BUMPER BMW 325i 1994 E36 Workshop Manual

General
Data
and



010
FundamentalsfortheDo-lt-YourselfOwner

Maintenance



020
Maintenance
Program

Engine

Transmission

Suspension,

Steering
and

Brakes

4
Body

100
Engine-General

110



Engine
Removal
and
Installation
113



Cylinder
Head
Removal
and
Installation
116



Cylinder
Head
and
Valvetrain
117



Camshaft
Timing
Chain

119



Lubrication
System

200
Transmission-General
210
Clutch
230
Manual
Transmission

510



Exterior
Trim,
Bumpers



520



Seats

Bo
y
Equipment



512
DoorWTdws



540



nr
t

513



InteriorTrim



541



Convertible
Top

515



Central
Locking
and
Anti-Theft

600



Electrical
System-General



620



Instruments

Electrical
S



stem
610
Electrical
Component
Locations



630
Exterior
Lighting

611



Wipers
and
Washers



640



Heating
and
Air
Conditioning

6



612



Switches
and
Electrical
Accessories



650



Radio

Equipment
and



720
SeatBelts

Accessories



721
Airbag
System
(SRS)

Electrical
Wiring

Diagrams

Foreword
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v

Warnings
and
Cautions
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.vii

Index
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..
back
of
book

300



Suspension,
Steering
and



330



RearSuspension

Brakes-General



331



Final
Drive

310



Front
Suspension



340



Brakes

320



Steering
and
Wheel
Alignment

400
Body-General



411
Doors

410



Fenders,
Engine
Hood



412



Trunk
Lid

120



Ignition
System
121



Battery,Starter,
Alternator
130



Fue¡
Injection
160



Fuel
Tank
and
Fuel
Pump
170



Radiator
and
Cooling
System180



Exhaust
System

240



Automatic
Transmission
250



Gearshift
Linkage

260
Driveshaft

Non-returnable
Parts

FUNDAMENTALS
FOR
THEDO-ITYOURSELF
OWNER
010-
7

Many
independent
repair
shops
make
a
point
of
using
genu-



Original
body
paneis
and
other
large
components
are
identi-

ine
BMW
parts,
even
though
they
may
at
times
be
more
expen-



fied
by
a
label
bearing
the
VINand
two
BMW
roundellogos
.
Re-

sive
.
Theyknow
the
value
of
doing
thejob
right
with
the
right



placement
parts
have
a
similar
label,
bearing
one
BMW
roundel

parts
.
Parts
from
other
sources
can
beas
good,
particularly
if



logo
and
the
letters
DOT-R
.
See
Fig
.
6
.
Parts
or
assemblies

manufactured
by
one
of
BMWs
original
equipment
suppliers,



bearing
the
label
arethe
engine,
transmission,
front
and
rear

but
it
is
often
difficult
to
know
.



bumpers,
front
fenders,
rear
quarter
paneis,
hood,
trunk
lid
and

doors
.
These
labels
shouldnot
be
removed
as
they
will
tear

BMW
is
constantly
updating
and
improving
their
cars,
often



apart
.

making
improvements
during
a
given
model
year
.
BMW
may

recommend
a
newer,
improved
part
as
a
replacement,
and

your
authorized
dealer's
parts
department
will
know
about
it

and
provide
it
.
The
BMW
parts
organization
is
best
equipped
to
deal
with
any
BMW
parts
needs
.

Some
parts
cannot
be
returned
for
credit,
even
if
they
arethe

wrong
parts
forthe
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
beas
sure
as
possible
that
P-
DOT~
R

a
replacement
is
needed,
especially
for
expensive
parts
such
as
electronic
control
units
.
It
may
bewise
to
let
an
authorized



B328FUN

BMW
dealeror
other
qualified
shop
confirm
your
diagnosisbe-

fore
replacing
an
expensive
part
that
cannot
be
retuned
.



Fig
.
6
.



