300 BMW 323i 1995 E36 Workshop Manual
[x] Cancel search | Manufacturer: BMW, Model Year: 1995, Model line: 323i, Model: BMW 323i 1995 E36Pages: 759
Page 3 of 759
General
Data
and
010
FundamentalsfortheDo-lt-YourselfOwner
Maintenance
020
Maintenance
Program
Engine
Transmission
Suspension,
Steering
and
Brakes
4
Body
100
Engine-General
110
Engine
Removal
and
Installation
113
Cylinder
Head
Removal
and
Installation
116
Cylinder
Head
and
Valvetrain
117
Camshaft
Timing
Chain
119
Lubrication
System
200
Transmission-General
210
Clutch
230
Manual
Transmission
510
Exterior
Trim,
Bumpers
520
Seats
Bo
y
Equipment
512
DoorWTdws
540
nr
t
513
InteriorTrim
541
Convertible
Top
515
Central
Locking
and
Anti-Theft
600
Electrical
System-General
620
Instruments
Electrical
S
stem
610
Electrical
Component
Locations
630
Exterior
Lighting
611
Wipers
and
Washers
640
Heating
and
Air
Conditioning
6
612
Switches
and
Electrical
Accessories
650
Radio
Equipment
and
720
SeatBelts
Accessories
721
Airbag
System
(SRS)
Electrical
Wiring
Diagrams
Foreword
.
...
.
.
.
..................
.
.
.
.....
.
............
.
...
.
.
.
.
.
................
.
.
.
.....
.
......
.
................
.
.
.
.....
v
Warnings
and
Cautions
.....
.
...
.
.
.
.
.
..........
.
...
.
.
.
.
.
......
.
.........
.
.
.
...
.
.
.
......
.
.
.
.
.
............
.
.
.
.
.
.
.vii
Index
..............
.
.
.
.....
.
............
.
...
.
.
.
.
.
........
.
...
.
.
.
.
.
.......
.
......
.
...
.
.
.
.
.
.
.
........
.
.
.
..
back
of
book
300
Suspension,
Steering
and
330
RearSuspension
Brakes-General
331
Final
Drive
310
Front
Suspension
340
Brakes
320
Steering
and
Wheel
Alignment
400
Body-General
411
Doors
410
Fenders,
Engine
Hood
412
Trunk
Lid
120
Ignition
System
121
Battery,Starter,
Alternator
130
Fue¡
Injection
160
Fuel
Tank
and
Fuel
Pump
170
Radiator
and
Cooling
System180
Exhaust
System
240
Automatic
Transmission
250
Gearshift
Linkage
260
Driveshaft
Page 4 of 759
BMW
SERVICE
MANUUAS
BMW
7
Series
Service
Manual
:
1988-1994
7351,735iL,
740i,
740iL,
750iL
Robert
Bentley
ISBN
0-8376-0328-5
BMW
3
Series
Service
Manual
:
1992-1998
M3,
3181,323i,325i,
328i,
Sedan,
Coupe
and
Convertible
Robert
Bentley
ISBN
0-8376-0326-9
Glory
Days
:
When
Horsepowerand
BMW
Z3
Service
Manual
:
1996-1998
Passion
Ruled
Detroit
4-cylinder
and
6-cylinder
models
Jim
Wangers
ISBN
0-8376-0208-4
RobertBentley
ISBN
0-8376-0327-7
Alfa
Romeo
Owner's
BibleTM
BMW
3-Series
Service
Manual
:
1984-1990
Pat
Braden
with
foreword
by
Don
Black
3181,
325,325e(es),
325i(is),
and
325i
ISBN
0-8376-0707-9
Convertible
RobertBentley
ISBN
0-8376-0325-0
Ford
F-Series
Pickup
Owner's
BibleTM
Moses
Ludel
ISBN
0-8376-0152-5
BMW
5-Series
Service
Manual
:
1989-1995
5251,
530i,535i,
540i
including
Touring
Robert
Bentley
ISBN
0-8376-0319-6
BMW
5-Series
Service
Manual
:
1982-1988
528e,
5331,
535i,
535is
RobertBentley
ISBN
0-8376-0318-8
ENTHUSIAST
TITLES
Complete
Roundel
1969-1998
:30
Years
of
the
Magazine
of
the
BMW
Car
Club
of
America
(CD-ROM)
ISBN
0-8376-0322-6
A
French
Kiss
WithDeath
:
Steve
McQueen
and
the
Making
ofLe
Mans
Michael
Keyser
ISBN
0-8376-0234-3
The
Speed
Merchants
:
A
Journey
Through
The
World
of
Motor
Racing,1969-72Michael
Keyser
ISBN
0-8376-0232-7
Mustang
5
.0
Technical
Reference
&
Performance
Handbook
Al
Kirschenbaum
ISBN
0-8376-0210-6
Maximum
Boost
:
Designing,
Testing,
and
Installing
Turbocharger
Systems
Corky
Bell
ISBN
0-8376-0160-6
Volkswagen
Sport
Tuning
for
Street
and
Competition
Per
SchroederISBN
0-8376-0161-4
Sports
Carand
CompetitionDriving
Paul
Frérewithforewordby
PhilHill
ISBN
0-8376-0202-5
Automotive
Books
From
Robert
Bentley
GTI,
Golf,
and
Jetta
Service
Manual
:
1985-
The
Design
and
Tuning
of
Competition
1992
Gasoline,
Diesel,
and
Turbo
Diesel,
EnginesPhilipH
.
