fuel cap BMW 318i 1997 E36 Workshop Manual

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

010-2



FUNDAMENTALS
FOR
THE
DO-ITYOURSELF
OWNER

HOW
TO
USE
THIS
MANUAL

A
note
contains
helpfulinformation,
tipsthat
will
hefp
in
The
manual
is
divided
into
ninesections
:



doinga
better
job
and
completing
!t
more
easíly
.

0
GENERAL
DATA
AND
MAINTENANCE

1
ENGINE

2
TRANSMISSION

3
SUSPENSION,
STEERING
AND
BRAKES

4
BODY

5
BODY
EQUIPMENT

6
ELECTRICAL
SYSTEM

7
EQUIPMENTANDACCESSORIES

ELECTRICAL
WIRING
DIAGRAMS

0
GENERAL
DATA
AND
MAINTENANCE
coversthe
rec-

ommended
maintenance
schedules
and
service
procedures

needed
to
perform
BMW
scheduled
maintenance
work
.
Also

within
this
section
is
the
010
Fundamentals
for
the
Do-It-

Yourself
Owner
section,
which
contains
basic
instructions,
tips
and
helpful
hints
for
do-it-yourself
maintenance
and
repair
.

The
next
seven
sections
(1
through
7)
are
repair
based
and

are
further
broken
down
into
three
digit
repair
groups
.
Each
ma-

jor
section
begins
with
a
General
repair
group,
e
.g
.
100En-

gine-General
.
These
"00"
(doublezero)
groups
aremostly

descriptive
in
nature,
covering
topics
suchas
theory
of
opera-
tion
and
troubleshooting
.
The
remainder
of
the
repair
groups

contain
the
more
involved
repair
information
.
The
last
major

section
contains
detailed
electrical
wiring
diagram
schematics
.

A
master
listing
of
the
9major
sections
and
the
correspond-
ing
individual
repair
groups
can
befoundon
the
inside
front
cover
.

Each
repair
group
begins
with
a
Table
of
Contents
listing
the

majos
subject
headings
within
the
group
.
Page
numbers

throughout
the
manual
are
organizedaccording
to
the
repair
groupsystem
.
For
example,
youcan
expect
tofind
repair
infor-
mation
on
brakes
(Repair
Group
340)
beginning
on
page
340-
1
.
A
comprehensive
index
can
be
found
at
the
back
of
the
man-

ual
.

Warnings,
Cautions
and
Notes
Throughout
this
manualare
many
passages
with
the
head-
ings
WARNING,
CAUTION,
or
NOTE
.
These
very
important
headings
have
diflerent
meanings
.

WARNING
-

The
text
under
this
heading
warns
of
unsafe
practic-
es
thatare
very
likelyto
cause
ínjury,
eitherby
dírect
threat
to
the
person(s)
pertorming
the
work
or
by
in-
creased
risk
of
accident
or
mechanfcal
fallure
whíle
driving
.

CAUTION-

A
caution
calls
attention
to
important
precautions
to
beobserved
during
the
repair
work
that
will
helo
prevent
accidentally
damaging
the
caror
its
parts
.

GETTING
STARTED

Safety

NOTE-

Please
read
every
WARNING,
CAUTION,
and
NOTE
at
the

front
of
the
manual
and
as
they
appear
in
repair
procedures
.

They
are
very
important
.
Read
them
before
you
begin
any

maintenance
or
repair
job
.

Some
WARNINGs
and
CAUTIONs
are
repeated
wherever

they
apply
.
Read
them
all
.
Do
not
skip
any
.
These
messages
are
important,
even
to
the
owner
who
never
intends
to
workon

thecar
.

GETTING
STARTED

Most
of
the
necessary
maintenance
and
minor
repair
that
an

automobile
will
need
canbe
done
with
ordinary
tools,
evenby

owners
with
little
or
no
experience
in
car
repair
.
Below
is
some

important
information
on
how
to
work
safely,
a
discussion
of

what
tools
will
be
needed
and
how
to
use
them
.

