warning BMW 323i 1993 E36 Manual PDF
[x] Cancel search | Manufacturer: BMW, Model Year: 1993, Model line: 323i, Model: BMW 323i 1993 E36Pages: 759
Page 185 of 759
160
Fuel
Tank
and
Fuel
Pump
GENERAL
.
.
.
.
.
.
...........
.
....
.
.
.
.
.
.
160-1
Operating
fuel
pump
for
tests
.
.
.
.
.
.
.......
.160-6
Fuel
Pump
Electrical
Tests
.
.
.
.
.
.
.
...
.
.
.
.
.
160-7
FUEL
TANK
AND
LINES
..
.
.
.
..........
160-2
Fuel
pump
electrical
circuit,
testing.
...
.
.
.
.
.
160-7
Fuel
tank,
draining
..
.
.
.
.
.
.
.
.
.
..........
160-2
Fuel
pump
power
consumption,
testing
.
.
.
.
.
.
160-7
Fuel
tank,
removing
and
installing
.........
160-3
Fuel
Delivery
Tests
....
.
.
.
...
.
.....
.
.
.
..
160-8
Fuel
Tank
Evaporative
Control
System
.....
160-4
Relieving
fuel
pressure
and
connecting
fuel
pressure
gauge
..
.
...........
.
.
.
..
160-8
FUEL
LEVEL
SENDERS
.
.
.
.
.
.......
.
.
.
160-4
System
pressure,
testing
.................
160-9
Fuel
level
senders,
testing
.
.
.
.
.
.......
.
.
.
160-5
Fuel
delivery
volume,
testing
.............
160-10
Fuel
leve¡
sender
and
fuel
pump
(right
side),
emoving
and
installing
.
.
.
.
.
.
160-5
TABLES
Fuel
leve¡
sender
(left
side),
a
.
FuelLeve¡
Sender
Resistances
...........
.
.
..
.160-5
removing
and
installing
.........
.
.
.
.
.
.
.
160-6
b
.
Fuel
Pump
Current
...
.................
..
...
160-8
c
.
Fuel
Pressure
Specifications
..............
.
..
160-10
FUEL
PUMP
.
.
.
................
.
.
.
.
.
.
.
160-6
d
.
Fuel
Pump
Delivery
Specifications
.........
.
..
160-10
Fuel
Pump
Fuse
and
Relay
.
.
.
....
.
.
.
.
.
.
.
160-6
GENERAL
This
repair
group
covers
service
information
specifically
for
The
cautions
and
warnings
on
this
page
should
beob
the
fuel
supply
system
.
Information
on
the
fue¡
injection
sys-
served
when
servicing
the
fuel
system
.
tem
is
covered
in
130
Fuel
Injection
.
NOTE-
Fue¡
filter
replacement
is
covered
in
020
Maintenance
Program
.
WARNING
-
"
The
fuel
system
is
designed
to
retain
pressure
even
when
the
ignition
isoff
.
When
working
with
the
fuel
system,
loosen
the
fuel
lines
slowly
toal-
low
residual
fuel
pressure
to
dissipate
gradually
.
Avoid
spraying
fuel
.
"
Before
beginning
any
work
on
the
fuel
system,
place
a
tire
extinguisher
in
the
vicinity
of
the
work
area
.
"
Fuel
is
highly
flammable
.
When
working
around
fuel,
do
not
disconnect
any
wires
that
could
cause
electrical
sparks
.
Do
not
smoke
or
work
near
heaters
or
other
tire
hazards
.
"
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
fines
.
"
Do
not
use
a
work
light
near
any
fuel
.
Fuel
may
spray
onto
the
hot
bulb
causing
a
tire
.
"
Make
sure
the
work
area
is
properly
ventifated
.
FUEL
TANK
AND
FUEL
PUMP
160-1
CAUTION-
"
Prior
to
disconnecting
the
battery,
read
the
bat-tery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viü
.
"
Before
making
any
electrical
tests
with
the
ignition
tumed
on,
disable
the
ignition
system
as
de-
scribed
in
120
Ignition
System
.
