fuel injection BMW 318i 1992 E36 Repair Manual

GENERAL
.
.
.......
.
......
.
...
.
.
.
.
.
...
180-1



Exhaust
system,
removing
and
installing
.
...
.180-3

EXHAUST
SYSTEM
REPLACEMENT
.
...
180-1



Exhaust
manifolds,
removing
and
installing
.
.
.180-5

GENERAL

The
exhaust
system
is
designed
to
be
maintenance
free,
al-
though
regular
inspection
is
warranted
due
to
the
harsh
oper-
atingconditions
.
Under
normal
conditions,
the
catalytic

converter
does
not
require
replacement
unless
it
is
damaged
.

On
1996
and
later
cars,
a
pre-
and
post-catalytic
converter

oxygen
sensor
is
used
at
each
catalytic
converter
.
Be
sure
to

take
care
when
removingthe
system
not
to
damage
the
sen-



EXHAUST
SYSTEMREPLACEMENT
sors
.

See
130
Fuel
Injection
for
information
on
testing
oxygen

sensors
.

NOTE-

OnM52
engines,
two
resonator
pípes
(short
and
long)
are
incorporated
into
the
rear
muffler
assembly
.
See
Fíg
.
1
.
An
exhaust
flap
is
integrated
into
the
outlet
side
of
the
short
pipe
.
The
flap
is
operated
by
a
vacuum
ac-
tuator
via
the
Siemens
MS
41
.1
engine
control
mod-
ule)
.
The
flap
is
closed
at
engine
speeds
below
2,500
rpm
.
This
allows
exhaust
gasses
to
flow
through
the
long
resonator
pipe
and
reduce
noise
.
Above
2,500rpm,
the
exhaust
flap
is
open
(no
vacuum
applied
to
the
actuator)
and
allows
exhaust
gasses
to
flow
through
the
short
pipe
for
maximum
performance
.

180
Exhaust
System

0013101

Fig
.
1
.



Rear
muffler
(active
silencer
usedon
M52
engines)
.
Vacuum

operated
flap
(A)
changesbetween
short
and
long
pipes,
de-

pending
on
engine
speed
.

EXHAUST
SYSTEM



180-1

WARNING
-

Exhaust
gases
are
colorless,
odorless,
and
very
toxic
.
Run
the
engine
only
ín
a
well-ventilated
area
.
Immediately
repair
any
leaks
in
the
exhaust
system
or
structural
damage
to
the
car
body
that
might
al-
lowexhaust
gases
to
enter
the
passenger
compart-
ment
.

Exhaustsystem
components
are
detailed
in
Fig
.
2
through

Fig
.
4
.

New
fasteners,
clamps,rubber
mounts,
and
gaskets
should

be
used
when
replacing
exhaust
components
.
A
liberal
appli-
cationof
penetrating
oil
to
the
exhaustsystem
nuts
and
bolts
in
advance
may
make
removal
easier
.

WARNING
-

"
The
exhaust
system
and
catalytic
converter
op-
erate
at
high
temperatures
.
Allow
components
to
cool
before
servicing
.
Wear
protectíve
clothíng
to
prevent
bums
.
Do
not
use
flammable
chemicals
near
a
hot
catalytic
converter
.

"
Old,
corroded
exhaust
system
components
crumble
easíly
and
often
have
exposed
sharp
edges
.
To
avoid
injury,
wear
eye
protection
and
heavy
gloves
when
working
with
old
exhaust
parts
.

EXHAUST
SYSTEM
REPLACEMENT

T

Ambient
temperaturelclock

MÍM
Aa
.Mi}rm
-Mil"
IMua~naa~u~itacar
"
za
.~

Central
Body
Electronics

0013028

Fig
.
4
.



Different
versionsof
Multi-information
Display(MID)
installed
in
E36
cars
.

The
E36
cars
are
equipped
with
a
sophisticated
centralized

body
electric/electronics
plan
.
The
system
is
self-diagnostic

and
incorporates
many
functions
into
a
single
control
module
.

The
consolidation
of
several
systems
into
a
single
control

module
minimizes
power
requirements
and
the
incorporation

of
the
diagnostic
link
results
in
more
efficient
and
accurate

troubleshooting
.