Labels
used
to
identiy
parts
.
Original
equipment
labelwith

VIN
number
and
roundel
logos
(top)
and
replacement
part
la-

bel
with
one
roundel
logos

Information
You
Need
to
Know

Engine
.
3-Seriescars
covered
in
this
manualare
powered

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



by
either
a
4-or
6-cylinder
engine
.
For
information
-
on
engine

correct
model
designation
for
your
car
.
Models
covered
in
this



codes
and
engine
applications,
see100
Engine-General
.

manual
are
E36
3
Series
in
both
4-
and
6-cylinderconfigura-

tions
.



Transmission
.
The
transmissiontype
with
its
identifying

code
may
be
important
when
buying
clutch
parts,
seals,
gas

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



kets,
and
othertransmission-relatedparts
.
For
information
on

manufacture
or
date
of
sale
.
A
1997
model
may
havebeen



transmission
codes
and
applications,
see200
Transmission

manufactured
in
late
1996,
and
perhaps
not
sold
until
early



General
.

1997
.
It
is
still
a1997
model
.
Model
years
covered
by
this
man-

ual
are
1992
to
1998
.

SERVICE
Date
of
Manufacture
.
This
information
is
helpful
when
or-

dering
replacement
parts
or
determining
if
any
of
the
warranty



BMW
dealers
are
uniquely
qualified
to
provide
service
for
recalls
are
applicable
to
your
car
.
The
label
on
the
driver's
door



BMW
cars
.
Their
authorized
relationship
with
the
large
BMW
below
the
door
latch
will
specify
the
month
and
year
that
the
car



serviceorganization
means
that
they
are
constantly
receiving
was
built
.



new
tools
and
equipment,
together
with
the
latest
and
most
ac-

curate
repair
information
.
Vehicle
Identification
Number
(VIN)
.
This
is
a
combination

of
letters
and
numbers
that
identify
the
particular
car
.
TheVIN

appears
on
the
state
registration
document,
and
on
thecar
it-

self
.
One
location
isin
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
theftrateto
have
the

VINmarked
on
specific
parts
of
thecar
when
manufactured
.
On

BMW
cars,
these
parts
are
identified
byan
adhesive
label
.

)WBADK00000000

0
000
0

The
BMW
dealers
service
technicians
are
highlytrained
and

very
capable
.
Unfke
most
independent
repair
shops,
autho-

rized
BMW
dealers
are
intensely
committed
tosupporting
the

BMW
product
.
They
share
the
owners
interest
in
BMW
value,

performance,
and
reliability
.
On
the
other
hand,
there
are
many

independent
shops
that
specialize
in
BMW
service
and
are
ca-

pable
of
doing
high
quality
repair
work
.
Checking
with
other

BMW
owners
for
recommendations
on
service
facilitiesis
a

good
way
to
leam
of
reputable
BMW
shops
in
yourarea
.

SERVICE

If
steam
is
coming
from
the
engine
compartment
thenthere
is



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



battery
cables
or
wires
at
the
battery
or
thealtemator
.
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
theengine



tors
may
solve
the
problem
.
Also
check
drive
belt
tension
as
cool
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
of
the
hole,
then
thecarshouldnot
be
driven
until
repairs
are
made
.
lf
there
is
slight
seepage,
then
it
may
be
possible
to
drive



TOWi
ng

a
short
distance,
adding
coolant
as
needed
.
The
cars
covered
by
this
manual
should
be
towed
witha
tow
truck
using
wheel
lift
or
flat
bed
equipment
.
Do
not
tow
thecar
on
all
four
wheels
except
for
very
short
distances
to
move
it
to
a
safe
place
.
If
thered
engine
oil
pressure
warning
light
illuminates,
imme-
diately
stop
thecar
and
turn
off
the
engine
.
Have
the
vehicle



A
towing
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
is
covered
ín
119
Lubrication
System
.

Brake
Fluid
Leve¡

The
brake
fluid
leve¡
warning
light
may
bean
indicator
of
brake
fluid
loss
.
Problems
with
the
brakesystem
should
be
checked
and
repaired
immediately
.
See
340Brakes
for
more

information
.

