air pump BMW 328i 1997 E36 User Guide

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

100-
1
4
ENGINE-GENERAL

0013131

Fig
.
13
.
Main
chassis
ground
(arrow)
inleft
front
of
engine
compart-
ment
.

Fuel
Supply

For
the
engine
tostart
and
run
properly,
the
injection
sys-

tem
must
deliver
fuel
in
precise
proportion
to
the
amount
of
air

entering
the
engine
.
Todo
this,
the
injection
system
requires

an
unrestricted
supply
of
fuel
from
the
fuel
pump
.

If
the
fuel
pump
is
not
working,
the
engine
will
notrun
.
If
the
fuel
filter
or
a
fuel
line
is
restricted,
the
engine
may
run
poorly
.
If
the
restriction
is
severe
enough
the
engine
will
not
start
.
lf

fuel
delivery
problemsare
suspected,
perform
the
tests
de-

scribed
in
160
Fuel
Tank
and
Fuel
Pump
.

The
fuel
pressure
created
by
the
fuel
pump
is
controlled
by
a
pressure
regulator
thatreturns
excess
fuelto
the
tank
.
Any
change
in
fuel
pressure
will
cause
a
change
in
the
base
air-fuel

mixture
delivered
to
the
engine
.
If
the
fuel
pressure
is
too
low,
the

base
air-fuel
mixture
will
be
lean
.
lf
the
fuel
pressure
is
too
high,
the
base
mixture
will
be
rich
.
Fuel
pressure
tests
aredescribed
in
160
Fuel
Tank
and
Fuel
Pump
and130
Fuel
Injection
.

NOTE-

Fuel
pressure
tests
require
a
pressure
gauge
.
If
thistoolís
not
avaílable,
the
tests
can
be
performed
byan
authorized
BMW
dealer
or
other
qualified
shop
.

DRIVEABILITY
TROUBLESHOOTING

Properly
operating
fuel
injectors
play
amajor
role
in
fuel
de-

livery
.
The
DMEECM
switches
the
injectors
on
and
off
at
the

negative
(-)
or
ground
side
of
the
connectors
.
Posítíve
(+)
bat-

tery
voltage
is
always
present
at
the
connectors
when
theen-

gine
is
running
.
An
injector
that
fails
or
loses
power
will
not

open,
creating
a
lean
air-fuel
mixture
and
causing
the
engine
to

run
poorly
when
coldor
stumble
on
acceleration
.
An
injector

that
shorts
to
ground
will
remain
open
constantly
when
the
en-

gine
is
running,
creating
a
richair-fuel
mixture
that
can
dilute

engine
oil,
foul
the
spark
plugs,
cause
a
rough
idle,
and
damage

the
catalytic
converter
.

Table
e
lists
additional
symptoms
of
common
engine
drive-

ability
problems,
their
probable
causes,
and
the
suggested

corrective
actions
.
The
entries
in
boldtype
in
the
corrective

action
column
indicate
the
repair
groups
where
applicable
test

and
repair
procedures
can
befound
.

NOTE-

Most
of
the
symptoms
fisted
in
Table
e
will
also
cause
the
Check
Engine
light
to
come
on
.
If
the
light
is
on,

check
for
any
stored
faults
as
the
first
step
ín
trouble-
shooting
driveability
complaints
.

al
Icld

Table
e
.
Engine
Driveability
Troubleshooting

c
l



1



I



f



I



I
Oxygen
sensor
faulty



Test
oxygen
sensor
.

ENGINE-GENERAL
100-
1
5

SYMPTOMS

a
.
Engine
fafs
tostart

b
.
Engine
startsbut
stops
immediately

c
.
Erratic
engine
idle

d
.
Poor
engine
responseon
acceleration

e
.
Erratic
engine
operation
in
al¡
speed
ranges

f
.
Excessive
fuel
consumption
g
.
Poor
enginepower,
fails
to
rev
up
h
.
CO
content
toolow

i.
CO
content
too
high

CAUSES



CORRECTIVE
ACTION

a



Fuel
pump
faulty



Test
fuel
pump
.
Repair
Group
160

a



e



Ignition
system
faulty



Test
ignition
system
.
Repair
Group
120
a



Main
relay
or
fuel
pump
relay
faulty



Test
main
relay
.
Repair
Group
130
a



Crankshaft/rpm
position
sensor
faulty



Test
crankshaft/rpm
sensor
.
120
b



c



h



i



ldle
speed
control
valve
faulty



Test
idle
speed
control
valve
.

c



d



e



Throttle
position
sensor
faulty
or
idle
signal
to



Test
throttle
position
sensor
.
DME
control
module
missing
.

c



d



h



i



Mass
air
flow
sensor
faulty



Test
mass
air
flow
sensor
Repair
Group
130
a



b



c



d



e



h



Large
air
intake
system
leak



Check
for
major
intake
air
leaks
downstream
of
mass
air
flow
sensor
.

a



c



d



e



g



h



Fuel
pressure
too
low



Test
fuel
pressure
.
Repair
Group
130

?



