cylinder head cover BMW 318i 1992 E36 Repair Manual

170-10



RADIATOR
AND
COOLING
SYSTEM

Coolant
pump,
replacing

The
engine
coolant
pump
is
mounted
in
the
frontof
the
en-

gine
on
the
timing
cover
.
See
Fig
.
16
.

Fig
.
16
.
Coolant
pump
mounted
on
timing
cover
.

NOTE-

Onlyreplacement
coolant
pumps
with
metal
¡mpellers
should
be
installed
.
Pumps
with
plastic
impellers
should
not
be
used
.

1.
Drain
cooling
system
as
described
earlier
.

0013197

WARNING
-

Allow
cool¡ng
system
to
cool
before
open¡ngor
drain¡ng
system
.

2
.
Remove
primary
cooling
fan
shroud
and
cooling
fan
(belt-driven
or
electric)
as
described
earlier
.

Fig
.
17
.
Engine
drive
belt
tensioner
being
released
on
M44
engine
.
Pry
off
tensioner
cover
and
then
lever
tensioner
in
counterciock-
wise
direction
(as
facing
engine)
and
slip
belt
off
pulleys
.

Fig
.
18
.
Drive
belt
tensioner
being
released
on
M52
engine
.
Pry
off
3
.
Disconnect
hoses
from
thermostat
housing
.
Unbolt



tensioner
cover
and
then
lever
tensioner
clockwise
(as
facing
thermostat
housing
from
front
of
cylinder
head
.



engine)torelease
belt
tension
.

4
.
Remove
coolant
pump
drive
belt
.
See
Fig
.
17
or
Fig
.
18
.

NOTE-

-
Mark
direction
of
drive
belt
rotation
if
reusing
belt
.



"
The
6-cylinder
coolant
pump
¡s
mounted
on
studs
and
retained
by
nuts
.
"
Severa¡
drive
belt
and
tensioner
configurations
havebeenused
in
E36
models
.
Refer
to
020
Maintenance
Program
and
640
Heating
and
Air
Conditioning
.

5
.
Remove
coolant
pump
pulley
from
pump
.

6
.
Remove
mounting
fasteners
from
pump
.

COOLING
SYSTEM
SERVICE

NOTE-

"
The
4-cylinder
coolant
pump
¡s
mounted
us¡ng
two
dif-
terent
length
bolts
.
Note
where
thelonger
bolt
fits
dur-
ing
disassembly
.

0011989

7
.
Insert
twoscrews
(M6)
in
tapped
bores
and
tighten
uni-
formly
until
pump
is
free
from
timing
chain
cover
.
See
Fig
.
19
.

GENERAL
..
.
.
.
.
.
.
.
.
.
.
.
.
.
......
.
......
210-1



CLUTCH
MECHANICAL
.
.
.
.
.
...
.
.....
.
.
210-3

CLUTCH
HYDRAULICS
.
.
.
.............
210-1



Clutch,
removing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
210-4

Clutch,inspecting
and
installing
.
.
.
.
.
.
.
.
.
.
.
.210-5Clutch
hydraulic
system,



Transmission
pilot
bearing,replacing
.
.
.
.
...
210-6
bleeding
and
flushing
.
.
.
.
.
.......
.
.....
210-2

Clutch
master
cylinder,
replacing
..
.
.
.
.
.
...
210-2



Table

Clutch
slave
cylinder,
replacing
...
.
.
.
.
.
.
.
.
210-3



a
.
Clutch
Disc
Diameter
.............
..
..
.
......
210-3

GENERAL



CLUTCH
HYDRAULICS

This
repair
group
covers
replacement
of
the
clutch
mechan-



The
Clutch
is
hydraulically
actuated
by
the
master
and
slave
¡cal
and
hydraulic
components
.
Special
tools
may
be
required



cylinders
.
Clutch
disc
wear
is
automatically
taken
upby
the
for
some
of
the
procedures
.
Read
the
procedure
through
be-



pushrod
travelof
the
slave
cylinder,
making
periodic
adjust-fore
beginning
a
job
.



ments
unnecessary
.

