radiator cap BMW 318i 1997 E36 Workshop Manual
[x] Cancel search | Manufacturer: BMW, Model Year: 1997, Model line: 318i, Model: BMW 318i 1997 E36Pages: 759
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 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 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 85 of 759
GENERAL
CYLINDER
HEAD,
DISASSEMBLY
AND
ASSEMBLY
CYLINDER
HEAD
AND
VALVETRAIN
116-1
116
Cylinder
Head
and
Valvetrai
n
GENERAL
.
.....
.
.
.
...
.
.
.
.
.
.
.
.
.
.......
116-1
Hydraulic
cam
followers,
checking
and
replacing
(M42
and
al¡
6-cylinder
engines)
.
...
.....
.
..
116-9
CYLINDER
HEAD,
Valve
guides
.
.
.
...
.
.
.
.
.
.
...
.
.
.
.
.
.
.
.
.
.
116-10
DISASSEMBLY
AND
ASSEMBLY
...
.
...
116-1
Valves
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
...
.
.
.
.
.
...
.
.
116-11
Camshafts,
removing
and
installing
(M42
engine)
....
.
....
.
.
.
.
.
.
.
.
.
.....
.
.
116-1
Valves,
leak
test
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
.
.
.
116-11
Camshafts,
removing
and
installing
Valve
stem
oil
seals
.
.
.
.......
.
.
.
.
.
...
.
.
116-11
(M44
engine)
.........
.
.
.
.
.
.
.
.
.
.......
116-3
Valve
seats
.
.
.
.
.
.
.
.
.
...
.
...
.
.
.
.
.
...
.
.116-12
Camshafts,
removing
and
installing
Valve
springs
.
.
.
.
.
.
.
.
...
.
...
.
.
.
.
.
.....
116-12
(6-cylinder
engine)
.....
.
.
.
.
.
.
.
.
.
.......
116-4
Valves,
removing
and
installing
........
.
....
116-6
TABLES
CYLINDER
HEAD
AND
VALVETRAIN,
a
.
Cylinder
Head
Height
........
....
.
..
..........
116-7
RECONDITIONING
.
...
.
.
.
.
.
.
.
.
.
.......
116-7
b
.
Camshaft
Specifications
.......
..
.
..
........
.116-7
Cylinder
head
...
.
.
.
...
.
.
.
.
.
.
.
.
.
....
.
..
116-7
c
.
Valve
Guide
Specifications
....
...
.
..
........
116-10
d
.
Valve
Specifications
...........
..
.
..
........
116-11
Camshaft
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
.......
116-7
e
.
Valve
Seat
Dimensions
.........
.
..
..
......
.116-12
Hydraulic
valve
adjusters,
checking
and
replacing
(M44
engine)
..
.
.
.
116-8
Camshafts,
removing
and
installing
(M42
engine)
This
repair
group
covers
cylinder
head
and
valvetrain
ser-
vice
and
repair
.
Most
of
the
repairs
described
here
require
that
The
camshafts
can
be
removed
with
the
cylinder
head
the
cylinder
head
first
be
removed
as
described
in
113
Cylin-
mounted
on
the
engine
.
The
first
step
is
to
remove
the
cylinder
der
HeadRemoval
and
Installation
.
head
cover
.
See
113
Cylinder
HeadRemoval
and
Installa-
tion
.
NOTE-
Special
BMW
service
tools
should
always
be
used
to
remove
"
For
timing
chain
and
VANOS
repair
information,
see
and
install
the
camshafts
.
Removal
and
installation
of
the
cam-
117
Camshaft
Timing
Chain
.
shafts
without
the
special
tools
can
result
in
camshaft
and
valve
"
If
it
is
determined
that
the
cylinder
head
will
require
train
damage
.
significant
reconditioning
work,
a
remanufactured
cyl-
inder
head
may
bea
good
alternative
.
Remanufac-
WARNING-
tured
cylinder
heads
are
available
froman
authorized
The
process
of
evenly
loosening
the
camshaftbear
BMW
dealer
.
ing
cap
nuts
is
NOT
an
acceptable
method
of
re-
moving
the
camshafts
.
Be
sure
to
read
the
The
information
given
in
this
repair
group
is
organized
ac-
procedure
through
before
starting
the¡ob
.
cording
to
engine
code
.
For
engine
applicationinformation,
see100
Engine-General
.
1
.
Disconnect
negative
(-)
battery
cable
.
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manualonpage
viii
.
BMW
special
tools
are
required
for
most
cylinder
head
ser-
2
.
Remove
radiator
cooling
fan
shroud
and
cooling
fan
.
vice
described
in
this
repair
group
.