I



F
ue
l
pr
essu
r
e
t
oo
high



T
est
f
u
el
pressure
.
Repair
Group
130
d



e



g



h



Fuel
pump
delivery
volume
too
low



Test
fuel
pump
delivery
volume
.
Repair
Group
160
a



c



e



f



h
q
C
oo
l
a
nt
t
e
mp
e
r
a
t
u
r
e
se
n
so
r
f
au
lty



--]
T
est
coo
l
a
n
t
temp
erature
sensor
.

c



e



~



f



i



~
Fuel
injectors
leaking



Check
fuel
injectors
and
replace
leaking
injectors
.

~
Repair
Group
130

Throttle
plate
binding
or
incorrectly
adjusted



Check
throttle
plate
and
adjust
if
necessary
.

a



c



Electrical
connections
loose,
broken,
or
cor-



Visually
inspect
connectors
and
correct
any
roded



faults
.
Repair
Group
600
Ground
connections
loose,
broken,
or
corroded



Visually
inspect
ground
connections
and
correct
any
faults
.
Repair
Group
600

c



e
~



f



CO
content
too
high



Test
air
flowor
mass
air
flow
sensor
.
Repair

~
Group
130
a



b



c



d



e



CO
content
too
low



Test
mass
air
flow
sensor
.
gb



c



d



e



f



g



h



i



Inputsignals
to
ECM
missing,
ECM
in
limp



Make
electrical
tests
at
DMEECM
relay
.
Repair

home
mode



Group
130
a
~
b
~
c
~
d



e]



f



g



h



i



ECM
faulty



Test
DMEECM
inputs
.
If
all
inputs
are
correct,
replace
ECM
.

DRIVEABILITY
TROUBLESHOOTING

113-10



CYLINDER
HEAD
REMOVAL
AND
INSTALLATION

Tightening
Torques

"
Coolant
drain
plug
to
cylinder
block
.
.
25
Nm
(18
ft-1b)

"
Intake
manifold
support
to
manifold
.
.
15
Nm
(11
ft-Ib)

"
Lower
intake
manifold

to
cylinder
head
.
..........
.
..
...



15
Nm
(11
ft-Ib)

"
Lower
intake
manifold

to
upper
manifold
..........
.
..
...
15
Nm
(11
ft-Ib)

"
Radiator
cooling
fan
to
coolant
pump
.
40
Nm
(30
ft-Ib)

"
Radiator
drain
screw
to
radiator
...
.
2
.5
Nm
(22
in-lb)

CYLINDER
HEAD,
6-CYLINDER

For
ease
of
use
this
procedure
is
broken
into
subsections,

as
follows
:

General
Coolingsystem,
draining
Cyiinder
head
cover,
removing

Intake
manifold,
removing

Timing
chains,
uncoupling

Cylinder
head
assembly,
removing

WARNING
-

Allow
the
engine
to
cool
before
beginning
this
pro-
cedure
.

General

1
.
Working
inside
luggage
compartment,
disconnect
neg-
ative
(-)
battery
cable
.

CAUTION-

"
Prior
to
disconnectiog
the
battery,
read
the
bat-
tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.

"
Disconnecting
the
battery
may
erase
fault
code(s)
stored
in
control
module
memory
.
Check
for
fault
codes
using
special
BMW
diagnostic
equipment

2
.
Remove
front
exhaust
pipes
from
manifolds
.
Discard
nuts
.

3
.
Remove
air
filter
housing
complete
with
mass
air
flow
sensor
and
intake
air
ducting
.
Disconnect
vacuum
hos-
es
from
throttle
housing
.

4
.
On
M52
and
S52US
engines
:
Remove
secondary
air
injection
check-valve
from
front
of
engine
and
set
aside
.

CYLINDER
HEAD,
6-CYLINDER

Coolingsystem,
draining

5
.
Drain
engine
coolant
and
Rmove
coolant
hoses
from

thermostat
housing
.
Drain
engine
block
by
removing

block
drain
.
See
170
Radiator
and
Cooling
System
.

NOTE-

The
block
drain
is
on
the
exhaust
side
of
the
engine,
near
cylinder
no
.
5
.