Self-diagnostic
codes
are
accessible
electronically
through

the
data-link
connector
in
the
engine
compartment
.
See610

Electrical
Component
Locations
.

BODY-GENERAL
400-
5

Two
versions
of
central
body
electronics
are
used
depend-

ing
on
model
year
.

1992
and
1993
models
are
equipped
with
a
central
locking

module
(ZVM)
which
incorporates
control
of
the
following
sys-

tems
:

"Interiorlighting
"
Central
locking
with
double
lock
feature

"
Output
relays
for
powerwindows
and
sunroof

"
Electronic
power
protection

E36
cars
since
the
1994
model
year
are
equipped
with
ZKE

IV
.
This
is
an
electronic
comfort
and
convenience
system
that

includes
the
following
additional
features
:

"
One
touch
up/down
power
window
operation

"
Power
window
and
sunroof
closure
from
driver
or
pas-

sengerdoor
lock

"
Vehicle
locking
or
unlocking
from
the
trunk
lock
.

Other
features
of
the
system
are
discussed
in
515
Central

Locking
and
Anti-Theft
.

Electronic
Immobilization
System

Beginning
in
model
year
1994,
all
E36
vehicles
incorporate

adriveaway
protection
system
regardless
of
whether
the
vehi-

cle
is
equipped
with
a
BMW
Alarm
System
or
an
On-Board

computer
.
Two
types
of
factory
systems
were
installed,
de-
pending
on
vehicle
production
date
.

On
the
early
system
(model
year
1994
up
to
January
1995),

the
ignition
and
fuel
injection
functions
are
disabled
whenever

the
vehicle
is
locked
in
the
double
lock
mode
.
This
is
referred

lo
as
EWS
or
EWS
I
.

Beginning
in
January
1995,
the
driveaway
protection
sys-

tem
was
upgraded
to
a
more
sophisticated
system,
called

EWS
II
.
This
system
uses
a
wireless
communication
link
be-

tween
a
transponder
chip
in
the
ignition
keyand
the
ring
an-

tenna
surrounding
the
ignition
switch
.
The
EWS
II
control

module
blocksthe
starting
of
the
vehicle
unlessthe
correct

coded
ignition
key
is
used
.

For
further
information
about
drive
away
protection
sys-

tems,
see
515
Central
Locking
and
Anti-Theft
.

INTERIOR
EQUIPMENT

515-8



CENTRAL
LOCKING
AND
ANTI-THEFT

Central
Body
Electronics
(ZKE
IV)



Electronic
Immobilization
System
(EWS)

Beginning
withvehicles
produced
9193
(model
year
1994),



The
electronic
anti-theft
system
known
as
EWS
was
first
in-

the
centrallocking
system
was
integrated
with
sunroof
and



troduced
in
January
1994
.
The
early
version
of
the
system

window
closure
into
the
Central
Body
Electronics
(ZKE
IV)



uses
a
starting
inhibition
module
to
interrupt
the
ignition,
the

(generation
four)
system
.
The
control
module
for
this
system



fuel
injection
and
the
starter
motor
.
This
system
is
activated

ís
mounted
in
front
of
the
glove
compartment
.



and
deactivated
by
the
centrallockíng
system
.
The
control

module
for
the
system
is
installed
under
the
left
side
of
the

Inthis
system
two
microswítches
are
operated
viathe
door



dashboard
.

lock
cylinder
at
both
front
doors
.
Turning
the
key
approximate-

ly
45°
(position
1)
operates
the
door
locking
microswitch
and



Startingwith
modeis
built
since
January
1995,
E36
cars

activates
the
alarm
system
.
Holding
the
key
in
thatposition



come
equipped
with
a
sophisticated
coded
electronic
immobi

also
closes
any
open
windows
and
the
sunroof
.



lization
system
called
EWS
II
.
Foraschematic
of
the
system,

refer
to
Fig
.
21
.

Turning
the
key
approximately
45°
in
the
opposite
direction

through
position
0
actuates
theunlocking
microswitch
and
de-

activates
the
alarm
system
(position
2)
.
See
Fig
.
20
.
NOTE
-

The
EWS
11
system
is
also
sometimes
referred
to
as
the

Driveaway
Protection
System
or
the
electronic
immobi-
lization
system
.

