battery BMW 318i 1996 E36 Manual Online
[x] Cancel search | Manufacturer: BMW, Model Year: 1996, Model line: 318i, Model: BMW 318i 1996 E36Pages: 759
Page 185 of 759
160
Fuel
Tank
and
Fuel
Pump
GENERAL
.
.
.
.
.
.
...........
.
....
.
.
.
.
.
.
160-1
Operating
fuel
pump
for
tests
.
.
.
.
.
.
.......
.160-6
Fuel
Pump
Electrical
Tests
.
.
.
.
.
.
.
...
.
.
.
.
.
160-7
FUEL
TANK
AND
LINES
..
.
.
.
..........
160-2
Fuel
pump
electrical
circuit,
testing.
...
.
.
.
.
.
160-7
Fuel
tank,
draining
..
.
.
.
.
.
.
.
.
.
..........
160-2
Fuel
pump
power
consumption,
testing
.
.
.
.
.
.
160-7
Fuel
tank,
removing
and
installing
.........
160-3
Fuel
Delivery
Tests
....
.
.
.
...
.
.....
.
.
.
..
160-8
Fuel
Tank
Evaporative
Control
System
.....
160-4
Relieving
fuel
pressure
and
connecting
fuel
pressure
gauge
..
.
...........
.
.
.
..
160-8
FUEL
LEVEL
SENDERS
.
.
.
.
.
.......
.
.
.
160-4
System
pressure,
testing
.................
160-9
Fuel
level
senders,
testing
.
.
.
.
.
.......
.
.
.
160-5
Fuel
delivery
volume,
testing
.............
160-10
Fuel
leve¡
sender
and
fuel
pump
(right
side),
emoving
and
installing
.
.
.
.
.
.
160-5
TABLES
Fuel
leve¡
sender
(left
side),
a
.
FuelLeve¡
Sender
Resistances
...........
.
.
..
.160-5
removing
and
installing
.........
.
.
.
.
.
.
.
160-6
b
.
Fuel
Pump
Current
...
.................
..
...
160-8
c
.
Fuel
Pressure
Specifications
..............
.
..
160-10
FUEL
PUMP
.
.
.
................
.
.
.
.
.
.
.
160-6
d
.
Fuel
Pump
Delivery
Specifications
.........
.
..
160-10
Fuel
Pump
Fuse
and
Relay
.
.
.
....
.
.
.
.
.
.
.
160-6
GENERAL
This
repair
group
covers
service
information
specifically
for
The
cautions
and
warnings
on
this
page
should
beob
the
fuel
supply
system
.
Information
on
the
fue¡
injection
sys-
served
when
servicing
the
fuel
system
.
tem
is
covered
in
130
Fuel
Injection
.
NOTE-
Fue¡
filter
replacement
is
covered
in
020
Maintenance
Program
.
WARNING
-
"
The
fuel
system
is
designed
to
retain
pressure
even
when
the
ignition
isoff
.
When
working
with
the
fuel
system,
loosen
the
fuel
lines
slowly
toal-
low
residual
fuel
pressure
to
dissipate
gradually
.
Avoid
spraying
fuel
.
"
Before
beginning
any
work
on
the
fuel
system,
place
a
tire
extinguisher
in
the
vicinity
of
the
work
area
.
"
Fuel
is
highly
flammable
.
When
working
around
fuel,
do
not
disconnect
any
wires
that
could
cause
electrical
sparks
.
Do
not
smoke
or
work
near
heaters
or
other
tire
hazards
.
"
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
fines
.
"
Do
not
use
a
work
light
near
any
fuel
.
Fuel
may
spray
onto
the
hot
bulb
causing
a
tire
.
"
Make
sure
the
work
area
is
properly
ventifated
.
FUEL
TANK
AND
FUEL
PUMP
160-1
CAUTION-
"
Prior
to
disconnecting
the
battery,
read
the
bat-tery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viü
.
"
Before
making
any
electrical
tests
with
the
ignition
tumed
on,
disable
the
ignition
system
as
de-
scribed
in
120
Ignition
System
.
Be
sure
the
bat-tery
is
disconnected
when
replacing
components
.
