rear brake line BMW M3 1998 E36 Workshop Manual
Page 23 of 759
020
Maintenance
Program
GENERAL
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020-2
BMW
Service
Indicator
......
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020-2
Oil
Service
.....
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020-2
Inspection
I
and
Inspection
II
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020-2
Resetting
Service
Indicator
....
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020-3
MAINTENANCE
TABLES
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020-3
FLUID
AND
LUBRICANT
SPECIFICATIONS
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020-8
Manual
Transmission
Fluid
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020-8
Automatic
Transmission
Fluid
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020-8
Final
Drive
Gear
Oil
................
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020-9
Brake
Fluid
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020-9
Engine
Coolant
(Anti-freeze)
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020-9
Power
Steering
Fluid
........
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......
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020-9
ENGINE
OIL
SERVICE
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020-9
Engine
oil,
checking
leve¡
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020-9
Engine
oil
and
filter,
changing
....
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......
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020-9
ENGINE
COMPARTMENT
MAINTENANCE
...
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......
020-10
Air
filter,
replacing
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020-11
Spark
plugs,
replacing
...
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020-11
¡dle
Speed
.
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.
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020-12
Battery,
checking
and
cleaning
.......
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...
020-12
Battery,
replacing
.
.....
.
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...
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)
.
.
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..
......
020-13
Cooling
System
Service
.
...
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020-14
Power
steering
fluid,
checking
leve¡
.
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.
.
020-14
Oxygen
Sensors
....
...
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.....
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020-15
MAINTENANCE
PROGRAM
020-1
UNDER-CAR
MAINTENANCE
.
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.020-16
'
Fuel
filter,
replacing
...
.
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.020-16
Tires,
checking
inflation
pressure
.
.....
.
....
020-17
Tires,
rotating
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....
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
......
.
.....
..
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020-17
Exhaust
system,
inspecting
....
..
.....
.
...
.020-18
Manual
Transmission
Senrice
..
..
.....
.
....
020-18
Manual
transmission
fluida
checking
and
filling
..
.
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..
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020-18
AutomaticTransmission
Service
.
....
...
....
020-18
Front
suspension
and
steeringlinkages,
inspecting
..
.
:.....
.
....
..
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..
...
.
.020-18
Rear
suspension,
inspecting
.
..
...
...
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..
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
...
..
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..
020-19
BODY
AND
INTERIOR
MAINTENANCE
.
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.020-19
Windshield
Wiper
Blade
Maintenance
....
.
.
020-19
Body
and
hinges,
lubricating
.
.....
..
......
.
020-19
Seat
Belts
...
..
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.....
.
.
020-20
Exterior
Washing
..
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.020-20
Waxing
.....
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020-20
Polishing
..
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.'020-20
Washing
Chassis
.
...
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020-20
Special
Cleaning
.
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.020-20
Interior
Care
.
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020-20
Leather
Upholstery
and
Trim
...
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020-20
TABLES
a
.
Oil
Service
......
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---
020-4
b
.
Inspection
1
Service
..
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020-5
c
.
Inspection
11
Service
.
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...
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020-6
d
.
Scheduled
Maintenance-Time/Mileage
Intervals
..
020-7
e
.
Fluids
and
Lubricants
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020-8
Page 27 of 759
Table
b
.
Inspection
I
Service
MAINTENANCE
PROGRAM
020-5
ad
d
d
ID
a
r
c
d
a~
;v
a
:
Q~
wE
y
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
Page 28 of 759
020-6
MAINTENANCE
PROGRAM
Group
310/330
Table
c
.
Inspection
II
Service
a
d
d
a
a>
0
d
a
r
.c
mm
L
m
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
Page 39 of 759
Tires,
checking
inflation
pressure
Brake
pad/rotor
wear,
checking
Correct
tire
pressuresare
important
to
handling
and
stability,
Al¡
E36
cars
are
fitted
withdisc
brakes
at
al¡
four
wheels
.
