belt BMW 328i 1995 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

010-12



FUNDAMENTALSFOR
THE
DO-IT
YOURSELF
OWNER

Jump
Starting
Car

Cars
with
discharged
or
dead
batteries
can
be
jump-started
using
the
good
battery
from
another
car
.
When
jump-starting

the
engine,
always
note
the
following
warnings
.

WARNING
-

"
Battery
acid
(electrolyte)
can
cause
severe
burns,
and
will
damage
the
car
and
clothing
.
lf
electrolyte
is
spilled,
wash
the
surface
with
large
quantities
of
water
.
lfit
gets
finto
eyes,
flush
them
with
water
for
severa¡
minutes
and
cal¡
a
doctor
.

"
Batteries
produce
explosive
and
noxious
gas-
ses
.
Keep
sparks
and
flames
away
.
Do
not
smoke
near
batteries
.

"
Do
not
jump-start
the
engine
if
you
suspect
that
the
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
donot
ex-
ceed
15
volts
at
the
battery
with
the
boosting
cables
attached
.
Wait
at
least
one
minutebefore
boosting
the
battery
a
second
time
.

"
Some
electrical
system
'comfort"
features
may
not
function
correctly
once
battery
power
is
restored
.
For
example,
the
front
window
one-touch-up
func-
tion
may
be
disabled
.
Some
electrical
systems
will
need
to
be
reinitialized
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
thecar
with
the
good
battery
.

2
.
Connect
oneend
of
the
positive
(+)
cable
to
the
positive
(+)
post
of
the
good
battery
.
Remove
the
coverfromthe

positive
(B+)
junction
post
in
the
engine
compartment
of
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
of

thecar
with
the
dead
battery
.

4
.
Start
thecar
with
the
good
battery
and
runthe
engine

at
about2,000
rpm,
then
start
the
car
with
the
dead
bat-
tery
.

5
.
With
the
engine
at
¡dle,
switch
on
the
headlights,
blower

motor
and
rear
window
defogger
to
avoid
damaging
the

cars
electrical
system
.
Carefully
disconnect
the
jumper

cables,
starting
with
the
negative
cable
on
the
engine

block
.
Turn
all
electrical
consumers
off
.

NOTE-

The
engineshould
be
run
for
at
least
an
hour
to
re-
charge
the
battery
.

Overheating

lf
the
temperature
gauge
needle
goes
into
the
red
band
on
the
gauge
face,
the
coolant
temperature
is
too
high
.
Find
a
safe
place
to
stop
and
turn
the
engine
off
.
Open
the
hood
and
allow

the
engine
to
cool
until
the
temperature
gauge
needle
is
at
the

lower
thirdof
the
scale
.
Continuing
to
drive
an
overheated
car

can
cause
extensive
engine
damage
.

WARNING
-

Do
not
remove
the
coolant
reservoir
or
radíator
cap
with
the
engine
hot
.
Undoing
either
couldspray
hot
coolant
and
cause
burns
or
damage
the
engine
.

CAUTION-

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

NOTE-

If
the
enginecannot
be
safely
tumed
off,
make
sure
the
air
condifioner
isoff
and
turn
the
heater
to
high
.
This
will
helo
cool
the
engine
until
a
salestopping
place
canbe
reached
.

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

lf
no
leaks
are
found,
add
coolant
after
the
engine
has
cooled
.
The
carcan
be
driven,
but
have
the
cooling
system
thoroughly
checked
assoonas
possible
.
lf
replacement
cool
0013245



-



ant
is
not
available,
then
plain
water
canbe
used,
butthe
cool-
antshould
later
be
drained
and
refilled
with
theproper
mixture
Fig
.
17
.
Battery
jump
starting
posts
(arrows)
behind
right
frontstrut



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

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

010-14



FUNDAMENTALS
FOR
THE
DO-ITYOURSELF
OWNER

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

if
absolutely
necessary,
cars
with
automatic
transmissions
can
be
towed
with
the
rear
wheels
on
the
ground,
butthe
tow

should
not
exceed
25
miles
(40
km),at
speeds
at
or
below30
mph
(35
km/h)
.
Be
sure
the
transmission
fluid
hasbeen
topped

off
before
starting
the
tow
.
Always
tow
thecar
with
the
transmis-

sion
lever
in
"N"
(neutral)
.
If
the
tow
must
exceed25
miles
(40

km),
add
one
quart
of
ATF
to
the
transmission,
or
better
yet,
re-

move
the
driveshaft
.
Be
sure
to
drain
or
pump
outthe
added
flu-
id
once
the
tow
has
been
completed
.