Although
an
automobile
presents
many
hazards,
common

sense
and
good
equipment
can
helo
ensure
safety
.
Many
acci-

dents
happen
because
of
carelessness
.
Pay
attention
and
stick
to
these
few
important
safety
rules
.

WARNING
-

"
Never
run
the
engine
in
the
work
area
unless
it
is
well-ventflated
.
Theexhaustshouldbe
vented
to
the
outside
.
Carbon
monoxide
(CO)
in
theex-
haust
kilts
.

"
Remove
all
neckties,
scarts,
loose
clothing,
or
jewelry
when
working
near
running
engines
or
power
tools
.
Tuck
in
shirts
.
Tie
long
haír
and
se-
cure
it
under
a
cap
.
Severe
injury
can
result
from
these
things
beíngcaught
in
rotating
parts
.

"
Remove
ríngs,
watches,
and
bracelets
.
Asíde
from
the
dangersof
moving
parts,
metallic
jew-
elry
conducts
electricity
and
may
cause
shorts,
sparks,
bums,
or
damage
to
the
electrical
sys-
tem
when
accidentally
contacting
the
battery
or
other
electrical
terminals
.

"
Disconnect
the
battery
negative
()
cable
when-
ever
working
on
ornear
the
fuel
system
or
any-
thlng
that
is
electrically
powered
.
Accidental
electrícal
contact
may
damage
the
electrical
system
or
cause
a
fire
.

010-10



FUNDAMENTALS
FOR
THE
DO-IT
YOURSELF
OWNER

TOOLS

Torque
Wrench

B021FNG

Fig
.
12
.
Jack
stand
for
safely
supporting
car
to
work
underneath
.

B022FNG

Fig
.
13
.
Oil
change
equipment
includesdrainplug
wrench
(17mm),
8
qt
.
drain
pan,
and
funnel
.

A
torque
wrench
is
used
to
precisely
tighten
threaded
fasten-



Fig
.
15
.
Feeler
gauge
set
.
ers
to
a
predetermined
value
.
Many
of
the
repair
procedures
in
this
manual
include
BMW-specified
torquevalues
in
Newton-
meters
(Nm)
and
the
equivalent
values
in
foot-pounds
(ft-Ib)
.



Digital
Multimeter

A
torque
wrench
with
a
range
up
to
about
150
Nm
(185
ft-lb)
has
adequate
capacity
for
most
of
the
repairs
covered
in
this
manual
.
For
recommended
torque
values
of
10
Nm
or
below,the
English
system
equivalent
is
given
in
inch-pounds
(in-lb)
.
These
small
values
may
be
most
easily
reached
using
a
torque
wrench
calibrated
in
inch-pounds
.
To
convert
inch-pounds
to
foot-pounds,
divide
by12
.

Fig
.
14
.
Torque
wrenches
.
Inexpensive
beam-type
(top)
is
adequate
but
must
be
read
visually
.
Ratchet-type
(bottom)
can
be
pre-
set
to
índicate
(click)
when
torquevalue
has
been
reached
.

Feeler
Gauges

B018FNG

Feeler
gauges
are
thin
metal
strips
of
precise
thickness,

used
to
measure
small
clearances
.
They
are
normally
available

as
a
set,
covering
a
range
of
sizes
.
See
Fig
.
15
.

Several
types
of
torque
wrenches
are
available
.
They
al¡
do



Many
of
the
electrical
tests
in
Chis
manual
cal¡
for
the
mea-
the
same
job,
bu¡
óffer
different
convenience
features
at
differ-



surement
of
resistance
(ohms)
or
voltage
values
.
For
safe
and
ent
prices
.
Two
typical
torque
wrenches
are
shown
in
Fig
.
14
.



accurate
tests
of
ignition,
fuel
injection,
and
emission
control
The
most
convenient
ones
have
a
built-in
ratchet,
and
can
be



systems,
the
multi-meter,
shown
in
Fig
.
16,
should
be
digital,
preset
to
indicate
when
a
specific
torque
value
has
been



with
high
(at
least
10,000
ohms)
input
impedance
.
Some
reached
.
Followthe
wrench
manufacturer's
directions
for
use



meters
have
automotive
functions
suchas
dweil
and
pulse
to
achieve
the
greatest
accuracy
.



width
that
are
useful
fortroubleshooting
ignition
and
fuel
injec-
tion
problems
.

