radiator BMW 318i 1992 E36 Workshop Manual
[x] Cancel search | Manufacturer: BMW, Model Year: 1992, Model line: 318i, Model: BMW 318i 1992 E36Pages: 759
Page 3 of 759
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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.
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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
Page 7 of 759
Please
read
these
warnings
and
cautions
before
proceeding
with
maintenance
and
repair
work
.
WARNING-
"
Friction
materials
(such
as
brake
pads
or
shorts
or
clutchdiscs)
contain
asbestos
fibers
or
other
friction
materials
.
Do
notcreate
"
See
also
Cautionson
page
viü
dustby
grinding,
sanding,
orby
cleaning
with
compressed
air
.
"
Some
repairs
may
be
beyond
your
capability
.
If
you
lack
the
Avoid
breathing
dust
.
Breathing
any
friction
material
dust
can
lead
skills,
tools
and
equipment,
or
a
suitable
workplace
for
any
proce-
to
serious
diseases
and
may
result
in
death
.
duredescribed
in
this
manual,
we
suggestyou
leave
such
repairs
"
Batteries
give
off
explosive
hydrogen
gas
during
charging
.
to
an
authorized
BMW
dealer
service
department
or
other
quali-
Keep
sparks,
lighted
matches
and
open
flame
away
from
the
top
fied
shop
.
of
the
battery
If
hydrogen
gas
escaping
from
the
cap
vents
is
"Do
not
re-use
any
fasteners
that
are
worn
or
deformed
in
normal
ignited,
it
will
ignite
gas
trapped
in
the
cells
and
cause
the
battery
use
.
Many
fasteners
are
designed
to
be
used
only
once
and
to
explode
.
become
unreliable
and
may
fail
when
used
a
second
time
.
This
"
Connect
and
disconnect
battery
cables,
jumper
cablesora
bat-
includes,
but
is
not
limited
to,
nuts,
bolts,
washers,
self-locking
nuts
or
bolts,
circlips
and
cotterpins
.
Always
replace
these
fasteners
with
new
parts
.
"Do
not
quick-charge
the
battery
(for
boost
starting)
for
longer
"
Never
work
under
a
lifted
car
unless
it
is
solidly
supportedon
than
one
minute
.
Wait
at
least
one
minute
before
boosting
the
bat-
stands
designed
for
the
purpose
.
Do
not
support
a
car
on
cinder
tery
a
second
time
.
blocks,
hollow
tiles
or
other
props
that
may
crumble
under
contin-
uous
load
.
Never
work
under
acar
that
is
supported
solely
by
a
"Do
not
allow
battery
charging
voltage
to
exceed
16
.5
volts
.
If
the
jack
.
Never
work
under
thecar
while
the
engine
is
running
.
battery
beginsproducing
gas
or
boiling
violently,
reduce
the
charg-
ing
rate
.
Boosting
a
sulfated
battery
at
a
high
charging
rate
can
"
If
you
are
going
to
work
under
acar
on
the
ground,
make
sure
cause
an
explosion
.
that
the
ground
is
level
.
Block
the
wheels
to
keep
the
carfrom
roll-
ing
.
Disconnect
the
battery
negative
(-)
terminal
(ground
strap)to
"
The
air-conditioning
system
is
filled
with
chemical
refrigerant,
prevent
others
from
starting
thecar
while
youare
under
it
.
which
is
hazardous
.
TheA/C
system
should
be
servicedonly
by
trained
technicians
using
approved
refrigerant
recovery/recycling
"
Never
run
the
engine
unless
the
work
area
is
well
ventilated
.
equipment,
trained
in
related
safetyprecautions,
and
familiar
with
Carbon
monoxide
kills
.
regulations
governing
the
discharging
and
disposal
of
automotive
"
Finger
rings,
bracelets
and
other
jewelry
shouldbe
removed
so
chemical
refrigerants
.
tery
charger
only
with
the
ignition
switched
off,
to
prevent
sparks
.