NOTE-

"
ATF
draining
and
filling
is
covered
in
240
Automatic
Transmission
.

"
Driveshaft
removal
is
covered
in
260
Driveshaft
.

EMERGENCIES

úo1W¿b

Spare
Parts
Kit

Carrying
a
basic
set
of
spare
parts
can
prevent
a
minor

breakdown
from
turning
into
a
major
annoyance
.
Many
of
the

following
itemswon't
allow
you
todo
major
repair
workon
the

car,
but
they
will
help
in
the
event
of
the
failure
of
something
that

can
disable
thecar
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
gallonof
premixed
50/50
anti-freeze

and
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,
DOT
4
specification)

"
Main
relay
for
DME
system

020
Maintenance
Program

GENERAL
.
.
...
.
.
.
...
.
.
.
.
.
.
.
.
.
.
.
...
.
..
020-2

BMW
Service
Indicator
......
..
....
..
...
..
.
020-2

Oil
Service
.....
.
..........
..
...
...
...
..
.
020-2

Inspection
I
and
Inspection
II
.
..
....
..
...
..
.
020-2

Resetting
Service
Indicator
....
.
....
..
...
..
.
020-3

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

FLUID
AND
LUBRICANT

SPECIFICATIONS
.
.
.
.
.
.
.
...
.
.
.
....
.
...
020-8

Manual
Transmission
Fluid
..
.
.
.
.
.
....
.
.
.
.
020-8

Automatic
Transmission
Fluid
.
.
.
.
.
....
.
.
.
.
020-8

Final
Drive
Gear
Oil
................
.
.
.
.
020-9
Brake
Fluid
.
.
.
.
.
................
.
.
.
.
020-9
Engine
Coolant
(Anti-freeze)
.
.
...
.
....
.
.
.
.
020-9

Power
Steering
Fluid
........
..
......
.
.
.
.
020-9

ENGINE
OIL
SERVICE
.
.
...
.
.
.
...
.
.
.
.
.
.
020-9

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

ENGINE
COMPARTMENT

MAINTENANCE
...
.
.
.
.
.
.
.
.
.
.
.
.
.
......
020-10

Air
filter,
replacing
.
...
...
.
.....
.
.....
.
...
020-11

Spark
plugs,
replacing
...
.
......
.
...
..
...
020-11

¡dle
Speed
.
..
...
...
....
.
......
.
...
..
...
020-12

Battery,
checking
and
cleaning
.......
..
...
020-12

Battery,
replacing
.
.....
.
.....
.
.....
..
...
020-12

Accelerator
and
Throttle
Linkage
.
.....
..
...
020-13

Engine
DriveBelts
.....
.
....
..
...
...
...
.
020-13

V-belt,
replacing

(4-cylinder
engines
built
up
to
1/94)
..
....
.
020-13

Poly-ribbed
belt,
replacing

(4-cylinder
engines
built
from
1194

and
all
6-cylinder
engines)
.
.
....
..
......
020-13

Cooling
System
Service
.
...
..
....
..
....
..
020-14

Power
steering
fluid,
checking
leve¡
.
..
....
.
.
020-14

Oxygen
Sensors
....
...
..
..
....



.
.....
.
.
020-15

MAINTENANCE
PROGRAM



020-1

UNDER-CAR
MAINTENANCE
.
..
.
...
.
.
.020-16
'

Fuel
filter,
replacing
...
.
.....
..
.....
..
..
.020-16

Tires,
checking
inflation
pressure
.
.....
.
....
020-17

Tires,
rotating
...
..
.....
..
....
..
....
.
....
020-17

Wheels,
aligning
..
.....
.
...........
.
....
'020-17

Brake
system,
inspecting
.
.
....
.
.....
..
...
020-17

Brake
pad/rotor
wear,checking
.
......
.
....
020-17

Brake
fluid,
replacing
.........
..
.



