exhaust manifold BMW 318i 1997 E36 User Guide

116-
6



CYLINDER
HEAD
AND
VALVETRAIN

9
.
Camshaft
installation
is
reverse
of
removal,noting
the

following
:

"
Prior
to
installation,
check
al¡
components
for
wear
as
described
below
under
Cylinder
Head
and
Val-

vetrain
Reconditioning
.

"
Crankshaft
must
be
at
least
45°
away
from
MC
before

installing
camshafts
to
cylinder
head
.

"
Lubricate
camshafts
prior
to
installation
.
"
Insta¡¡
camshafts
into
cylinder
head
with
lobes
for
cyl-
inder
no
.
1
pointing
up
and
towards
each
other
.
See
Fig
.
8
.

"
After
installing
camshaft(s),
observe
specified
waiting

time
for
hydraulic
cam
followers
to
fully
compress
be-

fore
bringing
crankshaft
back
to
TDC
.

Fig
.
8
.



Camshaft
correctly
positioned
for
reassembly
so
thatcylinder
no
.
1
lobes
(arrows)
face
each
other
.

Tightening
Torques

"
Camshaft
bearing
caps
to
cylinder
head
(M7)
.
..
...
..
.
....
15
Nm
(11
ft-Ib)
"
Cylinder
head
cover
to
cylinder
head
(M6)
..
.
..........
10
Nm
(89
in-lb)

"
Primary
timing
chaintensioner
to
cylinder
head-see
117
Camshaft
Timing
Chain
"
Spark
plugs
(M12)
.............
.
.
23
Nm
(17
ft-Ib)

"
Timing
chain
sprocket
to
camshaft
flange
(M6)-see
117
Camshaft
Timing
Chain

CYLINDER
HEAD,
DISASSEMBLYAND
ASSEMBLY

Valves,
removing
and
installing

1
.
Remove
cylinder
head
as
described
in
113
Cylinder

HeadRemoval
and
Installation
.
Remove
exhaust

manifold(s)
.

2
.
Remove
camshafts
using
special
tools
as
descríbed

earlier
.

3
.
On
M42
and
al¡
6-cylinder
engines
:
Remove
camshaft

carriers
by
pulling
them
straight
up
off
mounting
studs
.

CAUTION-

"
Do
not
let
the
hydraulic
cam
followers
fa¡¡
out
as
the
camshaft
carrier
is
removed
.
Special
suction
cupsare
available
from
BMW
to
hold
the
hydrau-
lic
cam
followers
in
place
during
carrier
removal
.
Camshaft
installation
waiting
times

"
at
or
above
68°F
(20
0
C)
....
..
.
..
......
10
minutes

"
50-68°F
(10-20°C)
...
.
..
....
.
..
......
30
minutes

"
32-50°F
(0-10°C)
....
.
..
....
.
..
......
75
minutes
4
.
On
M44
engines
:
Remove
all
hydraulic
valve
adjusters
.
See
Hydraulicvalve
adjusters,
checking
and
re-
"
Reinstall
timing
chainsprockets
and
tensioner
as
spe-



placing
(M44
engine),
later
in
this
section
.
cifically
described
in
117
Camshaft
Timing
Chain
.
"
Waít
at
least
10
minutes
before
cranking
engine
over



CAUTION-
withstarter
motor
for
the
first
time
.



Hydraulic
valve
adjusters
should
be
stored
in
an
upright
position
.
lf
necessary,
use
amagnetic
tool
to
aid
in
removal
of
the
adjusters
.

"
Hydraulic
cam
followers
shouldbe
stored
in
an
upright
position
.

5
.
Remove
valves
using
a
valve
spring
compressor
.

NOTE-

"
The
M44
cylinder
head
has
recessed
valve
stems
.
This
requires
the
use
of
a
special
valve
spring
com-
pressor
tool
.

"
Label
each
valve
assembly
as
it
is
removed
so
it
can
be
installed
in
its
original
position
.

6
.
Remove
and
discard
valve
stem
oil
seals
from
valve
guides
.
See
Valve
stem
oil
seals
later
in
this
section
.

