Handle BMW 318i 1996 E36 Workshop Manual

Please
read
these
warnings
and
cautions

before
proceeding
with
maintenance
and
repair
work
.

WARNING-



"
Friction
materials
(such
as
brake
pads
or
shorts
or
clutchdiscs)
contain
asbestos
fibers
or
other
friction
materials
.
Do
notcreate
"
See
also
Cautionson
page
viü



dustby
grinding,
sanding,
orby
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
.

duredescribed
in
this
manual,
we
suggestyou
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
top
fied
shop
.



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

"Do
not
re-use
any
fasteners
that
are
worn
or
deformed
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
cablesora
bat-
includes,
but
is
not
limited
to,
nuts,
bolts,
washers,
self-locking
nuts
or
bolts,
circlips
and
cotterpins
.
Always
replace
these
fasteners

with
new
parts
.
"Do
not
quick-charge
the
battery
(for
boost
starting)
for
longer
"
Never
work
under
a
lifted
car
unless
it
is
solidly
supportedon



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
acar
that
is
supported
solely
by
a



"Do
not
allow
battery
charging
voltage
to
exceed
16
.5
volts
.
If
the

jack
.
Never
work
under
thecar
while
the
engine
is
running
.



battery
beginsproducing
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
acar
on
the
ground,
make
sure



cause
an
explosion
.
that
the
ground
is
level
.
Block
the
wheels
to
keep
the
carfrom
roll-

ing
.
Disconnect
the
battery
negative
(-)
terminal
(ground
strap)to



"
The
air-conditioning
system
is
filled
with
chemical
refrigerant,

prevent
others
from
starting
thecar
while
youare
under
it
.



which
is
hazardous
.
TheA/C
system
should
be
servicedonly
by

trained
technicians
using
approved
refrigerant
recovery/recycling
"
Never
run
the
engine
unless
the
work
area
is
well
ventilated
.



equipment,
trained
in
related
safetyprecautions,
and
familiar
with
Carbon
monoxide
kills
.



regulations
governing
the
discharging
and
disposal
of
automotive

"
Finger
rings,
bracelets
and
other
jewelry
shouldbe
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
theycannot
cause
electrical
shorts,
get
caught
in
running



"
Do
not
expose
any
partof
the
A/Csystem
to
high
temperatures
machinery,
or
be
crushed
by
heavy
parts
.



suchas
open
flame
.
Excessiveheat
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
extremely
running
engines
.
If
your
hair,
clothing,
or
jewelry
were
to
get
caught



cautious
when
repairing
a
tire
that
may
havebeen
inflated
using
in
the
machinery,
severe
injury
could
result
.



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

"
Do
not
attempt
to
work
onyourcar
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
toyourself
and
others
if
you
are
tired,



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

upset
or
have
takenmedication
or
any
other
substance
that
may



Pletely
remove
the
tire
from
the
rim
beforeattempting
any
repair
.

keep
you
from
being
fully
alert
.

"
Illuminate
your
work
areaadequately
but
safety
.
Use
a
portable

safety
light
for
working
inside
or
under
thecar
.
Make
surethe
bulb

is
enclosedbya
wire
cage
.
The
hot
filament
of
an
accidentally
bro-

ken
bulb
can
ignite
spilled
fuel
or
oil
.

"
Catch
draining
fuel,
oil,
orbrake
fluid
in
suitable
containers
.
Do

not
use
food
or
beverage
containers
that
mightmislead
someone

into
drínking
from
them
.
Store
flammable
fluids
away
from
fire
haz-

ards
.
Wipe
up
spills
at
once,
but
do
not
store
the
oily
rags,
which

can
ignite
and
burn
spontaneously
.

"
Always
observe
good
workshop
practices
.
Wear
goggles
when

youoperate
machine
tools
or
work
with
battery
acid
.
Gloves
or

other
protectioeclothing
should
be
worn
whenever
thejob
requires

working
with
harmful
substances
.