See
fuel
economy,
and
tire
wear
.
Tire
pressures
change
with
temper-
Fig
.
24
.
Although
thebrakesare
equipped
with
a
brake
pad
ature
.
Pressures
should
be
checked
often
during
seasonal
tem-
warning
system,
the
system
only
monitors
one
wheel
per
axle
.
perature
changes
.
Correct
inflation
pressures
canbe
found
on
It
is
recommended
that
pad
thickness
should
be
checked
the
driver's
door
pillar
and
in
the
owner's
manual
.
Note
that
tire
whenever
the
wheels
are
off
or
brakework
is
beggg
done
.
pressuresshould
be
higher
when
thecar
is
more
heavily
loaded
.
WARNING
-
Do
not
inflate
any
tire
to
a
higher
pressure
than
the
tiress
maximum
ínflation
pressure
listed
on
the
side-
wall
.
Use
cara
when
addlng
air
to
warm
tires
.
Warm
tire
pressures
can
increase
as
much
as4
psi
(0.3
bar)
over
their
cold
pressures
.
Tires,
rotating
BMW
does
not
recommend
tire
rotation
.
Due
to
the
cars
sus-
pension
design,
the
fronttires
begin
to
wear
first
at
the
outer
shoulder
and
the
rear
tires
begin
to
wear
first
at
themiddle
of
the
tread
or
inner
shoulder
.
Rotating
the
tires
may
adversely
af-
fect
roadhandling
and
tire
grip
.
NOTE-
The
main
purpose
of
tire
rotation
isto
promote
even
wear
and
maximum
tire
life
.
Tire
life
may
be
decreased
slightly
if
the
tires
are
not
rotated
.
Wheels,
aligning
Routine
maintenance
of
the
brake
system
includes
maintain-
ing
the
brake
fluid
in
the
reservoir,
checking
brakepads
for
wear,
checking
hand
brake
functíon,
and
inspecting
the
system
for
fluid
leaks
or
other
damage
.
Check
that
brake
hoses
are
correctly
routed
to
avoidchafing
or
kinkíng
.
Inspect
unions
and
brake
calipers
for
signs
of
fluid
leaks
.
Inspect
rigid
fines
for
corrosion,
dents,
or
other
damage
.
Inspect
flexible
hoses
for
cracking
.
Replace
faulty
hoses
or
lines
as
described
in
340Brakes
.
WARNING
-
Incorrect
installation
or
overtightening
hoses,
fines,
and
unions
may
cause
chafing
or
leakage
.
This
can
lead
to
partíal
or
completebrake
system
failure
.
MAINTENANCE
PROGRAM
020-
1
7
B323
Fig
.
24
.
Disc
brake
pad
wear
can
checked
through
opening
in
caliper
.
The
brake
caliper
should
be
unbolted
from
the
suspension
strut
to
properly
inspect
the
brake
pads
and
the
rotors
.
See
Fig
.
25
.
Brake
caliper
removal
and
installation
procedures
are
given
in
340
Brakes
.
BMW
recommends
checking
the
front
and
rear
alignment
once
a
year
and
whenever
new
tires
are
installed
.
See320
Steering
and
Wheel
Alignment
for
a
more
detailed
discus-
sion
of
alignment
requirements
and
specifications
.
Brake
Pad
Lining
Minimum
Thickness
(Dimension
A)
Brake
system,
inspecting
"
Front
and
reardisc
brake
pads
....
3
.0
mm
(0
.12
in)
Brake
fluid,
replacing
BMW
strictly
recommends
replacing
the
brake
fluid
every
two
years
.
This
will
help
protect
against
corrosion
and
the
ef-
fects
of
moisture
in
the
(luid
.
See340
Brakes
for
brake
fluid
flushing
procedures
.
Parking
brake,
checking
The
parking
brakesystem
is
independent
of
the
main
braking
system
and
may
requireperiodic
adjustment
dependingon
use
.