Smith,
6th
editionrevised
by
including
16V
Robert
Bentley
David
N
.
Wenner
ISBN
0-8376-0140-1
ISBN
0-8376-0342-0
Going
Faster
:
The
Skip
BarberRacing
Corrado
Official
Factory
Repair
Manual
:
School
Carl
Lopez
ISBN
0-8376-0227-0
1990-1994
Volkswagen
United
States
9M-f,
Ir-
Win
n
on
Alexander
with
foreword
ISBN
0-8376-0387-0
by
Mark
Martín
ISBN
0-8376-0070-7
Passat
Service
Manual
:
1990-1993,
The
Technique
of
Motor
Racing
Piero
including
Wagon
Volkswagen
United
States
Taruf
fi
with
foreword
by
Juan
Manuel
Fangio
ISBN
0-8376-0378-1
ISBN
0-8376-0228-9
Cabriolet
and
SciroccoService
Manual
:
Race
Car
Aerodynamics
1985-1993,
including
16V
Joseph
Katz
ISBN
0-8376-0142-8
RobertBentley
ISBN
0-8376-0362-5
The
Scientific
Design
of
Exhaust
and
VolkswagenFox
Service
Manual
:
1987-
Intake
Systems
Philip
H
.
Smith
and
John
C
.
1993,
including
GL,
GL
Sport
and
Wagon
Morrison
ISBN
0-8376-0309-9
RobertBentley
ISBN
0-8376-0363-3
Volkswagen
Model
Documentation
Rabbit,
Scirocco,
Jetta
Service
Manual
:
Joachim
Kuch
ISBN
0-8376-0078-2
1980-1984
Gasoline
Models,
including
Volkswagen
Beetle
:
Portrait
of
a
Legend
Pickup
Truck,
Convertible,
and
GTI
Robert
Edwin
Baaske
ISBN
0-8376-0162-2
Bentley
ISBN
0-8376-0183-5
Jeep
Owner's
BibleTM
Moses
Ludel
ISBN
0-8376-0154-1
Eurovan
Official
Factory
Repair
Manual
:
MANUUAS
Volkswagen
Inspection/Maintenance
(I/M)
Emission
Test
Handbook
:1980-1997
Volkswagen
of
America
ISBN
0-8376-0394-3
Rabbit,
Jetta
Service
Manual
:
1977-1984Diesel
Models,
including
Pickup
Truck
and
Turbo
Diesel
RobertBentley
ISBN
0-8376-0184-3
Super
Beetle,
Beetle
and
Karmann
Ghia
Official
Service
Manual
Type1
:1970-1979Volkswagen
United
States
ISBN
0-8376-0096-0
Beetle
and
Karmann
Ghia
Official
Service
Manual
Type1
:1966-1969
Volkswagen
United
States
ISBN
0-8376-0416-8
Harley-Davidson
Evolution
V
Twin
Owner's
BibleTM
Moses
Ludel
ISBN
0-8376-0146-0
Audi
100,
A6
Official
Factory
Repair
Manual
:
1992-1997,
including
S4,
S6,
quattro
and
Wagon
models
.
Toyota
Truck
&
Land
Cruiser
Owner's
Audi
of
America
.
ISBN
0-8376-0374-9
BibleTM
Moses
Ludel
ISBN
0-8376-0159-2
Audi
80,
90,
Coupe
Quattro
Official
AUDI
SERVICE
MANUUAS
The
Racing
Driver
Denis
Jenkinson
Factory
Repair
Manual
:
1988-1992
ISBN
0-8376-0201-7
including
80
Quattro,
90
Quattro
and
20-valve
models
Audi
of
America
Unbeatable
BMW
:
Eighty
Years
of
FUEL
INJECTION
ISBN
0-8376-0367-6
Engineering
and
Motorsport
Success
Ford
Fuel
Injection
and
Electronic
Engine
Audi
100,
200
Official
Factory
Repair
JeremyWalton
ISBN
0-8376-0206-8
Charles
O
Probst,
SAE
Manua1
:1988-1991
Audi
of
America
Control
:
1788-1993
.