"
Greases,
lubricants
and
other
automotive
chemicals
contain

toxic
substances,
many
of
which
are
absorbed
directly
through
the

skin
.
Read
the
manufacturer's
instructions
and
warnings
carefully
.

Use
hand
andeye
protection
.
Avoid
direct
skin
contact

"
Cars
covered
by
this
manual
are
equipped
with
a
supplemental

restraint
system
(SRS),
that
automatically
deploys
an
airbag(s)
in

theevent
of
a
frontal
ímpact
.
The
airbag(s)
is
inflated
byan
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
when

working
ona
car
with
the
engine
running
or
the
ígnition
switched
on
.

"
Place
jack
stands
only
at
locations
specified
bymanufacturer
.

The
vehicle
lifting
jacksupplied
with
the
vehicle
is
intended
for
tire

changes
only
.
A
heavy
duty
floor
jack
shouldbe
used
to
lift
vehicle

before
installing
jack
stands
.
See
010
Fundamentals
for
theDo-
.

it-Yourself
Owner
.

"
Battery
acid
(electrolyte)
can
cause
severeburns
.
Flush
contact

area
with
water,
seek
medical
attention
.

"
Aerosolcleaners
and
solvents
may
contain
hazardous
ordeadly
vapors
and
are
highly
flammable
.
Use
only
in
a
wellventilated

area
.
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
theengine

whenever
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
an

approved
fire
extinguisher
handy
.



continued
on
next
page
vii

010-
8



FUNDAMENTALSFORTHE
DO-ITYOURSELF
OWNER

TOOLS

Mostmaintenance
can
be
accomplished
with
a
small
selec-
tion
of
the
right
tools
.
Toolsrange
in
quality
from
inexpensive
junk,
which
may
brakk
at
first
use,
tovery
expensive
and
well-
made
tools
for
the
professional
.
The
best
tools
for
most
do-it
yourself
BMW
owners
He
somewhere
in
between
.



O

Many
reputable
tool
manufacturers
offer
good
quality,
mod-
erately
priced
tools
with
a
lifetime
guarantee
.
These
are
your
best
buy
.
They
cost
a
little
more,
but
they
are
good
quality
tools
that
will
dowhat
is
expected
of
them
.
Sears'
Craftsman®
line
is
one
such
source
of
good
quality
tools
.

Some
of
the
repairs
covered
in
this
manual
require
the
use
of
special
tools,
suchas
a
custom
puller
or
specialized
electrical
test
equipment
.
These
special
tools
are
called
out
in
the
text
andcan
be
purchased
through
an
authorized
BMW
dealer
.
As
an
alternative,
some
special
tools
mentioned
may
be
pur-
chased
from
the
following
tool
manufacturers
andlor
distribu-
tors
:

"
Assenmacher
Specialty
Tools
6440
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
below
canbe
used
to
accom-
plish
most
of
thesimple
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
handlealmost
all
screws
used
on
BMWs
.
Two
orthree
different
sizes
of
each
type
will
be
required,
since
a
screwdriver



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



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



wrenches
would
inciude
6mm
through
19mm
sizes
.
typescrewdrivers
.

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

A
12-point
box-end
can
loosen
a
nut
or
bolt
where
there
is
less
room
for
movement,
while
a
6-point
box-end
provides
bet-
ter
grip
.
Forhex
fasteners
on
fluid
lines,
like
brake
lines
and
fuel
lines,
a
fiare-nut
wrench
offers
the
acivantages
of
a
box-end
wrench
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
.
Socketsperform
the
same
job
asbox-end
wrench-
es,
but
offer
greater
flexibility
.
They
are
used
with
a
ratchet
han-
dle
for
speed
and
conveniente
and
can
be
combined
with
extensions
and
universal
joints
(swivels)
to
reach
fasteners
more
easily
.
Sockets
come
with
different
size
connections
to
drive
handies
or
extensions,
called
the
drive
size
.
The
most
common
drive
sizes
are
1
/4
in
.,
318
in
.,
and
1
/2
in
.