Adjust
the
parking
brake
if
the
brake
lever
can
be
pulled
up
more
than
8
clicks
.
Check
that
the
cable
moves
freely
.
A
de-
scription
of
the
parking
brake
and
parking
brake
adjustment
can
be
found
in
340Brakes
.
UNDER-CARMAINTENANCE
Page 41 of 759
NOTE-
Use
a14
mm
or17
mm
alíen
bit
socket
to
remove
the
drain
plug
.
"
If
thecar
is
raised
in
the
air,
it
shouldbe
leve¡
.
Fuel
tank
and
fuel
fines,
inspecting
0012474
Inspect
the
fuel
tank,
fuel
lines,
and
fuel
system
for
damage
or
leaks
.
Check
for
fuel
leaks
in
the
engine
compartment
or
fuel
odors
in
the
passenger
compartment
.
Check
for
faultyfuel
lines
bybending
them
.
If
any
leaks
are
present,
fuel
should
be
expelled
.
Check
for
any
evaporative
emissions
hoses
that
may
have
become
disconnected,
checking
carefully
at
the
charcoal
canister
and
evaporative
emissionspurge
system
.
See130
Fuel
Injection
and
160
Fuel
Tank
and
Fuel
Pump
for
component
locations
and
additional
information
.
WARNING
-
When
checking
for
fuel
leaks,
the
engine
must
be
cold
.
A
hot
exhaust
manifold
or
exhaust
system
could
cause
the
fuel
to
ignite
or
explode
causing
se-
rious
personal
injury
.
Uentilate
the
workarea
and
clean
up
spilled
fuel
immediately
.
Clutch
fluid,
checking
The
hydraulic
clutch
and
the
brake
system
share
the
same
reservoir
and
the
same
brake
fluid
.
Clutch
fluid
leve¡
and
brake
fluid
level
are
checked
at
the
same
time
.
See340
Brakes
for
more
information
.
See210
Clutch
for
information
on
the
clutch
and
the
hydraulic
clutch
operating
system
.
MAINTENANCE
PROGRAM
020-19
Drive
axie
joint
boots,
inspecting
100
Engine-General
The
protective
boots
must
be
closely
inspected
for
cracks
andany
other
damage
that
will
allow
contaminants
to
get
ínto
the
joint
.
If
the
rubber
boots
faf
,
the
water
and
dirt
that
enter
the
joint
will
quickly
damage
¡t
.
Replacement
of
the
drive
axle
joint
boots
and
inspection
of
the
joints
are
described
in
330
Rear
Suspension
.
BODY
AND
INTERIOR
MAINTENANCE
Windshield
Wiper
Biade
Maintenance
Common
problems
with
the
windshield
wipers
include
streaking
or
sheeting,
water
drops
after
wiping,
and
blade
chat-
ter
.
Streaking
is
usually
caused
when
wiper
blades
are
coated
with
road
film
or
car
wash
wax
.
Clean
the
blades
using
soapy
water
.
If
cleaning
theblades
does
not
cure
the
problem
then
they
should
be
replaced
.
BMW
recommends
replacing
the
wip-
er
blades
twice
a
year,
before
and
after
the
cold
season
.
Onold-
er
cars,
check
the
tension
spring
that
holds
the
wiper
to
the
glass
.
Replace
the
wiper
arm
if
the
springs
are
weak
.
Drops
that
remainbehind
after
wipingare
caused
by
oil,
road
film,
or
diesel
exhaust
coating
the
windshield
.
Use
an
alcohol
or
ammonia
solution,
or
a
non-abrasive
cleanser
to
clean
the
windshield
.
Wiper
blade
chatter
may
be
caused
by
dirty
or
worn
blades,
bya
dirty
windshield,
or
by
bentor
twisted
wiper
arms
.
Clean
the
blades
and
windshield
as
described
above
.