..
..



.
020-17

Parking
brake,
checking
......
.
.....
..
....
020-17

Exhaust
system,
inspecting
....
..
.....
.
...
.020-18

Manual
Transmission
Senrice
..
..
.....
.
....
020-18

Manual
transmission
fluida

checking
and
filling
..
.
....
..



.
.
..
..
....
020-18

AutomaticTransmission
Service
.
....
...
....
020-18

Front
suspension
and
steeringlinkages,
inspecting
..
.
:.....
.
....
..
.....
..
...
.
.020-18

Rear
suspension,
inspecting
.
..
...
...
....
..
020-18

Final
drive
oil
leve¡,
checking
.
.
.
...
....
...
..
020-18

Fuel
tank
and
fuel
lines,
inspecting
.
.....
....
020-19

Clutch
fluid,
checking
...
...
...
...
....
.....
020-19

Drive
axle
joint
boots,
inspecting
...
..
.....
..
020-19

BODY
AND
INTERIOR

MAINTENANCE
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.020-19
Windshield
Wiper
Blade
Maintenance
....
.
.
020-19

Body
and
hinges,
lubricating
.
.....
..
......
.
020-19

Seat
Belts
...
..
...
...
...
..
.....
..
.....
.
.
020-20

Exterior
Washing
..
...
...
..
.
.
...
..
......
.020-20

Waxing
.....
..
...
...
...
..
.....
..
.......
020-20

Polishing
..
...
...
...
....
..
..........
..
.
.'020-20

Washing
Chassis
.
...
....
.
....
..
.....
.
...
020-20

Special
Cleaning
.
.
.....
..



...
.
.....
..
..
.020-20

Interior
Care
.
....
..
....
..
..



.
.
......
.
...
020-20

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

TABLES

a
.
Oil
Service
......
...
.
..
.............
...
---
020-4

b
.
Inspection
1
Service
..
.
.
.............
....
...
020-5

c
.
Inspection
11
Service
.
.
...
...........
..
.
..
..
020-6

d
.
Scheduled
Maintenance-Time/Mileage
Intervals
..
020-7

e
.
Fluids
and
Lubricants
..
...
...........
.....
..
020-8

020-
4



MAINTENANCE
PROGRAM

L



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a



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£
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E

Maintenance
ítem



z



3



c

Engine
compartment
maintenance

Change
oil
and
oil
filter

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

Under
car
maintenance

Check
steeringrack
and
steeringlinkages
for
leaks
andexcess
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
.
Repair
Group
340

Check
and
adjust
tire
pressures,
including
spare

Body
and
interior
maintenance

Check
operation
of
exterior
and
interior
lights,
including
glove
box
light,
engine
compartment
light,
trunk
light,
instrument
panel
lights,
horns,
headlight
flasher
anddimmer
switch
.
Check
headlight
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
of
washer
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
specialreset
tool
.

MAINTENANCE
TABLES

Table
a
.
Oil
Service

Table
b
.
Inspection
I
Service

MAINTENANCE
PROGRAM
020-5

ad

d
d
ID

a



r



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a
r
E
R
:
L-



0
Maintenance
ítem



1



z



3
~



c
d

Engine
compartment
maintenance

Change
oil
and
oil
filter
.

Check
brake/clutch
fluid
leve¡

Check
battery
acid
leve¡
and
correct
asnecessary
.
Repair
Group
121

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

Lubricate
throttie
linkage

Under
car
maintenance

Check
transmission
for
externa¡
leaks
.

Check
manual
transmission
oil
leve¡
andadd
asnecessary
.
Repair
Group
230

Check
final
drive
lubricant
and
addasnecessary
.

