376-0160-6Volkswagen Sport Tuningfor Street and CompetitionPer SchroederISBN 0-8376-0161-4Sports Car and Competition DrivingPaulFrére with foreword by Phil HillISBN 0-8376-0202-5

Automotive Books From Robert Bentley

GTI, Golf, and Jetta Service Manual: 1985-The Design and Tuning of Competition

1992 Gasoline, Diesel, and Turbo Diesel,Engines PhilipH. Smith, 6th edition revised by

including 16V Robert BentleyDavid N. Wenner ISBN 0-8376-0140-1

ISBN 0-8376-0342-0Going Faster: The Skip Barber Racing

Corrado Official Factory Repair Manual:School Carl Lopez ISBN 0-8376-0227-0

1990-1994 Volkswagen United States9M-f, Ir-Win non Alexander with foreword

ISBN 0-8376-0387-0by MarkMartín ISBN 0-8376-0070-7

Passat Service Manual : 1990-1993,The Technique of Motor Racing Piero

includingWagon Volkswagen United StatesTaruffi with foreword byJuan ManuelFangio

ISBN 0-8376-0378-1ISBN 0-8376-0228-9

Cabriolet and Scirocco Service Manual :Race Car Aerodynamics

1985-1993, including 16VJoseph Katz ISBN 0-8376-0142-8

Robert Bentley ISBN 0-8376-0362-5

The Scientific Design of Exhaust and

Volkswagen Fox Service Manual: 1987-Intake Systems PhilipH. Smith andJohn C.

1993, including GL, GL Sport and WagonMorrison ISBN 0-8376-0309-9

Robert Bentley ISBN 0-8376-0363-3Volkswagen Model Documentation

Rabbit, Scirocco, Jetta Service Manual :Joachim Kuch ISBN 0-8376-0078-2

1980-1984 Gasoline Models, includingVolkswagen Beetle: Portrait of a Legend

Pickup Truck, Convertible, and GTIRobertEdwin Baaske ISBN 0-8376-0162-2 Bentley ISBN 0-8376-0183-5

Jeep Owner's BibleTMMoses Ludel ISBN 0-8376-0154-1

Eurovan Official Factory RepairManual :

MANUUAS

Volkswagen Inspection/Maintenance(I/M) Emission Test Handbook:1980-1997Volkswagen of America ISBN 0-8376-0394-3

Rabbit, Jetta Service Manual: 1977-1984Diesel Models, including Pickup Truckand Turbo Diesel Robert BentleyISBN 0-8376-0184-3Super Beetle, Beetle and Karmann GhiaOfficial Service Manual Type 1:1970-1979Volkswagen United States ISBN 0-8376-0096-0Beetle and Karmann Ghia Official ServiceManual Type 1:1966-1969 VolkswagenUnited States ISBN 0-8376-0416-8Harley-Davidson EvolutionVTwin

Owner's BibleTM Moses LudelISBN 0-8376-0146-0

Audi 100, A6 Official Factory RepairManual: 1992-1997, including S4, S6,quattro and Wagon models .

Toyota Truck&Land Cruiser Owner's

Audi ofAmerica. ISBN 0-8376-0374-9BibleTM Moses Ludel ISBN 0-8376-0159-2

Audi 80, 90, Coupe Quattro Official

AUDI SERVICEMANUUAS

The Racing Driver DenisJenkinson

Factory Repair Manual: 1988-1992ISBN 0-8376-0201-7

including 80 Quattro, 90 Quattro and20-valve models Audi ofAmerica

Unbeatable BMW: Eighty Years of

FUEL INJECTION

ISBN 0-8376-0367-6Engineering and Motorsport Success

Ford Fuel Injection and Electronic Engine

Audi 100, 200 Official Factory RepairJeremy Walton ISBN 0-8376-0206-8

Charles O Probst, SAE

Manua1:1988-1991Audi ofAmericaControl: 1788-1993 .BMW6 Series Enthusiast's CompanionTM

ISBN 0-8376-0301-3

ISBN 0-8376-0372-2JeremyW.11�ISBN 0-8376-0149-5 Ford Fuel Injection and Electronic Engine

Audi 50005 5000CS Official Fa,ctoryBMWEnthusiast's CompanionTMBMW

Control: 1980-1987 Charles O. Probst, SAE

Repair Manual : 1984-1988 Gasoline,Car Club ofAmerica ISBN 0-8376-0321-8

ISBN 0-8376-0302-1

Turbo, and Turbo Diesel, includingWagonBMWNotecards Series 1 Photography by

Bosch Fuel In1ection and Engne

andQuattro Audi ofAmerica ISBN 0-8376-iKlaus Schnitzer ISBN 0-8376-0211-4

Management Charles O. Probst, SAE

0370-6ISBN 0-8376-0300-5

Audi 5000, 50005 Official Factory RepairManual : 1977-1983 Gasoline and Turbo

VOLKSWAGEN OFFICIAL SERVICE

Gasoline, Diesel and Turbo DieselMANUUAS

Audi ofAmerica ISBN0-8376-0352-8

New Beetle Service Manual: 1998-1999

Audi 40005, 4000CS, and Coupe GTRobert Bentley ISBN 0-8376-0385-4

Official Factory Repair Manual : 1984-1987including Quattro and Quattro Turbo AudiJetta, Golf, GTI, Cabrio Service Manual:

ofAmerica ISBN 0-8376-0373-01993-early 1999, including VR6and TDIRobert Bentley ISBN 0-8376-0366-8

SAAB OFFICIAL SERVICE

1992-1999 Volkswagen ofAmerica

Saab 90016 Valve Official Service Manual:ISBN 0-8376-0335-8

19851993 Robert Bentl

ISBN 0837603129-ey---Saab 900 8 Valve Official Service Manual:1981-1988 Robert BentleyISBN0-8376-0310-2

Passat Official Factory Repair Manual :

VOLVO SERVICEMANUAL1995-1997 Volkswagen ofAmerica

Volve240 Service Manual : 1983-1993ISBN 0-8376-0380-3

Robert Bentley ISBN 0-8376-0285-8

Robert Bentley has published servicemanuals and automobilebooks since1950 . Please write Robert Bentley, Inc .,Publishers, at 1734 MassachusettsAvenue, Cambridge, MA 02138, visitourweb síte at http://www.rb.com, orcall 1-800-423-4595 fora free copyofourcomplete catalog, including titles andservice manuals for Jaguar, Triumph,Austin-Healey, MG,and other cars .

Foreword

This service manual covers 1992 through 1998 BMW 3 Series models, and is specifically de-signed to cover only those models built for sale in the United States .

BMW, and most accessories and parts sellers specializing in BMWs, refer to the 3 Series carscovered by this manual as the E36model. The code "E36" is BMW's internal code for the basic plat-form shared by al¡ of the cars covered bythis manual . Exceptfor the engine andafew other compo-nents, the models covered by this manual share many of same components such as suspensionparts, body panels, and the interior pieces . When ordering parts, especially body parts, knowing theE36 code may be helpful .

BMW also uses an interna¡ code for the engines used in the3 Series models . Consult the text inthe 100 Engine-General repair group of this manual foracomplete listing of engine codes. Engine -code information is primarily used internally by BMW, but maybe helpful if you have access to BMWtechnical information .

Forthe BMWownerwith basic mechanical skills, this manual gives detailed maintenance and re-pair information . In addition, the BMW ownerwho has no intention of working on his or her owncarwill find that owning and reading this manual will make it possible to be better informed and to dis-cuss repairs more intelligently with a professional technician . This manual has been prepared fromthe repair information that BMWprovides to its factory-trained technicians andhas been developedprimarily with the do-it-yourself BMW owner in mind . The aim throughout has been clarity and un-derstanding with practical descriptions, step-by-step procedures, and accurate specifications.

TheBMWowner intending to do maintenance and repair should have aset of tools including a setof metric wrenches and sockets, screwdrivers, a torque wrench, and feeler gauges, since these ba-sic tools will be used to do the majority of the maintenance and repair procedures described in thismanual . This manual includes detailed information on these basic tools and other tips for the begin-ner in the first section of the manual, entitled 010 Fundamentals for the Do-It-Yourself Owner.For some of the repairs described in this manual, BMW technicians use special tools . The text willnote when a repair requires these special tools and, where possible, will recommend practica¡ alter-natives.

We have endeavored to ensure the highest degree of accuracy possible . When the vast array ofdata presented in the manual is taken into account, however, no claim to infallibility can be made .We therefore cannot be responsible for the result ofany errors that mayhave crept into the text. Thepublisher encourages comments from the readers of this manual with regard to any errors and, al-so, suggestíons for improvement in the presentation of technical material. These communicationshave been and will be carefully considered in the preparation of future printings of this and othermanuals. Please contact Robert Bentley, Inc . using the contact information on the copyright pageat the beginning of this manual .

BMW offers extensive warranties, especially on components of the fuel delivery and emissionscontrol systems. Therefore, before deciding to repair a BMWthat may still be covered wholly or inpart by any warranties issued by BMWof North America, consultyour authorized BMWdealer . Youmay find that he can make the repair eitherfree or at minimum cost .

Regardless of its age and whetheror not it is still protected by warranty, your BMWis an easy carto get serviced . So if at any time a repair is needed that you feel is too difficult to do yourself, atrained BMWtechnician is ready to do the job for you. Each authorized BMWdealer senrice depart-ment has made a significant investment in service and diagnostic test equipment, specials tools,and BMW original parts. It is also the best source of the most up-to-date repair and service tech-niques, which includes factory training and technical literature . Servicing your BMWthrough an au-thorized BMWdealer will insure that your investment will be protected while maintaining the highestdegree of service standards.

Robert Bentley

Please read these warnings and cautionsbefore proceeding with maintenance and repair work.WARNING-

" Friction materials (such as brake pads or shorts or clutch discs)contain asbestos fibers or other friction materials. Do not create

" See also Cautions on page viü

dust by grinding, sanding, or by cleaning with compressed air.