Check
Engine
Warning
Light

Dim
Lights

FUNDAMENTALS
FOR
THE
DO-IT
YOURSELF
OWNER



010-13

If
the
"CHECK
ENGI
NE"
warning
light
comes
on
or
flashes,
it
indicates
that
an
emissions-related
fault
has
occurred
.
Faults
suchas
a
failed
oxygen
sensor
or
a
faultyfuelinjector
can
tum

the
light
on,
causing
the
exhaust
or
evaporative
emissions
to

exceed
a
specified
limit
.
The
engine
can
be
safely
driven
with

the
light
on,
although
the
emission
systems
should
be
checked

assoonas
possible
.
See
100
Engine-General
for
more
infor-

mation
on
the
Check
Engine
Light
and
the
On-board
diagnostic

system
.

Headlights
and
instrument
panel
illuminationthat
are
dim
or

gradually
getting
dimmer
generally
indicate
a
problem
with
the

battery
or
charging
system
.
The
battery
charge
indicator
light

may
come
on
as
the
lights
are
dimming
.
In
either
case,
theen-

gine
and
accessories
are
running
off
of
the
battery
alone,
and

will
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
the

starting
system
torestart
the
engine
.
Instead,turn
off
as
many

electrical
consumers
as
possible
.
This
will
reduce
the
current

drain
and
will
allow
thecar
to
be
driven
farther
before
you
lose

all
battery
power
.

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

When
towingthecar
from
the
front
with
the
rear
wheelson

the
ground,
a
maximum
distance
of
20
miles
is
acceptable
.
If

thecar
needs
to
be
towed
further,
have
the
rear
wheels
placed
on
dollies
.

CA
UTION-

"
Do
not
tow
with
sling-type
equipment
The
front
spoilers
andbumper
covers
may
sustain
dam-
age
.

"
Towínga
BMW
with
an
automatic
transmission
with
the
rear
wheelson
the
ground
can
resuft
in
transmission
damage
due
to
lackof
lubrication
and
should
be
avoided
.

0013128

EMERGENCIES

170-8



RADIATOR
AND
COOLING
SYSTEM

Electric
cooling
fan,
replacing

On
late
4-cylinder
models
(M44
engine)
with
manual
trans-
mission,
the
primary
cooling
fan
is
electrically
operated
and
is
mounted
on
the
engine
side
of
the
radiator
.

1
.
If
necessary,
remove
cover
from
top
of
radiator
.
See
Fig
.
10
.

0012505
Fig
.
10
.
Air
cover
in
back
of
radiator
.
Unclip
cover
from
fan
shroud
af-
ter
removing
mounting
screws
.

2
.
Disconnect
fan
harness
connector
at
bottom
left
of
ra-
diator
.

3
.
Remove
fan
shroud
mountingscrews
at
left
and
right
side
of
radiator
.
Lift
fan
assembly
straight
up
and
offra-
diator
.

4
.
Installation
is
reverse
of
removal
.
Be
sure
to
align
side
tabs
on
fan
housíng
with
retaining
tabs
on
radiator
when
reinstalling
fan
.

Auxiliary
cooling
fan,
replacing

The
auxiliary
electric
cooling
fan
is
mounted
behind
the
front
bumper,
in
front
of
the
A/C
condenser
.
There
aretwo
ver-
sions
of
auxiliary
fans
installed,
depending
on
model
and
en-
gine
installed
.

TType
1
(u
p
to
9192)

1
.
Remove
front
radiator
air
shroud
.
See
Fig
.
11
.

2
.
Remove
fan
mountingscrews
.
See
Fig
.
12
.

3
.
Tilt
fan
forward
.
Disconnect
electrical
harness
connec-
tor
before
lifting
fan
up
.

COOLING
SYSTEM
SERVICE

Fig
.
11
.
Front
radiator
air
shroud
fasteners
(arrows)
.

Fig
.
12
.
Version
1
auxiliary
fan
mountingscrews
(arrows)
.

