1992 BMW 325i 1992 E36 Workshop Manual

B
mw

3
Series

M3,
3181,3231,3251,
3281

Sedan,
Coupe
and
Convertible

1992,1993,1994,1995,
1996,1997,
1998

Bentley,
Publishers

Cambridge,
Massachusetts

B
-
1
ROBERT
BENTLEY,
INC
.
I
AUTOMOTIVE
PUBLISHERS

Information
that
makes



1734
Massachusetts
Avenue
the
difference
o
Cambridge,
MA
02138
USA
800-423-45951617-547-4170
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.co
m



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:
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m

WARNING-Important
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Notice

Technical
Contact
Information

We
value
your
feedback
.
Technical
comments
and
suggestions
are
helpful
to
us
.
Please
send
your
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and
thoughts
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.bmw@rb
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m

From
timeto
time,
updates
may
be
made
tothis
manual
.
A
listing
of
updates
canbe
found
on
the
web
Iat
www
.rb
.com/update
s

Do
not
use
this
manual
unless
you
are
familiar
with
basic
automotive
repair
procedures
and
safe
workshop
practices
.
This
manual
illustrates
the
workshop
procedures
required
for
most
service
work
.
It
is
not
a
substitute
for
fui¡
and
up-to-dateinformation
from
the
vehicie
manufacturer
or
for
proper
training
asan
automotive
technician
.
Note
that
it
is
not
possible
for
us
to
anticipate
al¡
of
the
ways
or
conditions
under
which
vehicles
may
be
serviced
or
to
provide
cautions
as
to
all
of
the
possible
hazards
that
may
result
.

The
vehicie
manufacturer
will
continue
to
issue
service
information
updates
and
parts
retrofits
after
the
editorial
closing
of
this
manual
.
Some
of
those
updates
and
retrofits
will
apply
to
procedures
and
specifications
in
this
manual
.
We
regret
that
we
cannot
supply
updates
to
purchasers
of
this
manual
.

We
haveendeavored
to
ensure
the
accuracy
of
the
information
in
this
manual
.
Please
note,
however,
that
considering
thevast
quantity
and
the
complexity
of
the
service
information
involved,
we
cannot
warrant
the
accuracy
or
completeness
of
the
information
contained
in
this
manual
.

FORTHESE
REASONS,NEITHERTHEPUBLISHER
NORTHE
AUTHOR
MAKES
ANY
WARRANTIES,
EXPRESS
OR
IMPLIED,THATTHE
INFORMATION
IN
THIS
BOOK
IS
FREE
OF
ERRORS
OR
OMISSIONS,
AND
WE
EXPRESSLY
DISCLAIMTHE
IMPLIED
WARRANTIESOF
MERCHANTABILITY
AND
OF
FITNESS
FOR
A
PARTICULAR
PURPOSE,
EVEN
IF
THE
PUBLISHER
OR
AUTHOR
NAVEBEEN
ADVISED
OF
A
PARTICULAR
PURPOSE,
AND
EVEN
IF
A
PARTICULAR
PURPOSE
IS
INDICATED
IN
THE
MANUAL
.
THE
PUBLISHER
AND
AUTHOR
ALSO
DISCLAIM
ALL
LIABILITY
FOR
DIRECT,
INDIRECT,
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
THAT
RESULT
FROM
ANYUSE
OF
THE
EXAMPLES,
INSTRUCTIONS
OR
OTHER
INFORMATION
IN
THIS
BOOK
.I
N
NO
EVENTSHALL
OUR
LIABILITY
WHETHER
INTORT,
CONTRACT
OR
OTHERWISE
EXCEEDTHECOST
OFTHIS
MANUAL
.

Your
common
sense
and
good
judgment
are
crucial
to
safe
and
successful
service
work
.
Read
procedures
through
before
starting
them
.
Thinkabout
whether
the
condition
of
your
car,
your
leve¡
of
mechanical
skill,
or
your
leve¡
of
reading
comprehension
might
result
in
or
contribute
in
some
way
to
an
occurrence
which
might
cause
you
injury,
damage
your
car,or
result
in
an
unsafe
repair
.
lf
you
have
doubts
for
these
or
other
reasons
about
your
ability
to
perform
safe
repair
workon
your
car,
have
the
work
done
at
an
authorized
BMW
dealeror
other
qualified
shop
.