7
.
Valve
installation
is
reverse
of
removal
.

"
Reinstall
exhaust
manifold(s)
with
new
gaskets
.
Use
Molycote
HSC'
5
or
equivalent
anti-seize
thread
com-
pound
on
fasteners
.

Tightening
Torque

"
Exhaust
manifold
to
cylinder
head
M7
............
..
...
....
.
...
..
20
Nm
(15
ft-Ib)

FUEL
INJECTION



130-
3

Fuel
metering
.
The
ECM
meters
fuel
bychanging
the



The
engine
management
system
compensates
automatical-
opening
time
(pulsewidth)
of
the
fuel
injectors
.
To
ensure
that



ly
for
changes
in
the
engine
due
to
age,
minor
wear
or
small
injector
pulsewídth
is
the
only
factor
that
determines
fuel
me-



problems,
such
as
a
disconnected
vacuum
hose
.
Asa
result,
tering,fuel
pressure
is
maintained
bya
fuel
pressure
regula-



idle
speed
and
mixture
do
not
need
lo
be
adjustedas
partof
tor
.
The
injectors
are
mounted
lo
a
common
fuel
supply
called



routine
maintenance
.
the
fuel
rail
.

The
ECM
monitors
engine
speed
to
determine
the
duration



NOTE-

ofinjector
openings
.
Other
signals
to
the
ECM
help
determine



Poordriveabilitymaybe
encountered
when
the
batteryis

injector
pulse
time
for
different
operating
conditions
.
A
tem-



disconnected
and
reconnected
.
when
the
battery
is
dis-
connected,
the
adaptive
memory
is
lost
The
system
will
perature
sensor
signals
engine
temperature
for
mixture
adap-



readaptafterabout
ten
minutes
of
drfving
.
tion
.
A
throttle
position
sensor
signals
throttle
position
.
The
exhaust
oxygen
sensor(s)
signal
information
about
combus-
tion
efficiency
for
control
of
the
air-fuel
mixture
.
1992
to
1995



DISA
(Dual
Resonance
Intake
System)
engines
are
equipped
with
a
single
sensor
.
1996
and
later
(OBD
II)
engines
are
equipped
with
an
oxygen
sensor
before



TheE36
4-cylinder
engine
is
equipped
with
a
dual
intake
andone
after
each
catalytic
converter
.
Forexample,the
M52



runner
system,
termed
DISA
.
DISA
offers
the
advantages
of
engine
is
equipped
withfour
oxygen
sensors
.



both
short
and
long
intake
pipes
.
Long
intake
runners
are
most
useful
at
low
to
medium
engine
rpm
for
producing
good
Idle
speed
control
.
ldle
speed
is
electronically
controlled



torque
characteristics
.
Short
intake
runners
produce
hígherviathe
idle
speed
control
valve,
which
maintains
idle
speed
by



horsepower
at
hígher
engine
speeds
.
bypassing
varying
amounts
of
air
around
theclosed
throttle
valve
.
Idle
speed
is
not
adjustable
.



NOTE-

Knock
(detonation)
control
.
Knock
sensors
monitor
and



The
term
DISA
comes
from
the
German
words
Differen-

control
ignition
knock
through
the
ECM
.
The
knock
sensors



zierte
Sauganlage,
and
can
roughlybe
translated
as
"dif-
fering
intake
manifold
configuration
."
See
100
Engine-
function
like
microphones
and
are
able
to
convert
mechanical



General
foradditional
information
on
DISA
operation
.
vibration
(knock)
into
electrical
signals
.
The
ECM
is
pro-

grammed
to
react
to
frequencies
that
are
characteristic
of
en-



Manifold
construction
:
The
intake
manifold
is
a
two-piece
gine
knock
and
adapt
the
ignition
timing
point
accordingly
.



metal
construction,
with
a
pair
of
runners
in
thetop
section
See120
Ignition
System
for
further
details
.



and
four
runners
in
the
lower
section
.
A
butterfly
valve
is
in-
stalled
in
the
lower
section,
enabling
the
DISA
solenoid
toiso-

NOTE-



late
one
pair
of
runners
from
the
other
pair
.
See
Fig
.
2
.