NOTE
-

If
necessary,
remove
front
bumper
or
lowerengine
cov-
erto
access
electrical
harnessconnector
.

4
.
Installation
is
reverse
of
removal
.

l)
Type
2
(from
9192)
2
.
Remove
fan
mounting
screws
.
See
Fig
.
13
.

0013137

1.
Remove
front
bumper
and
radiator
grilles
.
See
510
Ex-
terior
Trim,
Bumpers
.

3
.
Angle
fan
up
and
forward,
disconnecting
electrical
har-
nessconnectorbehind
it
.
Remove
it
through
bumper
opening
.

Fig
.
13
.
Version
2
auxiliary
fan
mounting
screws
(arrows)
.
Front
bumper
hasbeen
removed
.

4
.
Installation
is
reverse
of
removal
.

Thermostat,
replacing

0013146

The
coolant
thermostat
is
instalied
in
a
housing
at
the
front

of
the
cylinder
head
.
See
Fig
.
14
.

Fig
.
14
.
Coolantthermostat
and
housíng
.

NOTE-

On
M44
engines,
the
thermostat
is
integrated
into
the
thermostat
housíng
.
If
the
thermostat
requiresreplace-
ment,
the
complete
thermostathousing
mustbe
replaced
.

RADIATOR
AND
COOLING
SYSTEM



170-
9

WARNING
-

Allow
the
cooling
system
to
cool
before
opening
ordraining
the
system
.

2
.
Remove
belt-driven
cooling
fan
and
fan
shroudas
de-

scribed
earlier
.

3
.
On
M52/S52US
engines
:
Unclip
wiring
duct
retaining
clips
and
remove
duct
from
above
thermostat
housing
.

Also
remove
engine
front
lifting
bracket
.

4
.
Remove
thermostat
housing
from
front
of
engine
.
See
Fig
.
15
.

Fig
.
15
.
Thermostat
housíng
shown
removed
(6-cylinder
engine)
.

NOTE-

Some
thermostats
have
a
direction
arrowor
venthole
near
the
edge
.
Install
the
thermostat
so
that
either
the
arrow
or
hole
are
at
thetop
.

CAUTION
-

Be
sure
to
reconnect
ground
wire(s)
at
thermostat
housing
mounting
bolt,
where
applicable
.

5
.
Remove
thermostat
.
Note
thermostat
direction
and
ori-

entation
before
removing
.

6
.
Insta¡¡
new
thermostat
and/or
thermostat
housing
using

new
O-ring
and
gasket(s)
as
necessary
.

oo131ss



7
.
Installation
is
reverseof
removal
.
Fill
system
with
cool-

ant
as
described
under
Coolant,draining
and
filling
.

Tightening
Torques

1
.
Drain
radiator
as
described
above
under
Coolant,



"
Thermostat
housing
cover

draining
and
filling
.



to
housing
orcoolant
pump
..
..
....
10
Nm
(89
in-lb)

"
Engine
lifting
bracket
bolt
to
thermostat
housing

(M52/S52US
engine)(M8)
....
..
...
22
Nm
(17
ft-Ib)

COOLING
SYSTEM
SERVICE

Rear
shock
absorber,

removing
and
installing

1.
Raisecar
and
remove
rear
wheels
.

WARNING
-

Make
sure
that
thecar
is
firmly
supportedon
jack
stands
designed
for
the
purpose
.
Place
the
jack
stands
beneatha
structural
chassis
point
.
Do
not
place
jack
stands
undersuspension
parts
.

2
.
Remove
rear
speakers
.
See
650
Radio
.

3
.
Pryoutluggage
compartment
liner
retaining
clips
and
peel
back
liner
to
gain
access
to
upper
shock
absorber
mounting
nuts
.
See
Fig
.
3
.

Fig
.
3
.



Rear
shock
upper
mounting
nuts
(arrows)
in
luggage
com-
partment
.
Liner
hasbeen
peeled
back
.

NOTE-

On
convertible
models,
the
uppershock
absorber
mount
is
in
the
convertible
top
compartment
behind
the
rear
seat
.