BMW
6
Series
Enthusiast's
CompanionTM
ISBN
0-8376-0301-3
ISBN
0-8376-0372-2
Jeremy
W
.11
ISBN
0-8376-0149-5
Ford
Fuel
Injection
and
Electronic
Engine
Audi
50005
5000CS
Official
Fa
,ctory
BMW
Enthusiast's
CompanionTM
BMW
Control
:
1980-1987
Charles
O
.
Probst,
SAE
Repair
Manual
:
1984-1988
Gasoline,
Car
Club
of
America
ISBN
0-8376-0321-8
ISBN
0-8376-0302-1
Turbo,
and
Turbo
Diesel,
including
Wagon
BMW
Notecards
Series
1
Photography
by
Bosch
Fuel
In1ection
and
Engne
and
Quattro
Audi
of
America
ISBN
0-8376-
i
Klaus
Schnitzer
ISBN
0-8376-0211-4
Management
Charles
O
.
Probst,
SAE
0370-6
ISBN
0-8376-0300-5
Audi
5000,
50005
Official
Factory
Repair
Manual
:
1977-1983
Gasoline
and
Turbo
VOLKSWAGEN
OFFICIAL
SERVICE
Gasoline,
Diesel
and
Turbo
Diesel
MANUUAS
Audi
of
America
ISBN
0-8376-0352-8
New
Beetle
Service
Manual
:
1998-1999
Audi
40005,
4000CS,
and
Coupe
GT
RobertBentley
ISBN
0-8376-0385-4
Official
Factory
Repair
Manual
:
1984-1987including
Quattro
and
Quattro
Turbo
Audi
Jetta,
Golf,
GTI,
Cabrio
Service
Manual
:
of
America
ISBN
0-8376-0373-01993-early
1999,
including
VR6
and
TDI
Robert
Bentley
ISBN
0-8376-0366-8
SAAB
OFFICIALSERVICE
1992-1999
Volkswagen
of
America
Saab
90016
Valve
Official
Service
Manual
:
ISBN
0-8376-0335-8
19851993
RobertBentl
ISBN
0837603129
-ey---
Saab
900
8
Valve
Official
Service
Manual
:
1981-1988
Robert
Bentley
ISBN
0-8376-0310-2
Passat
Official
Factory
Repair
Manual
:
VOLVO
SERVICE
MANUAL
1995-1997
Volkswagen
of
America
Volve
240
Service
Manual
:
1983-1993
ISBN
0-8376-0380-3
Robert
Bentley
ISBN
0-8376-0285-8
Robert
Bentley
has
published
service
manualsand
automobile
books
since
1950
.
Please
write
Robert
Bentley,
Inc
.,
Publishers,
at
1734
Massachusetts
Avenue,Cambridge,
MA
02138,
visit
our
web
síte
athttp
://www
.rb
.com,
or
call
1-800-423-4595
for
a
free
copy
of
our
complete
catalog,
including
titles
and
service
manuals
for
Jaguar,
Triumph,
Austin-Healey,
MG,
and
other
cars
.
Page 36 of 759
020-
1
4
MAINTENANCE
PROGRAM
uu11989
Fig
.
14
.
Engine
drive
belt
tensíoner
being
released
on
late
4-cylinder
engine
.
Pry
off
tensioner
cover
and
then
lever
tensioner
in
clockwise
direction
(as
facing
engine)
and
slip
beltoff
pulleys
.
Fig
.
17
.
Engine
drive
belt
routing
for
late
4-cylinder
engine
with
poly-
ribbed
drivebelts
.
CA
UTION-
Use
only
BMW
approved
phosphate-free
anti-
freeze
when
filling
the
cooling
system
.
Use
of
anti-
B11177
freeze
containing
phosphates
!s
considerad
to
be
Fig
.
15
.
Engine
drive
belt
tensioner
being
released
on
6-cylinder
en-
harmful
to
the
cooling
system
.
gine
.
Pry
off
tensioner
cover
and
then
lever
tensioner
in
clock-
wise
direction
(as
facing
engine)
and
slipbelt
off
pulleys
.
A
translucent
expansion
tank,
or
overflow
resenroir,
providesmonitóring
of
coolant
leve¡
.
Because
the
expansion
tank
is
translucent,
thecoolant
level
can
be
checked
visually
without
opening
the
system
.
Always
check
thecoolant
leve¡
with
theen-gine
cold
.
The
coolant
leve¡
should
be
at
the
maximum
mark
on
O
o
'~
I
the
expansion
tank,
as
shown
in
Fig
.
18
.