The
1992
M50
engine
is
not
equipped
with
knock
sen-



Operation
.
With
the
DISA
butterfly
valve
closed,
the
pipes
sors
.
All
other
engines
are
equipped
with
two
knock



in
thetop
half
of
the
manifold
act
together
with
the
ram
air
sensors
.



pipes
in
the
lower
halfto
producea
single,
long
air
intake
pipe
for
each
cylinder
.
See
Fig
.
3
.
The
column
of
aír
oscíllating
in

Basic
Engine
Settings



this
combined
pipe
significantly
increases
engine
torque
in
the

medium
rpm
range
.

Idle
speed,
idle
mixture
(%CO),
and
ignition
timing
arenot

adjustable
.
The
adaptive
engine
management
system
is
de-

signed
to
automatically
compensate
for
changes
in
engine
op-

eratingconditions,
although
the
adaptive
range
is
limited
.
Once

these
limits
are
exceeded,
driveability
problems
usually
be-

come
noticeable
.

Above
approximately
4,800
rpm,
the
butterfly
valve
between
the
intake
air
pipes
for
the
two
cylinder
groups
is
opened
.
The
shorter
pipes
in
the
lower
manifold
section
now
become
the

main
suppliers
of
ram
air
to
the
cylinders,yielding
greater
pow-

er
at
the
upper
end
of
the
engine
rpm
range
.
See
Fig
.
4
.

Control
components
.
The
DISA
butterfly
valve
is
actuated

NOTE-



electro-pneumatically
via
the
engine
control
module
(ECM)
.

lf
the
system
adaptive
limits
are
exceeded,
the
Check



The
valve
begins
to
open
as
engine
speed
rises
aboye
4,840

Engine
light
will
most
likely
come
on,
indicating
an



rpmand
closes
below
4,760
rpm
.
The
action
of
the
valve
is
de-
emissions-
related
fault
For
Check
Engine
light
diag-



liberately
delayed
to
prevent
it
from
opening
and
closing
repeat-
nostics,
see100
Engine-General
.



edly
within
a
short
time
.

GENERAL

The
fuel
injection
systems
used
on
the
1996
and
later
cars
covered
bythis
manual
are
OBD
II
compliant
.
This
system
is
in-
corporated
into
both
the
Bosch
M5
.2
(M44
engine)
and
the
Si-
emens
MS
41
.1
(M52/S52US
engine)
engine
management
systems
.
OBD
II
systems
use
sophisticateddiagnostic
soft-
ware
capable
of
recognizing
and
electronically
storing
hun-
dreds
of
DTCs
in
the
system
ECM
.
DTCs
can
only
be
accessed
using
special
scan
tooltest
equipment
.
The
BMW
dealer
is
equipped
with
the
specialized
OBD
II
scan
toolto
quickly
and
efficiently
locate
engine
management
problems
.
Alternately,
a
"generic"
scan
tool
can
be
used
to
access
OBD
II
fault
informa-
tion
.

NOTE-

"
At
the
time
this
manual
went
to
press,
generic
scan
tools
were
notwidely
available
for
BMW
vehicles
.
The
generic
sean
tool
is
a
specialized
toolthat
plugs
into
a
standardized
OBD
11
connector
on
1996
and
later
pas-senger
vehícles
built
for
sale
in
the
US
.

"
The
OBD
11
fault
memory
(including
an
illuminated
Check
Engine
light)
can
only
be
reset
using
the
spe-
cial
scan
tool
.
Removing
the
connector
trom
the
ECM
or
disconnecting
the
battery
will
not
erase
the
fault
memory
.

"
The
16-pin
OBD
11
diagnostic
connector
is
located
on
the
lower
left
dash
panel
.
Refer
to
Fig
.
1
.