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

If
a
battery
cableconnection
hasno
visible
faults,
but
is
still
suspect,
measure
the
voltage
drop
across
the
connection
.
A
large
drop
indicates
excessive
resistance,
meaning
the
con-
nection
is
corroded,
dirty,
or
damaged
.
Clean
or
repair
the
connection
and
retest
.

NOTE-

For
instructions
on
conducting
a
voltage
drop
test,
and
other
general
electrical
troubleshooting
information,
see600
Electrical
System-General
.

Wiring
and
Harness
Connections

The
electronic
fuel
injection
and
ignition
systems
operate
at

low
voltage
and
current
values,
making
them
sensitive
to

small
increases
in
resistance
.
The
electrical
system
is
routine-

ly
subjected
to
corrosion,
vibration
and
wear,
so
faults
or
cor-

rosion
in
the
wiring
harness
and
connectors
are
common
causes
of
driveability
problems
.

Visually
inspect
all
wiring,
connectors,
switches
and
fuses
in
the
system
.
Loose
or
damaged
connectors
can
cause
inter-

mittent
problems,
especially
the
smallterminals
in
the
ECM

connectors
.
Disconnect
the
wiring
harness
connectors
to

check
for
corrosion
;
and
use
electrical
cleaning
spray
to
re-

move
contaminants
.
Often,
simply
disconnecting
and
recon-

necting
a
dirty
connector
several
times
will
clean
the
terminals
and
help
to
reestablish
good
electrical
contact
.

If
a
wiring
harnessconnectorhasno
visible
faults,
but
is
still

suspect,
measure
the
voltage
drop
across
the
connector
.
A

large
drop
indicates
excessive
resistance,
meaning
the
con-

nector
is
corroded,
dirty
or
damaged
.
Clean
or
repair
the
con-

nector
and
retest
.

Ground
Connections

For
any
electrical
circuit
to
work,
it
must
make
acomplete

path,
beginning
at
the
positive
(+)
battery
terminal
and
ending

at
the
negative
(-)
terminal
.
The
negative
(-)
battery
cable
is

attached
to
the
car's
chassis
.
Therefore,
any
wireor
metal

part
attached
to
the
chassis
provides
a
good
ground
path
back

to
the
negative
(-)
battery
terminal
.

Poorground
connections
are
amajor
source
of
driveabílity

problems
.
If
any
of
themainground
connections
for
the
igni-
tion
system
or
the
fuelinjection
system
are
faulty,
the
in-

creased
resistance
in
that
circuit
will
cause
problems
.

Visually
inspect
al¡
ground
wires
and
connections
for

breaks,
looseness
or
corrosion
.
Be
careful
because
wires

sometimes
break
internally
or
in
areas
not
easily
visible
.
The

main
grounds
for
the
DME
system
are
shown
in
Fig
.
11,Fig
.

12,
and
Fig
.
13
.
Also
check
the
main
fuel
pump
ground
in
the
center
console,
below
the
emergency
brake
handle
.

If
a
ground
connection
has
no
visiblefaults,
but
is
still
suspect,

measure
the
voltage
drop
acrossthe
connection
.
A
large
drop

indicates
high
resistance,
meaning
the
connection
is
corroded,

dirty
or
damaged
.
Clean
or
repair
the
connection
and
retest
.

ENGINE-GENERAL
100-
1
3

UU,~uyi

Fig
.
11
.
Mainground
(arrow)
for
engine
management
system
.
Grounds
are
in
right
rear
of
engine
compartment
.

Fig
.
12
.
Mainground
for
ignition
coils
on
MS
41
.1
engine
manage-
ment
system
(arrow)
.

DRIVEABILITY
TROLIBLESHOOTING

250-
4



GEARSHIFT
LINKAGE

r%
;
5

(((((C
"
~
;

Fig
.
7
.