Adjust
the
wiper
arm
so
that
there
is
even
pressure
along
the
blade,
and
so
that
the
blade
is
perpendicular
to
the
windshield
atrest
.
Lubricate
the
wiper
linkage
with
a
light
oil
.
The
linkage
is
located
under
the
hood
on
the
drivers
side
.
If
the
problem
persists,
theblades
are
excessively
aged
or
worn
and
should
be
replaced
.
See
611
Wipers
and
Washers
.
Body
and
hinges,
lubricating
The
door
locks
and
lock
cylinders
canbe
lubricated
with
an
oil
that
contains
graphite
.
The
body
and
door
hinges,
the
hood
latch,
and
the
door
check
rods
should
be
lubricated
with
SAE
30
or
SAE
40
engine
oil
.
Lubricate
the
seat
runners
with
multipurpose
grease
.
Do
not
apply
any
oil
to
rubber
parts
.
If
door
weatherstrips
are
sticking,
lubricate
them
with
silicone
spray
or
talcum
powder
.
The
hood
release
cable
should
be
lubricated
as
well
.
The
use
of
winter
lock
de-icer
spraysshould
be
kept
to
an
ab-
solute
minimum,
as
the
alcohol
in
the
de-icer
will
wash
the
grease
out
of
the
lock
assemblies,
and
may
cause
the
locks
to
corrode
internally,
or
become
difficult
to
operate
.
ENGINE-GENERAL
100-1
Page 60 of 759
110-2
ENGINE
REMOVAL
AND
INSTALLATION
8
.
Drain
engine
coolant
andremove
coolant
hoses
at-
10
.
Remove
radiator
cooling
fan
and
radiator
as
described
tached
to
cylinder
head
.
in
170
Radiator
and
Cooling
System
.
"
Drain
radiator
and
engine
block
.
See
170
Radiator
and
Cooling
System
.
NOTE-
"
Disconnect
hoses
from
thermostat
housing
at
front
of
Some
late
4-cylinder
modelsuse
an
electric
prímary
cylinder
head
.
cooling
fan
.
"
Disconnect
heater
hoses
at
rear
of
engine
.
See
Fig
.
2
.
CAUTION-
NOTE-
On
cars
with
viscous-type
cooling
fans,
the
radia-
"
The
block
drain
plug
is
located
on
the
exhaust
side
to-
tor
fan
has
left
hand
threads
.
wards
rear
of
engine
.
"
Remove
small
plastic
lock
clíp
to
pull
radiator
drain
11
.
Remove
upper
intake
manifold,
unfasten
cable
duct
plug
out
completely
.
from
lower
intake
manifold,
crankcase
vent
valve
hose
(M44
engine
only)
0012687
Fig
.
2
.
Coolant
hoses
at
heater
valve
and
heatercore
to
be
discon-
nected
(arrows)
.
9
.
Remove
air
shroud
from
top
of
radiator
.
See
Fig
.
3
.
ENGINE
REMOVAL
AND
INSTALLATION
12
.
Disconnect
fuel
supply
and
fuel
return
lines,
main
en-
gine
electrical
connectors,
and
lower
intake
manifold
as
described
in
113
Cylinder
HeadRemoval
and
Instal-
lation
.
See
Fig
.
4
.
0012504
Fig
.
4
.
Crankcase
ventvalve
(A)
on
top
of
lower
intake
manifoldof
M44
engine
.
Fueldelivery
and
retum
lines
shown
at
B
.
Engine
harness
and
sensor
connectors
shown
at
C
.
WARNING
-
"
Fuel
may
be
expelled
under
pressure
.
Do
not
smoke
orworknear
heaters
or
other
fire
haz-
ards
.
Keep
a
fire
extinguisher
handy
.
Before
dis-
connecting
fuel
hoses,
wrap
a
cloth
around
fuel
hoses
to
absorb
any
leaking
fuel
.
Plug
all
open
fuel
lines
.
"
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
lines
.
CAUTION-
0013137
I
Stuff
clean
rags
into
the
open
intake
ports
topre-
Fig
.