CAUTION-

The
DME
system,
central
body
electronics,
and
other
electronic
systems
may
be
damaged
by
the
high
current
draw
of
a
test
fight
with
a
normal
in-
candescent
bulb
.
As
a
general
rule,
usea
high
ím-
pedance
digital
multimeter
or
an
LED
test
fightforall
electrfcal
testfng
.

B020FNG

Fig
.
16
.
Multimeter
or
Digital
Volt/Ohmmeter
(DVOM)
.

BMW
Special
Tools

FUNDAMENTALS
FOR
THE
DO-ITYOURSELF
OWNER
010-11

0012223

Some
of
the
more
challenging
repairs
covered
in
this
manual

cal¡
for
the
use
of
BMW
special
tools
.
This,
however,
does
not

automatically
mean
that
thejob
is
too
complicated
or
out
of

reach
of
thenovice
.

Many
of
the
BMW
special
tools
mentioned
in
this
manual
are
simplythe
best
thing
to
use
to
do
thejob
correctly
.
In
these
cas-

es,
the
tool
is
identified
with
a
BMW
part
number
.
See
your
au-

thorized
BMW
dealer
parts
department
for
information
on
how

to
order
special
tools
.

There
are
some
jobs
for
which
expensive
special
tools
are

essential,
and
not
a
cost-effective
purchase
for
one-time
repair

by
the
do-it-yourself
owner
.
This
manual
includes
such
repairs

for
the
benefit
of
these
with
the
necessary
experience
and
ac-

cess
to
tools
.
For
the
do-it-yourselfer,
the
need
for
special
tools

is
noted
in
the
text,
and
whether
or
not
BMW
dealer
service
is

recommended
.

EMERGENCIES

Changing
a
Tire

Stop
thecar
onas
flat
a
surface
as
possible,
in
a
place
where

you
canbe
easily
seen
by
other
drivers
.
Avoid
stopping
just

over
the
crest
of
a
hill
.
Turnon
the
emergency
flashers,
and
set

out
(lares
or
emergency
markers
well
behindthecar
.
Chock
the

wheel
(wheel
chock
located
in
trunk)
diagonally
opposite
to
the
one
being
changed
.
Passengers
shouldgetout
of
thecar
and

stand
well
away
from
the
road
.
Remove
the
spare
tire
from
the
spare
tire
storage
tray,
as
described
later
.

WARNING
-

If
a
tire
goes
fíat
while
drtving,
pull
well
off
the
road
.
Changing
a
tire
ona
busy
street
or
highway
is
very
dangerous
.
If
necessary,
drive
a
short
distance
on
the
fíat
tire
to
get
to
a
sale
place
.
tt
is
much
better
to
ruin
a
tire
or
rim
than
to
risk
being
hit
.

Take
the
jack
and
tools
from
the
tool
area
beneath
the
trunk

mat
.
Remove
the
spare
tire
from
the
tire
storage
tray
.

Loosen
the
wheel
bolts
while
the
car
is
on
the
ground,
but

leave
them
a
little
snug
.
Placethe
jack
in
the
lifting
point
nearest

the
wheel
beingchanged,
lifting
points
are
shown
in
Fig
.
1
and

Fig
.
2)
.
Use
a
board
to
provide
a
firm
footing
for
the
jack
if
the

ground
is
soft
.
Raise
the
car
only
lar
enough
so
that
the
wheel
is

fully
off
the
ground
and
then
remove
the
wheel
nuts
and
the

wheel
.