Selector
lever
cable
clamping
nut
(A)
.
Counterhold
clamping
bolt
when
loosening
nut
.

Gear
position/neutral
safety
switch,

replacing
(automatic
transmission)

NOTE-

The
gear-positionlneutral
safetyswitch
is
also
some-
times
referred
to
as
the
automatic
transmission
range
switch
.

Failure
of
the
gear
positionlneutral
safetyswitch
can
cause

a
no-start
condition
.
In
acidition,
since
it
signals
gearshift
posi-

tion
tothe
transmission
control
unit,
a
faulty
switch
can
cause

erratic
transmission
operation
.

1
.
Remove
hex-head
screw
(3mm
allen
key)
from
shift
le-

ver
handle
and
remove
handle
.
Carefully
pry
up
cover

from
gearshift
lever
console
.

2
.
Disconnect
harness
connector
from
gear
positionlneu-

tral
safety
switch
andremove
mounting
screws
.
See

Fig
.
8
.

3
.
Remove
gear
positionlneutral
safety
switch
by
moving

selector
until
pin
on
lever
aligns
with
slot
on
switch
.
Pull

switch
straight
up
and
off
.
See
Fig
.
9
.

4
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Before
installing
switch,
align
plastic
contact
slide
in-

sideswitch
with
slot
in
switch
.
See
Fig
.
10
.

"
Instan
switch
so
that
contact
slide
on
switch
aligns
with

slot
on
switch
.
Then
position
gearshift
lever
pin
to
slot

on
switch
and
install
switch
.

"
When
installing
shift
lever
handle,
engage
pín
on
re
leasebutton
to
hole
in
pulí
rod
.
See
Fig
.
11
.



Fig
.
9
.



Contact
slide
in
switch
aligns
toslot
on
switch
and
pin
on
le-
ver
.

Tightening
Torques

"
Console
to
body
..............
...
.
7
Nm
(62
in-lb)

"
Gear
positionlneutral
safety
switch

to
shift
console
.................
.
4
.5
Nm
(40
in-lb)

AUTOMATIC
TRANSMISSION
GEARSHIFT

Fig
.
8
.



Disconnect
harness
connector
to
gear
position/neutral
safety

switch
by
pressing
connector
retaining
clips
together
(ar-
rows)
.
Switch
mountingscrews
shown
at
1
.

Fig
.
10
.
Align
contact
slide
(1)
with
slot
in
switch
housing
(2)
before
in-
stalling
gear
position/neutral
safety
switch
.

Fig
.
11
.
Engage
release
button
pin
to
hole
in
pull
rod
before
installing

The
automatic
shiftlock
uses
an
electríc
solenoid
to
lock
the
selector
lever
in
P
or
N
.
Depressing
the
foot
brake
withthe
ig-
nition
on
energizes
the
solenoid,
allowingthe
lever
to
be
moved
into
a
drive
gear
.
The
solenoid
is
energized
only
when

the
engine
speed
is
below
2,500
rpmand
thevehicle
speed
is

below
3
mph
.
The
solenoid
ís
mounted
in
the
right-hand
side

of
theselector
lever
housing
.
See
Fig
.
12
.

1
.
With
engine
running
and
car
stopped,
place
selector
le-
ver
in
P
or
N
.

2
.
Without
depressing
brake
pedal,
check
that
selector
le-

ver
is
locked
in
position
P
or
N
.

3
.
Depress
brakepedal
firmly
.
Solenoid
should
be
heard

to
energize
.

GEARSHIFT
LINKAGE



250-
5

Fig
.
12
.
Automatic
shiftlock
prevents
drive
gear
selection
until
the
brakepedal
is
depressed
.

4
.
Check
thatselector
lever
can
now
be
moved
out
of
P
or
N
.

NOTE
-

The
next
test
should
be
performed
in
anopen
area
with
the
parking
brake
on
and
with
extreme
caution
.