" Some repairs may be beyond your capability. If you lack the

Avoid breathing dust. Breathing any friction material dust can lead

skills, tools and equipment, or a suitable workplace for any proce-

to serious diseases and may result in death .

dure described in this manual, we suggest you leave such repairs

" Batteries give off explosive hydrogen gas during charging .to an authorized BMW dealer service department or other quali-

Keep sparks, lighted matches and open flame away from the topfied shop .

of the battery If hydrogen gas escaping from the cap vents is

" Do not re-use any fasteners that are worn ordeformed in normal

ignited, it will ignite gas trapped in the cells and cause the battery

use . Many fasteners are designed to be used only once and

to explode .

become unreliable and may fail when used a second time. This

" Connect and disconnect battery cables, jumper cables ora bat-includes, but is not limited to, nuts, bolts, washers, self-locking nutsor bolts, circlips and cotter pins . Always replace these fastenerswith new parts.

" Do not quick-charge the battery (for boost starting) for longer" Never work under a lifted car unless it is solidly supported on

than one minute . Wait at least one minute before boosting the bat-stands designed for the purpose . Do not support a car on cinder

tery a second time .blocks, hollow tiles or other props that may crumble under contin-uous load . Never work under a car that is supported solely by a

" Do not allow battery charging voltage to exceed 16.5 volts. If thejack. Never work under the car while the engine is running .

battery begins producing gas or boiling violently, reduce the charg-ing rate . Boosting a sulfated battery at a high charging rate can

" If you are going to work under a car on the ground, make sure

cause an explosion .that the ground is level . Block the wheels to keep the car from roll-ing . Disconnect the battery negative (-) terminal (ground strap) to

" The air-conditioning system is filled with chemical refrigerant,prevent others from starting the car while you are under it.

which is hazardous . The A/C system should be serviced only bytrained technicians using approved refrigerant recovery/recycling

" Never run the engine unless the work area is well ventilated .

equipment, trained in related safety precautions, and familiar withCarbon monoxide kills .

regulations governing the discharging and disposal of automotive

" Finger rings, bracelets and other jewelry should be removed so

chemical refrigerants.

tery charger only with the ignition switched off, to prevent sparks.Do not disconnect the battery while the engine is running .

that they cannot cause electrical shorts, get caught in running

" Do not expose any part of the A/C system to high temperaturesmachinery, or be crushed by heavy parts .

such as open flame. Excessive heat will increase system pressure

" Tie long hair behind your head . Do not wear a necktie, a scarf,

and may cause the system to burst .

loose clothing, or a necklace when you work near machine tools or

" Some aerosol tire inflators are highly flammable . Be extremelyrunning engines . If your hair, clothing, orjewelry wereto get caught

cautious when repairing a tire that may have been inflated usingin the machinery, severe injury could result .

an aerosol tire inflator. Keep sparks, open flame or other sources

" Do not attempt to work on your car if you do not feel well . You

of ignition away from the tire repair area . Inflate and deflate the tire

increase the danger of injury to yourself and others if you are tired,

at least four times before breaking the bead from the rim . Com-

upset or have taken medication or any other substance that may

Pletely remove the tire from the rim before attempting any repair.

keep you from being fully alert .

" Illuminate your work area adequately but safety. Use a portablesafety light for working inside or under the car. Make sure the bulbis enclosed by a wire cage . The hot filament of an accidentally bro-ken bulb can ignite spilled fuel or oil .

" Catch draining fuel, oil, or brake fluid in suitable containers. Donot use food or beverage containers that might mislead someoneinto drínking from them . Store flammable fluids awayfrom fire haz-ards . Wipe up spills at once, but do not store the oily rags, whichcan ignite and burn spontaneously.

" Always observe good workshop practices. Wear goggles whenyou operate machine tools or work with battery acid . Gloves orother protectioe clothing should be worn whenever the job requiresworking with harmful substances .

" Greases, lubricants and other automotive chemicals containtoxic substances, many of which are absorbed directly through theskin . Read the manufacturer's instructions and warnings carefully.Use hand and eye protection . Avoid direct skin contact

" Cars covered bythis manual are equipped with a supplementalrestraint system (SRS), that automatically deploys an airbag(s) inthe event of a frontal ímpact . The airbag(s) is inflated by an explo-sive device. Handled improperly or without adequate safeguards,can be accidently activated and cause serious injury.

" The ignition system produces high voltages that can be fatal .Avoid contact with exposed terminals and use extreme care whenworking on a car with the engine running orthe ígnition switched on .

" Place jack stands only at locations specified by manufacturer.The vehicle lifting jack supplied with the vehicle is intended for tirechanges only. A heavy duty floor jack should be used to lift vehiclebefore installing jack stands. See 010 Fundamentals for the Do- .it-Yourself Owner.

" Battery acid (electrolyte) can cause severe burns . Flush contactarea with water, seek medical attention .

" Aerosol cleaners and solvents may contain hazardous ordeadlyvapors and are highly flammable . Use only in a well ventilatedarea . Do not use on hot surfaces (engines, brakes, etc .) .

" Disconnect the battery negative (-) terminal (Ground strap)

" Do not remove coolant reservoir or radiator cap with the enginewhenever you work on the fuel system orthe electrical system . Do

hot. Danger of bums and engine damage .not smoke or work near heaters or other fire hazards . Keep anapproved fire extinguisher handy.

continued on next pagevii

Please read these warnings and cautionsbefore proceeding with maintenance and repair work.

CAUTION-

" See also Warnings on page vi¡

" Before doing any electrical welding on cars equipped with ABS,disconnect the battery negative (-) terminal (ground strap) and the

" If you lack the skills, tools and equipment, or a suitable work-

ABS control unit connector.shop for any procedure described in this manual, we suggest youleave such repairs to an authorized BMW dealer or other qualified

" On cars equipped with anti-theft radios, make sure you knowtheshop.

correct radio activation code before disconnecting the battery orremoving the radio. lf the wrong code is entered into the radio

" BMW is constantly improving its cars and sometimes these

when power is restored, that radio may lock up and be renderedchanges, both in parts and specifications, are made applicable to

inoperable, even if the correct code is then entered .earlier models. Therefore, part numbers listed in this manual arefor reference only. Always check with your authorized BMW dealer

" Always make sure ignition is off before disconnecting battery.parts department for the latest information .

" Label battery cables before disconnecting . On some models," Before starting a job, make certain that you have all the neces-

battery cables are not color coded .sary tools and parts on hand . Read al¡ the instructions thoroughly,do not attempt shortcuts . Use tools appropriate to the work and

" Disconnecting the battery may erase fault code(s) stored in con-use only replacement parts meeting BMW specifications . Make-

trol module memory Using special BMW diagnostíc equipment,shift tools, parts and procedures will not make good repairs .

check for faultcodes prior to disconnecting the batterycables. If theCheck Engine light is illuminated, see 100 Engine-General for

" Use pneumatic and electric tools only to loosen threaded parts

On-Board Diagnostics (OBD) fault code information . lf any otherand fasteners . Never use these tools to tighten fasteners, espe-

system faults have been detected (indicated by an ílluminatedcially on light alloy parts. Always use a torque wrench to tighten

warning light), see an authorized BMW dealer.fasteners to the tightening torque specification listed .

" If a normal or rapid charger is used to charge battery, the battery" Be mindful ofthe environment and ecology. Beforeyou drain the

must be disconnected and removed from the vehicle in order tocrankcase, find out the proper way to dispose of the oil . Do not

avoid damaging paint and upholsterypour oil onto the ground, down a drain, or into a stream, pond orlake . Dispose of in accordance with Federal, State and Local laws.

" Do not quick-charge the battery (for boost starting) for longerthan one minute . Wait at least one minute before boosting the bat-e If battery power is lost or the battery has been disconnected, the

tery a second time .power windows must be re-initialized . Both one touch up/downand pinch-protection will be inactive until windows are re-initial-

" Connect and disconnect a battery charger only with the batteryized . See 512 Door Windows .

charger switched off.

" The control module for the anti-lock brake system (ABS) cannotwithstand temperatures from a paint-drying booth or a heat lampin excess of 203°F (95°C) and should not be subjected to temper-atures in excess of 185°F (85°C) for more than two hours .

" Sealed or"maintenance free" batteries should be slow-chargedonly, at an amperage rate that is approximately 10% of the bat-tery's ampere-hour (Ah) rating .

" Do not allow battery charging voltage to exceed 16.5 volts. If thebattery begins producing gas orboiling violently, reduce the charg-ing rate . Boosting a sulfated battery at a high charging rate cancause an explosion .

GENERAL

FUNDAMENTALS FORTHE DO-ITYOURSELF OWNER

010-1

010 Fundamentals for theDo-lt-Yourself Owner

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . .010-1

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-8Basic Tool Requirements . . . . . . . . . . . . . . . . 010-8

HOW TO USE THIS MANUAL . . . . . . . . . . . 010-2

Jack Stands . . . . . . . . . . . . . . . . . . .

. . . . . . 010-9Warnings, Cautions and Notes . . . . . . . . . . . . 010-2

Oil Change Equipment . . . . . . . . . . . . . . . . . . 010-9

GETTING STARTED. . . . . . . . . . . . . . . . . . . .010-2

Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . 010-10Feeler Gauges . . . . . . . . . . . . . . . . . . . . . . . 010-10

Safety

. . . . . . . . . .

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

Digital Multimeter

. . . . . . . . . . . . . . . . . . . . . 010-10Lífting the Car . . . . . . . . . . . . . . . . . . . . . . . . . . 010-3

gMW Special Tools . . . . . . . . . . . . . . . . . . . . 010-11Raising car safely . . . . . . . . .

. . . . . . . . . . . . . 010-3Working under car safely . . . . . . . . . . . . . . . . . . . 010-4

EMERGENCIES . . . . . . . . . . . . . . . . . . . . . . 010-11

ADVICE FOR THE BEGINNER . . . . . . . . . . 010-4

Changing a Tire . . . . . . . . . . . . . . . . . . . . . .010-11Car Will Not Start . . . . . . . . . . . . . . . . . . . . .010-11

Planning Ahead . . . . . . . . . . . . . . . . . . . . . . . . 010-4

Jump Starting Car . . . . . . . . . . . . . . . . . . . . . 010-12Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-4

Overheating

. . . . . . . . . . . . . . . . . . . . . . . . . 010-12Non-reusable Fasteners . . . . . . . . . . . . . . . . . . 010-5

Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . 010-13Tightening Fasteners . . . . . . . . . . . . . . . . . . . . 010-5

Brake Fluid Level

. . . . . . . . . . . . . . . . . . . . . 010-13Gaskets and Seals . . . . . . . . . . . . . . . . . . . . . . 010-5

Check Engine Warning Light . . . . . . . . . . . . 010-13Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . 010-6

pim Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-13Wire Repairs

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

Towíng

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

BUYING PARTS

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

Spare Parts Kit . . . . . . . . . . . . . . . . . . . . . . . 010-14

Genuine BMW Parts . . . . . . . . . . . . . . . . . . . . 010-6Non-returnable Parts . . . . . . . . . . . . . . . . . . . . 010-7

TABLES

Information You Need to Know . . . . . . . . . . . . 010-7

a. General Bolt Tightening Torques

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-7

Although the BMW is a sophisticated and complex machine,basic maintenance can be accomplished by an interested own-er with mechanical skills and the right information . Most of thepreventive maintenance that is required in the lifetime ofthe av-erage BMW isweil within the capabilities of thedo-it-yourseifer.