Insta¡¡
the
spare
wheel
.
Install
the
wheel
nuts
and
tighten

them
by
hand,
then
lower
the
car
.
With
all
wheelson
the

ground,
fully
tighten
the
nuts
in
a
crisscross
pattern
.
Torque
the

wheel
nuts
when
installing
the
wheel
.
Check
the
inflation
pres-

sure
of
the
spare
tire
.

Tightening
torques

"
Wheel
to
wheel
hub
.....
100
t
10
Nm
(74
t
7
ft-Ib)

Car
Will
Not
Start

If
the
engine
tucos
over
slowly
or
not
at
all,
especially
on
cold

mornings,
the
battery
may
not
be
sufficiently
charged
.
Jump-

starting
the
battery
from
another
car
may
help
.

WARNING
-

On
carswith
manual
transmisston,
push
starting
(or

tow
starting)
acar
ts
not
recommended
by
BMW
.

NOTE-

Be
sure
to
read
the
cautions
underJump
Starting
Car
prior
boosting
a
low
battery
.
Fatlure
to
followthe
cau-

tions
may
result
in
damage
to
the
electronic
compo-
nents
in
the
car
.

If
the
engine
is
turning
over
at
normal
speed
with
the
starter

motor,
the
battery
and
starter
are
fine
.
Check
to
make
sure
that

there
is
fuel
in
the
tank
.
Do
not
rely
on
the
fuel
gauge,
it
may
be

faulty
.
Instead,
remove
the
gas
filler
cap
and
rock
thecar
.
If

there
is
gas
in
the
tank,
you
should
hear
a
sloshing
sound
at
the

filler
neck
.
lf
there
is
plenty
offuel
in
the
tank,
see100
Engine-

General
for
in-depth
diagnostics
and
troubleshootingproce-

dures
.

EMERGENCIES

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

020-
1
2



MAINTENANCE
PROGRAM

6-cylinder
engines
use
a
coil-on-plug
configuration,
and
re-



Battery
cablesshould
be
tight
.
The
terminals,
the
cable
moval
of
thetop
engine
cover
(between
the
camshafts)
and
ig-



clamps,
and
the
battery
case
should
be
freeof
the
white
deposits
nition
cofs
are
necessary
.
See
Fig
.
12
.
Blow
away
any
dust
or



that
indicate
corrosion
and
acid
salts
.
Even
a
thin
¡ayer
of
dust
dirt
around
the
ignition
coils,
and
then
remove
the
coils
.
Blow



containing
conductive
acid
salts
can
cause
battery
discharge
.
away
any
dustor
dirt
around
the
sparkplugs
.
Remove
the
spark

plugs
.



To
remove
battery
corrosion,
begin
by
disconnecting
theca-

bles
.
Disconnect
the
negative
(-)
cable
first
.
Clean
the
terminal

posts
and
the
cable
clamps
with
a
wire
brush
.
Clean
the
main
chassis
ground
terminal
next
to
the
battery
.
Corrosion
can
be
washedaway
with
a
baking
soda
and
water
solution
that
will
neutralize
the
acid
.
Apply
the
solution
carefully,
though,since
ít
will
also
neutralize
the
acid
inside
the
battery
.
Reconnect
the
ca-
ble
clamps,
positive
(+)
cable
first
.
Lightly
coat
the
outside
of
the

terminals,
hold
down
screws,
and
clamps
with
petroleum
jelly,
grease,
or
a
commercial
battery
terminal
corrosion
inhibitor
.

Fig
.
12
.
Ignition
coil
being
removed
from
spark
plug
on
M52
engine
.

NOTE-

If
necessary,
see
120
Ignition
System
for
more
details
on
coil
removal
.

B11004

Lightlylubricate
the
new
spark
plug
threads
with
a
small
amount
of
anti-seize
compound
.
Thread
the
plugs
into
the
cyl-
inder
head
byhand
to
prevent
cross-threading
.