"
To
prevent
damage
to
the
ignition
system
or
the
electronic
fuel
system
components,
including
the
control
unit,
aiways
connect
and
disconnect
wires
and
test
equipment
with
the
ignition
off
.
"
Cleanliness
is
essential
when
working
with
the
fuel
system
.
Thoroughly
clean
the
fuel
fine
unionsbefore
disconnecting
any
of
the
fines
.
"
Use
only
clean
tools
.
Keep
removed
parts
clean
and
sealed
or
covered
with
a
clean,
lint-free
cloth,
especially
if
completion
of
the
repair
is
delayed
.
"
Do
not
move
the
car
while
the
fuel
system
is
open
.
"
Avoid
using
high
pressure
compressed
air
to
blow
out
fines
and
componente
.
High
pressure
can
rupture
infernal
seals
and
gaskets
.
"
Always
replace
seals
and
O-rings
.
GENERAL
Page 186 of 759
160-2
FUEL
TANK
AND
FUEL
PUMP
0011943
1
.
Filler
pipe
10
.
Fuel
compensating
siphon
pump
and
hose
assembly
2
.
Filler
pipe
grounding
tab
(models
built
from
1/95)
3
.
Vent
pipe
11
.
Fueltank
4
.
Threaded
collar
12
.
Tank
support
strap
5
.
Rubber
ring
seal
13
.
Bolt-tighten
to
23
Nm
(17
ft-Ib)
6
.
Fuel
pump
14
.
Fuel
expansion
tank
7
.
Left
side
fuel
leve¡
sender(models
built
from
1/95)
15
.
Fuel
tank
pressure
sensor
(OBD
II)
8
.
Right
side
fuel
leve¡
sender9
.
Left
side
fuel
leve¡
sender
with
fuel
compensating
siphon
pump
(models
built
up
to
1/95)
Fig
.
1
.
E36
fuel
tank
assembly
.
FUEL
TANK
AND
LINES
Fuel
tank,
draining
The
plastic
fuel
tank
is
mounted
beneath
the
center
of
the
car
(beneath
rear
seat)
.
Mounted
in
the
fuel
tank
are
the
fuel
pump
and
fuel
leve¡
sending
units
.
Connecting
lines
for
the
evaporative
emission
control
systemand
expansion
tank
are
also
attached
to
the
tank
.
When
performing
the
procedures
that
follow,
refer
toFig
.
1
.
Fuel
tank
capacity
for
E36
modeis
"All
ex
.
1996
M3
(3
.0
L)
.....
.
..
..
65
liters
(17
.0
gal)
"
1996
M3
(3.0L)
modeis
.
...
.
..
.
.62
liters
(16
.4
gal)
FUEL
TA
NKAND
LINES
The
fuel
tank
should
be
drained
into
an
approved
storage
unit
or
another
car's
fuel
tank
.
WARNING
-
"
Before
removing
the
tank,
be
sure
that
afl
hot
components
such
as
the
exhaust
system,
are
completely
cooled
down
.
"
Fuel
may
be
spilled
.
Do
not
smoke
or
worknear
heaters
or
other
Pire
hazards
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
paga
vi¡¡
.
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 189 of 759
Fuel
leve¡
senders,
testing
Fuel
leve¡
sender
(right
side)
The
left
and
right
fuelleve¡
sending
units
are
wired
in
series
.
and
fuel
pump,
removing
and
installing
The
fuel
gauge
receives
a
signal
that
is
the
average
of
the
two
1
.
Disconnect
negative
(-)
cable
from
battery
.
input
values
.
1
.
Remove
rear
seat
cushion,
lift
up
insulation
mats,
andremove
both
fuel
tank
access
covers
.
2
.
Disconnect
white
plug
on
each
sending
unit
.
See
Fig
.
6
.
3
.
Check
resistance
value
of
eachsending
unit
.
Values
should
be
the
same
.
5
.
If
valuesare
different,
remove
sending
units
as
described
below,
and
check
resistance
valuésacross
terminals
.
Table
a
lists
resistance
values
for
senders
at
various
float
positions
.
Table
a
.