Do
not
disconnect
the
battery
while
the
engine
is
running
.
that
theycannot
cause
electrical
shorts,
get
caught
in
running
"
Do
not
expose
any
partof
the
A/Csystem
to
high
temperatures
machinery,
or
be
crushed
by
heavy
parts
.
suchas
open
flame
.
Excessiveheat
will
increase
system
pressure
"
Tie
long
hair
behind
your
head
.
Do
not
wear
a
necktie,
a
scarf,
and
may
cause
the
system
to
burst
.
loose
clothing,
or
a
necklace
when
you
work
near
machine
tools
or
"
Some
aerosol
tire
inflators
are
highly
flammable
.
Be
extremely
running
engines
.
If
your
hair,
clothing,
or
jewelry
were
to
get
caught
cautious
when
repairing
a
tire
that
may
havebeen
inflated
using
in
the
machinery,
severe
injury
could
result
.
an
aerosol
tire
inflator
.
Keep
sparks,
open
flame
or
other
sources
"
Do
not
attempt
to
work
onyourcar
if
you
do
not
feel
well
.
You
of
ignition
away
from
the
tire
repair
area
.
Inflate
and
deflate
the
tire
increase
the
danger
of
injury
toyourself
and
others
if
you
are
tired,
at
least
four
times
before
breaking
the
bead
from
therim
.
Com-
upset
or
have
takenmedication
or
any
other
substance
that
may
Pletely
remove
the
tire
from
the
rim
beforeattempting
any
repair
.
keep
you
from
being
fully
alert
.
"
Illuminate
your
work
areaadequately
but
safety
.
Use
a
portable
safety
light
for
working
inside
or
under
thecar
.
Make
surethe
bulb
is
enclosedbya
wire
cage
.
The
hot
filament
of
an
accidentally
bro-
ken
bulb
can
ignite
spilled
fuel
or
oil
.
"
Catch
draining
fuel,
oil,
orbrake
fluid
in
suitable
containers
.
Do
not
use
food
or
beverage
containers
that
mightmislead
someone
into
drínking
from
them
.
Store
flammable
fluids
away
from
fire
haz-
ards
.
Wipe
up
spills
at
once,
but
do
not
store
the
oily
rags,
which
can
ignite
and
burn
spontaneously
.
"
Always
observe
good
workshop
practices
.
Wear
goggles
when
youoperate
machine
tools
or
work
with
battery
acid
.
Gloves
or
other
protectioeclothing
should
be
worn
whenever
thejob
requires
working
with
harmful
substances
.
"
Greases,
lubricants
and
other
automotive
chemicals
contain
toxic
substances,
many
of
which
are
absorbed
directly
through
the
skin
.
Read
the
manufacturer's
instructions
and
warnings
carefully
.
Use
hand
andeye
protection
.
Avoid
direct
skin
contact
"
Cars
covered
by
this
manual
are
equipped
with
a
supplemental
restraint
system
(SRS),
that
automatically
deploys
an
airbag(s)
in
theevent
of
a
frontal
ímpact
.
The
airbag(s)
is
inflated
byan
explo-
sive
device
.
Handled
improperly
or
without
adequate
safeguards,
can
be
accidently
activated
and
cause
serious
injury
.
"
The
ignition
system
produces
high
voltages
that
can
be
fatal
.
Avoid
contact
with
exposed
terminals
and
use
extreme
care
when
working
ona
car
with
the
engine
running
or
the
ígnition
switched
on
.
"
Place
jack
stands
only
at
locations
specified
bymanufacturer
.
The
vehicle
lifting
jacksupplied
with
the
vehicle
is
intended
for
tire
changes
only
.
A
heavy
duty
floor
jack
shouldbe
used
to
lift
vehicle
before
installing
jack
stands
.
See
010
Fundamentals
for
theDo-
.
it-Yourself
Owner
.
"
Battery
acid
(electrolyte)
can
cause
severeburns
.
Flush
contact
area
with
water,
seek
medical
attention
.
"
Aerosolcleaners
and
solvents
may
contain
hazardous
ordeadly
vapors
and
are
highly
flammable
.