Many
of
these
tools
areex-
See
170
Radiator
and
Cooling
System
.
pensive
and
only
available
through
an
authorized
BMW
dealer
.
If
the
special
tools
are
not
available,
one
altematve
is
to
remove
the
cylinder
head
and
have
it
disassembled
byan
authorized
CAUTION-
BMW
dealer
.
Be
sure
to
read
each
procedure
thoroughlybefore
Radiator
fa
n
has
left
hand
threads
.
starting
a
job
to
determinewhich
special
tools
and
equipment
will
be
necessary
.
CYLINDER
HEAD,
DISASSEMBLYANDASSEMBLY
Page 195 of 759
170
Radiator
and
Cooling
System
GENERAL
.
.
.....
.
...
.
.
.
.
.
....
.
.
.
.
.
.
.
.170-1
Coolant
Pump
and
Thermostat
........
.
.
.
.
170-1
Radiator
and
Expansion
Tank
.........
.
...
170-1
Cooling
Fans
.
....
.
.
.
.
.
.
.
.
.
.....
.
......
170-2
Warnings
and
Cautions
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
170-2
TROUBLESHOOTING
...
.
.
.
...
.
.
.
.
.
.
.
.
.170-2
Cooling
System
Pressure
Test
...
.
.
.
.
.
.
.
.
.
170-3
Thermostat
Quick
Check
.
.
.
.
...
.
.
.
.
.
.
.
.
.
170-3
Temperature
Gauge
Quick
Check
.
.
.
.
.
.
.
.
.
170-3
Cooling
fan,
testing
.
.
.
.
........
.
.
.
.
.
.
.
.
.
170-4
COOLING
SYSTEM
SERVICE
.
.
.
.
.
.
.
.
.
.
170-5
Coolant,draining
and
filling
.
.
......
.
.
.
.
.
..
170-5
Cooling
system,
bleeding
(radiator
with
integral
expansion
tank)
.....
170-6
GENERAL
This
section
covers
repair
and
troubleshooting
information
for
the
engine
cooling
system
.
For
heater
core
and
related
heating
and
air
conditioning
components,
see640
Heating
and
Air
Conditioning
.
Coolant
Pump
and
Thermostat
A
centrifuga¡-type
coolant
pump
is
mounted
to
the
front
of
the
engíne
.
The
belt-driven
pump
circulates
coolant
through
the
system
whenever
the
engíne
is
running
.
A
thermostat
con-
trols
the
flow
of
coolant
into
the
radiator
.
When
the
engíne
is
cold
the
thermostat
is
closed
so
coolant
bypasses
the
radiator,
recirculating
from
the
engíne
directly
back
to
the
pump
.
When
the
engíne
reaches
operating
tem-
perature,
the
thermostat
opens
and
coolant
circulates
through
the
whole
system
including
the
radiator
.
Radiator
and
Expansion
Tank
The
radiator
is
a
crossflow
design
.
A
translucent
expansion
tank
provides
for
coolant
expansion
at
higher
temperatures
and
easy
monitoringof
the
coolant
leve¡
.
On
4-cylinder
modeis,
the
radiator
expansion
tank
is
integral
with
the
radiator
.
See
Fig
.
1
.
RADIATOR
AND
COOLING
SYSTEM
170-1
Belt-driven
cooling
fan,
replacing
.
.......
.
.
.
170-7
Electric
cooling
fan,
replacing
.
.
.
.....
.
.
.
.
.
170-8
Auxiliary
cooling
fan,
replacing
.
.
.....
.
.
.
.
.
170-8
Thermostat,
replacing
.
.
.
.
.
.
.
.
.
.....
.
.
.
.
.
170-9
Coolant
pump,
replacing
..........
.
.
.
.
.
.
170-10
RADIATOR
SERVICE
.....
.
......
.
.
.
.
.
.
170-11
Radiator,
removing
and
installing
....
.
.
.
.
.
.
170-11
TABLES
a
.
Coolant
Temperature
Sensor
Wire
Colors
...
.
..
.
.
170-3b
.
Auxiliary
Cooling
Fan
Switching
Temperatures
.:.
.170-4
c
.
Auxiliary
Cooling
Fan
Temperature
Switch
Tests
..
..
.
...
...
.
.............
.
..
.
.
170-5d
.
Cooling
System
Capacities
..............
..
.
.
.
170-6
A
.
Expansion
tank
C
.
Dualtemperature
fan
switch
B
.
Radiator
drain
screw
Fig
.
1
.
Radiator
assembly
with
integral
expansion
tank
(4-cylinder
engine)
.