WARNING -Do not use this manual unless you are familiar withbasic automotive repair procedures and sale work-shop practices . This manual illustrates the work-shop procedures required for most service work; itis nota substitute for full and up-to-date informationfrom the vehicle manufacturer or for proper trainingas an automotive technician . Note that it is not pos-sible forus to anticipate al¡ of the ways or conditionsunder which vehicles maybe serviced ortoprovidecautions as to all of the possible hazards that mayresult '

in Nm (max . permissible) . . . . . . . . . . . . . . . . . . . . 010-5

WARNING-Your common sense andgoodjudgmentare crucialto sale and successful service work. Read proce-dures through before starting them. Think aboutwhether the condition ofyour car, your leve¡ of me-chanical skill, or your leve¡ of reading comprehen-sion might result in or contribute in some way to anoccurrence that might cause you injury damageyour car, or result in an unsafe repair. lf you havedoubts for these or other reasons about yourabilítyto perform sale repair work on your car, have thework done at an authorized BMW dealer or otherqualified shop.

This section of the manual is intended to help the beginnerget started . To begin with there is a discussion on How To UseThis Manual . Tips on mechanicas skills and workshop practic-es that can helpthe beginner do a faster and more thorough jobcan be found under Getting Started. The basic tools neededto do most of the procedures in this manual are found underTools. The section ends with aquick reference guide to Emer-gencies, including basic troubleshooting and information onhow to gauge the seriousness of a problem .

GENERAL

010-2

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

HOWTO USE THIS MANUALA note contains helpful information, tips that will hefp in

The manual is divided into nine sections :

doing a better job and completing !t more easíly.

0 GENERALDATA AND MAINTENANCE1 ENGINE2 TRANSMISSION3 SUSPENSION, STEERING ANDBRAKES4 BODY5 BODY EQUIPMENT6 ELECTRICAL SYSTEM7 EQUIPMENTANDACCESSORIESELECTRICAL WIRING DIAGRAMS

0 GENERAL DATA AND MAINTENANCE covers the rec-ommended maintenance schedules and service proceduresneeded to perform BMW scheduled maintenance work. Alsowithin this section is the 010 Fundamentals for the Do-It-Yourself Owner section, which contains basic instructions,tips and helpful hints for do-it-yourself maintenance and repair .

The next seven sections (1 through 7) are repair based andare further broken down into three digit repair groups . Each ma-jor section begins with a General repair group, e.g . 100 En-gine-General. These "00" (double zero) groups are mostlydescriptive in nature, covering topics such as theory of opera-tion and troubleshooting. The remainder of the repair groupscontain the more involved repair information. The last majorsection contains detailed electrical wiring diagram schematics .

A master listing of the 9 major sections and the correspond-ing individual repair groups can be found on the inside frontcover.

Each repair group begins with a Table of Contents listing themajos subject headings within the group . Page numbersthroughout the manual are organized according to the repairgroup system . For example, you can expect to find repairinfor-mation on brakes (Repair Group 340) beginning on page 340-1 . A comprehensive index can be found at the back of the man-ual.

Warnings, Cautions and Notes

Throughout this manual are many passages with the head-ings WARNING, CAUTION, or NOTE . These very importantheadings have diflerent meanings .

WARNING-The text under this heading warns ofunsafepractic-es thatare very likely to cause ínjury, eitherby dírectthreat to the person(s) pertorming the workorbyin-creased riskofaccident ormechanfcal fallure whíledriving.

CAUTION-A caution calls attention to important precautionsto be observed during the repair work that will heloprevent accidentally damaging the caror its parts.

GETTING STARTED

Safety

NOTE-

Please read every WARNING, CAUTION, and NOTE at thefront of the manual and as they appear in repair procedures .They are very important. Read them before you begin anymaintenance or repair job.

Some WARNINGs and CAUTIONs are repeated whereverthey apply. Read them all . Do not skip any. These messagesare important, even to the ownerwhonever intends to work onthe car.

GETTING STARTED

Most ofthe necessary maintenance and minor repair that anautomobile will need can be done with ordinary tools, even byowners with little or no experience in car repair . Below is someimportant information on how to work safely, a discussion ofwhat tools will be needed and how to use them .

Although an automobile presents many hazards, commonsense and good equipment can helo ensure safety. Many acci-dents happen because of carelessness . Pay attention and stickto these few important safety rules .

WARNING -" Never run the engine in the work area unless itis well-ventflated. Theexhaustshouldbe ventedto the outside. Carbon monoxide (CO) in the ex-haust kilts.

" Remove all neckties, scarts, loose clothing, orjewelry when working near running engines orpower tools. Tuck in shirts . Tie long haír and se-cure it undera cap. Severeinjury can resultfromthese things beíng caught in rotating parts.

" Remove ríngs, watches, and bracelets. Asídefrom the dangers ofmoving parts, metallic jew-elry conducts electricity and may cause shorts,sparks, bums, or damage to the electrical sys-tem when accidentally contacting the battery orother electrical terminals .

" Disconnectthe battery negative () cable when-ever working on or near the fuel system or any-thlng that is electrically powered. Accidentalelectrícal contact may damage the electricalsystem or cause a fire.

WARNING-" Never work under a lifted car unless it is solidlysupported on jack stands that are intended forthat purpose. Do not support a car on cinderblocks, bricks, or other objects that may shift orcrumble under continuous load. Never work un-dera car that is supported onlybythe lifting jack.

" Fuel is highly flammable. When working aroundfuel, do notsmoke or worknearheaters orotherfire hazards. Keep an approved fire extinguisherhandy.

" llluminate the work area adequately and safely.Use a portable safety light for working inside orunderthe car. A fluorescent type light is best be-cause it gives off less heat. If using a light with anormal incandescent butb, use rough servicebulbs to avoid breakage. The hot filament of anaccidentallybroken bulb can ignite spilled fuel oroil

" Keep sparks, lighted matches, and any openllame away from the topofthe battery. Hydrogengas emitted by the battery is highly flammable.Any nearby source of ignition may cause thebattery to explode.

" Never ¡ay tools or parts in the engine compart-ment or on top of the battery. They may fall intoconfined spaces and be difficult to retrieve, be-come caught in beits or other rotating partswhen the engine is started, or cause electricalshorts and damage to the electrical system.

" The fuel system is designed to retain pressureeven when the ignition is off. When working withthe fuelsystem, loosen the fuel fines slowly to al-low the residual pressure to dissipate gradually.Take precautions to avoid spraying fuel.

Lifting the Car

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER 010-3

For those repairsthat require raising the car, the properjack-ing points should be used to raise the car safely and avoid dam-age. There are four jacking points from which the car can besafely raised . The jack supplied with the car by BMW can onlybe used at the four side pointsjust behind the front wheel orjust in front ofthe rear wheel. See Fig. 1 .

WARNING-" When raising the car using a floor jack or a hy-draulic lift, carefully position the jackpad to pre-vent damaging the car body. A suitable liner(wood, rubber, etc .) should be placed betweenthe jack and the car to prevent body damage .

" Watch thejack closely. Make sure ft stays stableand does not shiftor tilt. As the car is raised, thecar may rol¡ slightly and the jack may shift.

Fig. 1.

3-Series jacking points (arrows) .

Raising car safely1 . Park car on flat, leve¡ surface .

2. Remove the round cover from jack mount using ascrewdriver. See Fig. 2.

0013126

Fig. 2.

Jack mount cover being removed from rocker panel .

3. Place jack fully into position . See Fig. 3. Make sure jackis resting on flat, solid ground . Useaboard or other sup-port to provide a firm surface for the jack, if necessary.

4. Raise car slowly while constantly checking position ofjack and car.

5. Once car is raised, block the wheel that is opposite andfarthest from jack to prevent car from unexpectedly roll-ing.

GET77NGSTARTER

010-4

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

Fig. 3.

BMWsupplied jack correctly positioned in front jacking point .

Most of the repairs and maintenance tasks described in thismanual can be successfully completed by anyone with basictools and abilities. To prevent getting in too deep, know what

WARNING-

the wholejob requires before starting . Read the procedurethor-" Do not rely on the transmission or the emergen-

oughly, from beginning to end, in order to know just what to excy brake to keep the car from rolling. They are

pect and what parts will haveto be replaced .not a substitute for positively blocking the oppo-site wheel.

" Never work undera car that is supportedonlybya jack Use jack stands that are properly de-signed to support the car. See Tools.

Working under car safely

1 . Disconnect negative (-) cable from battery so that noone else can start the car. Let others know what you willbe doing.

CAUTION-Priorto disconnecting the battery read the batterydisconnection cautions given at the front of thismanual on page vüi.

2. Raise car slowly as described above.

3. Use at least two jack stands to support the car. Ajackis a temporary lifting device and should not be usedalone to support the car while you are under it . Use jackstands designed for the purpose of supporting a car.For more information on jack stands, see Tools below.

WARNING -Do not use wood, concrete blocks, orbricks to sup-port a car. Wood may split. Blocks or bricks, whilestrong, are not designed for that kind of load, andmay brakk orcollapse .

ADVICE FOR THE BEGINNER

4 . Place jack stands on firm, solid surface. If necessary,use a flat board or similar solid object to provide a firmfooting .

5. Lower car slowly until its weight is fully supported byjack stands . Watch to make sure that the jack stands donot tip or lean as the car settles on them .