Fuel
Leve¡
Sender
Resistances
Float
position
Test
result
(ohms)
Right
side
empty
10
ohm
t2
Right
side
full
250
ohm
±
5
Left
side
empty
10
ohm
t
2
Left
side
fui¡
250
ohm
±
5
FUEL
TANK
AND
FUEL
PUMP
160-
5
CAUTION
-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautionsglven
at
the
front
of
this
manual
onpage
viii
.
2
.
Drain
fuel
from
tank
as
described
earlier
.
WARNING
-
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
fines
.
3
.
Remove
rear
seat
cushion
and
pull
back
insulation
pad
under
right
side
.
4
.
Remove
screws
holding
rightfuel
tank
accesscover
.
Remove
cover
.
5
.
Label
fuel
hoses
.
Disconnect
hoses
and
harness
con-
nectors
from
fuel
sending
unit
and
fuel
pump
.
6
.
Unscrew
threaded
collar
from
fuel
pumplfuel
leve¡
sender
.
Slowly
withdraw
assembly
from
tank,allowing
fuelto
drain
off
.
See
Fig
.
7
.
0013187
&
0013194
Fig
.
6
.
Fuel
pump/leve¡
sender
terminal
identification
.
Check
resis-
tance
at
terminals
of
white
connectors
(arrows)
.
"
If
necessary,
push
leve¡
sender
arm
toward
fuel
pump
assembly
to
facilitate
removal
.
NOTE
-
BMW
special
tool
no
.
16
1
020
should
beused
to
re-
move
and
install
the
threaded
collar
.
Damage
to
the
collar
may
result
if
the
special
tool
is
not
used
WARNING
-
NOTE-
Fuel
may
be
spilled
.
Do
not
smoke
or
work
near
The
compensating
siphon
pump
(Fig
.
1)
maintains
the
heaters
or
other
fire
hazards
.
fuel
leve¡
between
the
right
and
left
tank
lobes
.
If
the
re-
sistances
are
different
between
the
left
and
right
send-
ers,
remove
the
senders
and
visually
inspect
the
leve)
in
7
.
Using
a
new
sealing
ring,
install
pump
and
sending
each
lobe
.
If
the
leve¡
is
different,
check
the
siphon
com-
unit,
being
sure
that
fuel
line
connections
point
in
same
pensating
pump
.
direction
as
they
carne
out
.
8
.
Reconnect
harnessconnector
and
hoses
.
Fill
tank
and
check
for
leaks
by
running
engine
.
Insta¡¡
access
cover
and
its
mountingscrews
.
Reconnect
negative
(-)
cable
to
battery
.
CAUTION
-
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
LEVEL
SENDERS
Page 191 of 759
Fig
.
9
.
Fuel
pump
relay
terminal
identification
.
Fuel
Pump
Electrical
Tests
Troubleshooting
of
any
fuel
pump
fault
should
begin
with
checking
the
fuel
pump
fuse
and
the
fuel
pump
relay
.
The
DME
main
relay
should
also
be
checked
.
NOTE-
Special
tools
are
requíred
for
some
of
the
tests
de-
scribed
here
.
Fuel
pump
electrical
circuit,
testing
The
fuel
pump
electrical
circuit
diagram
is
shown
in
Fig
.
10
.
3
.
If
fuel
pump
does
not
run,
disconnect
black
harness
connector
from
tank
sender
unit
.
With
jumper
wire
con-
nectedas
described
in
step
2
above,
check
for
positive
(+)
batteryvoltage
at
harness
connector
terminals
.
See
Fig
.
11
.
FUEL
TANK
AND
FUEL
PUMP
160-
7
From
Main
Relay
(+15
power
with
key
in
run
From
B+juretion
point
orstartposition)
(batteryvoRageatalltirnes)
'
.5
RD/Nrr
1
.5
RD
1
.5
GNNI
From
Engine
2
.5
GNNI
Control
Module
15
2
.5
GNNI
Ground
(below
center
console)
Fig
.
10
.
Fuel
pump
electrical
circuit
.