OO
Hose
connectionhld
b
tiht
s
soueg
an
ddry
.
Coolánt
seepage
indicates
either
that
the
hose
clamp
is
loose,
that
the
pose
is
ENGINE
COMPARTMENT
MAINTENANCE
0012470
Fig
.
16
.
Engine
drive
belt
routing
for
6-cylinder
engine
.
A/C
compres-
sor
drive
belt
not
shown
.
'92
irá
Alternator
belt
Coolant~
0
pp
o0o
Belt
tensioner
Cooling
System
Service
0013000
Cooling
system
maintenance
consists
of
maíntaining
thecoolant
leve¡,
inspecting
hoses
.
Because
the
coolant's
anti-cor-
rosion
and
anti-freeze
additives
gradually
lose
their
effective-
ness,
replacement
of
thecoolant
every
two
years
up
to
1996
models,
and
every
three
years
from
1996
is
recommended
.
Asa
preventive
measure,
replacement
of
the
cooling
system
hos-
es
every
four
years
is
also
recommended
.
damaged,
or
that
the
connection
is
dirty
or
corroded
.
Dried
cool-
ant
has
a
chalky
appearance
.
Hoses
should
be
firm
and
springy
.
Replace
any
hose
that
is
cracked,
that
has
become
soft
and
limp,
or
has
been
contaminated
by
oil
.
See
Fig
.
19
.
Power
steering
fluid,
checking
leve¡
Check
the
power
steering
fluid
level
in
the
fluid
reservoir
.
Park
thecar
on
leve¡
ground
with
the
engine
off
.
The
level
is
cor-
rect
if
it
is
between
the
MIN
and
MAX
marks
on
the
dipstick
.
See
Fig
.
20
.
If
the
leve¡
is
below
the
MIN
mark,
start
the
engine
andadd
fluid
to
the
reservoir
to
bríng
the
leve¡
up
.
Stop
the
engine
and
recheck
the
leve¡
.
Hand-tighten
the
reservoir
cap
.
Page 40 of 759
020-
1
8
MAINTENANCE
PROGRAM
Fig
.
25
.
Inspect
brake
pads
with
the
caliper
removed
.
Minimum
brake
pad
thickness
shown
by
dimension
(A)
.
NOTE-
The
parking
brake
may
lose
some
of
its
effectiveness
if
it
is
not
used
frequently
.
This
is
due
to
corrosion
build-
up
on
the
parking
brake
drum
.
To
remove
corrosion,
ap-
plythe
parking
brake
just
until
it
begins
togrip,
then
pulí
the
lever
up
one
more
stop
(click)
.
Drive
thecar
approx-
imately
400
meters
(1,300
ft
.)
and
release
the
brake
.
To
recheck
the
adjustment
of
the
parking
brake
see340
Brakes
.
UNDER-CAR
MAINTENANCE
0011920
Manual
transmission
fluid,
checking
and
filling
The
manual
transmission
fluid
leve¡
should
be
checked
at
specified
intervals
.
Check
and
fill
the
transmission
with
the
car
ona
leve¡
surface
.
Transmission
(luid
leve¡
checking
and
re-
placement
procedures
are
covered
in
230
Manual
Transmis-
sion
.
Automatic
Transmission
Service
The
automatic
transmission
is
not
equipped
with
a
dipstíck
.
Therefore,
checking
the
ATF
level
is
an
ínvolved
procedure,
which
includes
measuring
and
maintaining
a
specified
ATF
temperature
during
the
checking
procedure
.
For
more
complete
ATF
service,
including
checking
ATF
lev-
e¡
and
ATF
filter
replacement
procedures,
see
240
Automatic
Transmission
.
Front
suspension
and
steering
linkages,
inspecting
Inspection
of
the
front
suspension'and
steering
includes
a
check
of
all
moving
parts
for
wear
and
excessive
play
.
Also
in-
spect
the
rubber
seals
and
boots
for
cracks
or
tears
that
could
allow
the
entry
of
dirt,
water,
and
other
contaminants
.
See
310
Front
Suspension
.
Exhaust
system,
inspecting
Rear
suspension,
inspecting
Exhaust
system
life
varies
widely
according
to
driving
habits
Final
drive
and
rear
drive
axle
service
consists
of
checking
and
environmental
conditions
.
If
short-distance
driving
pre-
and
changing
the
gear
oil,
inspecting
for
leaks,
and
checking
dominates,
the
moisture
and
condensation
in
the
system
will
the
rear
drive
axle
rubber
boots
for
damage
.
not
fully
dryout
.
This
will
lead
to
early
corrosion
damage
and
more
frequent
replacement
.
The
areas
where
leaks
are
most
likely
to
occur
are
around
the
driveshaft
and
drive
axle
mounting
flanges
.