Part
numbers
listed
inthis
manual
are
for
identification
purposes
only,
not
for
ordering
.
Always
check
with
your
authorized
BMW
dealer
toverifypart
numbers
and
availability
beforebeginning
service
work
that
may
requíre
new
parts
.

Before
attempting
any
work
on
your
BMW,
read
the
wamings
and
cautions
on
pages
vi¡
and
vi¡¡,
andany
waming
or
caution
that
accompanies
a
procedure
in
the
service
manual
.
Review
the
warnings
and
cautions
on
pages
vi¡
and
viü
each
time
you
prepare
to
workon
your
BMW
.

Special
tools
required
to
perform
certain
service
operations
are
identified
in
the
manual
and
are
recommended
for
use
.
Use
of
tools
other
than
those
recommended
inthis
service
manual
may
be
detrimental
to
the
car's
safe
operation
as
well
as
the
safety
of
the
person
servicing
thecar
.

Copies
of
this
manual
may
be
purchased
from
most
automotiveaccessories
and
parts
dealers
specializing
in
BMW
automobiles,
from
selected
booksellers,
or
directly
from
the
publisher
by
mail
.

The
publisher
encourages
comments
from
the
reader
of
this
manual
.
These
communications
havebeen
and
will
be
carefully
considered
in
the
preparation
of
this
and
other
manuals
.
Please
write
to
Robert
Bentley,
Inc
.,
Publishers
at
the
address
listed
on
the
top
of
this
page
.

This
manual
was
published
byRobert
Bentley,
Inc
.,
Publishers
.
BMW
has
not
reviewed
and
does
not
vouch
forthe
accuracy
of
thetechnical
specifications
and
procedures
described
in
this
manual
.

Libraryof
Congress
Cataloging-in-Publication
Data

BMW
3
SeriesService
ManualM3,
318i,
323i,3251,
328i,
Sedan,
Coupe
and
Convertible
:
1992,
1993,
1994,
1995,
1996,1997,
1998
.
p
.
c
m
.
Includes
index
.
ISBN
0-8376-0326-9
1
.
BMW
3
Series
automobile--Maintenance
and
repair--Handbooks,
manuals,
etc
.
I
.
Robert
Bentley,
inc
.
TL215
.13251356
1999
629
.28'
722--cic21



99-17179
CIP
Bentley
Stock
No
.
B398

Editorial
closing
01/99

0302010099
1098765432

The
paper
used
in
this
publication
is
acidfree
and
meets
the
requirements
of
the
National
Standard
for
Information
Sciences-
Permanence
of
Paper
for
PrintedLibrary
Materials
.
O

©Copyright
1999
Robert
Bentley,
Inc
.

All
rights
reserved
.
All
information
contained
in
this
manual
is
based
onthe
information
available
to
the
publisher
at
the
time
of
editorial
closing
.
The
right
is
reserved
to
make
changes
at
any
time
without
notice
.
No
partof
this
publication
may
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reproduced,
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or
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in
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orby
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.
This
includes
text,
figures,
and
tables
.
All
rights
reserved
underBerne
andPan-American
Copyright
conventions
.
Manufactured
in
the
UnitedStates
of
America

BMW
SERVICE
MANUUAS
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7
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Manual
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1988-1994
7351,735iL,
740i,
740iL,
750iL
Robert
Bentley
ISBN
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BMW
3
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Service
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1992-1998
M3,
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328i,
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Robert
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3181,
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RobertBentley
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including
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Robert
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ISBN
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BMW
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1982-1988
528e,
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RobertBentley
ISBN
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ENTHUSIAST
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Complete
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A
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WithDeath
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Michael
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Mustang
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Al
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Maximum
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Per
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The
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1992
Gasoline,
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Diesel,
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.
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6th
editionrevised
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including
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Robert
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David
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.
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Going
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BarberRacing



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School
Carl
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1990-1994
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9M-f,
Ir-
Win
n
on
Alexander
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by
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ISBN
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Passat
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:
1990-1993,

The
Technique
of
Motor
Racing
Piero



including
Wagon
Volkswagen
United
States

Taruf
fi
with
foreword
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ISBN
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SciroccoService
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Race
Car
Aerodynamics



1985-1993,
including
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Joseph
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The
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and



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.
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C
.