30
-~
Relay
Fuel
Pump
8~T
I
1
s
ám
61
Front
Power
I
a
1
Distribution
Box
I_
16
WIRING
COLOR
CODE
BK
-
BLACK
BR
-
BROWN
Fuel
Pump
RD
-
RED
(in-tank)
M
YL
YELLOWGN
-
GREENBU
-
BLUE
1
VI
-
VIOLET
GY
-
GREY
WT
-
WHITE
PK
-
PINK
0011946
4
.
If
voltage
and
groundare
present,
fuel
pump
is
proba-
bly
faulty
.
If
there
is
no
voltage,
check
wiring
From
fuel
pump
Reay
and
make
sure
Reay
is
functioning
correctly
.
CAUTION-
Fuseandrelaylocationsmayvary
.
Usecara
when
Fuel
pump
power
consumption,
testing
troubleshooting
the
electrical
system
at
the
fuselrelay
panel
.
To
resolve
problems
in
identify-
NOTE-
ing
a
relay,
see
en
authorízed
BMW
dealer
.
"
To
achieveaccurate
testresults,
fhe
battery
voltage
at
the
connector
should
be
approximately
13
volts
.
1.
Remove
rearseat
cushion,
pull
right
side
insulation
mat
Charge
the
battery
asnecessary
.
back
to
expose
fuel
tank
accesscover
.
Remove
cover
.
q
higher
than
normal
power
consumption
usually
fin-
to
expose
wiring
connections
.
dicates
a
worn
fuel
pump,
which
may
cause
intermit-
tentfuel
starvation
due
lo
pump
overheating
and
2
.
Remove
fuel
pump
relay
and
opérate
fuel
pump
as
de-
seizure
.
The
only
remedy
is
pump
replacement
.
Be
scribed
under
Operating
fuel
pump
for
tests
earlier
.
sure
to
check
that
thereturn
fine
and
the
pump
pickup
Pump
should
run
.
Disconnect
jumper
wire
when
fin-
are
not
obstructed
before
replacing
the
pump
.
ished
.
1
.
Remove
rear
seat
cushion,
pull
right
side
insulation
mal
back
to
expose
fuel
tank
accesscover
.
Remove
cover
to
expose
wiring
connections
.
2
.
Disconnect
(black)
harness
connector
from
fuel
pump
.
3
.
Connect
an
ammeter
and
an
insulated
jumper
wire
be-
tween
terminals
in
connector
and
corresponding
pump
terminals
.
See
Fig
.
12
.
FUEL
PUMP
Page 196 of 759
170-2
RADIATOR
AND
COOLING
SYSTEM
Cooling
Fans
TROUBLESHOOTING
Belt-driven
coolingfan
.
The
primary
cooling
fan
is
belt-
driven
.
It
is
mounted
to
the
frontof
the
coolant
pump
through
a
fan
clutch
.
The
fan
clutch
is
a
viscous
fluid
coupling
that
con-
trols
the
speed
of
thefan
based
on
engine
compartment
tem-
perature
.
Electric
cooling
fan
.
Models
with
M44
engine
and
stan-
dard
transmission
substitute
an
electric
fan
for
the
belt-driven
viscous
fan
.
This
is
attached
to
the
rear
of
the
radiator
and
controlledvia
the
DME
5
.2
engine
management
system
.
NOTE-
The
electric
cooling
fan
in
these
models
is
activated
by
the
engine
control
module
(ECM)
.
Auxiliary
coolingfan
.
In
al¡
models
a
two-speed
electric
auxiliary
cooling
fan
is
mounted
behind
the
front
grill
and
in
front
of
the
radiator
.
This
fan
is
primarily
used
for
the
A/C
sys-
tem,
but
also
operates
when
the
coolant
temperature
ex-
ceeds
a
predetermined
leve¡
.
Warnings
and
Cautions
The
following
warnings
and
Cautions
should
beobserved
when
working
on
the
cooling
system
.
WARNING
-
"
Atnormal
operating
temperature
the
cooling
sys-
tem
is
pressurized
.
Allow
the
system
to
cool
as
long
as
possible
before
opening-a
minimum
of
an
hour-then
release
the
cap
slowly
to
allow
sale
release
of
pressure
.