For
more
infor
Scheduled
maintenance
of
the
exhaust
system
is
limitedlo
mation
on
ídentifying
oil
leaks
and
their
causes,
see330
Rear
inspection
.
Check
for
restrictions
due
to
dents
or
kinks
.
Check
Suspension
.
for
weakness
or
perforation
due
to
rust
.
Check
lo
see
that
all
the
hangers
are
in
place
and
properly
supporting
the
system
and
that
the
system
does
not
strike
the
body
.
Alignment
of
the
sys-
Final
drive
oil
leve¡,
checking
temand
the
location
of
the
hangers
aredescribed
in
180
Ex-
haust
System
.
Check
the
lubricant
leve¡
with
thecar
level
.
Remove
the
oil
filler
plug
.
The
leve¡
is
correct
when
the
fluidjust
reaches
the
edge
of
the
filler
hole
.
Install
and
tighten
the
oil
filler
plug
when
Manual
Transmission
Service
the
oil
level
is
correct
.
See
Fig
.
26
.
Manual
transmissionservice
consists
of
inspectingfor
leaks
The
final
drive
should
be
filled
with
a
special
BMW
lubricant
and
checking
and
changing
the
fluid
.
available
through
an
authorized
BMW
dealer
.
In
addition,
the
lubricant
type
varies
depending
onwhether
or
nota
limited-slip
Evidence
of
transmissionleaks
is
fkely
to
beseenaround
the
differential
is
fitted
.
driveshaft
mounting
flange
and
at
the
bottom
of
the
bellhousing
.
For
more
information
on
identifying
oil
leaks
and
their
causes,
see230ManualTransmissionand210
Clutch
.
Tightening
Torque
"
Finaldrive
filler
plug
to
final
drive
housing
..................
70
Nm
(52
ft-Ib)
Page 43 of 759
GENERAL
.
.....
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
.
.
...
100-1
Cylinder
Block
and
Crankshaft
.
.
.
.
.
.
.
.
.
...
100-1
Connecting
Rods
and
Pistons
.
.
.
.
.
.
.
.
.
.
.
.
.
100-1
Cylinder
Head
and
Valvetrain
.
.
.
.
.
.
.
.
.
.
.
.
.
100-2
VANOS
(Variable
Valve
Timing)
.
.
.
.
.
.
.
.
...
100-2
DISA
(Dual
Resonance
Intake
System)
.
.
.
.
.
100-3
Engine
Management
System
.
.
.
.
.
.
.
.
.
.
.
.
.
100-3
Ignition
......
.
.
.
.........
.
.
.
.
.
.
.
.
.
.
.
.
100-5
Fuel
Delivery
..
.
.
.
.....
.
...
.
.
.
.
.
.
.
.
.
.
.
.
100-5
Cooling
System
.
...........
.
.
.
.
.
.....
.
.
100-5
Lubrication
System
.........
.
.
.
.
.
.
.
.
.
.
.
.
100-5
MECHANICALTROUBLESHOOTING
.
.
.
.
100-5
Warnings
and
Cautions
..
.
...
.
.
.
.
.
.
.
.
.
.
.
.
100-5
Cylinder
compression,
checking
.
.
.
.
.
.
.
.
.
.
.
100-6
EngineMechanical
Troubleshooting
Table
.
.
.
100-7
DRIVEABILITY
TROUBLESHOOTING
...
100-8
GENERAL
There
are
various
engíne
configurations
used
in
the
1992-
1998
E36
cars
.
See
Table
a
.
On
both
four-
and
6-cylinder
engines,
the
cylinder
block
is
cast
¡ron
with
integral
cyiinders
.
The
cyiinders
are
exposed
on
all
sides
to
circulating
coolant
.
The
fully
counterweighted
crankshaft
rotates
in
replaceable
split-shell
main
bearings
.
Oiiways
drilled
into
the
crankshaft
pro-
vide
bearing
lubrication
.
O¡I
seals
pressed
into
alloy
sea¡
hous-
ings
are
installedat
both
ends
of
the
crankshaft
.
100
Engine-General
Tablea
.
Engine
Specifications
ENGINE-GENERAL
100-1
On-Board
Diagnostics
(OBD)
...
.
.
.
.
.
.
.
.
.
.
.
100-8
Basic
Requirements
....
.
.
.
...
.
.
.
.
.
....
.100-11
Preventive
Maintenance
......
.
.
.
.
.
.....
100-11
Basic
Engine
Settings
..
.
.....
.
.
.
.
.
.....
100-11
Oxygen
Sensors
.
.
.
...
.
.
.
...
.
.
.
.
.
....
.100-11
Air
Flow
Measurement
and
Vacuum
Leaks
.
.100-12
Battery
Voltage
.