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1980-1984
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Volkswagen
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Portrait
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Robert

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Bentley
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Owner's
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Moses
Ludel
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Official
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:



MANUUAS

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Emission
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Volkswagen
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Rabbit,
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RobertBentley
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Super
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Ghia
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Type1
:1970-1979Volkswagen
United
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ISBN
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Beetle
and
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Ghia
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Type1
:1966-1969
Volkswagen
United
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ISBN
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Harley-Davidson
Evolution
V
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Ludel
ISBN
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Audi
100,
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Official
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Manual
:
1992-1997,
including
S4,
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quattro
and
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models
.
Toyota
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&
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Cruiser
Owner's



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of
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80,
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SERVICE
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:
1988-1992
ISBN
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including
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Audi
of
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Unbeatable
BMW
:
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Engineering
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100,
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JeremyWalton
ISBN
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BMW
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Charles
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Repair
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:
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Gasoline,
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ISBN
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VOLKSWAGEN
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RobertBentley
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:
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Turbo
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:



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Robert
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OFFICIALSERVICE

1992-1999
Volkswagen
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19851993
RobertBentl



ISBN
0837603129
-ey---

Saab
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8
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:
1981-1988
Robert
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Passat
Official
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:



VOLVO
SERVICE
MANUAL
1995-1997
Volkswagen
of
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Volve
240
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:
1983-1993
ISBN
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Robert
Bentley
ISBN
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Robert
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automobile
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.
Please
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Robert
Bentley,
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.,
Publishers,
at
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02138,
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://www
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Foreword

This
service
manual
covers
1992
through
1998
BMW
3
Series
models,
and
is
specifically
de-
signed
to
cover
only
those
models
built
for
sale
in
the
United
States
.

BMW,
and
most
accessories
and
parts
sellers
specializing
in
BMWs,
refer
to
the
3
Seriescars

coveredby
this
manual
as
the
E36
model
.
The
code
"E36"
is
BMW's
internal
code
for
the
basic
plat-

form
sharedby
al¡
of
the
cars
coveredby
this
manual
.
Except
for
the
engine
and
a
few
other
compo-

nents,
the
models
coveredby
this
manual
share
many
of
same
components
suchas
suspension

parts,
body
panels,
and
the
interior
pieces
.
When
ordering
parts,
especially
body
parts,
knowing
the

E36
code
may
be
helpful
.

BMW
also
usesan
interna¡
code
for
the
enginesused
in
the
3
Series
models
.
Consult
the
text
in

the
100
Engine-General
repair
group
ofthis
manual
for
a
complete
listing
of
engine
codes
.
Engine
-

code
information
is
primarily
used
internally
by
BMW,
but
may
be
helpful
if
you
haveaccess
to
BMW

technical
information
.

Forthe
BMW
ownerwith
basic
mechanical
skills,
this
manual
gives
detailed
maintenance
and
re-

pair
information
.
In
addition,
the
BMW
owner
who
hasno
intention
of
working
on
his
or
her
own
car

will
findthat
owning
and
reading
this
manual
will
make
it
possibleto
be
better
informed
and
todis-

cuss
repairs
more
intelligently
with
a
professional
technician
.
This
manual
has
been
prepared
from

the
repair
information
that
BMW
provides
to
its
factory-trained
technicians
and
has
been
developed

primarily
with
the
do-it-yourself
BMW
owner
in
mind
.
The
aim
throughout
has
been
clarity
and
un-

derstanding
with
practical
descriptions,
step-by-step
procedures,
and
accurate
specifications
.

The
BMW
owner
intending
to
do
maintenance
and
repair
should
have
a
set
of
tools
including
a
set

of
metric
wrenches
and
sockets,
screwdrivers,
a
torque
wrench,
and
feeler
gauges,
since
these
ba-

sic
tools
will
beused
to
do
the
majority
of
the
maintenance
and
repair
procedures
described
in
this

manual
.
This
manual
includes
detailed
information
onthese
basic
tools
and
other
tips
for
the
begin-

ner
in
the
first
section
of
the
manual,
entitled
010
Fundamentals
for
the
Do-It-Yourself
Owner
.

For
some
of
the
repairs
described
in
this
manual,
BMW
technicians
use
special
tools
.
The
text
will

note
when
a
repair
requires
these
special
tools
and,
where
possible,
will
recommend
practica¡
alter-

natives
.