On
6-cylinder
models,
a
standalone
expansion
tank
is
used
.
On
cars
with
automatic
transmission,
ATF
is
circulated
through
an
additional
heat
exchanger
(ATF
cooler)
.
GENERAL
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 197 of 759
Cooling
System
Pressure
Test
If
the
engine
overheats
and
no
other
cooling
system
testsindicate
trouble,
the
radiator
may
have
some
pluggedpassag-
A
cooling
system
pressure
test
is
used
to
check
for
internal
es
that
are
restricting
coolant
flow
.
leaks
.
Some
of
the
common
sources
ofinternal
leaks
are
a
faulty
cylinder
head
gasket,
a
cracked
cylinder
head,
or
a
Temperature
Gauge
Quick
Check
cracked
cylinder
block
.
The
coolant
temperature
sensor
is
located
on
the
intake
To
doa
cooling
system
pressure
test,
a
special
pressure
manifold
(left)
side
of
the
cylinder
head,
under
the
intake
man-
tester
is
needed
.
ifold
runners
.
See
Fig
.
2
.
WARNING
-
At
normal
operating
temperature
-
the
cooling
sys-
tem
is
pressurized
.
Allow
the
system
to
cool
before
opening
.
Release
the
cap
slowly
to
allow
sale
re-
tease
of
pressure
.
With
the
engine
cold,instan
a
pressure
tester
to
the
expan-
sion
tank
.
Pressurize
thesystem
to
the
specification
listed
be-
low
.
Pressure
should
not
drop
more
than
0
.1
bar
(1
.45
psi)
for
at
leakt
two
minutes
.
If
the
pressure
drops
rapidly
and
there
is
no
sign
of
an
externa¡
leak,
the
cylinder
head
gasket
may
be
faulty
.
Considera
compression
test
as
described
in
100
En-
gine-General
.
The
screw-on
type
expansion
tank
cap
should
also
be
test-
ed
using
a
pressure
tester
and
the
correct
adapter
.
Cooling
System
Test
Pressure
"
Radiator
test
pressure
.........
.
1
.5
bar
(21
.75
psi)
"
Radiator
cap
test
pressure
..
.
........
2
bar
(29
psi)
CA
UTION-
Exceeding
the
speclfied
test
pressure
could
dam-
age
the
radiatoror
other
system
components
.
Carefully
inspect
the
radiator
cap
for
damage
.
Replace
a
faulty
cap
or
a
damaged
cap
gasket
.
Thermostat
Quick
Check
In
later
models,
the
ECT
sensor
and
the
gauge
sender
are
combined
into
one
sender
unit
.
For
wire
colors
refer
to
Table
a
.
To
check
if
the
thermostat
is
opening
and
coolant
is
circulat-
ing
through
the
radiator,
allow
a
cold
engine
to
reach
operat-
ing
temperature
(temperature
gauge
needieapproximately
centered)
.
Shut
off
engine
.
Feel
the
top
radiator
hose
.
If
the
hose
is
hot
to
the
touch,
the
coolant
is
probably
circulating
cor-
rectly
.
If
there
are
any
cool
areas
in
the
hose
or
radiator,
cool-
ant
flow
to
the
radiator
is
probably
restricted
.
Check
for
a
faulty
thermostat
or
aplugged
radiator
.
NOTE-
A
thermostat
that
is
stuck
open
will
cause
the
engine
to
warmup
slowly
and
run
belownormal
temperature
at
highway
speed
.
A
thermostat
that
is
stuck
closed
will
re-
strict
coolant
flow
to
the
radiator
and
cause
overheating
.
RADIATOR
AND
COOLING
SYSTEM
170-
3
U
.¡ig
.v
Fig
.
2
.
Temperature
gauge
sender
on
M44
engine
.
Temperature
gauge
sender
location
is
similar
on
al]
engines
.
In
early
models,
the
engine
coolant
temperature
(ECT)
sen-
sor
for
the
fuel
injection
and
the
coolant
temperature
gauge
sender
are
located
side
by
side
.
Table
a
.
Coolant
Temperature
Sensor
Wire
Colors
Function
Sensor
Terminal
Wire
colors
location
number
Two
sensors
:
Temperature
Rear
1
Brown/violet
gauge
sender
2
Brown/yellow
ECT
sensor
Front
1
Brown/red
2
Brown
or
Brown/black
One
sensor
:
Temperature
Dual
1
Brown/yellow
gauge
sender
sensor
2
Brown/violet
ECT
sensor
3
Brown/red
4
Brown/black
or
Grey/black
TROUBLESHOOTING
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