3
.
Front
air
shroud
mounting
screws
(arrows)
.
vent
any
parts
from
falling
into
the
engine
intake
.
13
.
Disconnect
vacuum
hose
from
brake
booster
on
bulk-
head
.
Cover
bothhole
in
booster
and
plug
hose
end
.
Page 62 of 759
110-
4
ENGINE
REMOVAL
AND
INSTALLATION
Engine,
removing
and
installing
(6-cylinder
engines)
Engineremoval
procedures
for
the
various
6-cylinder
en-
gines
arecovered
in
this
section
.
Most
steps
in
theproce-
dures
are
similar
or
the
same
for
al¡
engines
.
Specific
differences
that
apply
are
noted
at
the
beginning
of
each
step
.
Be
sure
to
cover
all
painted
surfaces
before
beginning
the
removal
procedure
.
As
an
aid
to
installation,
label
all
compo-
nents,wires,
and
hoses
before
removing
them
.
Do
not
reuse
gaskets,
O-rings
or
seals
during
reassembly
.
WARNING
-
Due
to
risk
of
personal
injury,
be
sure
the
engine
is
cold
before
beginning
the
removalprocedure
.
1
.
Disconnect
negative
(-)
battery
cable
in
luggage
com-
partment
.
CAUTION-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
vi¡¡
.
2
.
Remove
engine
hood
or
place
hood
in
service
position
.
See410
Fenders,
Engine
Hood
.
NOTE-
1t
is
not
necessary
to
remove
the
engine
hood,
but
it
is
helpful
and
will
make
engine
removal
and
installation
easier
.
3
.
Remove
splash
guardunder
engine,
if
applicable
.
4
.
Remove
transmission
from
car
.
See
230
Manual
Transmission
or
240Automatic
Transmission
.
5
.
Remove
vacuum
hosefrom
brake
booster
on
bulkhead
.
Cover
hole
in
booster
and
plug
hose
end
.
6
.
Remove
intake
air
plenum
panel
in
rear
of
engine
com-
partment
.
See
640
Heating
and
AirConditioning
.
7
.
Remove
ground
strap
from
timing
case
cover,
if
appli-
cable
.
8
.
Remove
top
enginecovers
and
disconnect
ignition
coil
harness
connectors
.
Working
at
fuel
injectors,
pry
open
small
wire
clipsat
each
injector
.
Remove
main
harness
hold-down
nuts
and
lift
completeharness
away
.
See
Fig
.
7
.
ENGINE
REMOVAL
AND
INSTALLATION
Fig
.
7
.
Remove
mainharnessfrom
top
engine
and
place
at
base
of
windshield
.
0012703
Fig
.
8
.
Mass
air
flow
sensor
connector
air
duct
hose
clamp,
and
air
cleaner
housing
mounting
bolts
(arrows)
.
9
.
Unbolt
andremove
complete
air
cleaner
housing
with
10
.
On
cars
with
automatic
transmission,
remove
front
and
mass
air
flow
sensor,
disconnecting
and
labeling
con-
rearbrackets
holding
transmission
cooler
linesto
side
nectors,
ducting
and
hoses
asnecessary
.
See
Fig
.
8
.
of
engine
.
Page 187 of 759
2
.
Remove
fuel
tank
filler
cap
.
3
.
Remove
rearseat
cushion
and
pull
back
insulation
mats
to
expose
fuel
tank
access
covers
.
See
Fig
.
2
.
uui3140
Fig
.
2
.
Right
side
fuel
tank
access
cover
under
rear
seat
cushion
.
4
.
Remove
right
and
left
access
covers
to
expose
fuel
hoses
and
electrical
connections
at
tank
.
5
.
Label
fuel
hoses
.
Then
disconnect
hoses
and
harness
connectors
from
fuel
sending
units
and
fuel
pump
.
See
Fig
.
3
.