Non-returnable
Parts

FUNDAMENTALS
FOR
THEDO-ITYOURSELF
OWNER
010-
7

Many
independent
repair
shops
make
a
point
of
using
genu-



Original
body
paneis
and
other
large
components
are
identi-

ine
BMW
parts,
even
though
they
may
at
times
be
more
expen-



fied
by
a
label
bearing
the
VINand
two
BMW
roundellogos
.
Re-

sive
.
Theyknow
the
value
of
doing
thejob
right
with
the
right



placement
parts
have
a
similar
label,
bearing
one
BMW
roundel

parts
.
Parts
from
other
sources
can
beas
good,
particularly
if



logo
and
the
letters
DOT-R
.
See
Fig
.
6
.
Parts
or
assemblies

manufactured
by
one
of
BMWs
original
equipment
suppliers,



bearing
the
label
arethe
engine,
transmission,
front
and
rear

but
it
is
often
difficult
to
know
.



bumpers,
front
fenders,
rear
quarter
paneis,
hood,
trunk
lid
and

doors
.
These
labels
shouldnot
be
removed
as
they
will
tear

BMW
is
constantly
updating
and
improving
their
cars,
often



apart
.

making
improvements
during
a
given
model
year
.
BMW
may

recommend
a
newer,
improved
part
as
a
replacement,
and

your
authorized
dealer's
parts
department
will
know
about
it

and
provide
it
.
The
BMW
parts
organization
is
best
equipped
to
deal
with
any
BMW
parts
needs
.

Some
parts
cannot
be
returned
for
credit,
even
if
they
arethe

wrong
parts
forthe
car
.
The
best
example
is
electrical
parts,

which
are
almost
universally
considered
non-returnable
be-



,
..

cause
they
are
so
easily
damaged
internally
.

Buy
electrícal
parts
carefully,
and
beas
sure
as
possible
that
P-
DOT~
R

a
replacement
is
needed,
especially
for
expensive
parts
such
as
electronic
control
units
.
It
may
bewise
to
let
an
authorized



B328FUN

BMW
dealeror
other
qualified
shop
confirm
your
diagnosisbe-

fore
replacing
an
expensive
part
that
cannot
be
retuned
.



Fig
.
6
.



Labels
used
to
identiy
parts
.
Original
equipment
labelwith

VIN
number
and
roundel
logos
(top)
and
replacement
part
la-

bel
with
one
roundel
logos

Information
You
Need
to
Know

Engine
.
3-Seriescars
covered
in
this
manualare
powered

Model
.
When
ordering
parts
it
is
important
that
you
know
the



by
either
a
4-or
6-cylinder
engine
.
For
information
-
on
engine

correct
model
designation
for
your
car
.
Models
covered
in
this



codes
and
engine
applications,
see100
Engine-General
.

manual
are
E36
3
Series
in
both
4-
and
6-cylinderconfigura-

tions
.



Transmission
.
The
transmissiontype
with
its
identifying

code
may
be
important
when
buying
clutch
parts,
seals,
gas

Moda¡
Year
.
This
is
not
necessarily
the
same
as
date
of



kets,
and
othertransmission-relatedparts
.
For
information
on

manufacture
or
date
of
sale
.
A
1997
model
may
havebeen



transmission
codes
and
applications,
see200
Transmission

manufactured
in
late
1996,
and
perhaps
not
sold
until
early



General
.

1997
.
It
is
still
a1997
model
.
Model
years
covered
by
this
man-

ual
are
1992
to
1998
.

SERVICE
Date
of
Manufacture
.
This
information
is
helpful
when
or-

dering
replacement
parts
or
determining
if
any
of
the
warranty



BMW
dealers
are
uniquely
qualified
to
provide
service
for
recalls
are
applicable
to
your
car
.
The
label
on
the
driver's
door



BMW
cars
.
Their
authorized
relationship
with
the
large
BMW
below
the
door
latch
will
specify
the
month
and
year
that
the
car



serviceorganization
means
that
they
are
constantly
receiving
was
built
.



new
tools
and
equipment,
together
with
the
latest
and
most
ac-

curate
repair
information
.
Vehicle
Identification
Number
(VIN)
.
This
is
a
combination

of
letters
and
numbers
that
identify
the
particular
car
.
TheVIN

appears
on
the
state
registration
document,
and
on
thecar
it-

self
.
One
location
isin
the
rear
of
the
engine
compartment,
en-

other
in
the
lower
left
comer
of
the
windshield
.