5
.
With
selector
lever
in
P
or
N
and
brake
pedal
de-

pressed,
raise
engine
above
2,500
rpm
.
Check
that
se-

lector
lever
cannotbe
moved
outof
P
or
N
.

shift
lever
handle
.



If
any
faults
are
found
check
the
electrical
operation
of
the
shiftlock
solenoid
and
check
for
wiring
faultsto
or
from
the
Automatic
shiftiock,
checking
function



transmission
control
module(TCM)
.
See610
Electrical

(automatic
transmission)



Component
Locations
and
Electrical
Wiring
Diagrams
.

NOTE
-

The
solenoid
is
controlled
viathe
TCM,
using
brakepedal
position,
engine
speed,
and
road
speed
as
con-
trolling
inputs
.

AUTOMATIC
TRANSMISSION
GEARSHIFT

Door
Hinge
Adjustment

If
the
installed
door
is
uneven
or
out
of
parallel,
shims
can
be
used
to
correct
its
position
.
The
shims
are
placedbehind
the
hinge
plate
and
are
available
in
two
different
thicknesses
(0
.5
mm
and
1
.0
mm)
.
See
Fig
.
4
.

Tightening
Torque

"
Door
hinge
to
door
.............
..
21
Nm
(15
.5
ft-I
b)
"
Door
striker
to
door
...........
...
25
Nm
(18
ft-Ib)

DOOR
PANELS

0
l
o
0013102

Fig
.
4
.



Door
hinge
and
door
check
components
.
Front
and
rear
doors
are
similar
.

WARNING
-

Some
1997
and
all
1998
cars
are
fitted
with
side-im-
pact
airbags
in
the
front
doors
.
When
servicing
doors
on
cars
with
front
side-impact
airbags,
always
dis-
connect
the
negative
()
battery
terminal
.
See
721
Airbag
System
(SRS)
for
cautions
and
procedures
relating
to
the
airbag
system
.

Front
door
trimpanel,
removing
and
in-

stalling

1
.
On
cars
with
side-impact
airbags,
disconnect
negative

(-)
battery
cable
.

CAUTION
-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.

Fig
.
5
.



Pry
outside
mirror
switch
from
door
armrest
.

3
.
Unscrew
door
locking
knob
.

Fig
.
6
.



Pry
off
plugs
(arrows)
and
remove
screws
.

DOORS
411-
3

2
.
Carefully
pry
out
mirror
adjustment
switch
and
discon-
nect
harness
connector
from
switch
.
Fig
.
5
.

5
.
Unclip
door
panel
from
door
perimeter
.
See
Fig
.
7
.

0013168

4
.
Pry
off
trim
cover
for
insíde
door
handle
.
Pry
off
con-
cealing
plugs
from
armrest
.
Remove
door
panel
retain-
ing
screws
.
See
Fig
.
6
.

UU13169

DOOR
PANELS

411-
4
DOORS

6
.
Disconnect
radio
speaker
harness
connector
.

Fig
.
7
.



Door
panel
being
unclipped
from
door
.
Pull
panel
retaining

clips
off
one
at
a
time
.

7
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Replace
any
damaged
plastic
parts
orclips
.

"
Renew
vapor
barrier
ifit
is
damaged
.

"
Use
new
mounting
bolts
when
reinstalling
the
side-im-

pactairbag
to
the
door
(where
applicable)
.

"
When
installing
door
panel,
align
metal
retainers
on

window
sill
with
openingsontop
of
door
panel
.
See

Fig
.
8
.

"
Check
door-lock
mechanism
and
window
for
ease
of

movement
.

"
If
battery
was
disconnected,
re-initialize
window
regu-

lator
motors
as
described
in
512
Door
Windows
.

373

Fig
.
8
.



Metal
retainers
at
base
of
window
should
be
in
position
to
mate
with
openings
in
door
trim
panel
.

DOOR
PANELS

Reardoor
trimpanel,

removing
and
installing

1
.
Open
door
and
pry
out
power
window
switch
.
Discon-

nect
harness
connector
.