"
Releasing
the
cooling
system
pressure
lowers
the
coolants
boiling
point
and
the
coolant
may
boíl
suddenly
.
Use
heavy
gloves
and
wear
eye
and
laceprotection
to
guard
against
scalding
.
"
Use
extreme
care
when
draining
and
disposing
of
engine
coolant
.
Coolant
is
poisonous
and
lethal
to
humans
and
pets
.
Pets
are
attracted
to
coolant
because
of
its
sweet
smell
and
taste
.
Consult
a
veterinarian
immediately
if
coolant
is
ingested
byan
animal
.
CAUTION-
"
Avoidadding
cold
water
to
the
coolant
while
the
engine
is
hot
or
overheated
.
If
it
is
necessary
to
add
coolant
to
ahot
system,
do
so
only
with
the
engine
running
and
coolant
pump
tuming
.
"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.
TROUBLESHOOTING
Most
cooling
system
faults
can
be
grouped
into
one
of
three
categories
:
"
Cooling
system
leaks
"
Poor
coolant
circulation
"
Radiator
cooling
fan
faults
When
investigating
the
cause
of
overheating
or
coolant
loss,
begin
with
a
visual
inspection
.
Be
sure
to
check
the
con-
dition
and
tension
of
the
coolant
pump
drive
belt
.
Check
hoses
for
cracks
or
softness
.
Check
clamps
for
looseness
.
Check
the
coolant
leve¡
and
check
for
evidence
of
coolantleaks
from
the
engine
.
Check
that
the
radiator
fins
are
not
blocked
with
dirt
or
de-
bris
.
Clean
the
radiator
using
low-pressure
water
or
com-
pressed
air
.
Blow
outward,
fromthe
engine
side
out
.
Inspect
the
coolant
pump
by
first
removing
the
drive
belt
from
the
pump
.
Firmly
grasp
opposite
sídes
of
the
pulley
and
check
for
play
in
all
directions
.
Spin
the
pulley
and
check
that
the
shaft
runs
smoothly
.
NOTE-
The
coolant
provides
lubrication
for
the
pump
shaft,
soan
occasional
drop
of
coolant
leaking
from
the
pump
is
acceptable
.
If
coolant
drips
steadily
from
the
vent
hole,
the
pump
should
be
replaced
.
The
cooling
system
becomes
pressurized
at
normal
operat-
ing
temperature,
which
raises
the
boiling
point
of
the
coolant
.
Leaks
may
prevent
the
system
from
becoming
pressurized,
allowing
the
coolant
to
boil
at
a
lower
temperature
.
If
visual
ev-
idence
is
inconclusive,
a
cooling
system
pressure
test
can
help
to
pinpointhard-to-find
leaks
.
If
the
cooling
system
is
full
of
coolant
and
holds
pressure,
the
next
most
probable
cause
of
overheating
are
:
"
Faulty
radiator
fan
"
Loose
or
worn
drive
belt
"
Failed
thermostat
or
coolant
pump
"
Clogged/plugged
radiator
or
coolant
passages
.
NOTE
-
"
Some
early
style
coolant
pumps
were
fitted
wíth
fi-
berlplastic
type
impellers
.
Over
time,
this
impeller
can
wear
away
and
result
in
overheating
.
The
plastic
im-
peller
can
also
slip
or
free-wheel
on
the
pump
shaft
.
If
the
engine
overheats
and
no
other
faults
canbe
found,
theold
style
impeller
may
be
the
cause
of
the
problem
.
"
Only
pumps
with
the
updated
metal
impeller
should
be
used
for
replacement
.
Page 199 of 759
NOTE-
Some
cars
covered
by
this
manual
may
have
an
alter-
nate
cooling
fan
switchwith
switching
temperatures
of
176%190W
(80%88°C)
.
When
replacing
the
switch
check
theswitching
specifications,
whichshouldbe
stamped
on
the
switch
body
.
1
.
If
coolant
is
circulating
at
normal
operating
tempera-
ture,
but
auxiliary
cooling
fan
does
not
run,
disconnect
connector
from
radiator
temperature
switch
and
make
tests
listed
in
Table
c
.
Table
c
.