4
.
Support
trailing
arm
from
below
using
a
transmission

jack
orequivalent
.
See
Fig
.
4
.
Remove
shock
absorber

uppermounting
nuts
.

CAUTION-

The
shock
absorber
prevenís
the
drive
axle
and
trailing
arm
from
drooping
too
far,
so
always
sup-port
the
trailing
arm
before
removing
the
shock
.
Damage
to
drive
axle
CV
joints
can
result
.

0013224

5
.
While
supporting
shock
absorber,
carefully
remove

lower
mounting
bolt
.
Lower
shock
absorber
out
of

wheel
well
.

Fig
.
4
.



Support
rear
trailing
arm
from
below
before
removing
upper
or
lower
(arrow)
shock
mounting
.

6
.
Transfer
shocktopmounting
plate,
dust
coverand
relat-

ed
components
to
new
shock
absorber
.
See
Fig
.
5
.

'
Protective
cap

Upper
mounting
nut
14
Nm
(10
ft-Ib)

1120



Shock
upper
mount
,~,--~to
body
nuts
(renew)



I
-



'



~



24
Nm
(17
ft-Ib)



I
1
-Gasket
(renew)



I
1
pper
mount



I



Rear
I
shock
I
absorber
I
I
---spacer

REAR
SUSPENSION



330-
3

Rubber
bumper

Dust
shield

Fig
.
5
.



Rear
shock
absorber
assembly
.

Lower
mounting
bolt
77
Nm
I



(57
ft-Ib)

i

I

I
1
I

0013220
0013236

SHOCKABSORBERS
AND
SPRINGS

400-2
BODY-GENERAL

4-door
Sedan

Coupe

-
saas3
.7""

351
/



37
.3
O



I
x
`-193



267

o
oa

'3281
model
"M3
model

Convertible

BODYASSEMBLY

55
ass
.e
iss
""
-
66
.9
-

Fig
.
2
.



E36
body
dimensíons
.

BODY
ASSEMBLY

29
.4

29
4

The
BMW
3
Series
chassis
is
a
unibodydesign
constructed
ofhigh
strength
steel
.
Attaching
parts,
suchas
the
front
fend-
ers,
rear
quarter
panels,
doors,
trunk
lid
and
hood
are
also
constructed
of
steel
.

706
.31108
.7"



I
38
.5
174
.5

174
.5

O



oo

196
.3/106
.7'
"



35_5



1.
.
55
.9,566
".

106
.3/196
.7""



i.
358
-1745-

55
9/56
3'/56
6"
-
J

0013099

Windows
bonded
flush
to
the
body
and
the
guided
flow
of
cooling
air
into
the
engine
compartment
provide
a
good
coeffi-
cient
of
drag(CD)
.
TheE36
cars
have
a
CD
of
approximately
0
.30for
the
sedan
and
coupe
models,
and
0
.35
for
the
con-
vertible
models
:

The
exterior
panels
are
corrosion-resistant
zinc
coated

steel
.
The
front
fenders
are
bolted
on
and
easily
replaceabie
.
The
body
styles
of
E36
cars
coveredby
this
manual
arethe



See410
Fenders,
Engine
Hood
.
4-door
sedan,
2-door
coupe
and
convertible
.
Body
dimen-
sions
vary
slightly
betweenmodels
.
See
Fig
.
2
.



The
front
and
rear
bumpers
use
an
aluminum
framework
with
an
overlaid
high-impact,
deformable
plastic
cover
.
This
Exterior
and
Aerodynamics



bumper
system
keeps
damage
to
a
minimum
in
head-on
colli-
sions
of
up
to
10
m
.p
.h
.
(15
km/h)
.
See
510
Exterior
Trim,
TheE36
can
be
immediatelyrecognized
asa
typical
BMW
.



Bumpers
.
With
its
traditionalstyling
features,
suchas
the
BMW
kidney
grille,
circular
headlights
behind
a
glass
cover
(for
reasons
of
streamliníng),
and
the
"kick"
in
the
rearmost
roof
pillar
(C-pil-
lar)
.