6. Observe all jacking precautions again when raising carto remove jack stands.

ADVICE FORTHE BEGINNER

The tips in the paragraphs that follow are general advice tohelp any do-it-yourself BMWowner perform repairs and main-tenance tasks more easily andmore professionally .

Planning Ahead

Cleanliness

Keeping things organized, neat, and clean is essential to do-ing a good job. When working under the hood, fender coverswill protect the finish from scratches and other damage . Makesure the car is relatively clean so that di rt under the coverdoesnot scratch the finish .

Any repairjob will be less troublesome ifthe parts are clean.For cleaning old parts, there are many solvents and partscleaners commercially available.

For cleaning parts prior to assembly, commercially availableaerosol cans of parts cleaneror brake cleaner are handyto use,and the cleaner will evaporate completely.

WARNING -Virtually all solvents used for cleaning parts arehighly flammable, especially in aerosol form . Usewíth extreme care. Do not smoke. Do not use theseproducts near any source of heat, sparks or flame.

Let any solvent or cleaning product dry completely . Low-pressure, dry compressed air is helpful if available . Also, useonly lint-free rags for cleaning and drying .

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

010-5

WARNING -Avoid getting tools or clothing near the battery. Bat-tery electrolyte is a corrosive acid. Be careful withbrake fluid, as it can damage the cars paint Finally,keep rubber parts such as hoses and bolts freefrom oil orgasoline, as they willcause the materialto soften and fail prematurely.

Non-reusable FastenersMany fasteners used on the cars covered by this manual

must be replaced with new oses oncethey are removed. These

Fig. 4. General sequence for alternately tightening multiple fasten-

include but are not limited to : bolts, nuts (self-locking, nylock,

ers.

etc.), cotter pins, studs, brake fittings, rol¡ pins, clips and wash-ers. GenuineBMW parts should be the only replacement parts

NOTE-used for this purpose.

" Metric bolt classes or grades are marked on the bolt'head.

Some bolts are designed to stretch during assembly and arepermanently altered rendering them unreliable once removed.These are known as torque-to-yield fasteners. Always replacefasteners where instructed to do so . Failure to replace thesefasteners could cause vehicle damage and personal injury .See an authorized BMW dealer for applications and orderinginformation .

Tightening Fasteners

When tightening the bolts or nuts that attach a component, itis always good practice to tighten the boltsgraduallyand evenlyto avoid misalignment or over stressing any one portion of thecomponent. For components sealed with gaskets, this methodhelpsto ensure thatthe gasket will seal properly and complete-ly .

Where there are severa¡ fasteners, tighten them in a se-quence alternating between opposite sides of the component.Fig. 4 shows such asequence for tightening six bolts attachinga typical component. Repeatthe sequence until al¡ the bolts areevenly tightened to the proper specification.

" Do not confuse wrench size with bolt diameter size.For a listing of the common wrenches used on vari-ous bolt diameters, see Basic Tool Requirements.

Table a. General Bolt Tightening Torques in Nm(max. permissible)

Bolt Class (according to DIN 267)Boltdiameter 5.6 5 .8 6 .8 8.8 10.9 12.9

M5 2.5 3.5 4 .5 6 8 10

M6

4.5

6

7.5

10

14 ` 17

M8

11

15 -

18

24

34

40

M10 23 30 36 47 66 79

M12 39 52 62 82 115 140

M14 62 82 98 130 180 220

M16 94 26 150 200 280 340

M18 130 174 210 280 390 470

For some repairs a specific tightening sequence is neces-sary, or a particular order of assembly is required . Such special

Gaskets and Sealsconditions are noted in the text, and the necessary sequence isdescribed or illustrated . Where no specific torque is listed, Ta-

The smoothest metal mating surfaces still have imperfecble a can be used as a general guide for tightening fasteners.

tions that can allow leakage. To prevent leakage at critica¡joints, gaskets of soft, form-fitting material are used to fill in the

WARNING-

imperfections .Table a is a general reference only. The values list-ed in the table are notintended to be used as a sub-

To be most effective, gaskets are designed to crush and be-stitute for torques specifically called out in the text

come thinner as the mating parts are bolted together . Once athroughout this manual.

gasket has been used, it is no longer capable of making asgood a sea¡ as when new, and is much more likely to leak. Forthis reason, gaskets should not be reused . Always plan to usenew gaskets for any reassembly. Some gaskets-such ashead gaskets-are directional . Make sure that these are in-stalled correctly . This same logic applies to any part used forsealing, including rubber O-rings and copper sealing washers.

ADVICE FOR THE BEGINNER

010-6

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

In places where a shaft must pass through a housing, flexiblelip seals are used to keepthe lubricating oil or grease from leak-ing out past the rotating shaft. Seals should never be reusedonce they have been removed. When removing a seal, be care-ful notlo scratch orotherwise damage the metal surfaces. Evenminor damage to sealing surfaces can cause sea¡ damage andleakage.

The key to sea¡ installation is to get the sea¡ in straight withoutdamaging ¡t. Use a sea¡ driver that is the same diameter as theseal housing to gently and evenly insta¡I into place. If a propersize seal driver is not available, a socket of the right size will do .

When installing a seal, ¡t a good idea to coat the sea¡ with o¡Ito aid installation . Some seals are directional and special instal-lation instructions apply. Make sure ¡t is installed with the lip fac-ing the correct way. Normally the lip faces the inside. Note theinstallation direction of the old sea¡ before removing ¡t.

Electrical Testing

Many electrical problems can be understood and solved withonly a little fundamental knowledge of how electrical circuits

Insulate the finished connection . Electronics stores can sup-function .

ply heat-shrinkable insulating tubing that can be placed ontothe wire before connectiog, slid over the finished joint, and

Electric current only flows in a complete circuit . To operate,

shrunk to a tight fit with a heat gun or hair dryer. The next bestevery electrical device in the car requires a complete circuit in-

alternative is electrical tape . Make sure the wire is clean andcluding a voltage source and a path to ground . The positive (+)

free of solder flux or other contamination. Wrap the joint tightlyside of the battery is the original voltage source, and ground is to sea¡ out moisture . See 600 Electrical-General for more in-any retum path to the negative ( )- side of the battery° whetherli

formation.through the wiring harness or the car body . Except for portionsof the charging system, al¡ electrical current in the car is directcurrent (DC) and flows from positive (+) to negative (-).

BVYING PART$Switches are used to turn components on or off by complet-

ing or interrupting #he circuit . Aswitch is "open" when the circuit

Many of the maíntenance and repairtasks in this manual cal¡is ínterrupted, and "closed" when the circuit is completed. Fig. 5

forthe installation of new parte, or the use of newgaskets andshowsabasic circuit schematic. See600 Electrical System-

other materials when reinstalling parts. Most often, the partsGeneral for electrical troubleshooting.

that will be needed should be on hand before beginning the job.Read the introductory text and the complete procedure to de-termine which parts will be needed .

B029ELG

Fig. 5.

Schematic representation of simple circuit for light bulb . Igni-tion switch is shown closed, making circuit complete .

BVYING PARTS

Wire Repairs

Repairs to a wiring harness require special care to make therepair permanent.The wire ends must be clean. lf frayed oroth-erwisedamaged, cutoff the end. If the wire istoo short, splice ina new piece of wire of the same size and make two connec-tions .

Use connectors that are designed for the purpose. Crimped-on or soldered-on connectors are best. Crimp connectors andspecial crimping pliers are widely available. If soldering, useneedlenose pliers to hold the wire near the solder joint and cre-ate a "heat dam" . This keeps the heat and the solder from trav-eling up the wire . Always use a solder made specifically forelectrical work (rosin core).

NOTE-Twisting wires together to make a repair is not recom-mended. Corrosion and vibration will eventually spoilthe connection andmaylead to irreparable damage tosensitive electronic componente.

NOTE-Forsome bigger jobs, partial disassembly and inspec-tion are required to determine a complete parts list.Read the procedure carefully and, if necessary, makeother arrangements to get the necessary parts whileyour car is disassembled.

Genuine BMW Parts

Genuine BMW replacement parts from an authorized BMWdealer are designed and manufactured lo the same high stan-dards as the original parts. They will be the correct material,manufactured to the same specifications, and guaranteed lo fitand work as intended by the engineers whodesigned the car.Some genuine BMWparts have a limited warranty.

Non-returnable Parts

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER 010-7

Many independent repair shops make apoint of using genu-

Original body paneis and other large components are identi-ine BMW parts, eventhough they may at times be more expen-

fied by a label bearing the VIN and twoBMWroundel logos . Re-sive . They know the value of doing the job right with the right

placementparts have a similarlabel, bearing oneBMWroundelparts. Parts from other sources can be as good, particularly if

logo and the letters DOT-R. See Fig. 6. Parts or assembliesmanufactured by one of BMWs original equipment suppliers,

bearing the label are the engine, transmission, front and rearbut it is often difficult to know .

bumpers, front fenders, rear quarter paneis, hood, trunk lid anddoors. These labels should not be removed as they will tear

BMW is constantly updating and improving their cars, often

apart.making improvements during a given model year. BMW mayrecommend a newer, improved part as a replacement, andyour authorized dealer's parts department will know about itand provide it . The BMWparts organization is best equipped todeal with anyBMWparts needs.

Some parts cannot be returned for credit, even if they are thewrong parts for the car. The best example is electrical parts,which are almost universally considered non-returnable be-

,..cause they are so easily damaged internally .

Buy electrícal parts carefully, and be as sure as possible that P-DOT~ R

a replacement is needed, especially for expensive parts suchas electronic control units . It may be wise to let an authorized

B328FUN

BMWdealer or other qualified shop confirm your diagnosis be-fore replacing an expensive part that cannot be retuned.

Fig. 6.

Labels used to identiy parts . Original equipment label withVIN number and roundel logos (top) and replacement part la-bel with one roundel logos

Information You Need to KnowEngine. 3-Series cars covered in this manual are powered

Model. When ordering parts it is important that you know the

by either a 4- or 6-cylinder engine . For information -on enginecorrect model designation for your car. Models covered in this

codesand engine applications, see 100 Engine-General .manual are E36 3 Series in both 4- and 6-cylinder configura-tions .