Auxiliary
Cooling
Fan
Temperature
Switch
Tests
Wires
jumpered
Test
Test
resuits
conditions
Black/green
(terminal2)
and
Ignition
ON
Fan
runs
on
brown
(terminal
1)
low
speed
Black/gray
(terminal
3)
and
Ignition
ON
Fan
runson
brown
(terminal
I
1)
high
speed
2
.
If
fan
runs
only
when
powered
directly
by
jumpered
connector
and
hot
coolant
is
circulating
through
radia-
tor,
radiator
temperature
switch
is
most
likelyfaulty
.
Use
a
new
sealing
ring
when
replacing
switch
Tightening
Torque
"
Temperature
switch
to
radiator
......
15
Nm
(11
ft-Ib)
3
.
If
auxiliary
fan
does
notrun
when
powered
directly,
check
for
battery
voltage
at
temperature
switch
connec-
tor
(black/green
wire)
with
ignition
on
.
If
battery
voltage
is
not
present,
check
fuses
.
See
610
Electrical
Com-
ponent
Locations
.
RADIATOR
AND
COOLING
SYSTEM
170-
5
~r~nmm
a
00
0
Fig
.
4
.
Auxiliary
radiator
cooling
fan
low
speed
relay
(1)
and
high
speed
relay
(2)
in
power
distribution
box
.
(Relay
locations
may
vary
.)
Auxiliary
Cooling
Fan
Circuit
Fuses
Fig
.
5
.
Auxiliary
radiator
fan
resistor
(arrow)
.
"
Fuse16
.
...................
..
..
...
...
.5
amp
"
Fuse
41
(ex
.
M44
w/man
.
trans)
.
..
.
..
.....
30
amp
"
Fuse
48
(M44
w/man
.
trans
.
only)
..
.
..
.....
40
amp
COOLING
SYSTEM
SERVICE
0013034
4
.
If
no
faults
are
found,
remove
low
speed
relay
and
turn
Coolant,draining
and
filling
ignition
ON
.
See
Fig
.
4
.
1
.
Remove
expansion
tank
cap
.
Set
temperature
controls
"
Check
for
power
at
terminal
30
and
terminal
86
of
relay
to
full
warm
.
socket
.
"
Reinstall
low
speed
relay
and
repeat
testat
high
speed
WARNING
-
relay
socket
.
Fix
any
wiring
faults
found
.
Allow
the
cooling
system
to
cool
before
openlng
or
On
early
productioncars
(up
to
9/92)
:
If
fan
operates
only
on
draining
the
cooling
system
.
high
speed
and
no
electrical
faults
have
been
foundup
to
this
point,
usean
ohmmeter
to
check
that
fan
resistor
is
not
electri-
2
.
Place
3
ra
allo
ug
.
beneath
radiator
drain
plug
and
re-
cally
open
.
Resistor
is
mounted
on
auxiliary
cooling
fan
housing
move
drain
plg
.
See
Fig
.
6
.
behind
front
grille
.
See
Fig
.
5
.
Wiring
diagrams
for
the
radiator
cooling
fan
canbefoundunder
Electrical
Wiring
Diagrams
.
3
.
Place
3-g
pail
beneath
rear
of
engine
blo
.
Loos-
en
and
re
mlon
ove
engine
blockcoolant
drain
plug
k
.
COOLING
SYSTEM
SERVICE
Page 216 of 759
210-2
CLUTCH
Clutch
hydraulic
system,
bleeding
and
flushing
If
the
clutch/brake
fluid
is
murky
or
muddy,
or
has
not
been
changed
within
the
last
two
years,
the
system
should
be
flushed
.
Flushing
the
old
fluid
from
the
clutch
lines
is
done
us-
ing
a
brake
system
pressure
bleeder
.
1
.
Remove
brake
fluíd
reservoir
cap
.
Usinga
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
Refill
reservoir
with
clean
fluid
.
2
.
Attach
pressure
brake
bleeder
to
fluid
reservoír
.
CA
UTION-
Do
not
exceed
2
bar
(29
psi)
pressure
at
the
fluid
reservoir
when
bleeding
or
flushing
the
hydraulic
system
.