Use
only
in
a
wellventilated
area
.
Do
not
use
on
hot
surfaces
(engines,
brakes,
etc
.)
.
"
Disconnect
the
battery
negative
(-)
terminal
(Ground
strap)
"
Do
not
remove
coolant
reservoir
or
radiator
cap
with
theengine
whenever
you
work
on
the
fuel
system
orthe
electrical
system
.
Do
hot
.
Danger
of
bums
and
engine
damage
.
not
smoke
or
work
near
heaters
or
other
fire
hazards
.
Keep
an
approved
fire
extinguisher
handy
.
continued
on
next
page
vii
Page 20 of 759
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
.
Page 21 of 759
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
Page 22 of 759
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
Page 47 of 759
ignition
Table
b
.
Engine
Management
Systems
engine
has
high
mileage
.
Engine
1
System
4-cylinder
engines
M42
(1992-1995)
Bosch
DME
Ml
.7
M44
(1996-1998)
Bosch
DME
M5
.2
(OBD
II)
6-cylinder
engines
M50
(1992)
Bosch
DME
M3
.1
M50
VANOS
(1993-1995)
Bosch
DME
M3
.3
.1
M52
(1996-1998)
Siemens
MS41
.1
(OBD
II)
S50US
(1995)
Bosch
DME
M3
.3
.1
S52US
(1996-1998)
Siemens
MS41
.1
(OBD
II)
Both
the
4-cylinder
and
6-cylinder
engines
use
a
distributor-
less
ignition
system
with
individual
ignition
coils
for
each
cylin-
der
.
FuelDelivery
Pressurized
fuel
from
the
in-tank
fuel
pump
is
injected
via
solenoid-type
fuel
injectors
.
The
ECM
controls
the
opening
and
closing
of
the
injectors
by
switchingthe
ground
side
of
each
injector
circuit
.
The
exact
amount
of
fuel
injected
is
de-
termined
by
the
amount
of
timethe
injectors
are
open
.
Cooling
System
Whenever
the
engine
is
running,
acoolant
pump
circulates
coolant
through
the
engine
and,
if
either
heater
control
valves
are
open,
through
the
heater
core
in
the
passenger
compart-
ment
.
The
coolant
absorbs
excess
heat
and
carries
it
to
the
ra-
diator
where
it
is
transferred
into
the
passing
airstream
.
A
thermostat
controls
the
flow
of
coolant
through
the
radiator
based
on
engine
temperature
.
Lubrication
System
The
lubrication
system
is
pressurized
whenever
theengine
is
running
.
The
oil
pump
draws
oil
through
a
pickup
in
the
bot-
tom
of
the
oil
pan,thenforces
it
through
a
replaceable
oil
filter
and
finto
the
engine
oíi
passages
.
On
4-cylinder
engines,
the
oil
pump
is
mounted
to
the
front
engine
cover
.
On
6-cylinder
engines,thechain-driven
oil
pump
is
bolted
to
the
bottom
of
the
cylinder
block
.
A
pressure
relief
valve
limits
the
maximum
system
pres-
sure
.
A
bypass
valve
prevents
the
oil
filter
from
bursting
and
insures
engine
lubrication
should
the
filter
become
plugged
.
See
119
Lubrication
System
for
additional
information
.
ENGINE-GENERAL
100-
5
Various
versions
of
DME
systems
are
usedon
thecars
cov-
MECHANICAL
TROUBLESHOOTING
ered
by
this
manual
.
See
Table
b
.
Each
system
is
highly
adaptive
to
compensate
for
things
suchasengine
wear
and
When
troubleshooting
an
engine
that
fails
to
start
or
runs
vacuum
leaks
.
poorly,
first
check
its
mechanical
condition-particularly
if
the
Warnings
and
Cautions
For
personal
safety,
as
well
asthe
protection
of
sensitive
electronic
components,
the
following
warnings
and
cautions
must
be
adhered
to
during
all
troubleshooting,
maintenance,
and
repairwork
.