.
...........
.
.
.
.
.
.....
100-12
Wiring
and
Harness
Connections
.
.
.
.
.....
100-13
Ground
Connections
...
.
.....
.
.
.
.
.
.....
100-13
Fue¡
Supply
....
.
...........
.
.
..
.....
.100-14
TABLES
a
.
Engine
Specifications
...
...
...........
.
..
..
.100-1
b
.
Engine
Management
Systems
..
..
...........
..
100-5
c
.
Engine
Mechanical
Troubleshooting
..........
.
.
100-8
d
.
OBD
1
Fault
(Blink)
Codes
(1992-1995
models
only)
.
...
..
..
..........
..
.100-9
e
.
Engine
Driveability
Troubleshooting
...........
.100-15
Model
Engine
code
No
.
of
Dispiacement
Compression
Horsepower
cyiinders
liters
(cu
.
in
.)
ratio
SAE
net
@
rpm
318i/is/¡C
1992-1995
M42
4
1
.8
(109
.6)
10
.0
:1
100
@
6000
1996-1998
M44
4
1
.9
(115
.6)
~
10
.0
:1
103
@
6000
323ís/iC
1998
M52
6
2
.5
(152
.2)
10
.5
:1
168
@
5,500
325i/is/iC
1992-1995
M50
6
2
.5
(152
.2)
10
.0
:1
110
@
5,900
328i/is/iC
1996-1998
M52
6
2
.8
(170
.4)
10
.2
:1
190
@
5,300
M3
1995
S50US
6
3
.0
(182
.5)
10
.5:1
240
@
6,000
1996-1998
S52US
6
3
.2
(192
.3)
10
.5:1
240
@
6,000
Cylinder
Block
and
Crankshaft
Connecting
Rods
and
Pistons
The
forged
connecting
rods
use
replaceable
split-shell
bearings
at
the
crankshaft
endand
solid
bushings
at
the
pis-
ton
pin
end
.
The
pistonsare
of
the
three-ring
typewith
two
up-
per
compression
rings
and
a
lowerone-piece
o¡i
scraper
ring
.
Fui¡-floating
piston
pins
are
retained
with
circlips
.
GENERAL
Page 48 of 759
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
Page 70 of 759
113-4
CYLINDER
HEAD
REMOVAL
AND
INSTALLATION
20
.
Disconnect
main
engine
wiring
harness
connector
.
La-
bel
and
disconnect
harness
connectors
for
crankshaft
and
camshaft
sensors
.
See
Fig
.
8
.
0012504
Fig
..
Crankcase
vent
valve
(A),
camshaft
and
crankshaft
sensor
harness
connectors
(B),
locating
bushings
(C),
main
engine
wiring
harnessconnector
(D)
.
M44
engine
shown
.
NOTE-
Early
engines
do
not
havea
maín
disconnect
at
the
lower
intake
manifold
harness
.
lf
necessary,
remove
the
cable
ducting
bolts
and
set
harness
ducting
aside
.
21
.
Remové
lower
section
of
intake
manifold
.
"
Remove
Y
shaped
supportbracket
from
underside
of
manifold
.
(See
Fig
.
6
.)
"
Unbolt
support
brackets
from
alternator
and
starter
.
"
Remove
nuts
holding
manifold
to
cylinder
head
and
pull
manifold
back
until
harness
connectors
for
oil
pressure
switch
and
coolant
temperature
sensorare
accessible
.
Label
and
disconnect
connectors,
then
re-
move
manifold
and
set
aside
.
Timing
chains,
uncoupling
26
.
Lock
crankshaft
in
TDC
position
by
insertíng
BMW
spe-
22
.
On
M42
engines,
remove
thermostat
housing
from
up-
cial
tool
no
.
11
2
300
through
bore
and
into
hole
infly-
per
timing
chaincover
.
wheel
or
driveplate
.
See
Fig
.
11
.
23
.
On
late
M44
engines
(January
1997
and
later),
remove
NOTE-
secondary
air
injection
check-valve
from
front
of
engine
"
If
necessary,
remove
plug
from
locating
bore
in
lower
and
lay
aside
.
edge
of
bell
housing
to
insert
locking
tool
.
24
.
Remove
cylinder
identification
sensor
from
upper
tim-
ing
chaincover
.
Remove
upper
timing
chaincover
.
See
Fig
.
9
.
25
.
Set
engine
to
approximate
TDC
by
rotating
in
normal
operating
direction
until
camshaft
lobes
at
cylinder
no
.
1
are
facing
each
other
.
See
Fig
.
10
.
CYLINDER
HEAD,
4-CYLINDER
Fig
.
9
.
Upper
timing
chain
cover
bolts
(arrows)
.