Transmission . The transmission type with its identifyingcode may be important when buying clutch parts, seals, gas

Moda¡ Year. This is not necessarily the same as date of

kets, and other transmission-related parts. For information onmanufacture or date of sale . A 1997 model may have been

transmission codes and applications, see 200 Transmissionmanufactured in late 1996, and perhaps not sold until early

General.1997. It is still a 1997 model. Model years covered by this man-ual are 1992to 1998 .

SERVICEDate of Manufacture. This information is helpful when or-

dering replacement parts or determining if any of the warranty

BMWdealers are uniquely qualified to provide service forrecalls are applicable to your car. The label on the driver's door

BMWcars . Their authorized relationship with the large BMWbelowthe door latch will specifythe month and yearthat the car

service organization means that they are constantly receivingwas built .

newtools and equipment, together with the latest and most ac-curate repair information .

Vehicle Identification Number (VIN). This is a combinationof letters and numbers that identify the particular car. TheVINappears on the state registration document, and on the car it-self. One location is in the rear of the engine compartment, en-other in the lower left comer of the windshield .

The National Highway Traffic Safety Administration (NHT-SA) requires passenger cars with a high theft rate to have theVIN marked on specific parts ofthe car when manufactured . OnBMWcars, these parts are identified by an adhesive label.

)WBADK000000000 000 0

TheBMWdealers service technicians are highlytrained andvery capable. Unfke most independent repair shops, autho-rized BMW dealers are intensely committed to supporting theBMW product. They share the owners interest in BMWvalue,performance, and reliability. On the other hand, there are manyindependent shops that specialize in BMWservice and are ca-pable of doing high quality repair work. Checking with otherBMW owners for recommendations on service facilities is agood wayto leam of reputable BMWshops in your area .

SERVICE

010-8

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

TOOLS

Most maintenance can be accomplished with a small selec-tion of the right tools . Tools range in quality from inexpensivejunk, which may brakk at first use, to very expensive and well-made tools for the professional . The best tools for most do-ityourself BMWowners He somewhere in between.

O

Many reputable tool manufacturers offer good quality, mod-erately priced tools with a lifetime guarantee. These are yourbest buy. Theycost a little more, but they are good quality toolsthat will do what is expected of them . Sears' Craftsman® line isone such source of good quality tools .

Some of the repairs covered in this manual require the use ofspecial tools, such as acustom puller or specialized electricaltest equipment. These special tools are called out in the textand can be purchased through an authorized BMWdealer . Asan alternative, some special tools mentioned may be pur-chased from the following tool manufacturers andlor distribu-tors :

" Assenmacher Specialty Tools6440 Odell Place, Boulder, CO 80301(303) 530-2424

" Baum Tools Unlimited. Inc .PO. Box 87, Longboat Key, FL 34228(800) 848-6657

" Schley Products Inc .5350 E . Hunter Ave., Anaheim Hills, CA 92807(714) 693-7666

" Zelenda Machine and Tool Corp .66-02 Austin Street, Forest Hills, NY 11375(718) 896-2288

Basic Tool Requirements

The basic hand tools described belowcan be used toaccom-plish most of the simple maintenance and repair tasks.

Fig. 8.

Types of wrench heads. From left, open-end, 12-point box-Screwdrivers . The common fíat-blade type and the Phillips

end, 6-point box-end, fiare nut .type will handle almost all screws used on BMWs . Twoorthreedifferent sizes of each type will be required, since a screwdriver

The cómbination wrench is the most universal. It has oneof the wrong size will damage the screw head. See Fig. 7.

open-end and one box-end. 10mm and 13mm wrenches arethe most common sizes needed . A more complete set ofA complete set of screwdrivers should also include Torx@

wrenches would inciude6mmthrough 19mm sizes.type screwdrivers .

Wrenches . Wrenches come in different styles for differentuses . Fig. 8 shows several . The basic open-end wrench is themost widely used, but grips on only two sides. It can spreadapart and slip off more easily . The box-end wrench has bettergrip, on al¡ six sides of a nut or bolt.

A 12-point box-end can loosen a nut or bolt where there isless room for movement, while a 6-point box-end provides bet-tergrip . For hex fasteners on fluid lines, like brake lines and fuellines, a fiare-nut wrench offers the acivantages of a box-endwrench with a slot that ailows it to fit over the line .

TOOLS

B005FNG

Fig. 7.

Common flat-blade (top) and Phillips (bottom) screwdrivers.Offset screwdríver (right) is used for screws with limited ac-cess.

B002FNG

Sockets. Sockets perform the same job as box-end wrench-es, but offer greater flexibility. Theyare used with a ratchet han-dle for speed and conveniente and can be combined withextensions and universal joints (swivels) to reach fastenersmore easily . Sockets come with different size connections todrive handies or extensions, called the drive size . The mostcommon drive sizes are 1/4 in ., 318 in ., and 1/2 in .

Sockets come in 6-point and 12-point styles . For use with aratchet, the 6-point offers a better grip on tight nuts and bolts.6mm to 19mm sockets are the most needed sizes. Below is alist of typical bolt diameters and the corresponding wrench siz-es .

Solt Diameter andWrench Size" M5 . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 8 mm" M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 mm" M8 . . . . . . . . . . . . . . . . . . . . . . . . . 12mmor13mm" M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm" M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 mm" M14 . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm

Spark Plug Socket . A special socket for spark plugs is thecorrect size, is deep enough to accommodate a spark plug'slength, and includes a rubber insert to both protect the sparkplug from damage and grip it for easier removal. See Fig. 9.

Fig. 9.

Spark plug socket .

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER 010-9

B003FNG

Pliers . Afewofthe manytypes of pliers are shown in Fig. 10 .Most are used for holding irregular objects, bending, or crimp-ing. Some have special applications .

A needlenose plier is used for gripping small and poorly ac-cessible objects, and is useful for wiring and other electricalwork. A locking plier such as the Vise-Grip® is useful becauseof its tight grip .

Snap-ring and circlip pliers with special tipped jacas are usedlo remove and install snap-rings or circlips . A Channel-lock® orwater pump plier has adjustable jacas that can be quicklychanged to match the size ofthe object being held to give great-erleverage .

An adjustable wrench can be a useful addition to a small toolkit. See Fig. 11 . It can substitute in a pinch, if two wrenches ofthe same size are needed lo remove a nut and bolt . Use extracare with adjustable wrenches, as they tend to loosen, slip, anddamage fasteners .

Fig. 11 . Adjustable wrench .

B008FNG

Compared to a wrench of the correct size, an adjustablewrench is always second best. They should only be used whenthe correct size wrench is not available. Choose one ofaveragesize range, about6 to 8 inches in length .

Jack Stands

Strong jack stands are extremely important for any work thatis done under the car. Use only jack stands that are designedfor the purpose. Blocks of wood, concrete, bricks, etc. are notsafe or suitable substitutes .

WARNING -Ajack should be used only to raise the vehicle andshouldnotbe used to support the carfora long pe-riod. Always usejack stands to supporta raised ve-hicle.

Jack stands are available 1n severa¡ styles . A typical jackstand is shown in Fig. 12 . The best ones are made of heavy ma-terial for strength, have a wide base for stability, and areequippedlo positively lock in their raised positions . Get the bestones available.

Oil Change Equipment

Changing engine oil requires a 17mm socket or wrench toBOO6FNG-

loosen and tighten the drain plug and a drain pan (at least 8 qt .capacity). An oil filter wrench is not required . These items are

Fig. 10 . Pliers . From left, snap-ring,

needlenose, adjustable-joint

shown in Fig. 13 . Awide, loca drain pan wíll fit more easily under(Channellock©), slip-joint, and locking (Vise-Grip®) .

the car. Use a funnel lo pour the new oil into the engine .

TOOLS

010-10

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

TOOLS

Torque Wrench

B021FNG

Fig. 12 . Jack stand for safely supporting car to work underneath .

B022FNG

Fig. 13 . Oil change equipment includes drain plug wrench (17mm),8 qt . drain pan, and funnel .

Atorque wrench is used to preciselytighten threadedfasten-

Fig. 15 . Feeler gauge set .ers to a predetermined value. Many of the repair procedures inthis manual include BMW-specified torque values in Newton-meters (Nm) and the equivalent values in foot-pounds (ft-Ib) .

Digital Multimeter

Atorque wrench with a range up to about 150 Nm (185 ft-lb)has adequate capacity for most of the repairs covered in thismanual . For recommended torque values of 10 Nm or below,the English system equivalent is given in inch-pounds (in-lb) .These small values may be most easily reached using a torquewrench calibrated in inch-pounds . To convert inch-pounds tofoot-pounds, divide by 12 .

Fig. 14 . Torque wrenches . Inexpensive beam-type (top) is adequatebut must be read visually. Ratchet-type (bottom) can be pre-set to índicate (click) when torque value has been reached.

Feeler Gauges

B018FNG

Feeler gauges are thin metal strips of precise thickness,used to measure small clearances . They are normally availableas a set, covering arange of sizes. See Fig. 15 .

Several types of torque wrenches are available. They al¡ do

Many of the electrical tests in Chis manual cal¡ for the mea-the same job, bu¡óffer different convenience features at differ-

surement of resistance (ohms) orvoltage values . For safe andent prices . Two typical torque wrenches are shown in Fig. 14 .

accurate tests of ignition, fuel injection, and emission controlThe most convenient ones have a built-in ratchet, and can be

systems, the multi-meter, shown in Fig. 16, should be digital,preset to indicate when a specific torque value has been

with high (at least 10,000 ohms) input impedance. Somereached. Follow the wrench manufacturer's directions for use

meters have automotive functions such as dweil and pulseto achieve the greatest accuracy .

width that are useful fortroubleshooting ignition and fuel injec-tion problems .

CAUTION-The DME system, central body electronics, andother electronic systems may be damaged by thehigh current draw of a test fight with a normal in-candescent bulb. As a general rule, use a high ím-pedance digital multimeter oran LED test fight forall electrfcal testfng.

B020FNG

Fig. 16 . Multimeter or Digital Volt/Ohmmeter (DVOM) .

BMW Special Tools

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER 01 0-11

0012223

Some of the more challenging repairs covered in this manualcal¡ for the use of BMW special tools . This, however, does notautomatically mean that the job is too complicated or out ofreach of the novice .

Many of theBMWspecial tools mentioned in this manual aresimply the best thingto useto do the jobcorrectly . In these cas-es, the tool is identified with a BMW part number . See your au-thorized BMW dealer parts department for information on howto order special tools .