Be
sure
the
bat-tery
is
disconnected
when
replacing
components
.
"
To
prevent
damage
to
the
ignition
system
or
the
electronic
fuel
system
components,
including
the
control
unit,
aiways
connect
and
disconnect
wires
and
test
equipment
with
the
ignition
off
.
"
Cleanliness
is
essential
when
working
with
the
fuel
system
.
Thoroughly
clean
the
fuel
fine
unionsbefore
disconnecting
any
of
the
fines
.
"
Use
only
clean
tools
.
Keep
removed
parts
clean
and
sealed
or
covered
with
a
clean,
lint-free
cloth,
especially
if
completion
of
the
repair
is
delayed
.
"
Do
not
move
the
car
while
the
fuel
system
is
open
.
"
Avoid
using
high
pressure
compressed
air
to
blow
out
fines
and
componente
.
High
pressure
can
rupture
infernal
seals
and
gaskets
.
"
Always
replace
seals
and
O-rings
.
GENERAL
Page 186 of 759
160-2
FUEL
TANK
AND
FUEL
PUMP
0011943
1
.
Filler
pipe
10
.
Fuel
compensating
siphon
pump
and
hose
assembly
2
.
Filler
pipe
grounding
tab
(models
built
from
1/95)
3
.
Vent
pipe
11
.
Fueltank
4
.
Threaded
collar
12
.
Tank
support
strap
5
.
Rubber
ring
seal
13
.
Bolt-tighten
to
23
Nm
(17
ft-Ib)
6
.
Fuel
pump
14
.
Fuel
expansion
tank
7
.
Left
side
fuel
leve¡
sender(models
built
from
1/95)
15
.
Fuel
tank
pressure
sensor
(OBD
II)
8
.
Right
side
fuel
leve¡
sender9
.
Left
side
fuel
leve¡
sender
with
fuel
compensating
siphon
pump
(models
built
up
to
1/95)
Fig
.
1
.
E36
fuel
tank
assembly
.
FUEL
TANK
AND
LINES
Fuel
tank,
draining
The
plastic
fuel
tank
is
mounted
beneath
the
center
of
the
car
(beneath
rear
seat)
.
Mounted
in
the
fuel
tank
are
the
fuel
pump
and
fuel
leve¡
sending
units
.
Connecting
lines
for
the
evaporative
emission
control
systemand
expansion
tank
are
also
attached
to
the
tank
.
When
performing
the
procedures
that
follow,
refer
toFig
.
1
.
Fuel
tank
capacity
for
E36
modeis
"All
ex
.
1996
M3
(3
.0
L)
.....
.
..
..
65
liters
(17
.0
gal)
"
1996
M3
(3.0L)
modeis
.
...
.
..
.
.62
liters
(16
.4
gal)
FUEL
TA
NKAND
LINES
The
fuel
tank
should
be
drained
into
an
approved
storage
unit
or
another
car's
fuel
tank
.
WARNING
-
"
Before
removing
the
tank,
be
sure
that
afl
hot
components
such
as
the
exhaust
system,
are
completely
cooled
down
.
"
Fuel
may
be
spilled
.
Do
not
smoke
or
worknear
heaters
or
other
Pire
hazards
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
paga
vi¡¡
.
Page 187 of 759
2
.
Remove
fuel
tank
filler
cap
.
3
.
Remove
rearseat
cushion
and
pull
back
insulation
mats
to
expose
fuel
tank
access
covers
.
See
Fig
.
2
.
uui3140
Fig
.
2
.
Right
side
fuel
tank
access
cover
under
rear
seat
cushion
.
4
.
Remove
right
and
left
access
covers
to
expose
fuel
hoses
and
electrical
connections
at
tank
.
5
.
Label
fuel
hoses
.
Then
disconnect
hoses
and
harness
connectors
from
fuel
sending
units
and
fuel
pump
.
See
Fig
.
3
.