Tightening
Torque

"
Spark
plug
to
cylinder
head
.......
25
Nm
(18
ft-ib)

Idie
Speed

Engine
¡dle
speed
canchange
due
to
a
number
of
factors,
in-
cluding
normal
wear
.
The
idle
speed
is
electronically
adaptive
and
non-adjustable
.
See
130
Fuel
Injection
for
more
information
.

Battery,
checking
and
cleaning

The
battery
is
located
in
the
right
side
of
the
luggage
com-
partment
.
Simple
maintenance
of
the
battery
and
its
terminal
connections
will
ensure
maximum
starting
performance,
espe-
cially
in
winter
when
colder
temperaturesreduce
battery
power
.

ENGINE
COMPARTMENT
MAINTENANCE

WARNING
-

"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnection
cautions
given
at
the
front
of
this
manualonpage
viii
.

"
Battery
acid
is
extremely
dangerous
.
Take
care
to
keep
it
from
contacting
eyes,
skin,
or
clothing
.
Wear
eye
protection
.
Extinguish
all
smoking
ma-
terials
and
do
not
worknear
any
oyen
flames
.

Battery
electrolyte
should
be
maintained
at
the
correct
level
just
above
the
battery
plates
and
their
separators
.
The
correct
leve¡
is
approximately
5
mm
(
1
/4
in
.)
above
thetop
of
battery
plates
orto
thetop
of
the
indicator
marks
(if
applicable)
.
The
battery
plates
and
the
indicator
marks
can
beseen
once
the
fill-
er
caps
are
removed
.
If
the
electrolyte
level
is
low,
replenish
it
by
adding
distilled
water
only
.

Battery,
repiacing

Batteries
are
rated
by
ampere
hours
(Ah),
the
number
of
hoursa
specific
current
draín
can
be
sustained
before
complete
discharge,
or
by
cold
cranking
amps
(CCA),
the
number
of
amps
available
to
crank
the
engine
in
cold
weather
conditions
.
In
general,
replacement
batteries
should
alwaysbe
rated
equal
or
higherthan
the
original
battery
.

CAUTION-

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

The
battery
is
held
in
place
bya
single
hand
screw
and
píate
.
A
secure
battery
hold-down
is
important
in
order
to
prevent
vi-
brations
and
road
shock
from
damaging
the
battery
.

NOTE-
NOTE-
"
Always
disconnect
the
negative
()
cable
first,
and
Design
characteristics
of
the
convertible
body
cause
vi-



connect
ft
last
While
changing
batteries,
clean
away
brations
in
the
trunk
area
.
Therefore,
E36
convertibles



any
corrosion
in
or
around
the
battery
tray
.
require
a
specialbattery
designed
for
constant
vibra-
tion
.
When
repiacing
the
battery,
be
sure
the
replace-



"
Design
characteristics
of
the
convertible
body
cause
ment
is
designed
specffically
for
the
convertible
.



vibrations
to
oscillate
in
the
trunk
area
.
Therefore,
the
convertible
model
uses
a
specialbattery
designed
for
this
constant
vibration
.

100-6
ENGINE-GENERAL

Cylinder
compression,
checking

A
compression
tester
is
needed
to
make
a
compression
test
.

To
obtain
accurate
test
results,
the
battery
and
starter
must
be
capable
of
cranking
the
engine
at
250-300
rpm,
and
theen-

gine
should
be
at
normal
operating
temperature
.
Use
com-

pressed
air
to
clean
aroundthe
spark
plugs
before
removal
.

1
.
Disable
the
ignítion
system
by
removing
the
engine

management
system
main
relay
and
the
fuel
pump
re-
¡ay
.
See
Fig
.
6
.

WARNING
-

The
ignítion
system
produces
high
voltages
that
canbe
fatal
.
Avoid
contact
with
exposed
termínals
and

useextreme
caution
when
working
on
acar
wíth
the
ignítion
switched
on
or
the
engine
running
.

Fuel



DM
E
pump
main
re
ay



rel
ay
o
oa
ooa

.,
o00
oao

Fig
.
6
.