2
.
Remove
ash
tray
.

3
.
Pry
off
trim
cover
from
inside
door
handle
.

4
.
Pry
off
concealing
plugs
from
armrest
.
Remove
door

panel
retaining
screws
.
See
Fig
.
9
.

Fig
.
9
.



Pry
off
plugs
(arrows)
andremove
screws
.

5
.
Unscrew
door
locking
knob
.

6
.
Unclip
panel
from
door
perimeter,
starting
at
thetop
of

the
door
.

7
.
Installation
is
reverse
of
removal
.

"
Replace
any
damaged
plastic
parts
or
clips
.

"
Renew
vapor
barrier
ifit
is
damaged
.

"
Align
metal
retainers
on
window
sill
with
openings
in

trim
panel
.
Refer
to
Fig
.
8
.

"
Check
door-lock
mechanism
and
window
for
ease
of

movement
.

Rear
side
trim
panel,
removing
and
install-

ing
(coupe
models)

1
.
Remove
rear
seat
cushion
.
Remove
rear
backrest
side

section
.
See
520
Seats
.

2
.
Pull
off
edge
trimat
bottom
of
rear
side
window
.
See

Fig
.
10
.

3
.
Gently
unclip
trim
panel
andremove
.

4
.
Installation
is
reverse
of
removal
.

"
Replace
any
damaged
plastic
parts
or
clips
.

512-
8



DOOR
WINDOWS

NOTE-

To
achieve
an
accurate
window
adjustment
in
2-door
models
with
"close
with
door
shut"
feature,
simulate
a
closed
dooras
follows
:
On
early
cars,
manually
turn
the

latch
on
the
door
to
the
closed
position
.
See
Fig
.
16
.
On

latercars,
insert
a
wedge
of
wood
into
the
striker
on
the

body
to
close
the
striker
switch
.
Be
sure
to
open
thero-
tary
latch
(by
pulling
upon
the
door
handle)
or
remove
the
wedge
before
closing
the
door
.

0013066

Fig
.
16
.
To
manually
close
door
latch,
push
rotary
latch
in
direction
of
arrow
.

CAUTION-

Do
not
close
the
door
with
therotary
latch
in

closed
position,
orwith
a
wedge
in
the
striker
.

WINDOW
SERVICE,
2-DOOR
MODELS

A
Window
insertion
depth
at
A-pillar
B
B-pillar
preload
gap
(measure
gap
at
20
mm
from
top
of
door)
C
Window
insertion
depth
at
roof
line/window
parallelism
(make
measurement
at
3
.5
in
.
and
16
in
.
from
B-pillar
edge)

Fig
.
17
.
2-door
window
adjustment
positions
.

NOTE-

In"



some
models
covered
inthis
manual,
it
is
not
es-

sential
to
remove
the
side-impact
airbag
to
access
in-
terna¡
door
components
.
However,
the
procedure
is
recommended
for
safety
reasons
.

"
After
each
adjustment
step,
fully
lower
and
raise
win-
dow
and
check
adjustment
before
goingon
to
the
next

step
.

"
1f
parts
of
the
front
window
mechanism
were
replaced,

make
sure
initial
adjustments
are
in
the
center
of
their
travel
range
.
Once
the
glass
isinstalled,
position
glass
to
the
rear
guide
rail
as
shown
in
Fig
.
18
.

4
.
To
set
window
preload
B
(See
Fig
.
1
g
.):

0013076

When
making
adjustments
to
the
front
door
window,
see



"
Measure
up
20
mm
(0
.75
in
.)
from
topof
door
and

Fig
.
17
.



mark
position
on
glass
.

"
Close
door
just
until
top
of
glass
contacts
seal
.
1
.
On
cars
with
side-impact
airbags,
disconnect
negative



"
Measure
gap
between
glass
(at
20
mm
mark)
and
win-

(-)
cable
from
battery
.



dow
seal
.