6

1
.
Secondary
air
pump
2
.
Electric
solenoid
valve
3
.
One-way
check
valve
4
.
Intake
manifold
5
.
Exhaust
manifolds
6
.
Secondary
air
check-valve

®
G~



i

o
o



0
0
G
0000
o



,-
00

~

1111111
in

,,
0
1--

a

Fig
.
5
.



Components
of
6-cylinder
secondary
air
injection
system
.
4-
cylinder
system
is
similar
.

Secondary
AirInjection

FUEL
INJECTION



130-
5

All
OBD
II
6-cylinder
engines
are
equípped
with
asecond-
ary
air
injection
system
.
In
addition,
beginning
in
January
1997,
the
M44
engine
was
classified
as
a
TLEV
(Transitional
Low
Emission
Vehicle)
engine
and
is
also
equipped
with
sec-
ondary
air
injection
.

Typical
components
of
the
secondary
air
injection
system

are
depicted
in
Fig
.
5
.

Secondary
air
injection
usesan
electric
pump
to
pump
fresh
air
finto
the
exhaust
systemupstream
of
the
catalytic
converter
during
engine
warm-up
.
By
providing
extra
oxygen
to
the
un-
burned
fuel
in
the
exhaust,
hydrocarbons
oxidize
and
carbon

monoxide
combines
with
oxygen
to
form
carbon
dioxide
andwa-
ter
.
The
air
injection
pump
stops
within
a
specified
timed
intenral
.

4

0013120

GENERAL

130-
8



FUEL
INJECTION

Fig
.
8
.



Fuel
pump
relayterminal
identification
.
1.
Peel
back
rubber
boot
on
oxygen
sensor
electrical
har-
ness
connector
(car
wiring
side)
.
With
connector
at-
Oxygen
sensor,
testing



tached
to
sensor,
connect
digital
voltmeter
to
pins
1
(BOSch
systems
only)



and
2
in
rear
of
connector
.
See
Fig
.
10
.

CAUTION-

"
The
information
inthis
sectionapplies
to
Bosch
engine
management
systems
only
.

"
The
Siemens
MS
41
.1
system
uses
resistive-type
oxygen
sensors
.
This
sensor
uses
a
5-volt
refer-
ence
signal
input
and
the
output
to
the
ECM
var-
ees
from
1-5
volts,
in
stepped
increments
based
on
oxygen
content
in
the
exhaust
.

NOTE-

"
On
pre-08D
11(1992-1995)
cars,
there
is
one
oxygen
sensor
mounted
upstream
of
the
catalytic
convert-
er(s)
in
the
exhaust
pipe
.
See
Fig
.
9
.
"
On
OBD
11
cars
(1996-1998)
cars,
there
is
one
oxygen
sensor
before
andone
after
each
catalytic
converter
.

"
OnM52
and
S52US
engines,
the
front
pairof
oxygen
sensors
are
installed
in
the
exhaust
manifolds
.

The
oxygen
sensor
providesan
input
voltage
signal
(0-1
VDC)
to
the
ECM
based
on
the
oxygen
content
in
the
exhaust
gas
.
TO
generate
voltage,
the
sensor
temperature
must
exceed
575°F
(300°C)
.
Therefore
it
ís
electrically
heated
.

NOTE-

"
The
test
given
below
is
not
a
conclusive
test
of
oxygen
sensor
efficiency
and
does
not
test
how
quickly
the
oxygensensor
can
react
to
changing
conditions
.

"
Pin
numbers
and
wirecolors
can
vary
.
Always
check
the
wiring
diagrams
to
conflrm
wire
color
and
pinas-
signment
.

ELECTRICAL
CHECKS
AND
COMPONENT
TESTING

0013135

Fig
.
9
.



Oxygen
sensor
location
(arrow)
ahead
of
catalytic
converter
.
3181
model
with
M42
engine
shown
.

1
.
Black
(ground)
2
.
Grey
(signal)



4
.
White
(heater
circuit)
3
.
White
(heater
circuit)

0013189
Fig
.
10
.
Oxygen
sensor
connector
terminal
identification
(sensor
sede)
.
Terminals
numbers
are
molded
into
connector
.