GENERAL

This
repair
group
covers
replacement
of
the
front
fenders

and
removal
and
installation
of
the
engine
hood
.

NOTE-

The
body
is
painted
at
the
factoryafter
assembly
.
Re-
alignment
of
body
panels
may
expose
unpainted
metal
.

Paint
all
exposed
metal
once
the
work
fs
complete
.

FRONT
FENDERS

Front
fender,
removing
and
installing

1
.
Raise
hood
.
Raise
and
safely
support
front
of
vehicle
.

WARNING
-

"
When
raising
thecar
using
a
floor
jack
or
a
hy-

draulic
lift,
carefully
position
the
jack
pad
to
pre-

vent
damaging
thecar
body
.
A
suitable
liner
(wood,
rubber,
etc
.)
should
be
placed
between
the
jack
and
the
car
to
prevent
body
damage
.

"
Watch
the
jack
closely
.
Make
sure
it
stays
stable
and
does
not
shift
or
tilt
.
As
the
car
is
raised,
the

car
may
roll
slightly
and
the
jack
may
shift
.

2
.
Remove
front
wheel
.
Remove
inner
plastic
liner
from

wheel
well
.

3
.
Remove
front
bumper
.
See510
Exterior
Trim,

Bumpers
.

4
.
Working
atfront
corner
of
fender,
remove
front
grille

panel
bolts
(2
bolts
at
left
and
right)
.
See
Fig
.
1
.

FENDERS,
ENGINE
HOOD



410-1

410
Fenders,
Engine
Hood

GENERAL
...............
.
.
.
.
.
.
.
.
.
.
.
..
410-1



ENGINE
HOOD
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.410-3

Hood,
raising
to
service
position
.
.
.
.
.
.
.
.
...
410-3
FRONTFENDERS
........
.
.
.
.
.
.
.
.
.
.
.
.
.410-1



Hood,
removin



and
installin



410-3

Front
Pender,
removing
and
installing
.
.
.
....
410-1



Hood,
aligning
...
.
.
.
.
.
.
.
.....
.
.
.
.
.
.
.
...
410-4

Hood
release
cable
and
latches,
adjusting
...
410-4

001
.145

Fig
.
1
.



Front
grille
panel
to
front
fender
retaining
bolts
(arrows)
.
Front

bumpershown
removed
.

5
.
Remove
front
turn
signalliens
assembly
from
applica-

ble
front
corner
.
Carefully
pryout
side
directional
from

fender
(later
cars
only)
.
See
630
Exterior
Lighting
.

6
.
Remove
fender
attaching
bolts
atfront
underside
of

fender
.
See
Fig
.
2
.

7
.
Remove
bolts
along
top
edge
of
fender
:
See
Fig
.
3
.

8
.
Open
front
door
and
remove
fender
mounting
bolts
in

door
jamb
.
See
Fig
.
4
.

9
.
Carefully
remove
fender
from
body
.

FRONTFENDERS

410-4



FENDERS,
ENGINE
HOOD

4
.
With
aid
of
assistant,
remove
hood
hinge
bolts
from
left

and
Rght
sides
of
hood
.
Lift
hood
off
carefully
See
Fig
.
8
.

Fig
.
8
.



Hood
hinge
bolts
(arrows)
.
Right
side
shown
.

5
.
Installation
is
reverse
of
removal
.

NOTE-

The
hood
was
fitted
and
attached
to
an
unfinished
body
at
the
factory
.
Unfinished
surfaces
exposed
by
this
pro-
cedure
must
betouchedup
wfth
pafnt
.

Hood,
aligning

ENGINE
HOOD

0013149

6013150

Fig
.
9
.



Hood
panel
gaps
should
be
even
(approx
.
5
.5
mm)
at
all
points
(arrows)
.

Hood
release
cable
and
latches,
adjusting

Before
adjusting
hood
latches,
be
sure
the
hood
is
aligned

evenly
to
fenders
and
front
panel
.
The
hood
latch
and
cable

assembly
is
shown
in
Fig
.
10
.