6
.
Remove
radiator
cooling
fan
and
fan
shroud
.
See
170

Radiator
and
Cooling
System
.

NOTE-

The
radiator
cooling
fannut(32
mm
wrench)
has
left-
hand
threads
.

Cylinder
head,
removing

(6-cylinder
engine)



7
.
Disconnect
heater
hoses
at
rear
of
cylinder
head
.
See

Fig
.
26
.

'i

8
.
Remove
alternator
cooling
duct
.

Cylinder
head
cover,
removing

0012687

Fig
.
26
.
Disconnect
heater
hoses
at
heater
valve
(A)
and
heater
core
(B)
.

9
.
Remove
air
plenum
from
rear
of
engine
compartment
.

See640
Heating
and
Air
Conditioning
.

10
.
Remove
plastic
cylinder
head
covers
from
above
fuel
injectors
and
ignition
coils
.
Pull
larger
cover
forward

when
removing
.
See
Fig
.
27
.

11
.
Disconnect
crankcase
ventílation
hose
fitting
from
cyl-
inder
head
cover
.

12
.
Disconnect
ignition
coil
harness
connectors
from
coiis
.

Remove
ignition
coiis
and
spark
plugs
.
See
120
Igni-
tion
System
.

117-2



CAMSHAFT
TIMING
CHAIN

CAMSHAFT
TIMING
CHAIN,

4-CYLINDER

Special
BMW
service
tools
are
needed
for
timing
chain
re-
moval
and
installation
procedures
.
The
special
tools
assure

proper
timing
of
the
valvetrain
.
Precíse
marks
to
setthe
timing

on
the
camshafts
are
not
provided
for
reassembly
.
Read
the

procedures
through
before
beginning
the
job
.

CAUTION-

lf
the
camshaftsare
not
properly
timed,
the
pis-
tons
can
contact
thevalves
.

Camshaft
timing
chain,
removing

(4-cylinder
engines)
U0119-

Fig
.
3
.



Upper
timing
chain
covermounting
bolts(arrows)
.
Thermo-
1
.
Disconnect
negative
(-)cablefrom
battery
.



stat
housing
shown
removed
.
Cylinder
ídentification
sensor
(A)
also
shown
.

CAUTION-

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

2
.
Drain
engine
coolant
.
Drain
engine
block
byremoving
block
drain
.
Remove
radiator
cooling
fan
shroud
and
cooling
fan
.
See
170
Radiator
and
Cooling
System
..

WARNING
-

Allow
the
engine
to
cool
before
openingor
draining
the
cooling
system
.

CA
UTION-

On
cars
with
viscous-type
fan
clutch,
fan
has
left
hand
threads
.

NOTE-

The
block
drain
plug
is
located
on
the
exhaust
sideof
the
engine,
below
cylinder
no
.
4
.

3
.
Remove
cylinder
head
cover
.
See
113
Cylinder
HeadRemoval
and
Installation
.

NOTE-

Make
note
of
the
arrangement
of
the
rubber
insulators
when
removing
the
cylinder
head
cover
mounting
belts
.

4
.
Loosen
sparkplugs
.
See
120
Ignition
System
.

5
.
Disconnect
coolant
hoses
from
thermostat
housingon
front
of
cylinder
head
.
Unbolt
thermostat
housing
from
cylinder
head
.

6
.
Remove
cylinder
identification
sensor
from
upper
tim-
ing
chain
cover
.
Remove
upper
timing
chain
cover
.
See
Fig
.
3
.

CAMSHAFT
TIMING
CHAIN,
4-CYLINDER

7
.
Set
engine
to
approximate
TDC
by
rotating
in
normal
operating
direction
until
camshaft
lobes
at
cylinder
no
.

1
are
facing
up
and
toward
each
other
.
See
Fig
.
4
.

0011998
Fig
.
4
.



Engine
set
to
approximate
TDC
.
Cylinder
no
.
1
camshaft
lobes
face
in
and
sprocket
arrows
point
up
(arrows)
.

8
.
Remove
air
conditioning
drive
belt
.
Loosenand
push
aside
air
conditioning
compressor
.
Remove
air
condi-
tioning
compressor
mounting
bracket
.
See
640
Heat-
ing
and
Air
Conditioning
.

9
.
Remove
engine
drive
belts
and
coolant
pump
pulley
.
See
020
Maintenance
Program
.

10
.
Secure
crankshaft
vibration
damper
to
prevent
crank-
shaft
from
turning
.
Using
a
socket,
loosen
vibration
damper
hub
center
bolt
.