2
.
Start
engine
.
Oxygen
sensorshould
start
to
output
a
fluctuating
voltage
within
a
short
period
.
If
voltage
is
in-
correct,
turn
engine
off
and
check
preheater
circuit
as
described
below
.

WARNING
-

Exhaust
manifolds
and
pipes
can
be
hot
enough
to
cause
serious
burns
.
Wear
suitable
heavy
gloves
and
other
appropriate
protection
.

GENERAL
.
.
.......
.
......
.
...
.
.
.
.
.
...
180-1



Exhaust
system,
removing
and
installing
.
...
.180-3

EXHAUST
SYSTEM
REPLACEMENT
.
...
180-1



Exhaust
manifolds,
removing
and
installing
.
.
.180-5

GENERAL

The
exhaust
system
is
designed
to
be
maintenance
free,
al-
though
regular
inspection
is
warranted
due
to
the
harsh
oper-
atingconditions
.
Under
normal
conditions,
the
catalytic

converter
does
not
require
replacement
unless
it
is
damaged
.

On
1996
and
later
cars,
a
pre-
and
post-catalytic
converter

oxygen
sensor
is
used
at
each
catalytic
converter
.
Be
sure
to

take
care
when
removingthe
system
not
to
damage
the
sen-



EXHAUST
SYSTEMREPLACEMENT
sors
.

See
130
Fuel
Injection
for
information
on
testing
oxygen

sensors
.

NOTE-

OnM52
engines,
two
resonator
pípes
(short
and
long)
are
incorporated
into
the
rear
muffler
assembly
.
See
Fíg
.
1
.
An
exhaust
flap
is
integrated
into
the
outlet
side
of
the
short
pipe
.
The
flap
is
operated
by
a
vacuum
ac-
tuator
via
the
Siemens
MS
41
.1
engine
control
mod-
ule)
.
The
flap
is
closed
at
engine
speeds
below
2,500
rpm
.
This
allows
exhaust
gasses
to
flow
through
the
long
resonator
pipe
and
reduce
noise
.
Above
2,500rpm,
the
exhaust
flap
is
open
(no
vacuum
applied
to
the
actuator)
and
allows
exhaust
gasses
to
flow
through
the
short
pipe
for
maximum
performance
.

180
Exhaust
System

0013101

Fig
.
1
.



Rear
muffler
(active
silencer
usedon
M52
engines)
.
Vacuum

operated
flap
(A)
changesbetween
short
and
long
pipes,
de-

pending
on
engine
speed
.

EXHAUST
SYSTEM



180-1

WARNING
-

Exhaust
gases
are
colorless,
odorless,
and
very
toxic
.
Run
the
engine
only
ín
a
well-ventilated
area
.
Immediately
repair
any
leaks
in
the
exhaust
system
or
structural
damage
to
the
car
body
that
might
al-
lowexhaust
gases
to
enter
the
passenger
compart-
ment
.

Exhaustsystem
components
are
detailed
in
Fig
.
2
through

Fig
.
4
.

New
fasteners,
clamps,rubber
mounts,
and
gaskets
should

be
used
when
replacing
exhaust
components
.
A
liberal
appli-
cationof
penetrating
oil
to
the
exhaustsystem
nuts
and
bolts
in
advance
may
make
removal
easier
.

WARNING
-

"
The
exhaust
system
and
catalytic
converter
op-
erate
at
high
temperatures
.
Allow
components
to
cool
before
servicing
.
Wear
protectíve
clothíng
to
prevent
bums
.
Do
not
use
flammable
chemicals
near
a
hot
catalytic
converter
.

"
Old,
corroded
exhaust
system
components
crumble
easíly
and
often
have
exposed
sharp
edges
.
To
avoid
injury,
wear
eye
protection
and
heavy
gloves
when
working
with
old
exhaust
parts
.

EXHAUST
SYSTEM
REPLACEMENT

T

180-2



EXHAUST
SYSTEM

a

EXHAUST
SYSTEM
REPLACEMENT

Fig
.
2
.



Exhaust
systemon
1992-1995
6-cylinder
engines
.
3251
(M50)
exhaust
system
shown
.