WARNING
-
"
The
ignition
system
produces
high
voltages
that
can
be
fatal
.
Avoid
contact
with
exposed
termi-
nals
anduse
extreme
caution
when
working
on
a
car
with
the
ignition
switched
on
or
the
engine
running
.
"
Do
not
touch
or
disconnect
any
high
voltage
ca-
bles
from
the
coil,
distributor,
orspark
plugs
while
the
engine
is
running
or
being
cranked
by
the
starter
"
Connect
and
disconnect
the
engine
manage-
ment
system
wiring
and
test
equipment
leads
only
when
the
ignition
is
switched
off
.
"
Gasoline
is
highly
flammable
and
its
vapors
are
explosive
.
Do
not
smoke
or
work
on
a
car
near
heaters
or
other
fire
hazards
when
diagnosing
and
repairing
fuel
system
problems
.
Have
a
fire
extínguisher
available
in
case
of
an
emergency
.
"
Disconnecting
the
battery
may
erase
fault
code(s)
stored
in
control
module
memory
.
Using
special
BMW
diagnosnnc
equipment,
check
for
fault
codes
prior
to
disconnecting
the
battery
cables
.
If
the
Check
Engine
lightis
illuminated,
see
On-
Board
Diagnostics
(OBD)
forfault
code
infor-
mation
.
If
any
other
system
faults
havebeen
de-tected
(indicated
byan
illuminated
warning
light),
see
an
authorized
BMW
dealer
.
CAUTION-
"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnection
cautions
gíven
at
the
front
of
this
manual
on
page
viii
.
"
Do
notconnect
any
test
equipment
that
delivers
a
12-volt
power
supply
to
terminal15
(+)
of
the
ignition
coil
.
The
current
flow
may
damage
the
ECM
.
In
general,
connect
test
equipment
only
as
specified
by
BMW,
this
manual,
or
the
equip-
ment
maker
.
"
Do
not
disconnect
the
battery
with
the
engine
running
.
Do
notrunthe
engine
with
any
of
the
sparkplug
wires
disconnected
.
MECHANICAL
TROUBLESHOOTING
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 61 of 759
14
.
Unbolt
power
steering
fluid
reservoir
from
íts
mounting
bracket
.
Use
stiff
wire
to
hang
reservoir
to
one
side
.
Do
not
disconnect
fluid
lines
.
15
.
Remove
power
steering
pump
drive
belt
and
remove
pump
from
its
mounting
bracket
.
Use
stiff
wire
to
hang
pump
from
body
.
16
.
On
cars
with
automatic
transmission
remove
front
and
rear
brackets
holding
automatic
transmission
cooler
linesto
engine
.
17
.
Remove
A/C
compressor
from
its
mounting
bracket
without
disconnecting
any
refrigerantlines
.
See
Fig
.
5
.
ENGINE
REMOVAL
AND
INSTALLATION
110-
3
21
.
Remove
front
exhaust
pipefrom
exhaust
manifold
.
See
Fig
.
6
.
22
.
Install
an
engine
lifting
device
and
raise
engine
until
its
weight
is
supported
.
Remove
nuts
and
ground
strap
from
left
and
right
engine
mounts
.
0011967
Fig
.
6
.
Front
exhaustpipe
to
exhaust
mounting
nuts
(arrows),
as
viewed
from
below
on
4-cylinder
engine
.
23
.
Carefully
raíse
engine
out
of
car,
checking
for
any
wir-
ing
harnesses,
fuel
lines,
or
mechanical
parts
that
might
become
snagged
as
engine
is
removed
.
24
.
Installation
is
reverse
of
removal,
noting
the
following
:
"
Replace
all
gaskets,
O-rings
and
seals
.
"
Change
engine
oil
and
filter
and
check
al¡
other
fluid
levels
.
See020
Maintenance
Program
.
"
Refill
and
bleed
cooling
system
.
See
170
Radiator
and
Cooling
System
.
"
Insta¡¡
the
front
exhaust
pipes
using
new
gaskets
and
self-locking
nuts
.