On
EWS
II
equipped
cars,
the
ignition
key
is
embedded
with

a
computer
chip
and
permanently
encoded
.
A
primary
code
is

programmed
into
the
keyand
finto
the
vehicle
itself
.
A
second-

ary
code
is
changed
every
time
the
vehicle
is
started
.
If
thekey

code
and
EWS
II
control
module
code
do
notmatch,
the
en-

gine
management
control
module
and
the
starter
are
dis-

abled
.
EWS
II
ignition
keyscannot
be
duplicated
.

The
system
is
designed
to
have
up
to
ten
keys
and
only
an

authorized
BMW
dealer
can
provide
replacement
keys
.
j
NOTE-
0011762a



ft
is
possible
to
damage
the
electronic
circuítry
in
the
Fig
.
20
.
ZKE
IV
door
lock
cylinder
positions
.



key,
rendering
if
unusable
.
In
that
case,
a
new
key

shouldbe
purchased
and
initialized
byan
authorized
BMW
dealer
.

LOCKING
SYSTEM
AND
ELECTRONIC
IMM081LIZATION

GENERAL

E36
cars
are
equipped
with
integrated
automatic
heating

and
air
conditioning
systems
.
Many
of
the
procedures
given
in

this
repair
group
require
that
the
A/C
refrigerant
charge
be

evacuated
using
specialized
equipment
.
See
A/C
System
Warningsand
Cautions
later
in
this
repair
group
.

HEATER
AND
CONTROLS

Blower
motor,
removing
and
installing

NOTE-

On
6-cylinder
cars,
the
plastic
top
enginecover
and
fuel
rail
covermustbe
removed
.
The
fuel
injectorhamess
re-
taining
screws
must
be
removed
and
the
harness
set
aside
.
The
engine
control
module
(ECM)
cover
must
be
removed,
the
control
unit
connectors
unplugged
and
the
harness
pulled
out
of
the
way
.
See
130
Fuel
Injection
.

1
.
Disconnect
negative
(-)
cable
from
battery
.

2
.
Open
hood
.
Unclip
engine
bulkhead
plenum
grille
at

base
of
windshíeld
and
remove
grille
.
See
Fig
.
1
.

HEATING
AND
AIR
CONDITIONING



640-1

640
Heating
and
Air
Conditioning

GENERAL
.
...
.
....
.
.
.
.
.
.
.
.
.
.......
.
.
.
640-1



Heater
andA/C
air
distribution
motor,

replacing(rotary-knob)
.
.
...
.
.
.
.......
.
640-10

HEATER
AND
CONTROLS
.
.....
.
.
.
.
.
.
.640-1



Rear
Window
Defogger
.
.
.



.
.
.
.
.
.
.
...
.
.
.
640-10
Blower
motor,
removing
and
installing
.
.
.
.
.
.
640-1



Rear
Window
Blower
(convertible
models)
.
.640-10

Blowermotor
resistor
pack,
replacing



.
.
.
.
.
.
640-3



AIR
CONDITIONING
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
640-11
Heater
valve,
replacing
...........
.
.
.
.
.
.
.
640-3

Heater
box,
removing
and
installing
.
.
.
.
.
.
.
.
640-4



A/CSystem
Warnings
and
Cautions
.
.
.
.
.
.
:640-11

Heater
core,
replacing
.....
.
.
:
....
.
.
.
.
.
.
.
640-6



A/C
compressor,
replacing
.
.
::.
:
:
.
.
.
.
.
.
.
.640-12

Heater
core
temperature
sensor,
replacing
.
.
640-7



A/C
Compressor
Clutch
.
.
.
.
.
.
.
:
.
.
.
.
.
.
.
.
.
640-13

Heater
andA/C
Control
Head
.
.
....
.
.....
.
640-7



A/C
condenser,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
640-14

Heater
andA/C
control
head,
removing



A/C
receiver/drier,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
.
640-15
and
installing
(rotary-knob)
.
.
....
.
......
640-7



A/C
expansion
valve,

Heater
andA/C
control
head,
removing



removing
and
installing
...
.
.....
.
.
.
.
.
.
.
640-16
and
installing
(digital-display)
.
.....
.
.....
640-8