FUELTANK
AND
FUEL
PUMP
160-
3
NOTE-
"
If
necessary,
push
fuel
level
sender
arm
toward
fuel
pump
assembly
to
facilitate
removal
.
"
BMW
special
tool
no
.
16
1
020
should
beused
tore-
move
and
install
the
threaded
collar
.
Damage
to
thecollar
may
result
if
the
special
tool
is
not
used
.
"
Pump
out
contents
of
each
tanklobe
using
approved
pumpinglextraction
equipment
and
flexible
fuel-grade
hose
.
WARNING
-
Fuel
may
be
spilled
.
Do
not
smoke
or
work
near
heaters
or
other
fire
hazards
.
7
.
Installation
of
sending
units
is
reverse
of
removal,
not-
ing
the
following
:
"
Use
new
sealing
rings
when
installing
pump/sending
unit
assemblies
.
"
Be
sure
that
fuel
line
connections
point
in
same
direc-tion
as
they
carne
out
.
"
Fill
tank
and
check
for
leaks
by
running
engine
.
CA
UTION-
Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1.5
gallons
(5liters)
of
fuel
.
The
pump
will
be
damaged
if
you
run
it
without
fuel
.
Fuel
tank,
removing
and
installing
1.
Disconnect
negative
(-)cablefrom
battery
:
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.
2
.
Remove
fuel
tank
filler
capand
drain
tank
as
described
earlier
.
3
.
Working
in
left
access
tank
access
hole
(under
rear
seat
cushion),
remove
vent
pipe
fromtank
.
4
.
Working
inside
car,
disconnectparking
brake
cable
ends
from
parking
brake
lever
.
See
340
Brakes
.
5
.
Working
underneath
car,
gently
pry
fuel
lines
away
from
retaining
bracket
in
front
of
tank
.
Remove
clamps
and
disconnect
fuel
hoses
as
shown
in
Fig
.
4
.
6
.
Remove
exhaust
system
and
heat
shield
as
described
ooisiai
in
180
Exhaust
System
.
See
Fig
.
5
.
Fig
.
3
.
Fuel
pump/fuel
level
sender
assembly
in
top
offuel
tank
(right
side
shown)
.
Disconnect
supply
hose
(A),
return
hose
(B)
and
7
.
Remove
driveshaft
.
See
260
Driveshaft
.
harness
connector
(C)
.
8
.
Pull
parking
brake
cables
backward
away
from
bottom
of
6
.
Unscrew
threaded
collars
from
fuel
tank
.
Slowly
with-
fuel
tank,
disengaging
them
from
brackets
as
needed
.
draw
fuel
sender
assemblies
from
tank,allowing
fuel
to
drain
off
.
FUEL
TANKAND
LINES
Page 188 of 759
160-
4
FUEL
TANK
AND
FUEL
PUMP
Fig
.
4
.
Pinch
off
supply
and
retum
fuel
hoses
(arrows)
before
dis-
connecting
from
rigid
metal
lines
.
0013143
Fig
.
5
.
After
removing
exhaustsystem,
remove
heat
shield
screws
(arrows)
and
heat
shield
.
9
.
Working
underneath
car,
loosen
hose
clamp
and
dis-
connect
filler
hose
.
10
.
Support
tank
from
below
.
Remove
tank
strap
mounting
bolts
.
Lower
and
remove
tank,
disconnecting
right
side
TheE36
model
uses
a
two-lobed
fuel
tank
and
each
lobeof
vent
and
other
hoses/electrical
connectors
as
neces-
the
tank
has
its
own
fuel
level
sending
unit
.
sary
.
11
.
Installation
is
reverse
of
removal
.
"
Always
use
new
seals,
gaskets,
O-rings,
and
hose
clamps
.
"
Inspect
hoses
and
replace
any
that
are
chafed,
dried
outor
cracked
.
"
Inspect
heat
shield
and
replace
if
corroded
.
"
Inspect
rubber
buffers
and
liners
on
fuel
tank,
support
straps
and
on
underside
of
body
.
Replace
rubber
parts
that
are
hardened
or
damaged
.