Use
copper
pasteon
threads
.
See
180
Exhaust
System
.
Tightening
Torques
"
Coolant
drain
plug
to
cylinder
block
.
25
Nm
(18
ft-Ib)
Fig
.
5
.
A/
C
compressor
mounting
bolts
(arrows)
.
"
Engine
mount
to
subframe
M8
......:...
..
..
..
......,:..
22
Nm
(17
ft
-
1b)
,
18
.
Move
A/C
compressor
out
of
way
without
distorting
or
M10
.
...
.
..
...
.
.
...........
45
Nm
(33
ft'-Ib)
damaging
any
lines
.
Support
compressor
by
hanging
it
"
Intake
manifold
to
cylinder
head
from
chassis
using
stiff
wire
.
M7
.....
.
..
...
..
..
...........
15
Nm
(11
ft-Ib)
M8
...
.
.
.
..
..
...
..
...........
22
Nm
(16
ft-Ib)
19
.
Disconnect
wiring
from
starter
and
alternator
.
Move
`
"
Radiator
cooling
fan
to
coolant
pump40
Nm
(30
ft-Ib)
wiring
harness
out
of
way
.
See
121
Battery,
Starter,
"
Radiator
drain
screw
to
radiator
...
2
.5
Nm
(22
in-lb)
Alternator
.
"
Wiring
to
alternator
(M8
nut)
........
12
Nm
(9
ft-1b)
"
Wiring
to
starter
20
.
Remove
oil
dipstick
guide
tube
.
Note
O-ring
at
base
of
M6
nut
..
.
..
..
...
..
...........
.
:5
Nm
(44
in-lb)
tube
when
removing
.
M8
nut
..
.
..
..
...
..
............
12
Nm
(9
ft-Ib)
ENGINE
REMOVAL
AND
INSTALLATION
Page 63 of 759
11
.
Draín
engine
coolant
and
Rmove
coolant
hoses
at-
tached
to
cylinder
head
.
"
Drain
engine
block
byremoving
block
drain
.
"
Disconnect
hoses
from
thermostat
housing
in
front
of
cylinder
head
.
"
Disconnect
heater
hoses
at
rear
of
engine
.
See
Fig
.
9
.
"
Drain
radiator
by
removingthreaded
plastic
plug
from
lower
left
comer
.
NOTE-
"
The
block
drain
plug
is
located
oh
the
exhaust
side
to-
wards
rear
ofengine
.
"
Remove
small
plastic
lock
clipto
pulíradiator
draín
plug
out
completely
.
NOTE-
CAUTION-
Radiatorfan
has
left
hand
threads
.
ENGINE
REMOVAL
AND
INSTALLATION
110-
5
Fig
.
9
.
Coolant
hoses
at
heater
valve
and
heater
core
to
be
discon-
nected
(arrows)
.
12
.
Remove
radiator
cooling
fan
and
radiator
as
described
in
170
Radiator
and
Cooling
System
.
13
.
Label
and
disconnectcoolant
hoses,
cables,
and
har-
ness
connectors
from
throttle
housing
.
See
Fig
.
10
.
14
.
Working
atrearof
intake
manifold,
label
and
then
re-
move
fuel
supply
and
fuel
retum
lines
.
Disconnect
fuel
lines
from
support
bracket
on
manifold
.
See
Fig
.
11
.
uu12ivu
Fig
.
10
.
Throttle
housing
assemblyon
M52
engine
.
Disconnect
hos-
es,
cables
and
harness
connectors
at
and
around
housing
.
0012699
Fig
.
11
.
Special
fuelline
fitting
at
fuel
rail
on
M52/S52US
engine
.
Use
BMW
special
tool
16
1
050
to
releaselocking
fittings
at
ends
offuel
lines
.
WARNING
-
"
Fuel
may
be
expelled
under
pressure
.
Do
not
smoke
or
work
near
heaters
or
other
fire
haz-ards
.
Keep
a
fire
extinguísher
handy
.