117-
1
4



CAMSHAFT
TIMING
CHAIN

22
.
Installation
of
remaining
parts
is
reverse
of
removal,



When
theengine
is
running,
the
piston
housing
is
supplied

noting
the
following
:



with
pressurized
engine
oil
.
At
idie,
the
solenoid
isin
the
off

"
When
installing
thermostat,
make
sure
arrow
or
vent



position
(de-energized)
and
valve
timing
is
maintained
in
the

hole
faces
up,
if
applicable
.



normal
position
:
When
the
solenoid
is
energized,
the
gear
cup

"
Refill
cooling
systemas
described
in
170
Radiator



piston
moves
forward
to
advance
the
camshaftby
a
maximum

and
Coming
System
.



of
12
.5
.

"
Install
oil
pan
as
described
in
119
Lubrication
Sys-

tem
.
"
Fill
engine
with
oil
and
install
a
new
oil
filter
as
de-

scribed
in
020
Maintenance
Program
.

"
Insta¡¡
ground
wires
at
cylinder
head
cover
mounting

studs
and
at
front
of
cylinder
head
and
thermostat

housing,
where
applicable
.



VANOS
system
operation,
testing

Tightening
Torques



There
are3
special
tools
required
to
check
VANOS
opera-

"
Coolant
drain
plugto
cylinder
block
.
.
25
Nm
(18
ft-Ib)



tion
;
an
electricaltest
lead
(BMW
special
tool
no
.
12
6
410),
an

"
Radiator
cooling
fan
to
coolant
pump
.
40
Nm
(30
ft-Ib)



air
line
fitting
(BMW
special
tool
no
.
11
3
450),
and
a
crank-

"
Radiator
drain
screw
to
radiator
...
.
2
.5
Nm
(22
in-Ib)



shaft
TDC
locking
tool
(BMW
special
tool
no
.
112
300)
.

"
Upper
timing
chaincover
to
cylinder
head



The
test
leal
is
used
to
power
the
solenoid,
simulating
the
M6
nut
...
.....
.............
..
.
10
Nm
(89
in-lb)



ground
signal
from
the
DME
control
unit
.
The
air
line
fitting
M8
bolt
.....
....
.
.
.............
22
Nm
(17
ft-Ib)



takes
the
place
of
the
oil
supply
line
fitting
to
simulate
oil
Ares-
"
VANOS
control
unit
to
cylinder
head



sure
.
The
locking
tool
positions
and
locks
the
crankshaft
at

M6
nut
.........
..
..
.
..........
10
Nm
(89
in-lb)



TDC,
cylinder
no
.
l.
M8
bolt
........
...
.............
22
Nm
(17
ft-Ib)

"
VANOS
oil
supply
pipe
to
VANOS
control
unit



1
.
Remove
alternator
cooling
air
duct
.

banjo
bolt
.......
..
..
.
..........
32
Nm
(24
ft-Ib)

VANOS
(VARIABLE
VALVE
TIMING)



3
.
Remove
top
plastic
enginecovers
.
Disconnect
ignition

coil
harness
connectors
fromcofs
.
Remove
ignition

1993
and
later
6-cylinder
engines
are
equipped
with
a
vari-



coils
.

able
valve
timing
system
called
VANOS
.
This
system
is
con-

trolled
by
the
engine
management
system
and
dynamically



4
.
Remove
cylinder
head
cover
mounting
bolts
and
re-

adjusts
intake
camshaft
timing
based
on
engine
load,
engine



move
cylinder
head
cover
.
Unclip
andremove
oil
baffle

speed
and
engine
temperature
.



cover
from
above
intake
camshaft
.
See
113
Cylinder

Head
Removal
and
installation
.

The
main
components
of
the
VANOS
system
are
the
control

unit
with
piston
housing
and
integral
spool
valve,
and
the
mod-

ified
intake
camshaft
.
See
Fig
.
35
.

VANOS
(VARIABLE
VA
LVE
TIMING)

Fig
.
35
.
VANOS
control
unit
with
modified
intake
camshaft
.

B11001

WARNING
-

Special
BMW
service
tools
are
required
to
check
and
repair
the
VANOS
System
.
Read
theproce-

dures
through
before
beginning
the
job
.

2
.
Disconnect
crankcase
ventilation
hose
fitting
from
cyl-

inder
head
cover
.

NOTE-

Note
the
arrangement
of
the
cylinder
head
cover
bolt
insulators
and
gaskets
during
removal
.

5
.
Set
engine
to
approximate
TDC
by
rotating
in
normal

operating
direction
until
camshaft
lobes
at
cylinder
no
.

1
are
facing
each
other
.
See
Fig
.
20
.