3
.
Connect
a
length
of
hose
from
clutch
slave
cylinder
bleeder
valve
lo
a
container
.
See
Fig
.
2
.
0012003
Fig
.
2
.
Clutch
slave
cylinder
bleeder
valve
on
left
side
of
transmission
(arrow)
.
4
.
Open
bleeder
valve
and
allow
brake
fluid
to
expel
until
clean
fluid
comes
out
free
of
air
bubbles
.
5
.
Close
bleeder
valve
and
disconnect
pressure
bleeding
equipment
from
fluid
reservoir
.
Hose
on
bleeder
valve
remainsconnected
.
6
.
Slowly
operate
clutch
pedal
about10
times
.
Fill
reser-
voir
with
clean
fluid
asnecessary
.
7
.
Unbolt
slavecylinder
from
transmission
.
8
.
Position
slave
cylinder
so
that
bleeder
valve
is
facing
up
(highest
point)
.
CLUTCH
HYDRAULICS
9
.
Open
bleeder
valve
and
slowly
push
slave
cylinder
pushrod
al¡
the
way
in
.
Close
bleeder
valve
and
slowly
release
pushrod
.
Repeat
procedure
until
fluid
runs
out
clear
and
without
bubbles
.
10
.
Disconnect
bleeder
hose
.
Instan
slavecylinder
lo
trans-
mission
.
Add
cleanbrake
fluid
to
reservoir
as
neces-
sary
.
Check
clutch
operation
.
Tightening
Torques
"
Clutch
slave
cylinder
to
transmission
................
..
22
Nm
(17
ft
lb)
Clutch
master
cylinder,
replacing
The
clutch
master
cylinder
is
mounted
to
the
pedal
assem-
bly,
directly
above
the
clutch
pedal
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautionsgiven
at
the
front
of
this
manual
on
page
viii
.
2
.
Remove
brake
fluid
reservoir
cap
.
Usinga
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
CA
UTION-
Brake
fluid
is
poisonous,
highly
corrosive
and
dan-gerous
to
the
environment
.
Wear
safety
glasses
and
rubbergloves
when
working
with
brake
fluid
.
Do
notsiphonbrake
fluid
with
your
mouth
.
Imme-
diately
clean
away
any
fluid
spilled
on
painted
sur-
faces
and
wash
with
water,
asbrake
fluid
will
remove
point
.
3
.
Disconnect
fluid
supply
hose
from
master
cylinder
.
Placea
pan
under
hose
to
catch
any
excess
fluid
.
4
.
Working
in
engine
compartment,
disconnect
fluid
line
fitting
frommaster
cylinder
.
5
.
Working
in
passenger
compartment,
remove
lower
in-
strument
panel
trim
above
pedal
cluster
.
6
.
Disconnect
clutch
pedal
from
clutch
master
cylinder
push
rod
by
removing
clevis
pin
locking
clip
and
slide
out
clevis
pin
.
7
.
Remove
master
cylinder
mounting
bolts
.
See
Fig
.
3
.
8
.
Installation
is
reverse
of
removal
.
Fill
fluid
reservoir
with
clean
fluid
.
Bleed
clutch
hydraulics
as
described
earlier
.
Connect
negative
cable
to
battery
last
.
Page 226 of 759
230-
6
MANUAL
TRANSMISSION
Transmission,
removing
and
installing
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.
2
.
Insta¡¡
enginesupportacrossengine
bay
.
Raise
engine
so
that
weight
of
engine
ís
supported
.
See
Fig
.
10
.
Fig
.
10
.
Engine
support
equipment
used
to
support
engine
from
above
before
removing
transmission
.
3
.
Raise
vehicle
to
gain
access
to
underside
of
car
.
4
.
Support
transmission
with
transmission
jack
.
lf
applica-
ble,
remove
reinforcing
cross
brace
from
belowen-
gine/transmission
.
5
.
Disconnect
harnesscon
nector
from
reverse
light
switch
on
transmission
.
6
.
Remove
completeexhaustsystem
and
heat
shield
.
See
180
Exhaust
System
.