Before
dis-
connecting
fuel
hoses,
wrapa
cloth
around
fuel
hoses
to
absorb
any
leaking
fuel
.
Plug
all
oyen
fuel
fines
.
"
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
ín
the
tank
before
working
on
the
tank
or
lines
.
OnM52
and
S52US
engines,
special
fittings
are
used
to
retain
the
fuel
lines
to
the
fuel
rail
.
Use
BMW
special
16
.
Remove
intake
manifold
from
engine
byremoving
sev-
tool
no
.
161050
to
compress
the
locking
clip
insidethe
en
mounting
nuts
from
above
andtwo
mounting
bracket
end
of
the
fuel
line
fittings
to
release
the
fine
.
boits
from
below
.
See
Fig
.
12
.
15
.
Unbolt
power
steering
fluid
reservoir
from
its
mounting
CAllTION-
bracket
.
Use
stiff
wire
to
hang
reservoir
to
one
side
.
Do
Stuff
clean
rags
into
the
open
intake
ports
to
pre-
not
disconnect
fluid
fines
.
vent
any
parts
from
falling
into
the
engine
intake
.
ENGINE
REMOVAL
AND
INSTALLATION
Page 65 of 759
22
.
Move
A/C
compressor
out
of
the
way
without
distorting
26
.
Carefully
raise
engine
out
ofcar,
checking
for
any
wir-
or
damaging
any
lines
.
Support
compressor
by
hanging
ing,fuel
lines,
or
mechanical
parts
that
might
become
it
from
chassis
using
stiff
wire
.
snagged
as
engine
is
removed
.
23
.
Disconnect
wiring
from
starter
and
alternator
.
Move
27
.
Installation
is
reverse
of
removal,
noting
the
following
:
wiring
harness
out
of
the
way
.
See
121
Battery,
Start-
Replace
al¡
gaskets,
O-rings
and
seals
.
er,
Alternator
.
"
Change
engine
oil
and
filter
and
check
all
other
fluid
24
.
Remove
Fontexhaust
pipe
fromexhaust
manifold
.
See
levels
.
See
020
Maintenance
Program
.
"
Refill
and
bleed
cooling
system
.
See
170
Radiator
Fig
.
16
.
and
Cooling
System
.
"
Check
that
engine
drivebelts
properly
engage
the
pul-
ley
grooves
.
"
Install
the
Font
exhaust
pipesusing
new
gaskets
and
seif-locking
nuts
.
Use
copper
paste
on
threads
.
See
180
Exhaust
System
.
0012525
Fig
.
16
.
Front
exhaust
pipeto
exhaust
manifolds
mounting
nuts
on
6-
cylinder
engine
(arrows)
.
25
.
Install
an
engine
lifting
device
and
raise
engine
until
its
weight
is
supported
.
Remove
nuts
and
ground
strap
from
left
and
right
engine
mounts
.
ENGINE
REMOVAL
AND
INSTALLATION
110-
7
Tightening
Torques
"
Coolant
drain
plug
to
cylinder
block
.
25
Nm
(18
ft-Ib)
"
Engine
mount
to
subframe
M10
..
.
.
.
...
..............
..
.
45
Nm
(33
ft-Ib)
M8
..
..
.
..
................
...
22
Nm
(16
ft-Ib)
"
Intake
manifold
to
cylinder
head
M7
..
..
..
...
................
.
15
Nm
(11
ft-Ib)
M8
...
.
..
...
................
.
22
Nm
(16
ft-Ib)
"
Radiator
cooling
fan
to
coolant
pump40
Nm
(30
ft-Ib)
"
Radiator
drain
screw
to
radíator
...
2
.5
Nm
(22
in-lb)
"
Wiring
to
alternator
(M8
nut)
........
12
Nm
(9
ft-Ib)
"
Wiring
to
starter
M6
nut
.
..
...
..................
5
Nm
(44
in-lb)
M8
nut
.....
..
.
.
.
.
.............
12
Nm
(9
ft-Ib)
ENGINE
REMOVAL
AND
INSTALLATION