6
.
Set
engine
to
TDC
by
aligning
"0/T"
mark
(0°TDC)on

front
vibration
damper
withcast
boss
on
lower
timing
chain
cover
.
See
Fig
.
21
.

7
.
Lock
crankshaft
in
position
by
inserting
BMW
special

tool
no
.
11
2
300
through
transmission
bellhousing
and

into
hole
in
flywheelor
driveplate
.
See
Fig
.
36
.

NOTE-

Confirm
that
the
locking
tool
has
been
correctly
in-
stalled
by
trying
to
rotatethe
crankshaft
.

119-2



LUBRICATION
SYSTEM

NOTE-
Component
Location



If
the
light
does
not
go
out,
thewiring
to
theswitch
is"
Oil
pressure
switch



most
likely
grounded
somewhere
between
the
switch

all
engines
.......
...
.
..
......
ora
oil
filter
housing



terminal
and
the
warning
light
.
Sea
Electrical
Wiring

Diagrams
atrearof
manual
for
electrical
schematics
.

CAUTION-

Some
oil
may
drain
out
as
the
oil
pressure
switch
is
removed
.
Use
a
rag
to
soak
up
any
spills
.

2
.
Install
pressure
gauge
in
place
of
switch
.

3
.
With
gauge
instalied,
start
engine
and
allow
to
reach

operating
temperature
.
Check
oil
pressureboth
cold

and
hot
.

NOTE-

For
the
most
accurate
test
results,
the
engine
oil
(and
filter)
shouldbe
newand
of
the
correct
grade
.

Oil
Pressure

"
¡dle
(mínimum)
..
.
.
..............
.
.
0
.5
bar
(7psi)

"
Regulated
pressure
(elevated
engine
speed)

4-cylinder
engines
..
......
4
.3
±
0
.2
bar
(63
t3
psi)

6-cylinder
engines
.
.
.............
.
4
.0
bar
(59
psi)

4
.
Remove
pressure
gauge
and
reinstall
pressure
switch
.

If
testing
shows
low
oil
pressure,
one
or
more
of
the
follow-

ing
conditions
may
be
indicated
:
OIL
PAN

"
Worn
or
faulty
oii
pump
.

"
Worn
or
faulty
engine
bearings



The
oil
pancan
be
removed
with
the
engine
instalied,
al-

Severe
engine
wear
.



though
specíal
enginesupport
equipment
will
be
needed
.

Al¡
of
these
conditionsindicate
the
need
for
major
repairs
.

Oil
pressure
warning
system,
testing

When
the
ignition
is
tumed
ora,
the
oil
pressure
warning
light

comes
ora
.
When
the
engine
ís
started
and
the
oil
pressure
ris-

es
slightly,
the
oil
pressure
switch
opens
and
thewarning
light

goes
out
.
Make
sure
the
oil
leve¡
is
correct
before
making

tests
.

1
.
Turra
ignition
switch
ora
.

"
Warning
light
ora
instrument
panel
must
light
up
.

2
.
Remove
connector
from
oil
pressure
switch
.

"
Warning
light
ora
instrument
panel
must
go
out
.

OIL
PAN

3
.
If
warning
light
does
not
light
when
ignition
is
ora,
re-

move
connector
from
oil
pressure
switch
anduse
a

jumper
wire
to
ground
connector
terminal
to
a
clean

metal
surface
.

NOTE
-

If
the
warning
light
comes
ora,
check
the
switch
as
de-
scríbed
in
the
nextstep
.
If
the
warning
light
does
not
come
ora,
thewiring
to
the
instrument
cluster
or
to
the

light
itself
isfaulty
.

4
.
To
test
switch,
connect
ara
ohmmeter
between
terminal

in
switch
body
and
ground
.
With
engine
off,
these

should
be
continuity
.
With
engine
running,
oil
pressure

should
opera
switch
and
there
should
beno
continuity

Replace
a
faulty
switch
.

WARNING
-

Keep
in
mind
that
low
oil
pressure
may
be
prevent-

ing
the
switch
from
tuming
the
light
out
.
If
the
light

remains
ora
while
the
engine
is
running,
check
the

oil
pressure
asdescribed
earlier
.
Do
not
drive
the
car
until
the
problem
is
corrected
.
Theengine
may
be
severely
damaged
.

Oil
pan,
removing
and
installing

(4-cylinder
engines)

1
.
Raise
car
arad
place
securely
ora
jackstands
.

2
.
Remove
splash
shíeld(s)
from
under
engine,
where
ap-

plicable
.

3
.
Drain
engine
oil
as
described
in
020
Maintenance
Pro-
gram
.