FUEL
LEVEL
SENDERS
CAUTION-
"
Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1.5
gallons
(5
liters)
of
fuel
to
prevent
damaging
a
dry
fuel
pump
.
"
If
the
filler
neck
has
been
removed
from
the
body,
be
sure
toreattach
theneck's
grounding
screw
(where
applicable)
.
Check
electrical
resistance
between
the
ground
tab
and
wheel
hub
.
The
re-
sistance
shouldbeno
higher
than
0
.6
ohms
.
Tightening
Torques
"
Fuel
tank
to
body
.............
...
23
Nm
(17
ft-Ib)
"
Hose
clamps
(10
mm-16
mm
día
.)
..
2
.0
Nm
(18
in-lb)
Fuel
Tank
Evaporative
Control
System
The
fuel
tank
evaporative
control
system
is
used
to
vent
the
fuel
tank
to
a
charcoal
canister,
which
is
then
purgedby
en-
gine
vacuum
during
normal
engine
operatíon
.
This
controls
emission
of
raw
hydrocarbons
(fuel)
to
the
atmosphere
.
See
Fig
.
1
.
A
fuel
expansion
tank,
located
under
the
right
rear
fender,
traps
overflow
fuel
and
incorporates
extra
fuel
tank
plumbing
.
Startingwith
1996
models,
OBD
II
standards
require
that
the
fuel
tank
evaporative
control
system
be
monitored
for
leaks
.
This
is
accomplished
usingthe
fuel
tankpressuresen-
sor,
the
ventshut
off
valve,
and
the
evaporative
purge
valve
.
NOTE-
On
most
early
cars(1992-1995),
the
charcoal
canister
is
in
the
engine
compartment
.
On
latercars,
the
char-
coal
canister
is
under
the
spare
tire
in
the
luggage
com-
partment
.
FUEL
LEVEL
SENDERS
The
right
side
fuel
leve¡
sender
is
integrated
with
the
fuel
pump
.
Each
senderhas
a
float
connected
to
a
variable
resis-
tance
for
fuel
leve¡
.
When
replacing
the
sender/pump
assem-
bly
always
replace
hose
clamps,gaskets
and
O-rings
.
WARNING
-
When
removing
the
fuel
level
sender
or
the
fuel
pump,
the
fuel
tank
should
be
emptied
.
Page 189 of 759
Fuel
leve¡
senders,
testing
Fuel
leve¡
sender
(right
side)
The
left
and
right
fuelleve¡
sending
units
are
wired
in
series
.
and
fuel
pump,
removing
and
installing
The
fuel
gauge
receives
a
signal
that
is
the
average
of
the
two
1
.
Disconnect
negative
(-)
cable
from
battery
.
input
values
.
1
.
Remove
rear
seat
cushion,
lift
up
insulation
mats,
andremove
both
fuel
tank
access
covers
.
2
.
Disconnect
white
plug
on
each
sending
unit
.
See
Fig
.
6
.
3
.
Check
resistance
value
of
eachsending
unit
.
Values
should
be
the
same
.
5
.
If
valuesare
different,
remove
sending
units
as
described
below,
and
check
resistance
valuésacross
terminals
.
Table
a
lists
resistance
values
for
senders
at
various
float
positions
.
Table
a
.
Fuel
Leve¡
Sender
Resistances
Float
position
Test
result
(ohms)
Right
side
empty
10
ohm
t2
Right
side
full
250
ohm
±
5
Left
side
empty
10
ohm
t
2
Left
side
fui¡
250
ohm
±
5
FUEL
TANK
AND
FUEL
PUMP
160-
5
CAUTION
-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautionsglven
at
the
front
of
this
manual
onpage
viii
.
2
.
Drain
fuel
from
tank
as
described
earlier
.
WARNING
-
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
fines
.
3
.
Remove
rear
seat
cushion
and
pull
back
insulation
pad
under
right
side
.
4
.
Remove
screws
holding
rightfuel
tank
accesscover
.
Remove
cover
.
5
.
Label
fuel
hoses
.