There are some jobs for which expensive special tools areessential, and not a cost-effective purchase for one-time repairby the do-it-yourself owner. This manual includes such repairsfor the benefit of these with the necessary experience and ac-cess to tools . Forthe do-it-yourselfer, the need for special toolsis noted in the text, and whether or not BMW dealer service isrecommended.

EMERGENCIES

Changing a Tire

Stop the car on as flat a surface as possible, in a place whereyou can be easily seen by other drivers . Avoid stopping justover the crest of a hill . Turn on the emergency flashers, and setout (lares or emergency markers well behind the car. Chock the

wheel (wheel chock located in trunk) diagonally opposite to theone being changed. Passengers should get out of the car andstand well away from the road . Remove the spare tire from thespare tire storage tray, as described later .

WARNING -If a tire goes fíat while drtving, pull well offthe road.Changing a tire on a busy street orhighway is verydangerous . If necessary, drive a short distance onthe fíat tire to get toa sale place . tt is much better toruin a tire or rim than to risk being hit.

Take the jack and tools from the tool area beneath the trunkmat. Remove the spare tire from the tire storage tray.

Loosen the wheel bolts while the car is on the ground, butleavethem a little snug. Placethejack in the lifting point nearestthe wheel being changed, lifting points are shown in Fig. 1 andFig. 2) . Use a board to provide a firm footing for the jack if theground is soft . Raisethe caronly lar enough so that the wheel isfully off the ground and then remove the wheel nuts and thewheel.

Insta¡¡ the spare wheel. Install the wheel nuts and tightenthem by hand, then lower the car. With all wheels on theground, fullytighten the nuts in a crisscross pattern. Torque thewheel nuts when installing the wheel . Check the inflation pres-sure of the spare tire .

Tightening torques" Wheel to wheel hub . . . . . 100t 10 Nm (74 t 7 ft-Ib)

Car Will Not Start

If the engine tucos over slowly or not at all, especially on coldmornings, the battery may not be sufficiently charged. Jump-starting the battery from another car may help.

WARNING -On cars withmanual transmisston, push starting (ortow starting) a car ts not recommended by BMW.

NOTE-Be sure to read the cautions underJump Starting Carprior boosting a low battery. Fatlure to follow the cau-tions may result in damage to the electronic compo-nents in the car.

If the engine is turning over at normal speed with the startermotor, the battery and starter are fine . Check to make sure thatthere is fuel in the tank . Do not rely on the fuel gauge, it maybefaulty . Instead, remove the gas filler cap and rock the car. Ifthere is gas in the tank, you should hear a sloshing sound at thefiller neck . lf there is plenty of fuel in the tank, see 100 Engine-General for in-depth diagnostics and troubleshooting proce-dures.

EMERGENCIES

010-12

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

Jump Starting Car

Cars with discharged or dead batteries can be jump-startedusing the good battery from another car. When jump-startingthe engine, always note the following warnings.

WARNING -" Battery acid (electrolyte) can cause severeburns, and will damage the car and clothing . lfelectrolyte is spilled, wash the surface with largequantities of water. lf it gets finto eyes, flush themwith water forsevera¡ minutes and cal¡ a doctor.

" Batteries produce explosive and noxious gas-ses. Keep sparks and flames away. Do notsmoke near batteries.

" Do notjump-start the engine ifyou suspect thatthe battery is frozen. Trapped gas may explode.Allow the battery to thaw first.

" Do not quick-charge the battery (for boost start-ing) for longer than one minute, and do not ex-ceed 15 volts at the battery with the boostingcables attached. Wait at least one minute beforeboosting the battery a second time .

"Some electrical system 'comfort" features maynotfunction correctly once battery power is restored.For example, the front windowone-touch-up func-tion maybe disabled. Some electricalsystems willneedto bereinitialized Consult the appropriate re-pairgroup formore specific information.

1 . Place cars close together, but do not allow them to'touch each other. Turn off the engine of the car with thegood battery.

2. Connect one end ofthe positive (+) cable to the positive(+) post of the good battery. Remove the coverfrom thepositive (B+) junction post in the engine compartmentof the dead car and connect the other end of the posi-tive (+) cable to the junction post. See Fig. 17 .

EMERGENCIES

3. Connect one end of the negative (-) cable to the nega-tive (-) battery post of the good battery. Connect oppo-site end of the negative cable (-) to the engine block ofthe car with the dead battery.

4. Start the car with the good battery and run the engineat about 2,000 rpm, then startthe car with the dead bat-tery.

5. With the engine at ¡dle, switch on the headlights, blowermotor and rear window defoggerto avoid damaging thecars electrical system . Carefully disconnect the jumpercables, starting with the negative cable on the engineblock. Turn all electrical consumers off.

NOTE-The engine should be run for at least an hour to re-charge the battery.

Overheating

lf the temperature gauge needle goes into the red band onthe gauge face, the coolant temperature is too high . Find a safeplace to stop and turn the engine off. Open the hood and allowthe engine to cool until the temperature gauge needle is at thelower third of the scale. Continuing to drive an overheated carcan cause extensive engine damage .

WARNING-Do not remove the coolant reservoir orradíator capwith the engine hot. Undoing eithercouldspray hotcoolant and cause burns or damage the engine.

CAUTION-Do not add cold water or coolant to a hot engine.Enginedamage could result from the sudden tem-perature change .

NOTE-If the engine cannotbe safely tumedoff, make sure theair condifioner is off and turn the heater to high . Thiswill helo cool the engine until a sale stopping place canbe reached.

Overheating may be caused by low coolant leve¡ or a dam-aged engine drive belt. Visually check thecoolant leve¡ and en-gine belts as described in 020 Maintenance Program. lf thecoolant leve¡ is low, check the filler cap, hoses, clamps and ra-diator for signs of leakage. Check for leaks at the water pumpon the front of the engine .

lf no leaks are found, add coolant after the engine hascooled . The car can be driven, but have the cooling systemthoroughly checked as soon as possible . lf replacement cool

0013245

-

ant is not available, then plain water can be used, but the cool-ant should later be drained and refilled with the proper mixture

Fig. 17 . Battery jump starting posts (arrows) behind right front strut

of anti-freeze and water.tower. Lift cover to access positive post .

If steam is comingfromthe engine compartment thenthere is

With the engine and ignition off, check for loose or corrodedmost likely a burst coolant hose or a large leak in the cooling

battery cables or wires at the battery or the altemator. Discon-system . To find the leak, look for signs of coolant leakage on

necting, cleaning, and reinstalling corroded wires and connec-hoses, at hose connections, or on the radiator. Let the engine

tors may solve the problem. Also check drive belt tension ascool thoroughly, then add coolant or water to fill the system and

described in 020 Maintenance Program.start the engine. If a great deal of water or coolant flows out ofthe hole, then the car should not be driven until repairs aremade . lf there is slight seepage, then it maybe possible to drive

TOWinga short distance, adding coolant as needed .

The cars covered by this manual should be towed with a towtruck using wheel lift or flat bed equipment. Do not tow the caron all four wheels except forvery short distances to move it to asafe place.

If the red engine oil pressure warning light illuminates, imme-diately stop the car and turn off the engine . Have the vehicle

Atowing eye is provided in the luggage compartment tool kit .flat-bedded or towed to an authorized service center and have

The towing eye can be screwed into the front or rear bumper .the engine oil pressure checked.

See Fig. 18 and Fig. 19 .

Low Oil Pressure

NOTE-Detafed information on checking the oil pressure iscovered ín 119 Lubrication System .

Brake Fluid Leve¡

The brake fluid leve¡ warning light may be an indicator ofbrake fluid loss. Problems with the brake system should bechecked and repaired immediately . See 340 Brakes for moreinformation .

Check Engine Warning Light

Dim Lights

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

010-13

If the "CHECK ENGI NE" warning light comeson or flashes, itindicates that an emissions-related fault has occurred . Faultssuch as a failed oxygen sensor or a faulty fuel injector can tumthe light on, causing the exhaust or evaporative emissions toexceed a specified limit . The engine can be safely driven withthe light on, although the emission systems should be checkedas soon as possible . See 100 Engine-General for more infor-mation on the Check Engine Light and the On-board diagnosticsystem.

Headlights and instrument panel illumination that are dim orgradually getting dimmer generally indicate a problem with thebattery or charging system . The battery charge indicator lightmaycome on as the lights are dimming. In either case, the en-gine and accessories are running off of the battery alone, andwill soon discharge it altogether.

If possible, do not stop the engine unless you have the capa-bility to jump start ¡t. There may not be enough power in thestarting system to restart the engine . Instead, turn off as manyelectrical consumers as possible . This will reduce the currentdrain and will allow the car to be driven farther before you loseall battery power.

Fig. 18. Pry open rear tow lúg access panel .

When towing the car from the front with the rear wheels onthe ground, a maximum distance of 20 miles is acceptable . Ifthe car needs to be towed further, have the rear wheels placedon dollies .

CAUTION-" Do not tow with sling-type equipment The frontspoilers and bumper covers may sustain dam-age.

" Towíng a BMW with an automatic transmissionwith the rear wheels on the groundcan resuft intransmission damage due to lack of lubricationandshould be avoided.

0013128

EMERGENCIES

010-14

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

Fig. 19. Instaf rear tow lug into threaded hole .

if absolutely necessary, cars with automatic transmissionscan be towed with the rear wheels on the ground, but the towshould not exceed 25 miles (40 km), at speeds at or below 30mph (35 km/h). Be sure the transmission fluid has been toppedoff before starting the tow. Always towthe car with thetransmis-sion lever in "N" (neutral). If the tow must exceed 25 miles (40km), add one quart ofATF to the transmission, or better yet, re-move the driveshaft . Be sure to drain or pump out the addedflu-id once the tow has been completed.

NOTE-" ATFdraining and filling is covered in 240 AutomaticTransmission.

" Driveshaft removal is covered in 260 Driveshaft.

EMERGENCIES

úo1W¿b

Spare Parts Kit

Carrying a basic set of spare parts can prevent a minorbreakdown from turning into a major annoyance. Many of thefollowing items won't allow you todo major repair work on thecar, but they will help in the event of the failure of something thatcan disable the car or compromise its safety .