Remove
secondary
air
injection
check
valve
fromhose
(A)
on
M44
engine
.
Re-
move
cylinder
identification
sensor
from
chaincover
(B)
.
0011998
Fig
.
10
.
Engine
set
to
approximate
TDC
.
Cylinder
no
.
1
camshaft
lobes
face
in
and
arrows
on
sprockets
poínt
up
(arrows)
.
"
Confirm
that
the
locking
tool
has
been
correctly
in-
stalled
by
trying
to
rotate
the
crankshaft
.
27
.
Lock
camshafts
at
TDC
by
mounting
BMW
specíal
tool
no
.
113
240
over
square
ends
of
camshafts
.
See
Fig
.
12
.
NOTE-
Check
that
tool
is
squarely
seated
on
cylinder
head
gasket
surface
.
If
necessary,
rotate
camshafts
slightly
using
an
open-end
wrench
at
hex
oncamshafts
.
Page 71 of 759
Fig
.
11
.
BMW
special
tool
no
.
11
2300
installed
through
bellhousin
and
finto
flywheel
(arrow)
tolockcrankshaft
at
TDC
.
Fig
.
12
.
BMW
special
tool
no
.
11
3
240
installed
on
rear
of
camshafts
tohold
them
at
TDC
.
(M44
engine
shown
.
Other
engínes
are
similar
.)
CAUTION-
The
camshafts
must
be
locked
in
the
TDC
position
using
the
special
service
tool,
or
equivalent,
be-
fore
removing
the
timing
chaín
.
The
tool
holds
the
camshafts
parallel
to
each
other
and
perpendicu-
larto
the
valve
covergasket
surface
.
CYLINDER
HEAD
REMOVAL
AND
INSTALLATION
113-5
6011966
28
.
Remove
hydraulic
chain
tensiones
from
right
side
ofcyl-
inder
head
.
See
Fig
.
13
.
Fig
.
13
.
Hydraulic
chain
tensioner
(arrow)
.
NOTE-
It
is
not
necessary
to
remove
the
cam
sprockets
from
the
chainuntessthese
parts
are
being
reptaced
.
tire
tie
each
sprocket
to
the
chain
to
keep
the
sprockets
timed
to
each
other
.
Keeping
the
sprockets
timed
will
símplífy
instaftation
.
uu
11999
Fig
.
14
.
Chainguide
and
guide
adjusting
sleeve
(arrow)
.
Allen-head
retaining
screwhasbeen
removed
.
Use
slotted
screwdriver
to
loosen
adjusting
sleeve
.
29
.
Remove
mounting
bolts
from
left
and
right
camshaft
sprockets
.
Then
remove
camshaft
sprockets
from
cam-
_
Cylinder
head
assembly,
removing
shafts
.
On
M44
engines,
note
orientation
of
sensor
31
.
Remove
crankshaft
locking
tool
(BMW
special
tool
no
.
wheel
.
11
2
300)
.
Usingthe
crankshaft
vibration
damper
bolt,
30
.
Remove
upper
bolt
from
left
chainguide
.
Loosen
chain
turn
engine
opposite
its
normal
direction
of
rotation
guide
adjusting
sleeve
approximately
two
turns
.
See
(counterclockwise
asviewed
from
the
front)
approxi
Fig
.
14
.
mately
45°
.
This
prevents
accidental
contact
between
valves
and
pistons
during
installation
.
CYLINDER
HEAD,
4-CYLINDER
Page 73 of 759
7
.
Lightly
lubricate
new
cylinder
head
bolts
.
Loosely
instan
bolts
and
their
washers,
then
thread
them
in
until
they
are
finger
tight
.
NOTE-
Check
that
all
washers
for
the
cylinder
head
bolts
are
in
place
before
installing
the
bolts
.
8
.
Tighten
cylinder
head
bolts
in
correct
sequence
.
See
Fig
.
17
.
UU125U2
Fig
.
17
.
Cylinder
head
bolt
tightening
sequence
for
4-cylinder
en-
gines
.
Note
oil
supply
tube
seal
(arrow)
on
M44
engine
.
WARNING
-
The
bolts
should
be
tightennd
in
three
stages
as
líst-
ed
below
.
The
final
stages
require
the
use
of
a
spe-
cial
tool
(BMW
tool
No
.
11
2
110)
ora
suitable
protractor
to
tighten
the
bolts
to
a
specified
torqueangle
.
See
Fig
.
18
.
Tightening
Torques
"
Cylinder
head
to
engine
block
(Torx
El2
M10
bolts)
Stage
1
.
.
.....
.
.
.............
30
Nm
(22
ft-Ib)
Stage
2
.
...
...
.
.
...................
..
.
+90°
Stage
3
.....
...
.