The
National
Highway
Traffic
Safety
Administration
(NHT-

SA)
requires
passenger
cars
with
a
high
theftrateto
have
the

VINmarked
on
specific
parts
of
thecar
when
manufactured
.
On

BMW
cars,
these
parts
are
identified
byan
adhesive
label
.

)WBADK00000000

0
000
0

The
BMW
dealers
service
technicians
are
highlytrained
and

very
capable
.
Unfke
most
independent
repair
shops,
autho-

rized
BMW
dealers
are
intensely
committed
tosupporting
the

BMW
product
.
They
share
the
owners
interest
in
BMW
value,

performance,
and
reliability
.
On
the
other
hand,
there
are
many

independent
shops
that
specialize
in
BMW
service
and
are
ca-

pable
of
doing
high
quality
repair
work
.
Checking
with
other

BMW
owners
for
recommendations
on
service
facilitiesis
a

good
way
to
leam
of
reputable
BMW
shops
in
yourarea
.

SERVICE

d
a
d
_
L

G>
G1
a
N
.






G1
Ñ



N
N
O
.
r
d

Maintenance
ítem



°
~



Z



~
i
I
D
i
Body
and
Interior
Maintenance
(cont
.)

Replace
ventilation/A/C
micro-filter
.
Check
function
of
air
conditioning
.
Repair
Group
640

Check
function
of
seat
belts
.
Repair
Group
720

Check
windshield
washer
fluid
level
and
concentration,
add
asnecessary
.
Check
operation
of
washer
system
.
Check
condition
of
wiperblades
Repair
Group
611

Tighten
nuts
and
belts
for
door
locks
and
striker
plates
.

Replace
batteries
for
alarm/remote
control
in
masterkey
(where
applicable)
.

Check
ground
connection
(mounting
screws)
of
SRS
(airbag)
front
sensor
to
body,
if
applicable
.
Repair
Group
721

Road
Test

Check
braking
performance,
steering,
HVAC,
manual
or
automatic
transmission,
and
mirrors

Service
Interval
Reset

Reset
service
indicator
using
specialreset
tool
.

Maintenance
ítem

Replace
oxygen
sensor
.
Repair
Group
180
1992-1994
1995-
on

Flush
and
replace
brake
fluid/clutch
fluid
.
Repair
Group
340

Drain
and
flush
cooling
system
and
replace
coolant
.
Repair
Group
170
1992-19961997-1998

Anti-corrosion
warranty
inspection
.

Tablec
.
Inspection
II
Service
(continued)

Cabled
.
Scheduled
Maintenance-Time/Mileage
Intervais

MAINTENANCE
PROGRAM
020-7

e
~
e
e

i
:
l=
N



l
"
r
NM
I
«)

al



aN



-
11



>

O
Ó



I
Ó



I`
Ó

d
Ny
.
0



°
_



VÑ



Ñ



Ñ
1
ZG

NN

MAÍNTENANCE
TABLES

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

ignition

Table
b
.
Engine
Management
Systems



engine
has
high
mileage
.

Engine



1
System

4-cylinder
engines
M42
(1992-1995)



Bosch
DME
Ml
.7
M44
(1996-1998)



Bosch
DME
M5
.2
(OBD
II)

6-cylinder
engines
M50
(1992)



Bosch
DME
M3
.1
M50
VANOS
(1993-1995)



Bosch
DME
M3
.3
.1
M52
(1996-1998)



Siemens
MS41
.1
(OBD
II)
S50US
(1995)



Bosch
DME
M3
.3
.1
S52US
(1996-1998)



Siemens
MS41
.1
(OBD
II)

Both
the
4-cylinder
and
6-cylinder
engines
use
a
distributor-

less
ignition
system
with
individual
ignition
coils
for
each
cylin-

der
.

FuelDelivery

Pressurized
fuel
from
the
in-tank
fuel
pump
is
injected
via

solenoid-type
fuel
injectors
.
The
ECM
controls
the
opening

and
closing
of
the
injectors
by
switchingthe
ground
side
of

each
injector
circuit
.
The
exact
amount
of
fuel
injected
is
de-

termined
by
the
amount
of
timethe
injectors
are
open
.