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

Inspect
exhaust
system
.
Repair
Group
180

Check
steeringrack
and
steeringlinkages
.
Check
power
steering
system
for
leaks
.
Check
(luid
leve¡
.
Repair
Group
320

Inspect
brake
system
for
damaged
hoses
and
fines,
leaks
or
damage
.
Remove
calipers
and
check
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
wheelsand
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,
licenseplate
lights,
interior
lights,
glove
box
light,
engine
compartment
light,
trunk
light,
instrument
panel
lights,
turnsignals,
emer-gency
flashers,
stop
fights,
horas,
headlight
flasher
and
dimmer
switch

Replace
ventilation/A/C
micro-filter
.
Check
functionof
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
of
washer
system
.
Check
condition
of
wiperblades
.
Repair
Group
611

Tighten
nuts
and
bolts
for
door
locks
and
striker
plates

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

Road
Test

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

Service
Interval
Reset

Reset
service
indicator
using
specialreset
tool
.

MAINTENANCE
TALES

020-6



MAINTENANCE
PROGRAM

Group
310/330

Table
c
.
Inspection
II
Service

a
d

d



a



a>



0
d

a



r



.c



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L



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y



L
E

ó
3
E
ó

Maintenance
ítem



l
o-



z



~



c

Engine
compartment
maintenance

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

Lubricate
throttle
linkage
.

Replace
air
filter
.

Change
oil
and
oil
filter
.

Replacespark
plugs
.
Repair
Group
120

Check
brake/clutch
fluid
leve¡
.

Check
battery
acid
leve¡
and
correct
asnecessary
.
Repair
Group
121

Check
engine
coolant
leve¡
and
anti-freeze
protection
and
add
asnecessary
.
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
and
check
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
asnecessary
.

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

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

MAINTENANCE
TABLES

Continued
on
next
page

d
a
d
_
L

G>
G1
a
N
.



<C



G1
Ñ



N
N
O
.
r
d

Maintenance
ítem



°
~



Z



~
i
I
D
i
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
asnecessary
.
Check
operation
of
washer
system
.
Check
condition
of
wiperblades
Repair
Group
611

Tighten
nuts
and
belts
for
door
locks
and
striker
plates
.

Replace
batteries
for
alarm/remote
control
in
masterkey
(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
specialreset
tool
.

Maintenance
ítem

Replace
oxygen
sensor
.
Repair
Group
180
1992-1994
1995-
on

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

Drain
and
flush
cooling
system
and
replace
coolant
.
Repair
Group
170
1992-19961997-1998

Anti-corrosion
warranty
inspection
.

Tablec
.
Inspection
II
Service
(continued)

Cabled
.
Scheduled
Maintenance-Time/Mileage
Intervais

MAINTENANCE
PROGRAM
020-7

e
~
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e

i
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l=
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"
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r
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Ñ



Ñ
1
ZG

NN

MAÍNTENANCE
TABLES

Accelerator
and
Throttle
Linkage

The
accelerator
and
throttie
linkage
should
be
lubricated
pe-
riodically
.
Use
a
general
purpose
oil
on
the
joints
and
bearings

of
the
linkage
.
Use
a
multipurpose
grease
on
the
bearing
points

of
the
throttie
plate
.

Engine
Drive
Belts

Drive
belts
and
pulleys
transfer
power
from
theengine
crank-

shaft
to
various
accessories
.
See
Fig
.
13
.
Depending
on
model

and
model
year,
engine
driven
accessories
are
driven
by
V-

belts,
poly-ribbed
(serpentine)
belts,
or
a
combination
of
the

two
.
For
example,
early
4-cylinder
engines,
usetwo
V-belts
and
one
poly-ribbed
belt
.

Inspect
drivebelts
with
the
engine
off
.
lf
the
belt
shows
signs

of
wear,
cracking,
glazing,
or
missing
sections,
it
should
be
re-

placed
immediately
.

V
belt,
replacing

(4-cylinder
engines
built
up
to
1194)

0012472

Fig
.
13
.
Drive
belt
and
tensioner
assembly
for
late
4-cylinder
engine
wíth
poly-ribbed
drive
belt
.