FUELTANK
AND
FUEL
PUMP
160-
3
NOTE-
"
If
necessary,
push
fuel
level
sender
arm
toward
fuel
pump
assembly
to
facilitate
removal
.
"
BMW
special
tool
no
.
16
1
020
should
beused
tore-
move
and
install
the
threaded
collar
.
Damage
to
thecollar
may
result
if
the
special
tool
is
not
used
.
"
Pump
out
contents
of
each
tanklobe
using
approved
pumpinglextraction
equipment
and
flexible
fuel-grade
hose
.
WARNING
-
Fuel
may
be
spilled
.
Do
not
smoke
or
work
near
heaters
or
other
fire
hazards
.
7
.
Installation
of
sending
units
is
reverse
of
removal,
not-
ing
the
following
:
"
Use
new
sealing
rings
when
installing
pump/sending
unit
assemblies
.
"
Be
sure
that
fuel
line
connections
point
in
same
direc-tion
as
they
carne
out
.
"
Fill
tank
and
check
for
leaks
by
running
engine
.
CA
UTION-
Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1.5
gallons
(5liters)
of
fuel
.
The
pump
will
be
damaged
if
you
run
it
without
fuel
.
Fuel
tank,
removing
and
installing
1.
Disconnect
negative
(-)cablefrom
battery
:
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.
2
.
Remove
fuel
tank
filler
capand
drain
tank
as
described
earlier
.
3
.
Working
in
left
access
tank
access
hole
(under
rear
seat
cushion),
remove
vent
pipe
fromtank
.
4
.
Working
inside
car,
disconnectparking
brake
cable
ends
from
parking
brake
lever
.
See
340
Brakes
.
5
.
Working
underneath
car,
gently
pry
fuel
lines
away
from
retaining
bracket
in
front
of
tank
.
Remove
clamps
and
disconnect
fuel
hoses
as
shown
in
Fig
.
4
.
6
.
Remove
exhaust
system
and
heat
shield
as
described
ooisiai
in
180
Exhaust
System
.
See
Fig
.
5
.
Fig
.
3
.
Fuel
pump/fuel
level
sender
assembly
in
top
offuel
tank
(right
side
shown)
.
Disconnect
supply
hose
(A),
return
hose
(B)
and
7
.
Remove
driveshaft
.
See
260
Driveshaft
.
harness
connector
(C)
.
8
.
Pull
parking
brake
cables
backward
away
from
bottom
of
6
.
Unscrew
threaded
collars
from
fuel
tank
.
Slowly
with-
fuel
tank,
disengaging
them
from
brackets
as
needed
.
draw
fuel
sender
assemblies
from
tank,allowing
fuel
to
drain
off
.
FUEL
TANKAND
LINES
Page 217 of 759
Fig
.
3
.
Clutch
master
cylinder
mounting
bolts
.
Clutch
slave
cylinder,
replacing
0012589
Tightening
Torques
"
Clutch
master
cylinder
to
bulkhead
..
22
Nm
(17
ft-Ib)
"
Fluid
line
to
master
cylinder
orslave
cylinder
.................
16
Nm
(12
ft-1b)
The
clutch
slave
cylinder
is
mounted
on
the
left
side
of
the
transmission
.
CLUTCH
MECHANICAL
1
.
Remove
brake
fluid
reservoir
cap
.
Using
a
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
2
.
Disconnect
fluid
hose
from
slave
cylinder
.
Place
a
pan
under
hose
to
catch
any
excess
fluid
.
3
.
Unbolt
slave
cylinder
from
transmission
.
See
Fig
.
4
.
4
.
Installation
is
reverse
of
removal,
noting
the
following
:
"
Check
for
wear
on
pushrod
.
Any
other
wear
except
on
tipis
caused
by
misalignment
of
clutch
components
.
"
Lightly
coat
pushrod
tip
with
molybdenum
disulfide
grease
(Molykote
0
Longterm
2
or
equivalent)
.