A/C
evaporator,
removing
and
installing
.
.
..
640-17

Heater
andA/C
control
module,removing



A/C
evaporator
temperature
sensor,

and
installing
(rotary-knob)
.
.
...
.
.
.
.
.
.
.
.
640-8



replacing
.
.
.
.
.
.
..............
.
.
.
.
.
..
640-17

Heater
andA/C
control
module,removing



A/C
microfilter,
replacing
......
.
....
.
.
.
..
640-18

and
installing
(digital-display)
.
...
.
.
.
.
.
...
640-8

Sensor
fan
for
interior
temperature,



TABLES

replacing
.
.
.
....
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
640-9



a
.
Blower
Motor
Test
Values
.........
...
.
.
......
640-3

Heater
andA/C
AirDistribution
Motors
.
.
.
.
.
.
640-9



b
.
Heater
Core
Temperature
Sensor
Test
Values
...
.640-7

c
.
Evaporative
Temperature
Sensor
Test
Values
...
640-17

d
.
A/C
System
Fluid
Capacities
(total)
..
..........
640-18

0012527

Fig
.
1
.
Detach
grille
retaining
clips
(arrows)
and
pull
grille
upward
and
out
of
rubbergasket
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautionsgiven
at
the
front
of
this
manual
onpage
viii
.

HEATER
AND
CONTROLS

ELE-70
ELECTRICAL
WIRING
DIAGRAMS

I



02
SENS
SIB
I"7
7
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02SENSGNDI)
I



GROUNDI
2



BR
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I
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),
BRN
I



GROUNOI
3~
BR"
I
RUNIST
GRN
ARTI
S~
ENGINECONTROL
MODULE
(DME)

13B
START



1
GRN
I
DN

OFF
IGNITION
S
WITCH

8727
3

HOTATALLTIMES

UELINJECTION
VALVES

NCA"
=
It,
INCA
SPIN

BRN
GRN
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Engine
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19921
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FRONT_POWERDISTRIBUTIONBO%
_
_
___
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_
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EVAPORATIVE



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INTAKE
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EMISSION
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VALVE



VALVE



CHANGEOVER
VALVE

ELE-72
ELECTRICAL
WIRING
DIAGRAMS

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II

GROUND
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BR
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S
SB
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CYL61GNCOILI
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CVL
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BLK/WHT
I
CYLI!ONCO(L,
56
GRN
START/RUN
T
L______
ENGINECONTROL
MODULE
IOM
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HOTATALLTIMES
1
30
START
I
I
OFF
I
L_---_I
IGNITION
S
WITCH

1112
N3
N4
M5N6

Engine
Management

19922
.5L
(1
of
2)

FUEL
INJECTION
VALVES

117111
1121
1-

FI=-----r-_----1------k------f-----
:1
:NEI

IGNITION
COILS

FRONT
FO
W
ERDISTRIBUTION
BOX

871
851
87AAI
30y



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.
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RED/WHT
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CYLINDER
1



CYLINDER2



CYLINDER3



CYLINDER4



CYLINDERS



CYLINDERS



G703



IDLE
SPEED



EMISSION
CONTROLVALVE
VALVE

CYL
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FUEL
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N
BRN/GRN



I
GRN/VIO
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RED/WI-IT



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ELE-74
ELECTRICAL
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8727
7

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in
RED
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37



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I



70
71
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148
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FUEL
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VALVES

Engine
Management
1993-951
.8L
(1
of
2)

FRONTPOWERD_IS_TRI_BU_TIO_NBOX



_
______
I



ENGINE
CO
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MODULE
RELAY



FUEL
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-~
I



I
CVL1



DVL2



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CYL4



A/T
RANGE



TRANSMISSIONCONTROLMODULE
(EGS)
SWITCH

ELE-76
ELECTRICAL
WIRING
DIAGRAMS

1
87279

SOLIDSTATE

SOLENOIO
VALVE
(RUNNING
LOSSES)
(1995
ONLY)



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CYL4



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55
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I
IGNITION
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Engine
Management

1993-952
.51
(1
of
2)