NOTE-

See200
Transmission-General
for
transmission
applicatíon
information
.

The
major
components
of
the
clutch
system
are
shown
in

Fig
.
1
.

Engine



Pressure
plate

flywheel,,
assembly

Clutch

Flywheel
bolt

Pressure
plate
release
lever



Release
lever

Fig
.
1
.



Clutch
assembly
and
hydraufcs
.

210
Clutch

Release
bearing

Pushrod

A
soft
or
spongy
feel
to
the
clutchpedal,
long
pedal
free-
play,
or
grinding
noises
from
thegears
while
shifting
can
all
in-
dicate
problems
with
the
Clutch
hydraulics
.
In
these
circum-
stances
it
is
best
to
start
with
a
clutch
fluid
flush,
followed,
if

necessary,
byreplacement
of
the
hydraulic
parts
.

From
brake
fluid
reservoir

CLUTCH
210-1

0

0

Transmission
inputshaft

Clutch
master
cylinder

Bulkhead

Slave
cylinder
6535

CLUTCH
HYDRAULICS

611-
4



WIPERS
AND
WASHERS

2
.
Remove
wiper
arms
as
described
earlier
.

3
.
Place
engine
hood
in
service
position
.
See
410
Fend-

ers,
Engine
Hood
.

4
.
Unclip
engine
bulkhead
plenum
grille
at
base
of
wind-

shield
and
pulí
it
away
from
rubbergasket
.
See
Fig
.
5
.

Fig
.
5
.



Detach
grill
clips
(arrows)
and
pull
upward
.

0012527

5
.
Remove
wiring
harness
retaining
clip
frombulkhead
in
rear
of
engine
bay
.
Remove
screws
retaining
wiring
harness
protective
cover
.
See
Fig
.
6
.

0012529

Fig
.
6
.



Engine
bulkhead
wiring
harness
cover
screws
(arrows)
.

WINDSHIELD
WIPER
ASSEMBLY

Fig
.
7
.



Right
side
plenum
retaining
screws
(arrows)
.

7
.
On
driver's
side
of
air
plenum,
push
aside
wiring
har-

ness
and
remove
screw
retaining
plenum
.
Pull
plenum

up
andremove
from
engine
compartment
.
See
Fig
.
8
.

001¿534

Fig
.
8
.



Remove
screw
at
A
and
pull
plenum
housing
upward
.

8
.
On
6-cylinder
models
:
Remove
plastic
top
engine
cov-
ers
.
See
110Engine
Removal
and
Installation
.

NOTE-

Cover
ínside
edges
of
cowlpanelsheet
metal
with
thick
tape
to
prevent
damage
during
wiper
assembly
remov-
al
.

9
.
Remove
large
nut
and
washer
at
base
of
wiper
arm

shafts
cowi
panel
.
See
Fig
.
9
.

10
.
Remove
wiper
assembly
support
.
See
Fig
.
10
.

6
.
On
passenger
side
of
air
plenum,
push
aside
wiring



11
.
Separateharness
at
bulkhead
connector
.
See
Fig
.
11
.

harness
and
remove
twoscrews
retaining
plenum
housing
.
See
Fig
.
7
.



12
.
Wrap
protective
tape
around
wiper
shaft
on
driver's
side
to
prevent
damaging
painted
metal
during
remov-
al
.