V-belts
should
be
inspected
during
regular
maintenance
in-

tervais
.
Incorrect
tension
can
decrease
the
life
of
the
belt
and

the
component
it
drives
.
The
V-belt
tension
is
adjusted
through

a
toothed-rack
mechanism
.

Inspect
belts
with
the
engine
off
.
Twist
the
beltto
inspect
its

sidewalls
and
bottom
.
Beltstructural
damage,
glazed
or
shiny

sidewaljs
caused
by
a
loose
belt,
orseparation
are
al¡
reasons

to
replace
a
belt
.

Replacement
of
the
V-belts
every
four
years
is
recommend-

ed
.
Loosen
the
mounting
bolts
and
adjust
the
belt-driven
unit

until
the
belt
tension
is
as
loose
aspossible
.
Remove
the
belt
by

slipping
it
over
the
pulleys
.
In
some
cases
it
may
be
necessary

to
removeone
V-belt
to
get
to
another
.
Use
a
torque
wrench
and

a
crowfoot
wrench
to
turn
the
tensioning
gear
bolt
and
set
belt

tension
.
Hold
the
wrench
steady
and
tighten
the
locknut
on
the

rear
of
the
tensioning
gear
bolt
.
Tighten
al¡
other
mounting
nuts
.

MAINTENANCE
PROGRAM



020-
1
3

NOTE-

"
For
the
most
accurate
check,
V-belt
tension
should
be
checked
using
a
V-belt
tension
gauge
.

"
Belt
squealing
is
normally
caused
by
loose
beltten-sion
.
Belt
dressings
should
not
be
used
.

Tightening
Torques

"
Tensioning
gear
(alternator

belt
tensioning)
.
.
.
...............
7
Nm
(62
in-lb)

"
Tensioning
gear(power
steering

belt
tensioning)
...
..
...
8
to
8
.5
Nm
(71
to
75
in-lb)

"
Tensioning
gear
locking
nut
.......
24
Nm
(18
ft-Ib)

NOTE-

When
belts
are
replaced
with
new
ones,
store
the
old
set
in
the
luggage
compartment
for
emergency
use
.

When
installing
a
new
belt,
gently
pry
it
over
the
pulleys
.
Too

much
force
may
damage
the
belt
or
the
accessory
.
Tension
the

belt(s),
runthe
engine
for
a
few
minutes
(at
least
1500
rpm),

then
recheck
the
belt
tension
.

CAUTION-

Do
not
over
tighten
the
V-belts
.
Overtightening
will
cause
shaft
bearings
to
fail
prematurely
.

Poly-ribbed
belt,
replacing

(4-cylinder
engines
buiit
from
1194

and
all
6-cylinder
engines)

An
automatic
belt
tensioner
is
used
to
keep
the
belts
ten-

sioned
properly
.
Unless
the
tensioner
mechanism
malfunc-

tions,
the
poly-ribbed
belts
do
not
require
tension
adjustment
.

To
reduce
the
chance
ofbelt
failure
while
driving,
replace-

ment
of
the
belts
every
four
years
is
recommended
.
Mark
drive

belt
rotationdirectíon
if
removing
and
reusing
an
old
belt
.

To
remove
the
belt,
it
is
necessary
toretract
the
self-tension-

er
.
Using
a
breaker
bar
or
other
long
socket
assembly,
rotate

the
tensioner
to
loosenthe
belt
.
See
Fig
.
14
or
Fig
.
15
.
On
4-cyl-

inder
engines,
it
will
benecessary
to
remove
the
A/C
compres-

sor
belt
to
remove
the
main
drive
belt
.

WARNING
-

Observe
care
when
replacing
the
belt
.
Personal
in-
jury
could
result
if
the
tensioner
springs
back
into
position
uncontrollably
.

With
the
belt
removed
from
the
pulleys,
inspect
the
pulleys

for
wear
or
damage
that
may
cause
early
failureof
the
new
belt
.

This
is
also
a
good
opportunity
to
inspect
the
belt-driven
acces-

sories,
checking
for
bearing
wear
and
excess
play
.
Drive
belt

routing
is
shown
in
Fig
.
16
and
Fig
.
17
.

ENGINE
COMPARTMENT
MAINTENANCE