FUEL
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VALVES

STARTING
SYSTEM

1995
ONLY
r~I
~~

f

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PO
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DISTRIBUTION
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1995
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1995
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1995
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1995
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REDIWHTRED/WHTRED/WHT

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Bt
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POINT

CYL
1-fi
FUEL
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GRNIVIO

BPN/GRN

RED
RED

WIEGS

RED/WHT
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CVL1



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CYL4



CYL5



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6119



IDLE
SPEED



EMISSION
ACTUATOR



SLIP
CONTOLMODULE
CONTROLVALVEVALVE
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C)

ELE-78
ELECTRICAL
WIRING
DIAGRAMS

I
ACTIVATEVALVE
I
I
ACTIVATEVALVE
I
31
BR~NIVEI
I
ACTIVATEVALVEI
32
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ACTIVATEVALVEI
3
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88547

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1996
86
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31811
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UNLOADERRELAY



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I
RED
TERMINAL15



31871
l~
(19970NLY)

Engine
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1996-971
.9L
:
(1
of
2)

HOTINACC,RUN
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USE
POWER
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F46



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DISTRIBUTION
L
I
1
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BDXX
10016

mlulm

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EXCEPT
1997,
199831871
W/ABS
ABSCONTROL
MODULE/
HYDRAULIC
UNIT

MODULE
(ABSIASC)

FRONT
POWER
DISTRIBUTION
BOX



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rENGINECONTROLMODULERELAV
FUELPUMPRELAY

I

WIEGS
1

EXCEPT
1998
31811
mI
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II
IIII
II
I______
I
I_______________
6119



CYL1



CYL2



CYL3



CYL4



SLIFCONTROL



TRANSMISSION
CONTROL
MODULE
(EGS)

f-W/EGS

ELE-80
ELECTRICAL
WIRING
DIAGRAMS

88893

UNLOADER
RELAY
TERMINAL
IS
(1997
ONLY)

VARIABLE
CAMSHAFT
CONTROL
VALVE
1

I
CAMSHAFTCTRLI
21GR
ILU
CYL11NJI
1T
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CVL
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12424
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I
33
BBRNIGRN
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123
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CVL6INJ
ACTIVATE
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I
773
BRN
BATTERYI
2~
~
DRIVE
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GRN



*
ANTI-THEFT
SYSTEM
BATTERYI
87
REDIWHT
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54
REDIWHT
ACTIVATEAICI
16
BLK/GRY



PRESSURESWITCH
THROTTLEPOSI
45
WHT/GRY/YEL
ASC-SIGZWVIi81
WHT/GRY
ASC-SIGZAI
80
WH
T/GRN
ASC-SIG
MSRI
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ISB
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NIRF=D
CYL
4-6
KS
163~
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CYL4-6KSI
59



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RN
CYL1-3KSI
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I
57
YELCYL1-3KSI
38N
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GROUND
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68
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ACTIVATEVALVE



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WL



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I
4/
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GROUND
I
32



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CYLBIGNCOILI
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51GN
COIL
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31~S
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L=/BLU
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BLK/YEL

HOTATALLTIMES
START



I
1
GRNRUN
15
I4
1
I
ACC
II



OFF
____



_I
IGNITION
SWITCH

Engine
Management

1996-97
2
.8L
(1
of2)

FRONT
POWER
DISTRIBUTION
BOX
FUELINJECTIONVALVES



r
'EN
GINECONTRO
_
LMODU_LERELAV
_
_
_
_
CY
_
L
_1-E_FU_EL_PU_MP_RELAY
___
_
_
_

GNIT10N
COILS

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[711
ii
Tii
Mii



u

I
ail
2
3~
3,aj
223
3j,1
2
1
3223
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CYL1



CYL2



CYL3



CYL4



CYLS



CYL6



MILE
SPEED



EVAPORATIVE
CONTROL
EMISSION
VALVEVALVE
KNOCKSENSOR

EXCEPT
1996M3

HOTINRUN
ANDSTART

1
G312
R=D
RED

REDIWHT
RED/WHT

zlzlzlzlil
z



33.I



3



3



33~



3~
15
5
425
26

s
I
CYL1-3CYL4-8
I
________-
SLIPCONTROL
MODULE
(ABS/ASC)