"
During
installation
be
sure
pushrod
tip
engages
recess
in
clutch
release
lever
.
"
Fill
fluid
reservoir
with
clean
fluid
.
"
Bleed
clutch
hydraulics
as
described
earlier
.
CLUTCH
210-
3
Fig
.
4
.
Clutch
slave
cylinder
mounting
bolts
(arrows)
.
Tablea
.
ClutchDisc
Diameter
Model
Diameter
3181/is/iC
215
mm
(8
.46
in)
325i/is/iC
228
mm
(8
.98
in)
323is/iC
328i/is/iC
240
mm
(9
.45
in)
M3
0012715
Tightening
Torques
"
Clutch
slave
cylinder
to
transmission
.
.
................
22
Nm
(17
ft
lb)
"
Fluid
line
to
slave
cylinder
......
.17
Nm
(10-12
ft
lb)
The
transmission
must
be
removed
from
the
engine
to
ac-
cess
the
clutch
mechanical
components
.
It
is
recommended
that
the
clutch
disc,
pressure
plate
and
release
bearing
be
re-
placed
duringa
clutch
overhaul
.
Be
sure
to
check
the
bottom
of
the
bellhousing
for
oil
.
If
engine
oil
is
found,
check
for
a
faulty
rear
crankshaft
oil
seal
.
CLUTCH
MECHANICAL
Page 224 of 759
230-
4
MANUAL
TRANSMISSION
Output
shaft
sea¡,
replacing
(transmission
installed)
1
.
Raise
and
safely
support
vehicle
.
Support
transmission
with
transmission
jack
.
WARNING
-
"
When
raising
thecar
using
a
floor
jack
or
a
hy-
draulic
lift,
carefully
position
the
jack
pad
to
pre-vent
damaging
the
car
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
driveshaft
.
See
260
Driveshaft
.
3
.
Remove
transmission
crossmember
and
lower
trans-
mission
at
rear
.
CAUTION-
Tilting
the
engine
to
lower
thetransmissíon
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
.
-On
cars
with
AST
(traction
control)
remove
throt-
tle
body
before
tilting
engine
.
-Remove
brake
fluid
reservoir
if
necessary
.
4
.
Bend
back
and
remove
collar
nut
lockplate
.
5
.
Hold
flange
steady
andremove
collar
lock
nut
(use
30mm
thin-walled
deep
socket
.)
See
Fig
.
5
.
Fig
.
5
.
Use
holding
tool
when
loosening
output
shaft
collar
nut
.
6
.
Remove
flange
.
If
necessary,
use
a
puller
.
7
.
Use
a
sea¡
puller
to
remove
seal
from
transmission
housing
.
See
Fig
.
6
.
8
.
Coat
new
sea¡
wíth
transmission
fluid
and
drive
into
po-
sition
until
it
is
flush
with
housing
.
See
Fig
.
7
.
TRANSMISSIONSERVICE
Fig
.
6
.
Puller
used
to
remove
transmission
seal
.
Fig
.
7
.
Output
shaftseal
being
installed
using
seal
driver
(BMW
spe-
cial
tool
no
.
232
300)
.
9
.
Reinstall
output
flange
(and
shims,
if
applicable)
to
out-
put
shaft
.
NOTE-
On
Getrag
S5D200G
and
S5D
250G
transmissions
BMW
recommends
heating
theoutputflange
to
about
176°F
(80°C)
to
aid
in
installation
.
This
canbe
done
by
placing
the
flange
in
hot
water
.
10
.
Coat
bearingsurface
ofcollar
nut
withsealer
and
install
nut
.
Tighten
collar
nut
in
two
stages
.
Insta¡¡
new
lock-
plate
.
Bend
tabs
into
flange
grooves
.
NOTE-
BMW
recommends
the
use
of
a
sealer
such
as
Loctite
®
242
when
installing
the
flange
collar
nut
to
prevent
oil
from
leaking
past
the
threads
.