NOTE-
Disconnect
oxygensensor
hamess
connector(s)be-
fore
lowering
exhaust
system
.
7
.
Remove
driveshaft
.
See260
Driveshaft
.
8
.
Disconnect
shift
rod
from
transmission
selectorshaft
.
See
Fig
.
11
.
9
.
Disconnect
shift
console
fromtop
of
transmission
.
See
250
Gearshift
Linkage
.
TRANSMISSION
REMOVAL
AND
INSTALLATION
Washers
Shift
Shift
rod
rod
retaining
clip
0
0
,
Fig
.
11
.
Shift
lever
to
transmission
connection
.
Shift
console
0012024
10
.
Unbolt
clutch
slave
cylinder
from
sideof
transmission
.
Do
not
disconnect
fluid
hose
.
Suspend
slavecylinder
from
chassis
using
stiff
wire
.
CAUTION-
Do
not
operate
clutch
pedal
with
slave
cylinder
re-
moved
from
transmission
.
11
.
Support
transmission
from
below
with
jack
.
Remove
rear
support
crossmember
from
transmission
.
See
Fig
.
12
.
Fig
.
12
.
Rear
transmission
crossmember
(arrow)
.
12
.
Lower
transmission/engine
assembly
until
it
rests
on
front
suspension
crossmember
.
CAUTION-
Tilting
the
engine
to
lower
thetransmission
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
at
rear
of
engine
-On
cars
with
AST
remove
throttle
body
before
tilt-
ing
engine
.
-Remove
brace
fluid
reservoir
if
necessary
.
0013135
Page 232 of 759
240-
4
AUTOMATIC
TRANSMISSION
TRANSMISSION
REMOVALAND
INSTALLATION
Removal
and
installation
of
thetransmission
is
best
accom-
plished
on
a
lift
using
a
transmission
jack
.
Use
caution
and
safe
workshop
practices
when
working
beneath
car
and
low-
ering
transmission
.
WARNING
-
To
lift
the
vehicle
safely,
see010
Fundamentals
for
the
Do-it-Yourself
Owner
.
CAUTION-
"
Be
sure
the
vehicle
is
properly
supported
.
The
removal
of
the
transmission
may
upset
the
bal-
ance
of
the
vehicle
on
a
lift
.
"
Tilting
the
engine
to
remove
the
transmission
can
lead
to
damage
to
various
components
due
to
lack
of
clearance
.
-On
carswith
AST
remove
throttle
body
.
-Remove
brake
fluid
reservoir
if
necessary
.
Torx-head
bolts
are
used
to
mount
thetransmission
to
the
bellhousing
.
Be
sure
to
have
appropriate
tools
on
hand
before
starting
thejob
.
2
.
Install
engine
support
across
engine
bay
.
Raise
and
safely
support
vehicle
.
See
Fig
.
6
.
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
slightty
and
the
jack
may
shift
.
CAUTION-
Removal
of
transmission
will
cause
engine
to
tip
unlessengine
support
is
used
.
TRANSMISSION
REMOVAL
AND
INSTALLATION
Fig
.
6
.
Engine
support
equipment
used
to
support
engine
from
above
before
removing
transmission
.
3
.
Raise
vehicle
to
gain
access
to
underside
of
car
.
4
.
Drain
ATF
from
transmission
as
described
earlier
.
5
.
Disconnect
oxygen
sensor
harness
.
Remove
exhaust
system,
and
exhaust
heat
shield
.
See
180
Exhaust
System
.
Transmission,
removing
and
installing
6
.
Remove
driveshaft
.
See
260
Driveshaft
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
7
.
With
selector
lever
in
Park,
disconnect
shift
selector
le-
ver
cable
from
lever
and
remove
cable
bracket
.
Hold
CA
UTION-
linkage
clamping
bolt
stationary
when
loosening
Prior
to
disconnectiog
the
battery,
read
the
battery
clamping
nut
.
See
Fig
.
7
.
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.
Fig
.
7
.
Selector
lever
cable
clamping
nut
(A)
.
Loosen
cable
clamping
nut
(B)
and
remove
cable
from
bracket
.
Always
counterholdclamping
bolt
when
loosening
nut
.