Disconnect
hoses
and
harness
con-
nectors
from
fuel
sending
unit
and
fuel
pump
.
6
.
Unscrew
threaded
collar
from
fuel
pumplfuel
leve¡
sender
.
Slowly
withdraw
assembly
from
tank,allowing
fuelto
drain
off
.
See
Fig
.
7
.
0013187
&
0013194
Fig
.
6
.
Fuel
pump/leve¡
sender
terminal
identification
.
Check
resis-
tance
at
terminals
of
white
connectors
(arrows)
.
"
If
necessary,
push
leve¡
sender
arm
toward
fuel
pump
assembly
to
facilitate
removal
.
NOTE
-
BMW
special
tool
no
.
16
1
020
should
beused
to
re-
move
and
install
the
threaded
collar
.
Damage
to
the
collar
may
result
if
the
special
tool
is
not
used
WARNING
-
NOTE-
Fuel
may
be
spilled
.
Do
not
smoke
or
work
near
The
compensating
siphon
pump
(Fig
.
1)
maintains
the
heaters
or
other
fire
hazards
.
fuel
leve¡
between
the
right
and
left
tank
lobes
.
If
the
re-
sistances
are
different
between
the
left
and
right
send-
ers,
remove
the
senders
and
visually
inspect
the
leve)
in
7
.
Using
a
new
sealing
ring,
install
pump
and
sending
each
lobe
.
If
the
leve¡
is
different,
check
the
siphon
com-
unit,
being
sure
that
fuel
line
connections
point
in
same
pensating
pump
.
direction
as
they
carne
out
.
8
.
Reconnect
harnessconnector
and
hoses
.
Fill
tank
and
check
for
leaks
by
running
engine
.
Insta¡¡
access
cover
and
its
mountingscrews
.
Reconnect
negative
(-)
cable
to
battery
.
CAUTION
-
Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1
.5
gallons
(5liters)
of
fuel
.
The
pump
will
be
damaged
if
you
run
it
without
fuel
.
FUEL
LEVEL
SENDERS
Page 192 of 759
160-
8
FUEL
TANK
AND
FUEL
PUMP
UU131
tst5
Fig
.
11
.
Voltage
supply
to
fuel
pump
harness
(black)
connector
being
checked
(arrow)
.
00131ts7
Fig
.
12
.
Test
fuel
pump
for
current
draw
by
attadhing
ammeter
andjumper
wire
as
shown
.
CAUTION-
Do
not
allow
the
test
leads
to
short
to
ground
.
NOTE-
See
600
Electrical
System-General
for
information
on
electricaltests
using
a
digital
multimeter
(DMM)
.
4
.
Run
pump
as
described
in
Operating
fuel
pump
for
tests
.
FUEL
PUMP
5
.
Compare
ammeter
reading
with
specification
listed
in
Table
b
.
Maximum
current
5
.0
amps
consumption
FuelDelivery
Tests
Table
b
.
Fuel
Pump
Current
Checking
fuel
delivery
is
a
fundamental
part
of
trouble-
shooting
and
diagnosing
the
DME
system
.
Fuelpressure
di-
rectly
influences
fuel
delivery
.
An
accurate
fuel
pressure
gauge
will
be
needed
to
make
the
tests
.
There
arethree
significant
fuel
delivery
values
to
bemea-
sured
:
"
System
pressure-created
by
the
fuel
pump
and
main-
tained
by
the
pressure
regulator
.
"
Fuel
delivery
volume-created
by
the
fuel
pump
and
af-
fected
by
restrictions,
suchas
clogged
fuel
filter
.
"
Residual
pressure-the
pressure
maintained
in
the
closed
system
after
the
engine
and
fuel
pump
areshut
off
.
Procedures
for
measuring
the
first
two
quantities
arede-
scribed
here
.
Residual
fuel
pressure
is
checked
using
the
procedurede-
tailed
in
130
Fuel
Injection
.
Relieving
fuel
pressure
and
connecting
fuel
pressure
gauge
WARNING
-
"
Gasoline
is
highly
flammable
and
its
vaporsare
explosive
.