E~

)l-,malo
m~=

i

32592-95

1
.



Front
pipe
with
catalytic
convertor



6
.



Bracket



11
.



Bracket/clamp
(2)



16
.



Rear
pipewith
muffler
2
.



Gasket
(2)



7
.



Bracket
(2)



12
.



Rubber
mounting
ring
(2)



17
.



Rubber
mount
3
.



Exhaust
manifold



8
.



Bracket



13
.



Flange



18
.



Support4
.



Exhaust
manifold



9
.



Bracket



14
.



Gasket
(48mm)



19
.



Bracket
5
.
Manifold
gasket



10
.
Oxygen
sensor



15
.
Gasket
(48mm)

eme°"



k
:I>
-
8a

1
.



Exhaust
manifold



7
.



Front
pipe
with
catalytic
con-



9
.



Bolt
(M8X90)



14
.



Brackets
(rear
muffier)
2
.



Nut
(M10)



vertor



10
.



Compression
spring



15
.



Rear
muffler
and
pipe
3
.
Gasket
(clty
.
2)



8
.



Oxygen
sensor
(regulating)



11
.



Self-lockingnut
(M8



16
.



Bracket
(transmission)
4
.
Gasket



-tightento
55
Nm
(41
ft-Ib)



-always
replace



17
.



Brackets
(transmission)
5
.



Nut



8a
.



Oxygen
sensor
(monitoring)



12
.



Bracket
(rear
pipe)
6
.



Bolt
(M8X55)



-tightento
55
Nm
(41
ft-Ib)



13
.



Rubber
mounting
ring
(9ty
2)

Fig
.
3
.



Exhaust
systemon
1996-1998
4-cylinder
(M44)
engine
.1992-1995
4-cylinder
engine
exhaust
system
is
similar
.

1
.



Gaskets



5
.



Front
pipe
with
catalytic
con-



8
.



Flange
2
.



Exhaust
manifold



verter



9
.



Bolt
(M8x55)

3
.
Exhaust
manifold



6
.
Oxygen
sensor
(monitoring)



10
.
Rubber
mounting
ring
(48mm)
4
.



Oxygen
sensor
(regulating)



7
.



Nut
(M8)



11
.



Rear
pipewith
mufflers

Fig
.
4
.



Exhaust
systemon
1996-1998
6-cylinder
engines
.
M3
(S50US)
exhaust
system
shown
.

Exhaust
system,
removing
and
installing



NOTE-

The
automatic
transmission
will
be
supported
by
the

This
section
covers
removing
the
exhaust
system
as
a
com-



rear
crossmember
once
the
brace
is
removed
.

plete
unit
.
Once
the
system
is
removed
from
the
car,
individual

pipes
and
mufflers
can
be
more
easily
replaced
.

1.
With
exhaust
system
fully
cold,raise
and
support
car

for
access
to
exhaustsystem
.

WARNING
-

Do
not
work
undera
lifted
car
unless
it
is
solidly

supported
on
jack
stands
designed
for
that
pur-
pose
.
Never
work
under
a
car
that
is
supported
solely
by
a
jack
.

2
.
Disconnect
oxygen
sensor
connector(s)
.

NOTE
-

On
1996
and
later
cars
with
multiple
oxygen
sensors,

label
the
oxygen
sensor
connectorsbefore
disconnect-
ing
.

4
.
Where
applicable,
remove
support
brace
from
trans-

mission
.
See
Fig
.
5
.

EXHAUSTSYSTEM



180-
3

3
.
Loosen
andremove
bolts
holding
front
exhaust
pipes
to

exhaust
manifolds
.



transmission
.
See
Fig
.
6
.

0011940

Fig
.
5
.



Crossbracemounting
bolts
(arrows)
.

5
.
Disconnect
exhaust
support
bracket
assembly
from

6
.
Supportexhaustsystem
from
below
and
dísconnect

rubbersupports/rubber
rings
from
exhaust
system
.
Re-

move
exhaust
system
from
below
.
See
Fig
.
7
.