..
...................
..
+90°
9
.
Carefully
rotate
crankshaft
in
direction
of
engine
rota-
tion
and
lock
it
at
TDC
by
inserting
BMW
special
tool
no
.
11
2
300
through
transmission
bellhousing
.
See
Fig
.
19
.
CYLINDER
HEAD
REMOVAL
AND
INSTALLATION
113-
7
Fig
.
18
.
Protractor
and
pointer
being
used
to
tighten
bolts
to
specified
torqueangle
(6-cylinder
engine
shown)
.
Fig
.
19
.
BMW
special
tool
11
2
300
inserted
through
bellhousing
hole
and
finto
flywheel
(arrow)
to
lockcrankshaft
at
TDC
.
10
.
Turn
left
chainguide
adjusting
sleeve
in
until
it
just
con-
tacts
the
cylinder
head
(See
Fig
.
14
.)
.
Insert
chain
guide
retaining
screw
and
tighten
.
CAUTION-
11
.
Placechain
sprockets
with
chains
oncamshaftsso
that
Be
sure
timing
chain
does
not
bind
oncrank
gear
when
turning
crankshaft
.
arrowson
sprockets
point
up
and
elongated
holes
in
sprocketsare
centered
to
tapped
holes
in
camshafts
.
See
Fig
.
20
.
CYLINDER
HEAD,
4-CYLINDER
Page 78 of 759
113-12
CYLINDER
HEAD
REMOVAL
AND
INSTALLATION
18
.
Working
from
underside
of
intake
manifold,
disconnect
21
.
Detach
oil
dipstick
guide
tube
from
manifold
.
Disconharness
connectors,
vent
hoses,
and
air
bypass
nectvent
hose
at
base
of
dipstick
.
hoses)
.
22
.
Remove
intake
manifold
from
engine
byremoving
sev-19
.
Working
at
rear
of
intake
manifold,
label
and
disconnect
en
mounting
nuts
from
above
andtwo
support
bracket
fuel
supply
and
fuel
return
lines
.
Remove
fuelline
hold
bolts
from
below
.
See
Fig
.
32
.
down
bracket
to
free
lines
.
See
Fig
.
31
.
NOTE-
On
M52IS52US
engines,
a
special
fitting
is
used
to
re-tain
the
fuel
fines
to
the
fuel
rail
.
Use
BMW
special
tool
no
.
16
1
050
to
expand
the
locking
clip
inside
the
end
of
the
fuellíne
fittings
.
WARNING
-
"
The
fuel
system
is
desígned
to
retan
pressure
even
wheh
the
ignition
is
off
.
When
working
with
the
fuel
system,
loosen
the
fuel
lines
slowly
toal-
low
residual
fuel
pressure
to
dissipate
gradually
.
Avoid
spraying
fuel
.
"
Fuel
is
highly
flammable
.
When
working
around
fuel,
do
not
disconnect
any
wires
that
could
cause
electrfcal
sparks
.
Do
not
smoke
orwork
near
heaters
or
other
fire
hazards
.
"
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
lines
.
20
.
Remove
mountingscrews
and
release
wiring
harness
duct
at
rear
bulkhead
and
move
aside
.
Remove
wiring
harness
brackets
frombulkhead
.
CYLINDER
HEAD,
6-CYLINDER
Fig
.
32
.
Intake
manifoldnuts
and
support
bracket
bolts
(arrows)
.
CAUTION-
Stuff
clean
rags
into
the
open
intake
ports
topre-
001269s
vent
any
ports
from
falfing
into
the
engine
.
Fig
.
31
.
Fuel
lines
at
intake
manifold
on
M52/S52
engine
.
Use
BMW
special
tool
16
1
050
to
release
locking
fittings
at
ends
of
fuel
enes
.
1
Timing
chains,
uncoupling
23
.
Remove
VANOS
unit
from
frontof
cylinder
head
.
See
VANOS
section
in
117
Camshaft
Timing
Chain
.
24
.
Setengine
to
approximate
TDC
by
rotating
in
normal
operating
direction
until
camshaft
lobes
at
cylinder
no
.
1
are
facing
each
other
.
Arrows
on
camshaft
sprockets
should
be
pointing
up
.
NOTE-
To
confirm
that
the
crankshaft
is
set
to
the
TDC
posi-
tion,
check
that
the
OIT
mark
(0°
TDC)on
the
front
low-
er
timing
chain
cover
ís
aligned
with
the
víbration
damperSee
Fig
.
33
.
25
.
Lock
crankshaft
at
TDC
.
"
Insert
BMW
special
tool
no
.
11
2
300
through
transmis-
sion
bellhousing
and
finto
hole
in
flywheelor
drive
plate
.
See
Fig
.
34
.