Do
not
smoke
or
work
ona
car
near
heaters
or
other
fire
hazards
when
diagnosing
and
repairing
fuel
system
problems
.
Have
a
fire
extinguisher
available
in
case
of
an
emergency
.
"
When
working
onan
open
fuel
system,
wear
suit-
able
hand
protection
.
Prolonged
contact
with
fuel
can
cause
iflnesses
and
skin
disorders
.
CA
UTION-
Cleanliness
is
essential
when
working
withfuel
circuit
components
.
Thoroughly
clean
the
unionsbefore
disconnecting
fuel
fines
To
prevent
fuel
from
spraying
on
a
hotengine,
system
fuel
pressure
should
be
relieved
before
disconnecting
fuel
lines
.
One
method
is
to
tightly
wrap
a
shop
towel
around
a
fuel
line
fit-
ting
and
loosen
or
disconnect
the
fitting
.
Measuring
fuel
pressure
requires
special
tools
.
Earlier
cars
use
pressure
hose
with
clamps
for
fuel
delivery
.
These
can
be
attached
to
a
fuel
pressure
gauge
below
the
intake
manifold
.
Page 194 of 759
160-
1
0
FUEL
TANK
AND
FUEL
PUMP
3
.
Operate
fuel
pump
as
described
earlier
under
Operat-
ing
fuel
pump
for
tests
.
Check
that
fuel
pressure
cor-
responds
to
specifications
listed
in
Table
c
.
"
If
system
pressure
is
low,
repeat
test
whilegradually
pinching
off
return
hose
.
Pressure
should
rise
rapidly
.
If
not,fuel
pump
is
most
likely
faulty
.
"
If
system
pressure
is
too
high,
check
return
line
from
pressure
regulator
to
tank
.
Check
for
kinks
in
hose
.
Blow
compressed
air
through
line
to
check
for
block-
ages
.
If
no
faulty
canbe
found,
pressure
regulator
is
most
likely
faulty
.
See
130
Fuel
Injection
for
testing
and
replacementprocedures
.
Table
c
.
Fuel
Pressure
Specifications
Engine
1
Fuel
pressure
4-cylinder
M42/M44
3
.0
:e
0
.06
bar(43
.5
±0
.9
psi)
6-cylinder
M50/S50US
3
.0
:j-
0
.06bar(43
.5
t0
.9
psi)
M52/S52US
3
.5
t
0
.06
bar
(51
t0
.9psi)
CA
UTION-
Do
not
use
compressed
air
above
40
psi
to
blow
out
fines
or
components
.
Interna¡
damage
to
com-
ponents
may
result
.
4
.
When
finished,
disconnect
pressure
gauge
.
FUEL
PUMP
Fuel
delivery
volume,
testing
1
.
Disconnect
return
line
from
fuel
rail
in
engine
compart-
ment
.
2
.
Connect
a
length
of
hose
to
fitting
on
fuel
rail
and
place
open
end
of
hose
in
a
suitable
container
for
catching
fuel
(2-quart
capacity)
.
3
.
Run
fuel
pump
for
exactly
30
seconds
as
described
earlier
under
Operating
fuel
pump
for
tests
and
mea-
sure
fuel
collected
.
Refer
to
Table
d
.
WARNING-
Table
d
.
Fuel
Pump
Delivery
Specifications
Fuel
under
pressure
is
present
duringthe
test
.
Use
I
Engine
Delivery
rate
(30
seconds
@
12V)
hose
clamps
at
all
connections
.
4-cylinder
M42/M44
0
.875
fter
(0
.93
qt)
6-cylinder
M50/S50US
0
.875
fter(0
.93
qt)
M52/S52US
~
1
.12
liter
(1
.16
qt)
4
.
When
finished
testing,
reconnect
fuel
line
.
Tighten
all
hose
clamps
.
NOTE-
It
is
common
practice
to
replace
the
fuel
filter
any
time
the
fuel
pump
unit
is
replaced
.
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