EXHAUST
SYSTEM
REPLACEMENT

180-
4



EXHAUST
SYSTEM

Fig
.
6
.



Exhaust
system
support
bracket
on
6-cylinder
engine
.
Re-
move
bolts
(arrows)
to
separate
from
exhaust
pipe
.

Fig
.
7
.



Rubber
exhaust
system
hangers
.
Remove
hanger
by
prying
off
bracket
(arrows)
.

EXHAUST
SYSTEM
REPLACEMENT

7
.
Installation
is
reverse
of
removal
.

"
Where
necessary,
transfer
parts
from
old
system
to
re-
placement
system
.

"
Coat
manifold
studs
with
copper
paste
before
installing

nuts
.

"
Where
applicable,
tighten
front
pípewith
semi-flexible

compensator
last
when
installing
front
pipe
to
mani-

folds
.

"
Make
sure
there
is
at
least
20
mm
(
3
/4
in
.)
of
clearance

between
exhaust
systemand
car
body
at
every
point
.
"
Loosely
install
all
exhaust
system
mountinghardware
and
hangers
before
tightening
fasteners
to
their
final
torque
.

"
On
4-cylinder
engines
:
Tighten
center
mounting
flange
nuts
evenly
until
correct
dimension
is
obtained
.
See

Fig
.
8
.