Spare Parts Kit - Basic Contents" Drive belt (V-belt or poly-ribbed)" Engine oil (one or two quarts)" Engine coolant (1 gallon of premixed 50/50 anti-freezeand water)

" Fuse assortment (7.5A, 10A, 15A, 20A)" Radiator hoses (upper and lower)

Spare Parts Kit - Additional Contents" Exterior lighting bulbs (headlight, brakelight, turn signal,and taillight)

" Wiper biades" Brake fluid (new unopened bottle, DOT4 specification)" Main relay for DME system

020 Maintenance Program

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-2BMW Service Indicator . . . . . . . . . . . . . . . . . . . . 020-2Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-2Inspection I and Inspection II . . . . . . . . . . . . . . . 020-2Resetting Service Indicator . . . . . . . . . . . . . . . . . 020-3

MAINTENANCE TABLES . . . . . . . . . . . . . . . 020-3

FLUID AND LUBRICANTSPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 020-8Manual Transmission Fluid . . . . . . . . . . . . . . . 020-8Automatic Transmission Fluid . . . . . . . . . . . . . 020-8Final Drive Gear Oil . . . . . . . . . . . . . . . . . . . . 020-9Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 020-9Engine Coolant (Anti-freeze) . . . . . . . . . . . . . . 020-9Power Steering Fluid . . . . . . . . . . . . . . . . . . . . 020-9

ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . 020-9Engine oil, checking leve¡ . . . . . . . . . . . . . . . . . . 020-9Engine oil and filter, changing . . . . . . . . . . . . . . 020-9

ENGINE COMPARTMENTMAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 020-10

Air filter, replacing . . . . . . . . . . . . . . . . . . . . . . . 020-11Spark plugs, replacing . . . . . . . . . . . . . . . . . . . 020-11¡dle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-12Battery, checking and cleaning . . . . . . . . . . . . 020-12Battery, replacing . . . . . . . . . . . . . . . . . . . . . . . 020-12Accelerator and Throttle Linkage . . . . . . . . . . . 020-13Engine Drive Belts . . . . . . . . . . . . . . . . . . . . . . 020-13V-belt, replacing

(4-cylinder engines built up to 1/94) . . . . . . . 020-13Poly-ribbed belt, replacing(4-cylinder engines built from 1194and all 6-cylinder engines) . . . . . . . . . . . . . . 020-13

Cooling System Service . . . . . . . . . . . . . . . . . . 020-14Power steering fluid, checking leve¡ . . . . . . . . . 020-14Oxygen Sensors . . . . . . . . . . . . . . .

. . . . . . . . 020-15

MAINTENANCE PROGRAM

020-1

UNDER-CAR MAINTENANCE . . . . . . . . . .020-16'Fuel filter, replacing . . . . . . . . . . . . . . . . . . . . .020-16Tires, checking inflation pressure . . . . . . . . . . . 020-17Tires, rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-17Wheels, aligning . . . . . . . . . . . . . . . . . . . . . . . . '020-17Brake system, inspecting . . . . . . . . . . . . . . . . . 020-17Brake pad/rotor wear, checking . . . . . . . . . . . . 020-17Brake fluid, replacing . . . . . . . . . . . .

. . . .

. 020-17Parking brake, checking . . . . . . . . . . . . . . . . . . 020-17Exhaust system, inspecting . . . . . . . . . . . . . . . .020-18Manual Transmission Senrice . . . . . . . . . . . . . . 020-18Manual transmission fluidachecking and filling . . . . . . . . .

. .. . . . . . . . 020-18Automatic Transmission Service . . . . . . . . . . . . 020-18Front suspension and steering linkages,

inspecting . . . : . . . . . . . . . . . . . . . . . . . . . . . .020-18Rear suspension, inspecting . . . . . . . . . . . . . . . 020-18Final drive oil leve¡, checking . . . . . . . . . . . . . . . 020-18Fuel tank and fuel lines, inspecting . . . . . . . . . . 020-19Clutch fluid, checking. . . . . . . . . . . . . . . . . . . . . 020-19Drive axle joint boots, inspecting . . . . . . . . . . . . 020-19

BODY AND INTERIORMAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .020-19Windshield Wiper Blade Maintenance . . . . . . 020-19Body and hinges, lubricating . . . . . . . . . . . . . . . 020-19Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-20Exterior Washing . . . . . . . . . . . . . . . . . . . . . . . .020-20Waxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-20Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .'020-20Washing Chassis . . . . . . . . . . . . . . . . . . . . . . . . 020-20Special Cleaning . . . . . . . . .

. . . . . . . . . . . . . .020-20Interior Care . . . . . . . . . . . . . . .

. . . . . . . . . . . . 020-20Leather Upholstery and Trim . . . . . . . . . . . . . . . 020-20

TABLESa. Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 020-4b. Inspection 1 Service . . . . . . . . . . . . . . . . . . . . . . . . 020-5c. Inspection 11 Service . . . . . . . . . . . . . . . . . . . . . . . 020-6d. Scheduled Maintenance-Time/Mileage Intervals . . 020-7e. Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . 020-8

020-2

MAINTENANCE PROGRAM

GENERAL

The information given in this repair group includes the routinechecks and maintenance steps that are both required by BMWunder the terms of the vehicle warranty protection and recom-mended by BMWto ensure long and reliable vehicle operation.

GENERAL

NOTE-Aside from keeping yourcarin the best possible condi-tion, proper maintenanceplays a role in maintaining fullprotection under BMWs new-car warranty coverage. Ifin doubt about the terms and conditions of your carkwarranty, an authorized BMW dealer shouldbe able toexplain them .

NOTE-BMW is constantly updating their recommended main-tenance procedures and requirements. The informa-tion contained here is as accurate as possible at thetime of publication . If hhere is any doubt about whatpro-cedures apply to a specific model or model year, orwhat intervals should be followed, remember that anauthorized BMW dealer has the latest information onfactory-recommended maintenance.

BMW Service Indicator

The BMWService Indicator notifies the driver when mainte-nance is required . The service indicator consísts of multiplelight emitting diodes (lEDs)-typically five green, one yellow,and one red-as well as OIL SERVICE and INSPECTION indi-cators .

When the ignition is tumed on, the green LEDs come on .They go out when the engine is started. After the Service Indi-cator is reset, al¡ green LEDs will be illuminated with the key on .As the car is driven in normal use, fewer and fewer green LEDswill be illuminated before start-up, indicating that the next main-tenance interval is approaching .

When the car has accumulated sufficient use to require thenext maintenance interval, the yellow LED will come on alongwith either the OIL SERVICE indicator or the INSPECTION in-dicator . These LEDs will stay on after the engine is started . Ifmaintenance service is delayed, the red LED will also illuminateas a reminder that maintenance service is overdue.

An OIL SERVICE interval will always be followed by an IN-SPECTION interval, which will then be followed by an OIL SER-VICE interval, and so on . See Fig. 1 .

' 80 100/60

II" 1

,

ló1,4`20140s

#X120100 leo

AO,

80

km/h`F

*101

200 ,,~ 60

BMW has taken a unique approach to establishing mainte-nance intervals . BMW's Service Indicator System computesmaintenance intervais based not only on elapsed mileage, but

Fig. 1 .

Service indicator display in lower section of speedometer.also on such inputs as engine speed, engine temperature,numberof starts, and length of trips . At the appropriate time, thesystem indicates, through lights in the instrument cluster, when

Oil Servicethe next routine maintenance is due.

The Oil Service indicator signals the need for the most basiclevel of routine maintenance. BMW'srequired oil service speci-fies changing the engine lubricating oil and the engine oil filterafterthe engine has been warmed up. BMW-recommended ad-ditional maintenance for this service is listed in Table a.

NOTE-Forreference, the BMW Oil Service requirements areapproximately equivalent to the maintenance thatother European manufacturers specify at intervalswith a maximum of every 7,500 miles or 6 months.

CAUTION-Be sure to follow the ínstructions forresetting theOil Service indicator fight. The Inspection indica-torcan be accidentally reset rendering its functioninaccurate.

Inspection l and Inspection II

The Inspection indicator signals the need for more compre-hensive maintenance and Inspection . There are two sets of in-spection requirements, Inspection I and Inspection ll . Theseinspections alternate throughout acar's maintenance history . Ifthe last Inspection interval was Inspection I, the next Inspectioninterval (following an Oil Service) will be Inspection ll, the nextafter that will be Inspection I, and so on .

Inspection I tasks are listed in Table b. Inspection II in-cludes most of the tasks from Inspection I with additional In-spection 11 tasks. A complete listing of Inspection II tasks arelisted in Table c.

NOTE-

Aftermarket reset tools can be purchased from one ofthe fol-liftowng manuacurers:For referente, the BMW Inspection 1 and Inspection 11

requirements areapproximatelyequivalent to the main-tenance requirements that other European manufac-

AssenmacherBosturers specify. Inspection I is normally due at intervals

lder, CO 80301SpecialtyTools

with a maximum of 15,000 miles or 12months . lnspec-

(303) 530-2424tion 11 is normally due at intervals with a maximum of30,000miles or24 months.

Peake Research, Automotive Products DivisionP.O . Box 28776San Jose, CA 95159

Resetting Service Indicator

(408) 369-0406

When the specified maintenance has been carried out, theservice indicator memoryshould be reset.

MAINTENANCE TABLES

The senrice indicator is reset using a special tool . The tool isplugged into the diagnostic connector in the engine compart-ment . SeeFig. 2.

iiiFig. 2.

Service indicator reset tool installed in diagnostic connector(aftermarket tool shown) .

CAUTION-Follow the manufacturer's directions when reset-ting the service Indicator. If the reset proceduresare done incorrectly, the reset toolor the electron-ic service indicatormay be damaged.

MAINTENANCE PROGRAM 020-3

Table a, b, c, and d on the following pages list the routinemaintenance tasks specified by BMW. The intervals for most ofthese tasks are determined by the Service Indicator . The main-tenance intervals for a few additional items are based on eitherelapsed mileage or time . These intervals are indicated in sepa-rate tables .

Exceptwhere noted, the maintenance items listed applyto allmodels and model years covered by this manual . The columnson the right sitie of each table give quick-referente informationabout the job. The bold text references the repair groups whereadditional repair information can be found.