Cooling
System

Whenever
the
engine
is
running,
acoolant
pump
circulates

coolant
through
the
engine
and,
if
either
heater
control
valves

are
open,
through
the
heater
core
in
the
passenger
compart-

ment
.
The
coolant
absorbs
excess
heat
and
carries
it
to
the
ra-

diator
where
it
is
transferred
into
the
passing
airstream
.
A

thermostat
controls
the
flow
of
coolant
through
the
radiator

based
on
engine
temperature
.

Lubrication
System

The
lubrication
system
is
pressurized
whenever
theengine

is
running
.
The
oil
pump
draws
oil
through
a
pickup
in
the
bot-

tom
of
the
oil
pan,thenforces
it
through
a
replaceable
oil
filter

and
finto
the
engine
oíi
passages
.

On
4-cylinder
engines,
the
oil
pump
is
mounted
to
the
front

engine
cover
.
On
6-cylinder
engines,thechain-driven
oil

pump
is
bolted
to
the
bottom
of
the
cylinder
block
.

A
pressure
relief
valve
limits
the
maximum
system
pres-

sure
.
A
bypass
valve
prevents
the
oil
filter
from
bursting
and

insures
engine
lubrication
should
the
filter
become
plugged
.

See
119
Lubrication
System
for
additional
information
.

ENGINE-GENERAL
100-
5

Various
versions
of
DME
systems
are
usedon
thecars
cov-



MECHANICAL
TROUBLESHOOTING
ered
by
this
manual
.
See
Table
b
.
Each
system
is
highly
adaptive
to
compensate
for
things
suchasengine
wear
and



When
troubleshooting
an
engine
that
fails
to
start
or
runs
vacuum
leaks
.



poorly,
first
check
its
mechanical
condition-particularly
if
the

Warnings
and
Cautions

For
personal
safety,
as
well
asthe
protection
of
sensitive
electronic
components,
the
following
warnings
and
cautions
must
be
adhered
to
during
all
troubleshooting,
maintenance,
and
repairwork
.

WARNING
-

"
The
ignition
system
produces
high
voltages
that
can
be
fatal
.
Avoid
contact
with
exposed
termi-
nals
anduse
extreme
caution
when
working
on
a
car
with
the
ignition
switched
on
or
the
engine
running
.

"
Do
not
touch
or
disconnect
any
high
voltage
ca-
bles
from
the
coil,
distributor,
orspark
plugs
while
the
engine
is
running
or
being
cranked
by
the
starter

"
Connect
and
disconnect
the
engine
manage-
ment
system
wiring
and
test
equipment
leads
only
when
the
ignition
is
switched
off
.

"
Gasoline
is
highly
flammable
and
its
vapors
are
explosive
.
Do
not
smoke
or
work
on
a
car
near
heaters
or
other
fire
hazards
when
diagnosing
and
repairing
fuel
system
problems
.
Have
a
fire
extínguisher
available
in
case
of
an
emergency
.

"
Disconnecting
the
battery
may
erase
fault
code(s)
stored
in
control
module
memory
.
Using
special
BMW
diagnosnnc
equipment,
check
for
fault
codes
prior
to
disconnecting
the
battery
cables
.
If
the
Check
Engine
lightis
illuminated,
see
On-

Board
Diagnostics
(OBD)
forfault
code
infor-
mation
.
If
any
other
system
faults
havebeen
de-tected
(indicated
byan
illuminated
warning
light),
see
an
authorized
BMW
dealer
.

CAUTION-

"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnection
cautions
gíven
at
the
front
of
this
manual
on
page
viii
.

"
Do
notconnect
any
test
equipment
that
delivers
a
12-volt
power
supply
to
terminal15
(+)
of
the
ignition
coil
.
The
current
flow
may
damage
the

ECM
.
In
general,
connect
test
equipment
only
as
specified
by
BMW,
this
manual,
or
the
equip-
ment
maker
.

"
Do
not
disconnect
the
battery
with
the
engine
running
.
Do
notrunthe
engine
with
any
of
the
sparkplug
wires
disconnected
.

MECHANICAL
TROUBLESHOOTING

100-8
ENGINE-GENERAL

Symptom



1



Probable
cause
and
correctiveaction

1
.
Engine
will
not
start
or
run
.
Starter
cranks



a
.



No
fuel
reaching
engine
.
Check
forfuelin
tank
.

engine
at
normal
speed
.