612
Switches
and
Electrical
Accessories

GENERAL
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
...
.
......
.612-1



Headlight
switch,
replacing



..
.
...
.
.
.
.
.
.
.
.
.
612-5

Foglight
switch,
replacing
....
.
.
.
.
.
.
.
.
.
.
.
.
.
612-5
INTERIOR
SWITCHES
.
.
...
.
.
.
.
.
.
.
.....
612-1



Hazard
warning
switch,
replacing
.
.
.
.
.
.
.
.
.
.612-5
Turn
signal
switch
and
wiper
switch,



Powerwindow
switch,
replacing
.
.
.
...
.
.
.
.
.
612-5
replacing
.
.
.
.
.
.
.
...
.
.
.
.....
.
....
.
.
.
.
612-1



Outside
mirrorswitch,
replacing
.
.
.
.
.....
.
.
.612-6
Ignition
Switch
Assembly
.
.
.
.
.
.
.
.
....
.
...
612-3

Ignition
electrical
switch,
replacing
.
...
.
....
612-3



INTERIOR
LIGHTS
.
.
................
.
..
612-6

Ignition
lock
cylinder,
replacing
.
.
.
.
.....
.
..
612-4



Dome
light,
rear
map
lights,
trunk
light,

Headlight
and
Foglight
Switch
Assembly
.
.
.
.
612-5



replacing
bulbs
.
......
.
.
.
.
.
.
.
.
.
.....
.
.612-7

GENERAL



Turn
signal
switch
and
wiper
switch,

replacing
Thissection
covers
replacement
of
interior
switches
and
accessories
.



The
procedures
for
removing
the
turn
signal
stalk
switch
and
the
wiper
system
stalk
switchare
similar
.
When
working
on
electrical
switches,
always
disconnect
the
negative
(-)
cable
from
the
battery
and
insulate
the
cable
end
to
prevent
accidental
re-connection
.

CAUTION-

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

WARNING
-

The
cars
covered
by
this
manual
are
equipped
with
a
Supplemental
Restraint
System
(SRS)
that
auto-'
matically
deploys
one
or
more
airbags
.
Each
airbag
unit
houses
an
explosive
powerful
charge
.
Any
work
involving
the
SRS
system
should
only
be
per-
formed
byan
authorized
BMW
dealer
.
Making
re-
pairs
without
the
proper
knowledge
and
special
test
equipment
may
cause
serious
personal
injury
.
See
721
Airbag
System
(SRS)

3
.
With
front
wheels
pointed
straight
ahead,
remove
steer-
"
Testing
and
replacement
information
for
the
oil
ores-



¡ng
wheel
.
See
320
Steering
and
Wheel
Alignment
.
sure
switch
is
covered
in
119
Lubrication
System
.

NOTE-

"
Wirfng
diagramscan
be
found
in
Electrical
Wiring
Diagrams
.

"
Fuse,
relay
and
electrical
component
locations
can
be
found
in
610
Electrical
Component
Locations
.

"
Replacement
information
for
thetransmission
gear
position/neutral
safety
switch
is
covered
in
250
Gear-
shift
Unkage
.

INTERIOR
SWITCHES

NOTE
-

To
preventmarring
interior
trim,
wrap
the
tips
of
screw-
drivers
and
pliers
with
tape
beforeprying
out
switches
or
electrical
accessories
.

SWITCHES
AND
ELECTRICAL
ACCESSORIES



612-1

1
.
Disconnect
negative
(-)
cable
from
battery
and
cover
terminal
with
insulating
material
.

2
.
Remove
airbag
unit
from
steering
wheel
.
See
721
Air-
bag
System
(SRS)
.
Store
airbag
unit
in
a
safe
placew¡th
pad
facing
up
.

NOTE
-

To
helo
with
reassembly,
mark
steering
wheel
and
col-
umn
before
disassembly
.

4
.
Remove
trim
panel
from
lower
left
side
of
instrument
panel
.
See513
Interior
Trim
.

INTERIOR
SWITCHES

GENERAL

E36
cars
are
equipped
with
integrated
automatic
heating

and
air
conditioning
systems
.
Many
of
the
procedures
given
in

this
repair
group
require
that
the
A/C
refrigerant
charge
be

evacuated
using
specialized
equipment
.
See
A/C
System
Warningsand
Cautions
later
in
this
repair
group
.