MAINTENANCE TABLES

020-4

MAINTENANCE PROGRAM

L

~

~c.c a

a> mL

~

~ L

Lw

a

£ 'S

d E

Maintenance ítem

z

3

cEngine compartment maintenance

Change oil and oil filter

Check fluid levels (coolant, steering, brake/clutch, ATF)

Under car maintenance

Check steering rack and steering linkages for leaks and excess play. Repair Group 320

Inspect brake system . Check brake calipers, rotors, and brake pad thíckness . Inspect for dam-aged hoses and lines, leaks or damage . Check hand brake, adjust cable if necessary. RepairGroup 340

Check and adjust tire pressures, including spare

Body and interior maintenance

Check operation of exterior and interior lights, including glove box light, engine compartmentlight, trunk light, instrument panel lights, horns, headlight flasher and dimmer switch . Checkheadlight and driving light aiming . 6 Electrical System

Check function/condition of seat belts . Repair Group 720

Check windshield washer fluid level and concentration, add as necessary. Check operation ofwasher system . Check condition of wiper blades . Repair Group 611

Road Test

Check braking performance, steering, heating and ventilation, manual or automatic transmis-sion, and mirrors

Service Interval Reset

Reset service indicator using special reset tool .

MAINTENANCE TABLES

Table a. Oil Service

Table b. Inspection I Service

MAINTENANCE PROGRAM 020-5

ad

d dID

a

r

c

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0Maintenance ítem

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c dEngine compartment maintenance

Change oil and oil filter.

Check brake/clutch fluid leve¡

Check battery acid leve¡ and correct as necessary. Repair Group 121

Check engine coolant level and anti-freeze protection and add as necessary.Inspect for cooling system leaks. Repair Group 170

Lubricate throttie linkage

Under car maintenance

Check transmission for externa¡ leaks .

Check manual transmission oil leve¡ and add as necessary. Repair Group 230Check final drive lubricant and add as necessary.

Check fue¡ tank, fuel lines, and all connections for leaks .

Inspect exhaust system. Repair Group 180

Check steering rack and steering linkages . Check power steering system for leaks. Check (luidleve¡ . Repair Group 320

Inspect brake system for damaged hoses and fines, leaks or damage. Remove calipers andcheck brake pad wear. Check brake rotors for scoring damage . Repair Group 340

Check parking brake operation, adjust cable if necessary Repair Group 340

Inspect front and rear suspension, including wheel bearings, for play. Repair Group 320/330

Inspect wheels and tires, including spare, check tire pressure and condition

Body and Interior Maintenance

Lubricate door hinges and hood latch, hood hinges

Check headlight and driving light aiming and adjust as necessary.

Check operation of headlights, parking lights, back-up fights, license plate lights, interior lights,glove box light, engine compartment light, trunk light, instrument panel lights, turn signals, emer-gency flashers, stop fights, horas, headlight flasher and dimmer switch

Replace ventilation/A/C micro-filter. Check function of air conditioning . Repair Group 640

Check function of seat belts . Repair Group 720

Check tightness of mountfng screws on airbag front crash sensors (Airbag I) . Repair Group 721

Check windshield washer fluid leve¡ and concentration, add as necessary Check operation ofwasher system . Check condition of wiper blades . Repair Group 611

Tighten nuts and bolts for door locks and striker plates

Replace batteries for alarm/remote control in master key (where applicable) .

Road Test

Check braking performance, steering, HVAC, manual or automatic transmission, and mirrors

Service Interval Reset

Reset service indicator using special reset tool .

MAINTENANCE TALES

020-6

MAINTENANCE PROGRAM

Group 310/330

Table c. Inspection II Service

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Maintenance ítem

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cEngine compartment maintenance

Inspect V-belt /Poly-ribbed drive condition . Check V-belt tension, if applicable .

Lubricate throttle linkage .

Replace air filter.

Change oil and oil filter.

Replace spark plugs. Repair Group 120

Check brake/clutch fluid leve¡ .

Check battery acid leve¡ and correct as necessary. Repair Group 121

Check engine coolant leve¡ and anti-freeze protection and add as necessary.Inspect for cooling system leaks . Repair Group 170

Under car maintenance

Change automatic transmission fluid . Repair Group 240

Change manual transmission oil . Repair Group 230

Check clutch plate for wear . Repair Group 210

Check drive axle boots for leaks . Repair Group 330

Change final drive fluid (1995 and later models : change synthetic oil every 2nd Inspection II).

Replace fuel filter.

Check fuel tank, fuel lines, and af connections for leaks .

Inspect exhaust system . Repair Group 180

Check steering gear and steering ¡inkages. Check power steering system for leaks . Check fluidleve¡. Repair Group 320

Inspect brake system for damaged hoses and lines, leaks or damage . Remove calipers andcheck brake pad wear. Check brake rotors for scoring damage . Repair Group 340

Check parking brake operation, adjust cable if necessary. Check thickness of parking brake lin-ings. Repair Group 340

Inspect front and rear suspension, including front and rear wheel bearings, for play. Repair

Inspect wheels and tires, including spare, check tire pressure and condition .

Body and Interior Maintenance

Lubricate door hinges and hood latch, hood hinges.

Check headlight and driving light aiming and adjust as necessary.

Check operation of headlights, parking lights, back-up lights, license plate lights, interior lights,glove box light, engine compartment light, trunk light, instrument panel lights, turn signals, emer-gency flashers, stop lights, horns, headlight flasher and dimmer switch .

Check active check control panel for fauits (where applicable) . 6 Electrical System

MAINTENANCE TABLES

Continued on next page

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Maintenance ítem

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Body and Interior Maintenance (cont.)

Replace ventilation/A/C micro-filter. Check function of air conditioning . Repair Group 640

Check function of seat belts . Repair Group 720

Check windshield washer fluid level and concentration, add as necessary. Check operation ofwasher system . Check condition of wiper blades Repair Group 611

Tighten nuts and belts for door locks and striker plates.

Replace batteries for alarm/remote control in master key (where applicable) .

Check ground connection (mounting screws) of SRS (airbag) front sensor to body, if applicable .Repair Group 721

Road Test

Check braking performance, steering, HVAC, manual or automatic transmission, and mirrors

Service Interval Reset

Reset service indicator using special reset tool .

Maintenance ítem

Replace oxygen sensor. Repair Group 1801992-19941995- on

Flush and replace brake fluid/clutch fluid. Repair Group 340

Drain and flush cooling system and replace coolant . RepairGroup 1701992-19961997-1998

Anti-corrosion warranty inspection .

Table c . Inspection II Service (continued)

Cable d. Scheduled Maintenance-Time/Mileage Intervais

MAINTENANCE PROGRAM 020-7

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MAÍNTENANCE TABLES

020-8

MAINTENANCE PROGRAM

FLUID AND LUBRICANT SPECIFICATIONS

The fluids and lubricante specified by BMW are listed in Ta-ble e. Shown belowis engine oil viscosity (SAE grade) vs . oper-ating temperature range for the BMW engines covered in thismanual .

Engine Oil Viscosity Requirementsvs. Temperature

`SEAVicPQ SAE

swao

YCO

0

N

M42 engine

1 .1 I (1 .2 US qt .)M44 engine

1 .1 l(1 .2 US qt .)M50 engine

1 .1 1(1 .2 US qt .)M52 engine

1 .2 1(1 .3 US qt .)S50US engine

1 .2 1(1 .3 US qt .)S52US engine

1 .2 1(1 .3 US qt .)

°F

80

-

1o-0- 30 -----20

WARNING -The use of fluids that do not meet BMWs specifica-tions may impair performance and refability, andmay void warranty coverage .

Table e. Fluids and Lubricants

0013227

Fluid Approximate Specificationcapacity

Engine oil with filter changeM42 engine

5.01 (5.3 US qt .)M44 engine

5.0 I (5.3 US qt .)M50 engine

6.5 I (6 .9 US qt .)

API service SH orM52 engine

6.51 (6 .9 US qt .)

siS50US engine

6.51 (6 .9 US qt .)S52US engine

6.0 I (6 .3 US qt .)Manual transmission oil

FLUID AND LUBRICANT SPECIFICATIONS

See 230 ManualTransmission for

NOTE-fluid specification

Table e. Fluids and Lubricants (continued)Fluid Approximate Specification

capacityAutomatic transmission fluid (ATF) (drain and fill)(additional fluid required when installing a dry torque converter)A4S 310R

See 240 Automatic Transmission for fluidA4S 270R

specification informationA5S 310ZFinal drive (drain and fill)(Lifetime fluid ; no fluid change required)

4-cylinder

1 .1 I (1 .2 US qt .)

BMW SAF-XO6-cylinder

1 .7 l(1 .8 US qt .)

synthetic

oil

(ex.limited slip)BMW SAF-X1-Ssynthetic oil (limit-ed slip)

Power steering fluidAl¡ modeis

permanentlysealed

Dexron IIPATFno drain plug

rake fluidAll modeis

-~ SAEDot 4Engine coolantM42 engine

6.51(6.9 US qt .)M44 engine

6.51(6.9 US qt .)M50 engine

10.51 (11 .1 US qt .)

50%BMW anti-M52 engine

10.5 1 (11 .1 US qt .)

freezel 50% waterS50US engine

10.75 1(11 .4 qt.)S52US engine

10.75 I (11 .4 qt.)

CAUTION-Multi-viscosity engine oils should not be used inthe manual transmission . Use of such an oil couldshorten the service life ofthe transmission.

Manual Transmission Fluid

The manual transmissions installed in the E36 modeis arenormallyfilled with automatictransmission fluid (ATF), althoughalternative synthetic lubricants may have been used from - thefactory, depending on transmission type and model year. Con-sult 230 Manual Transmission for additional information onidentifying the type of fluid installed.

Automatic Transmission Fluid

The automatic transmissions installed in the E36 modeisare normally filled with Dexron 111 automatic transmission fluid(ATF), although alternative fluids have been installed from thefactory, depending on transmission type and model year .Some transmission are filled with a special BMW "life-time"automatic transmission fluid, whích does not require periodicfluid changes . Consult 240 Automatic Transmission for ad-ditional fluid specification information .

information

1

The

11-

11 lubrican type can be found on ti ¡e`Yypeplate" on the side of the transmission. Consult anauthorized BMW dealer for alternate fluid use and the

Continued

most-up-to-date information regarding transmission op-erating fluids.