ri

J%JJ

w

~~~JJJJ

1

Fig
.
8
.



On
4-cylinder
engines,
tighten
nuts
evenly
so
that
spríngs
are
preloaded
to
Dimension
A
.

NOTE-

To
prevent
exhaust
system
rattles
and
vibration,
pre-load
the
rear
clamping
brackets
in
the
íonaard
direction
.
See
Fig
.
9
.

0011937

Tightening
Torques

"
Cross
brace
to
chassis



..
.
...
.
..
..
21
Nm
(17
ft-Ib)

"
Exhaust
support
bracket

to
transmission
.
.
.
.
.......
.....,.
21
Nm
(17
ft-Ib)
"
Exhaust
system
mounting
clamps
...
15
Nm
(11
ft-Ib)

"
Front
exhaust
pipeto
exhaust
manifold
M10
nut
.
.
.
...
.
..
..............
30
Nm
(22
ft-Ib)

"
Front
exhaust
pipe
torear
pipe

M8
bolt/nut
..
....
.
..............
22
Nm
(16
ft-Ib)
with
compression
spring
................
See
Fig
.
8
"
Oxygen
sensor
to
exhaust
pipe
.....
55
Nm
(41
ft-Ib)

Dimension
A=15mm
(0
.60
in
.)

Fig
.
9
.



Preload
rear
clamping
bracket
as
specifíed
tohelp
prevent
system
rattling
.

Exhaust
manifolds,
removing
and

installing

WARNING
-

Do
not
work
under
a
lifted
car
unfess
itis
solidly
supportedonjackstands
designed
for
that
pur-
pose
.
Never
work
underacar
that
is
supported
solely
by
ajack
.

EXHAUST
SYSTEM



180-
5

2
.
On
1996
and
later
6-cylinder
engines,
disconnect
the
secondary
air
check
valve
and
eipe
from
the
exhaust
manifold
.

3
.
Unbolt
front
exhaust
pipe(s)
from
exhaust
manifold(s)
.

4
.
Remove
exhaustsupport
bracket
from
transmission
.

5
.
Loosen
andremove
nuts
fromexhaust
manifolds
and
remove
manifolds
.
Discard
nuts
and
gaskets
.

NOTE-

On
cars
wíth
oxygen
sensors
mounted
in
the
exhaust
manifolds,
usecare
when
removing
manifolds
.
Tobe
safe,
remove
the
sensors
from
the
manifolds
before
re-
moving
manifolds
.

6
.
Installation
is
reverse
of
removal
.

"
Coatexhaust
manifold
mounting
studs
with
copper
paste
before
installing
new
nuts
.
"
Insta¡¡
manifold
gaskets
with
arched
side
facing
mani-
folds
.

Always
use
new
retaining
nuts
and
gaskets
when
removing



Tightening
Torques

and
installing
the
exhaust
manifolds
.



"
Exhaust
manifold
to
cylinder
head

4-cylinder
engine
(M7
nut)
........
15
Nm
(11
ft-Ib)

1
.
With
exhaust
system
cold,raise
and
support
car
for
ac-



6-cylinder
engine
(M7
nut)
........
20
Nm
(15
ft-Ib)
cess
lo
exhaust
system
.

EXHAUST
SYSTEM
REPLACEMENT

Tablea
.
E36
Component
Locations

Component



Model
Year



Location



Refer
to
Engine
Compartment
Light
Switch



1993-1996



Over
right
headlight
assembly



Fig
.
7
.

Engine
Control
Module
(ECM)



1992-1998



Right
rear
enginecompartment,
behind
bulkhead
panel



Fig
.
7
.

Engine
Control
Module
(System)



1992-1998



I
Power
distribution
box



Fig
.
2
.
Relay
Engine
Coolant
Leve¡
Sensor



1
1992-1998



1
Left
front
of
enginecompartment,
radiator
coolant
reservoir

Engine
Coolant
Temperature



1992-1998



I
Left
front
of
engine
under
intake
manifold



I



Fig
.
19
.
Sensor



Fig
.
20
.

Evaporative
Emission
Valve



1992-1998



Left
side
strut
Power
area

Evaporator
Temperature
Sensor



1992-1998



Left
side
of
heater
box

EWS
II
Control
Module



1/1995
-
1998



Behind
glove
compartment



Fig
.
8
.
Fig
.
9
.

EWS
II
Ring
Antenna



1
1/1995
-
1998
1
At
ignition
cylinder

EWS
II
Transmitter
Module



1/1995
-
1998



Right
side
of
steering
column
in
auxiliaryrelay
panel



Fig
.
3
.

Exhaust
Gas
Flap
Valve



1996-1998



Left
rear
muffler
area

Flasher
Relay



1992-1998



Power
distribution
box



Fig
.
2
.

Foglight
Relay



1



1992-1998



1
Power
distribution
box



1



Fig
.
2
.

Fresh
Air
FlapActuator



1



1992



1
Right
side
of
heater
box

Fresh
Air
FlapActuator



1
1993-1995



1
Below
right
side
heater
box

Fresh
Air
FlapActuator



1
1996-1998



Below
left
side
heater
box

Fuel
Injectors



1992
-
1998



Top
left
side
of
engine

Fuel
Leve¡
Sensor,
Left



1
1992-1998



/
Under
left
side
of
rear
seat
infuel
tank

Fuel
Leve¡
Sensor,
Right



1



1992-1998



1
Under
right
side
of
rear
seat
in
fuel
tank



1



Fig
.
28
.

Fuel
Pump



1



1992-1998



1



Under
right
side
of
rear
seat
in
fuel
tank



1



Fig
.
28
.

Fuel
Pump
Relay



1



1992-1998



1
Power
distribution
box



1



Fig
.
2
.

Fuel
Pump/Start
Identification
Relay



1994
-
1996



Power
distribution
box

Fuel
Tank
Pressure
Sensor



1
1997-1998



1
Right
rear
wheel
well
behind
trim
liner

ELECTRICAL
COMPONENT
LOCATIONS



610-13

Fuse
andRelay



x(Power



11992-1998



I
Left
side
of
engine
compartment



I



Fig
.
2
.
Distribution
Box



Fig
.
7
Fig
.
10
.

Gas
Filler
LockMotor



1992-1998



Right
side
of
luggage
compartment

Gear
Position/Neutral
Safety
Switch



1992-1998



Next
to
gear
shift
lever
in
center
console



Fig
.
29
.
(Automatic
Transmission
Range
Switch)

Glove
Compartment
Lock
Motor



1994-1998



Behind
glove
compartment

Grounds

G
100



1995-1998



Front
of
left
front
fender
(headlights)



Fig
.
22
.

G
101



1992-1998



Front
of
right
front
fender

Continued

COMPONENT
LOCATIONS