Engine
management
relays
in
power
distribution
box
inleft
rear
of
engine
compartment
.

CAUTION-

"
On
OBD
11
cars,
making
a
compression
test
may
causea
faultto
set
in
the
ECM
and
may
also
il-
luminate
the
Check
Engine
light
.
The
light
can
only
be
tumed
out
using
special
scan
tool
equip-
ment,using
eíther
the
BMW
specialservíce
tool
or
using
a
"generic"
OBD
11
scan
tool
.
Discon-
necting
the
battery
will
not
erase
the
fault
mem-
orynor
turn
outthe
light
.

0013034,

0012630

Fig
.
7
.



Remove
spark
plug
wires
from
spark
plugs
on
4-cylinder
en-
gine
using
special
tool
.
Tool
is
stored
under
cover
at
rear
of
cylinder
head
(arrow)
.

Fig
.
8
.



Remove
engine
cover
on
6-cylinder
engine
byprying
off
nut
covers
and
removing
nuts
(A)
.
Be
careful
not
to
let
rubber
in-
sulators
fall
off
as
cover
is
removed
(arrows)
.

4
.
On
6-cylinder
engines,
disconnect
the
harness
connec-
tors
from
the
ignítion
coils
by
lifting
the
retaining
clip
.

Remove
the
coil
mounting
nuts
andremove
the
six
coils
.
See
Fig
.
9
.
Remove
the
sparkplugs
.
"
Failure
to
remove
the
main
relay
or
attempting
to
disable
the
ignítion
system
by
other
methods
may
resultin
damage
to
the
engine
control
module
.



NOTE-

Used
sparkplugs
should
be
reinstalled
in
the
same
cyl-

2
.
On
4-cylinder
engine
:
Remove
plastic
engine
cover
from



inder
fromwhich
they
were
removed
.

top
of
cylinder
head
.
Disconnect
spark
plug
wires
and
re-
move
spark
plugs
.
See
Fig
.
7
.



5
.
Insta¡¡
the
compression
gauge
in
the
first
cylinder's

3
.
On
6-cylinder
engine
:
Remove
top
engine
coverby
pry-



spark
plug
hole,
tight
enough
to
form
a
good
seal
.

ing
off
nut
covers
and
removing
mounting
nuts
.
See
Fig
.
8
.

MECHANICAL
TROUBLESHOOTING

100-
1
2
ENGINE-GENERAL

NOTE-

The
oxygen
sensor
signal
is
ignored
until
the
engine
reachesa
specified
minimum
temperature
.
Therefore,



The
primary
input
usedby
the
fuel
injection
system
to
deter-

when
troubleshooting
cold
engine
driveability
prob-



mine
how
much
fuel
should
be
delivered
is
the
signal
from
the

lems,
the
oxygensensor
canbe
ruled
out
asa
possible



mass
air
flow
sensor
in
the
intake
air
ductwork
.

cause
.

As
the
oxygen
sensor
ages,
its
ability
to
react
quickly
to

changing
conditions
deteriorates,
and
it
may
eventually
cease

to
produce
any
signal
at
all
.
To
check
the
operation
of
the
oxy-

gen
sensor,
see
130
Fuel
Injection
:

NOTE-

On
1996
and
latercars,
OBD
11
enhanced
emission
standards
require
the
engine
control
module
(ECM)
to
monitor
the
oxygen
content
in
the
exhaust
both
before
and
after
the
catalytic
converter
.
Thisallows
for
tighter
control
of
the
tail
pipe
emissions
and
also
allowsthe
ECM
to
diagnose
converter
problems
.
If
the
DME
de-
tects
that
catalytic
converter
or
oxygensensor
efficien-
cyhas
degraded
pasta
certain
pre-programmed
limit,
it
will
turn
on
the
Check
Engine
light,
and
store
a
diag-
nostic
trouble
code
(DTC)
in
the
ECM
.