4
.
Disconnect
vacuum
hose
adapter
from
vacuum
brake

booster
at
rear
of
engine
compartment
.

5
.
Remove
oil
dipstick
guide
tube
mounting
nut
and
pull
guide
tube
from
oil
pan
.
See
Fig
.
2
.

119-
4



LUBRICATION
SYSTEM

15
.
Remove
oil
pan
screws
.
Lower
andremove
oil
pan
to-

ward
rear
.



Tightening
Torques

"
Control
arm
bushing
carrier

CAUTION-



to
body(M10
bolt)
...............
42
Nm
(31
ft-Ib)

'



lf
the
oil
pan
does
not
separate
easily
from
the
en-



"
Engine
mount
to

gine
cylinder
block,
make
sure
all
mounting
bolis



suspension
crossmember
(M10
nut)
.
42
Nm
(31
ft-Ib)

have
been
removed
.
If
necessary,
a
few
tapswith



"
Front
suspension
crossmember
a
rubber
mallet
shouldbreak
it
free
.
Never
pry
the



to
body
.
.
..
...
..
.
....
See
310
Front
SusPension
oil
pan
loose
.
"
Oil
pan
to
engine
block
(M6
bolt)

8
.8
grade
..
....
.
...
...
.
........
10
Nm
(89
in-lb)
16
.
Installation
is
reverse
of
removal
.



10
.9
grade
...
..
.
....
..
.
.
.
.......
12
Nm
(9
ft-Ib)

"
Thoroughly
clean
all
old
gasket
material
from
mating



"
Power
steering
pump
to
bracket

surfaces
anduse
a
new
gasket
.



(self-locking
nuts)
....
..
.
....
..
.
..
22
Nm
(16
ft-Ib)

"
Applya
small
amount
of
non-hardening
sealer
(3-



"
Power
steering
pump
bracket
to
engine

Bond
O
l209
or
equivalent)
to
oil
pan
gasket
directly



block
or
oil
pan
(self-locking
nuts)
..
.
22
Nm
(16
ft-Ib)

below
joints
for
end
cover
and
front
timing
case
cover
.



"
Stabilizer
bar
link
to
control
arm
See
Fig
.
5
.



M8
nut
.................
...
.
...
22
Nm
(17
ft-Ib)
"
When
installing
oil
pan
to
engine,
tighten
forward



M10
nut
.....................
..
42
Nm
(31
Ib-ft)
screws
first,
then
tightenrear
.



"
Steering
column
universal
joint
"
Fill
engine
with
oil
as
described
in
020
Maintenance



to
steering
rack
spindle
(M8
bolt)
....
19
Nm
(14
ft-ib)
Program
.

0011950

Fig
.
5
.



Joint-mating
areas
at
oil
pan
gasket
where
sealer
should
be
applied
(arrows)
.
Apply
a
bead
3
mm
wideby
2
mm
high
.

OIL
PAN

WARNING
-

Always
use
new
bolis
when
mounting
the
subframe
to
the
body
.
The
one-timeonly
bolis
shouldbe
re-
placed
any
timethey
are
removed
.

NOTE-

The
oil
pickup
is
attached
to
the
oil
pan
using
self-tap-
ping
screws
.
For
this
reasonno
threading
for
the
pickup
is
present
on
new
oil
pans
.
Replace
the
seal
for
the
pickup
and
use
the
oíd
screws
to
rea
ttach
the
pickup
to
the
pan
.

Oil
pan,
removing
and
installing

(6-cylinder
engine,
1992models)

NOTE-

Cars
built
up
to
9/92
(1992models)usea
different
sus-
pension
crossmember
than
later
production
cars
.
Oil
pan
removalprocedureon
the
earlier
cars
requires
that
the
engine
be
raised
and
supportedfrom
above
.

1
.
Raise
car
and
place
securely
on
jackstands
.

2
.
Remove
splash
shield(s)
from
under
engine,
where
ap-

plicable
.

3
.
Drain
engine
oil
as
described
in
020
Maintenance
Pro-

gram
.

4
.
Remove
complete
exhaust
system
.
See180
Exhaust

System
.

5
.
Remove
air
filter
housing
complete
with
mass
air
flow

sensor
.
See
113
Cylinder
Head
Removal
and
Instal-

lation
.

6
.
Remove
alternator
cooling
duct
from
alternator
and
ra-
diator
support
.

7
.
Remove
radiator
cooling
fan
and
fan
shroud
.
Remove

radiator
securing
clips
at
top
of
radiator
.
See
170
Radi-

ator
and
Cooling
System
.