"
Repair
any
paint
damage
and
paint
any
exposed
metal
.

"
Check
hood
alignment
as
described
next
.



1
.
To
adjust
hood
cables
:

When
installing
the
hood,
align
the
hinges
as
close
to
the
original
paintedsurface
as
possible
.
Movement
of
the
hood
on
its'attaching
hardware
may
require
touch-up
paint
.

The
hood
should
be
aligned
so
that
gapson
all
sides
areas

even
as
possible
.
See
Fig
.
9
.

Clearance
Specification

"
Hood
edges
to
adjoining
body

panel
(gap)
........
..
..
..
.....
.5
.5
mm
(0.216
in)

"
Remove
left
and
right
radiator
grilles
.
See
510
Exterior

Trim,
Bumpers
.

"
Remove
electric
auxíliary
cooling
fan
.
See
170
Radia-

tor
and
Cooling
System
.

"
Adjust
cable
section
between
two
hood
latches
so

there
is
no
play
(cables
must
not
be
under
tension
ei-

ther)
.

2
.
Loosen
hood
latches
at
hood
on
left
and
right
sides
.

Loosen
bolts
only
enough
to
allow
movement
of
latch
.

See
Fig
.
11
.

3
.
Lower
(but
do
not
fully
latch)
hood
severa¡
times
so

latches
on
hood
center
themselves
in
lower
locks
.

CA
UTION-

Do
not
let
hood
fockwith
latchbolts
loose
.

4
.
Tighten
hood
latch
bolts
when
alignment
is
correct
.

5
.
Remove
one
screw
fromeach
side,
clean
and
coat
with
Loctite
O
270
or
equivalent,
and
reinstall
.

412-2



TRUNK
LID

Trunk
lid,
aligning

1.
Raise
trunk
lid
.

2
.
Loosen
boits
at
trunk
lid
lock
until
it
can
just
be
moved
.

See
Fig
.
3
.

Fig
.
3
.



Trunk
lid
lock
mounting
boits
(arrows)
.

0013172

3
.
Loosen
bolis
at
left
and
right
trunk
hinges
until
lid
can

just
be
moved
.

4
.
Working
at
lower
comers
of
trunk
lid,
screw
in
rubber

buffers
on
left
and
right
sides
fully
.

5
.
Prop
open
trunk
lid
and
remove
gas
pressure
strut
as

described
below
.

WARNING
-

"
Make
sure
to
support
trunk
lid
before
removing
strut
.

"
Trunk
lid
with
gas
pressure
strut
removed
will
drop
without
damping
.

6
.
Close
trunk
lid
and
align
lid
to
body
at
rear
and
front
.
Open
trunk
lid
and
tighten
hinge
bolis
.

7
.
Adjust
lock
so
that
closed
trunk
lid
is
approximately
1
mm
(0
.04
in
.)
belowtop
of
rear
fenders
.
Tighten
lock
bolts
.

TRUNK
LID

8
.
Open
trunk
lid
and
screw
outrubber
stops
so
that

closed
trunk
lid
is
flush
with
top
of
rear
fenders
.

9
.
Reinstall
gas
pressure
strut
.

Seam
Clearance
Specification

"
Trunk
lid
to
rear
fender

or
bumper
..........
4
.3
-
5
.3
mm
(0
.169
-
0
.209
in)

"
Max
.
deviation
from
parallel
.......
0
.5
mm
(0
.019
in)

Trunk
lid
support
strut,

removing
and
installing

WARNING
-

Make
sure
to
support
trunk
lid
before
removing
strut

1
.
Open
trunk
lid
.
Remove
spring
clip
from
support
strut

and
remove
strut
from
body
end
.
See
Fig
.
4
.

Fig
.
4
.



Support
strut
spring
clip
(arrow)
at
body
end
.

2
.
Remove
strut
from
trunk
lid
.

3
.
Installation
is
reverse
of
removal
.
Replace
any
trim
re-

taining
clips
damaged
during
removal
.