DRIVEABILITY
TROUBLESHOOTING

Catalytic

B9506

Air
Flow
Measurement
and
Vacuum
Leaks

Because
proper
fuel
metering
depends
on
accurate
mea-

surement
of
the
incoming
air,
any
unmeasured
air
that
enters

the
engine
downstream
of
the
mass
air
flow
sensor
will
cause

a
lean
air-fuel
mixture
and
possibly
affectdriveability
.

NOTE-

Fig
.
10
.
Regulating
oxygen
sensor
measures
oxygen
content
of
ex-



gattery
Voltage
hausY
gas
as
indicator
of
.¡_fi
.1
ratio
and
"-k,
.

E-
effi-
ciency
.
Monitoríng
oxygen
sensor
(not
shown)
monitors

If
a
large
air
leak
is
causing
driveability
problems,
the
Check
Engine
light
will
usually
be
illuminated
and
a
fault
will
be
stored
in
the
fault
code
memory
.
See
On
Board
Diagnostics
(OBD)
.

There
are
many
places
for
unmeasured
air
to
enter
theen-

gine
.
First,
inspect
all
hoses,
fittings,
ducts,
seals,
and
gaskets

in
the
intake
air
tract
for
cracks
or
looseness
.
It
may
be
neces-

sary
to
remove
parts
that
cannot
be
fully
checked
in
their
in-

stalled
positions
.
Also
make
sure
all
of
the
intake
manifold
and

throttle
body
mounting
nuts
are
tight
.

In
addition
to
air
leaks,
air
restrictions
can
also
cause
drive-

ability
problems
.
Remove
the
air
filter
and
hold
it
up
to
a
strong

light
source
.
If
the
filter
does
not
pass
light,
it
is
restricted
and

should
be
replaced
.
Also,
remove
the
intake
air
ductwork
and

check
for
oily
deposits
at
the
throttle
plate
.
Buildup
in
this
area

can
cause
an
erratic
idle
.
Clean
away
any
deposits
using
a

cloth
wetted
withcarburetor
cleaner
and
reinstall
the
ductwork
.

CAUTION-

Do
not
spray
carburetor
cleaner
directly
in
the
throt-
tle
anea
.
Spraying
cleaner
may
force
it
into
the
throt-
tle
position
switch
or
sensor
and
cause
damage
.

catalytic
converter
operation
.



All
of
the
electrical
components
in
the
fuelinjection
and
igni-
tion
systems
require
a
minimum
voltage
to
operate
properly
.

When
troubleshooting
engine
driveability
problems,
one
of
Replacement
of
oxygensensors
at
the
specified
intenrals
en-



the
first
checks
should
be
to
make
sure
the
battery
is
fully
sures
that
the
engine
and
emission
control
system
wili
continue



charged
and
capable
of
delivering
allits
power
to
the
electricalto
operate
as
designed
.
As
the
oxygen
sensor
ages,
its
ability
to



system
.
react
quickly
to
changing
conditions
deteriorates,
and
it
may
eventually
cease
to
produceany
signal
at
all
.



To
make
a
quick
check
of
battery
charge,
measure
the
volt-
age
across
the
battery
terminals
with
all
cables
attached
and
As
the
oxygen
sensor
ages,
its
ability
to
react
quickly
to



the
ignition
off
.
A
fully
charged
battery
will
measure
12
.6
volts
changing
conditions
deteriorates,
and
it
may
eventually
cease



or
slightly
more,
compared
to
12
.15
volts
for
a
battery
with
a
to
produce
any
signal
at
all
.
To
check
theoperation
of
the
oxy-



25%
charge
.
gen
sensor,
see130
Fuel
Injection
.

Even
a
fully
charged
battery
cannot
deliver
power
unless
it

is
properly
connected
to
the
electrical
system
.
Check
the
bat-
tery
terminals
for
corrosion
and
loosecableconnections
.
If
the
battery
does
not
maintain
the
proper
voltage,
the
charging
system
may
be
atfault
.
See
121
Battery,
Starter,
Alternator
.

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
.

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