Center
the
steering
spindle
to
the
steering
rack
before
in-



NOTE-

stalling
the
steering
column
shaft
.
See
320
Steering
and



The
radiator
cooling
fan
nut(32
mm
wrench)
has
left

Wheel
Alignment
for
specific
installation
markings
and
pro-



hand
threads
.

cedures
.

8
.
Remove
air
plenum
from
rear
of
engine
compartment
.
See
640
Heating
and
Air
Conditioning
.

9
.
Release
drive
belt
tension
and
remove
alternator
drive
belt
.
Remove
A/C
compressor
drive
belt
.
See
Fig
.
6
.

B11143
Fig
.
6
.



To
remove
poly-ribbed
drive
belt,
pry
cover
from
front
of
ten-
sioner
.
Then
using
8
mm
hex
key,
turntensioner
clockwise
(arrow)
torelease
tension
and
slip
belt
off
pulleys
.

10
.
Unbolt
power
steering
reservoir
and
pull
reservoir
off
engine
mount
bracket
.

11
.
Without
disconnecting
fluid
lines,
remove
power
steer-
ing
bracket
(with
pump)
from
oil
panand
engine
block
.
See
Fig
.
7
.
Disconnect
fluid
lines
from
bracket
on
en-
gine
mount
.
Hang
pump
from
chassis
using
wire
.

12
.
Without
disconnecting
refrigerant
lines,
remove
A/C
compressor
from
engine
block
.
Hang
compressor
from
chassis
using
wire
.
See
640
Heating
and
Air
Condi-
tioning
.

13
.
Remove
oil
dipstick
guide
tube
mounting
bolt
and
re-
move
tube
.
See
Fig
.
8
.

NOTE-

The
guide
tube
is
sealed
in
the
oil
pan
with
an
O-ring
.
Check
that
the
O-ring
comes
out
with
the
tube
.
Use
anew
O-ring
when
installing
the
tube
.

14
.
On
cars
with
automatic
transmission,
remove
brackets
holding
ATF
cooler
linesto
oil
pan
and
cylinder
block
.

LUBRICATION
SYSTEM



119-
5

Fig
.
7
.



Power
steering
pump
mounting
bolts
(arrows)
.

Fig
.
8
.



Oil
dipstick
guide
tube
being
removed
.
Usea
new
O-ring
(arrow)
during
installation
.

15
.
Insta¡¡
engine
lifting
equipment
at
front
engine
lifting
point
and
raise
engine
just
until
its
weight
is
supported
.

16
.
Remove
nuts
at
bottom
of
left
and
right
engine
mounts
.
Remove
ground
wire
from
right
engine
mount
.
1-oosen
nuts
at
top
of
left
and
right
engine
mounts
(do
not
re-
move)
.

OIL
PAN

GENERAL
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
.........
130-2



Intake
air
temperature
(IAT)
sensor,

Principles
of
Operatinn
.
.
.
.
.
.
.
.
.
.........
130-2



testing
and
replacing
...
.
...
.
.
.
.......
.
130-19

Basic
Engine
Settings
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
:
.
130-3



Throttle
position
sensor
(TPS),

DISA
(Dual
Resonance
Intake
System)
.
.
.
.
.
130-3



testing
and
replacing
...
.
...
.
.
.
.
.
...
.
.
.130-19

On-Board
Diagnostics
(OBD)



Idle
speed
control
valve,
testing
.
.
.
.
.
.
.
.
.
.
130-20

and
Fault
Diagnosis
.
.
....
.
......
.
.
.
...
130-4



Idle
speed
control
valve,
replacing
.
.
.
.
.
.
..
130-21

SecondaryAir
Injection
.
.
.....
.
.........
.
130-5



BOSCH
DME
M5
.2
COMPONENT
Warnings
and
Cautions
.
.
...
.
.
.
.........
.
130-6



REPLACEMENT
.....
.
......
.
....
.
.
.
..
130-21

ELECTRICAL
CHECKSAND



Mass
air
flow
sensor,
replacing
.
.
....
.
....
130-22

COMPONENT
TESTING
.
.
.
.
.
.
.
.
...
.
.
.
.
.
130-7



Engine
coolant
temperature
(ECT)

Main



sensor,
replacing
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
130-22
rela
y
testing



130
-7
,...
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.