HEATER
AND
CONTROLS

Blower
motor,
removing
and
installing

NOTE-

On
6-cylinder
cars,
the
plastic
top
enginecover
and
fuel
rail
covermustbe
removed
.
The
fuel
injectorhamess
re-
taining
screws
must
be
removed
and
the
harness
set
aside
.
The
engine
control
module
(ECM)
cover
must
be
removed,
the
control
unit
connectors
unplugged
and
the
harness
pulled
out
of
the
way
.
See
130
Fuel
Injection
.

1
.
Disconnect
negative
(-)
cable
from
battery
.

2
.
Open
hood
.
Unclip
engine
bulkhead
plenum
grille
at

base
of
windshíeld
and
remove
grille
.
See
Fig
.
1
.

HEATING
AND
AIR
CONDITIONING



640-1

640
Heating
and
Air
Conditioning

GENERAL
.
...
.
....
.
.
.
.
.
.
.
.
.
.......
.
.
.
640-1



Heater
andA/C
air
distribution
motor,

replacing(rotary-knob)
.
.
...
.
.
.
.......
.
640-10

HEATER
AND
CONTROLS
.
.....
.
.
.
.
.
.
.640-1



Rear
Window
Defogger
.
.
.



.
.
.
.
.
.
.
...
.
.
.
640-10
Blower
motor,
removing
and
installing
.
.
.
.
.
.
640-1



Rear
Window
Blower
(convertible
models)
.
.640-10

Blowermotor
resistor
pack,
replacing



.
.
.
.
.
.
640-3



AIR
CONDITIONING
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
640-11
Heater
valve,
replacing
...........
.
.
.
.
.
.
.
640-3

Heater
box,
removing
and
installing
.
.
.
.
.
.
.
.
640-4



A/CSystem
Warnings
and
Cautions
.
.
.
.
.
.
:640-11

Heater
core,
replacing
.....
.
.
:
....
.
.
.
.
.
.
.
640-6



A/C
compressor,
replacing
.
.
::.
:
:
.
.
.
.
.
.
.
.640-12

Heater
core
temperature
sensor,
replacing
.
.
640-7



A/C
Compressor
Clutch
.
.
.
.
.
.
.
:
.
.
.
.
.
.
.
.
.
640-13

Heater
andA/C
Control
Head
.
.
....
.
.....
.
640-7



A/C
condenser,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
640-14

Heater
andA/C
control
head,
removing



A/C
receiver/drier,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
.
640-15
and
installing
(rotary-knob)
.
.
....
.
......
640-7



A/C
expansion
valve,

Heater
andA/C
control
head,
removing



removing
and
installing
...
.
.....
.
.
.
.
.
.
.
640-16
and
installing
(digital-display)
.
.....
.
.....
640-8



A/C
evaporator,
removing
and
installing
.
.
..
640-17

Heater
andA/C
control
module,removing



A/C
evaporator
temperature
sensor,

and
installing
(rotary-knob)
.
.
...
.
.
.
.
.
.
.
.
640-8



replacing
.
.
.
.
.
.
..............
.
.
.
.
.
..
640-17

Heater
andA/C
control
module,removing



A/C
microfilter,
replacing
......
.
....
.
.
.
..
640-18

and
installing
(digital-display)
.
...
.
.
.
.
.
...
640-8

Sensor
fan
for
interior
temperature,



TABLES

replacing
.
.
.
....
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
640-9



a
.
Blower
Motor
Test
Values
.........
...
.
.
......
640-3

Heater
andA/C
AirDistribution
Motors
.
.
.
.
.
.
640-9



b
.
Heater
Core
Temperature
Sensor
Test
Values
...
.640-7

c
.
Evaporative
Temperature
Sensor
Test
Values
...
640-17

d
.
A/C
System
Fluid
Capacities
(total)
..
..........
640-18

0012527

Fig
.
1
.
Detach
grille
retaining
clips
(arrows)
and
pull
grille
upward
and
out
of
rubbergasket
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautionsgiven
at
the
front
of
this
manual
onpage
viii
.

HEATER
AND
CONTROLS