"
If
adjustment
is
necessary,
move
bottom
of
window

CAUTION-



guide
inor
out
to
correct
.
See
Fig
.
20
.

Prior
to
disconnecting
the
battery,
read
the
battery



"
If
further
adjustment
is
needed,
move
bottom
ofwin-

disconnection
cautionsgiven
at
the
front
of
this



dow
in
or
out
by
sliding
guide
bracket
.
Refer
to
Fig
.
18
.

manual
on
page
viii
.

2
.
Remove
interior
door
panel
and
vapor
barrier
.
See
411



Preload
Gap

Doors
.



"
B
(Referto
Fig
.
1
g
.)

Coupe
......................
.
.
.8
mm
(0
.32
in
.)

3
.
Where
applicable,



remove
side-impact
airbag
from



Convertible
..................
.
..
3
mm
(0
.12
in
.)

door
.
See
721
Airbag
System
(SRS)
.

512-
1
2



DOOR
WINDOWS

Fig
.
30
.
Vent
window
mounting
nuts
on
B-pillar
(arrows)
.

WINDOW
REGULATOR
SERVICE

0013071

Fig
.
29
.
Seat
belt
sliding
anchor
mounting
bolts
on
B-pillar
(arrows)
.

Notedoor
post
and
vent
window
trim
strips
peeled
away
.

Tightening
Torques

"
Latch
to
vent
window
(M5
screw)
.....
6
Nm
(53
in-lb)

"
Seat
belt
anchor
nut
..............
31
Nm
(23
ft-Ib)

"
Seat
belt
sliding
anchor

mounting
bolts
.
..
...
.
...........
24
Nm
(17
ft-Ib)

"
Vent
window
to
body(M6
nut)
.....
6
.2
Nm
(55
in-lb)

WINDOW
REGULATOR
SERVICE

Door
window
regulator
and
motor,

removing
and
installing

This
procedure
applies
to
front
or
rear
door
windows
.

1
.
Remove
door
panel
and
vapor
barrier
as
described
in

411
Doors
.

WARNING
-

"
Some
1997
and
all
1998
model
year
cars
are

equipped
with
front
side-impact
airbags
in
the

front
doors
.
Whenever
servicing
the
doors
orwin-

dows
on
cars
with
front
side-impact
airbags,
al-

ways
disconnect
the
negative
(-)
battery
cable
.
See
721
Airbag
System
(SRS)
for
cautions
and
procedures
relating
to
the
airbag
system
.

"
Prior
to
disconnectiog
the
battery,
read
the
bat-tery
disconnection
cautions
gíven
at
the
front
of

this
manual
onpage
vi¡¡
.

2
.
Remove
door
glass
as
described
earlier
in
this
section
.

3
.
Remove
inside
door
handle
.
See
Fig
.
31
.

4
.
Disconnect
wiring
connector
to
power
window
motor
.

5
.
Remove
regulator
mounting
bolts
or
drill
out
rivets
.
See

Fig
.
32
.

0013193
0013072



Fig
.
32
.
Front
window
regulator
mounting
fasteners
(arrows)
.

6
.
Remove
regulator
assembly
fromdoor
.

Fig
.
31
.
Inside
door
handle
.
Remove
screw
A,then
unhook
from
rod
B
.

7
.
Unbolt
power
window
motor
from
rear
of
regulator
.

NOTE-

Some
of
the
window
regulators
are
mounted
to
the
doors
with
rivets
.
The
rivets
must
be
drilled
out
.
During
installation,
M6
x
10
bolts
and
self-locking
nuts
can
be
substituted
.

8
.
Installation
is
reverse
of
removal
.

0013073

"
Adjust
door
window
as
described
earlier
.
"
Re-initialize
window
regulators
as
described
earlier
.

Tightening
Torques

"
Window
regulator
to
door
............
9
Nm
(7
ft-Ib)
"
Window
motor
to
regulator
...........
5
Nm
(4
ft-Ib)