Intake
air
temperature
(IAT)
sensor,
Fuel
pump
relay,
testing
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
130-7



rep
lacin
.
.
.
.
.
.
.
.
.
.
.g



.
.
.
.
.
.
.
...
.
.
.
..
.130-22
Oxygen
sensor,
testing
(Boschsystems
only)
130-8



Throttle
poson
sensor
(TPS)
replacing



13022
,



..
.-

FUEL
DELIVERY
TESTS
...
.
....
.
.
.
...
.
130-9



Idle
speed
control
valve,
replacing
...
.
....
.130-23

Operating
fuel
pump
for
tests
.
.
.......
.
...
130-9



SIEMENS
MS
41
.1
COMPONENT
Relieving
fuel
pressure
and



REPLACEMENT
.
...
.
.
.
.
.
.......
.
....
.130-23
connecting
fuel
pressure
gauge
......
.
..
130-10

Residual
fuel
pressure,
testing
.
.....
.
.
.
.
.
130-10



Mass
air
flow
sensor,
replacing
.
.......
.
.
.130-25

Fuel
pressure
regulator
response



Engine
coolant
temperature
(ECT)

to
engine
load,
testing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
130-11



sensor,
replacing
.....
.
.
.
.
.
.........
.130-25

Fuel
rail
and
injectors,
checking
...
.
.
.
.
.
.
.
130-11



Intake
air
temperature
(IAT)
sensor,
replacing
.
.
.
.
.
.....
.
.
.
.
.
.
.
.......
.
.
.130-25
Fuel
rail
and
injectors,
replacing



..
.
.
.
.
.
.
.
130-12



Throttleposition
sensor
(TPS),
replacing
.
.
.
130-26
Fuel
PressureRegulator
.........
.
.
.
.
.
.
.
130-13



Idle
s
eed
control
valve,
re
lacin



130-26
Fuel
pressure
regulatorreplacing



p



p



g
.'''...
.
'
,

(fuel
rail
mount)
...
.
.
.
.
.
.............
130-13



ECM
PIN
ASSIGNMENTS
.............
.
.
130-26
Fuel
pressure
regulator,
replacing



Engine
control
module
(ECM),
accessing
...
130-26
(undercar
mount)
.
.
.
.
.
.
.
.
.........
.
.
130-14

BOSCH
DME
M1
.7
COMPONENT

TESTS
AND
REPAIRS
.
.
.
.
.
...
.
.
.
.
.
.
.
.
130-14

Air
flow
sensor,
testing
and
replacing
.
.
.
.
.
.
130-14

Engine
coolant
temperature
(ECT)

sensor,
testing
and
replacing
...
.
.
.
.
.
.
.
.
130-15

Throttle
position
sensor
(TPS),

testing
and
replacing
.
..........
.
.....
130-16

Idle
speed
control
valve,
testing
and
replacing
.
.
.
.
.
............
130-16

BOSCH
DME
M3
.1
AND
M33
.1

COMPONENT
TESTS
AND
REPAIRS
.
.
.
130-17

Mass
Air
Flow
Sensor
.
.
.
.
.
.
.
.
.....
.
.
.
.
.130-17

Mass
air
flow
sensor
(hotwire),testing
and
replacing
.
.
.
.
.
.....
.
.
.
.
.
.
.
130-17

Mass
air
flow
sensor
(hot
film),

testíng
and
replacing
.
.
.
.....
.
.
.
.
.
.
.
.
.
130-18
Engine
coolant
temperature
(ECT)

sensor,
testing
and
replacing
..
.
.
.
.
.
...
.
130-18

130
Fuel
i
n
jection

FUEL
INJECTION



130-1

TABLES
a
.
Engine
Management
System
Variants
.........
.130-2
b
.
Mass
Air
Flow
Sensor
Variants
..
.
..
..........
.130-2
c
.
Fuel
Pressure
Specifications
..
.
.
...
..........
130-11
d
.
Engine
Coolant
Temperature
Sensor
or
Intake
Air
Temperature
Sensor
Test
Values
(DME
1
.7)
...
.
130-15
e
.
ThrottlePosition
Sensor
Tests
(DME
1
.7)
......
.130-16
f
.



Engine
Coolant
Temperature
Sensor
or
Intake
Air

Temperature
Sensor
Test
Values
(DME
3
.1/3
.3
.1)130-19
g
.
Throttle
Position
Sensor
Tests
(DME
3
.1/3.3
.1)
.
.130-20
h
.
ECM
Pin
Assignment-Bosch
DME
M1
.7
....
.
..
.130-28
i.



ECM
Pin
Assignment-Bosch
DME
M3
.1
.......
.130-30
j
.



ECM
Pin
Assignment-Bosch
DME
M3
.3
.1
.....
.130-32
k
.
ECM
Pin
Assignment-Bosch
DME
M5
.2
.......
.
130-34
I.



ECM
Pin
Assignment-Siemens
DME
MS
41
.1
..
.
130-36