Fuel
pump
notoperating
.
Repair
Group
160

b
.
No
spark
.
Check
ignition
system
.
Repair
Group
120

c
.
Incorrect
valve
timing
.
Check
timing
chain
.
Repair
Group
117

2
.
Check
Engine
warning
light
illuminated
.



a
.
DME
engine
management
system
self-diagnostic
fault
detected
.
Sea
an
authorized
BMW
dealer
or
other
qualified
shop
for
OBD
II
fault
code
diagnosis
.
See
also
On-
board
Diagnostics(OBD),
given
later
inthis
repair
group
.

3
.
White
exhaust
smoke
(steam)
.



a
.
Failed
cylinder
head
gasket
(probably
accompanied
bylowcompression
readings)
.

Replace
gasket
and
resurface
cylinder
head
if
necessary
.
Repair
Group
113
4
.
Blue-gray
exhaust
smoke
and
oily
spark



a
.
Contaminated
or
gasoline-diluted
engine
oil
.
Change
engine
oil
and
replace
oil
filter
.
plugs
.
Indicates
oii
burning
in
combustion
.



Repair
Group
020

b
.
Faulty
valve
guide
seals
or
valve
guides
.
Replace
valve
guide
oil
seals
or
overhaul
cylinder
head
.
Repair
Group
116

5
.
Pinging
or
rattling
when
under
load,



a
.
Ignition
timing
too
advanced
.
Ignition
knocksensors
faulty
(CheckEngine
light
traveling
uphill,
or
accelerating,
especially



illuminated)
.
Repair
Group
120fromlow
speeds
.
Indicates
pre-ignition
or



b
.
Fuel
octane
leve¡
toolow
.
detonation
.



c
.
Engine
running
too
hot
or
overheating
.
Check
cooling
system
.
Repair
Group
170

6
.
Light
metallic
tapping
that
varies
directly
with
engine
speed
.
Oil
pressure
warning
light
not
illuminated
.

7
.
Light
metallic
knock
that
varies
directly
with
enginespeed
.
Oil
pressure
warning
light
blinking
or
fully
illuminated
;
may
be
most
noticeable
during
hard
stops
or
cornering
.

8
.
Screeching
or
squealing
under
load
that



a
.
Loose,worn,
or
damaged
drive
belt
.
Inspect
belt(s)
.
Repair
Group
020
goesaway
when
coasting
.

9
.
Growling
or
rumbling
that
varieswith
engine



a
.
Remove
drive
belt(s)toidentifyfaulty
component
.
Check
for
play,
bearing
roughness,
rpm
.
Indicates
abad
bearing
or
bushing
in



and
loose
mountings
.
Refer
to
appropriate
repair
group
for
repair
procedures
.
an
engine-driven
accessory
.

DRIVEABILITY
TROUBLESHOOTING



On-Board
Diagnostics
(OBD)

On-Board
Diagnostics
is
incorporated
into
al¡
engine
man-



Two
generations
of
OBD
are
usedon
thecars
covered
by
agement
systems
used
on
the
cars
covered
by
this
manual
.



this
manual
:
Therefore,
checking
for
fault
codes
should
be
the
first
step
in
troubleshootinga
driveability
problem
.
For
additional
informa-



On-Board
Diagnostics
tion
on
engine
management
and
repair
see130
Fuel
Injec-
tion
.



"
1992-1995models
....
.
..
....
.
..
.......
OBD
I

"
1996-1998models
.
....
..
.
.
.
..
.
........
OBD
II

DRIVEABILITY
TROUBLESHOOTING

Tablec
.
Engine
Mechanical
Troubleshooting

b
.
Warped
or
cracked
cylinder
head
.
Resurface
or
replace
cylinder
head
.
Repair
Group
113

c
.
Cracked
cylinder
block
.
Replace
engine
or
short
block
.

c
.
Worn
piston
rings
.
Overhaul
or
replace
engine
.

d
.
Failed
cylinder
head
gasket
.
Replace
gasket
.
Repair
Group
113

d
.
Air/fuel
mixture
too
lean
(Check
Engine
light
illuminated)
.
Repair
Group
130

a
.
Valveclearances
excessive
.
Check
hydraulic
valve
adjusters
.
Repair
Group
116

b
.
Low
oil
pressure
orpossibly
defective
warning
light
circuit
.
Check
oil
pressure
andwarning
light
circuit
.
Repair
Group
119
c
.
Dirty
oil
.
Change
oil
.
Repair
Group
020
.

a
.
Low
oil
leve¡
.
Check
and
correct
oil
leve¡
.

b
.
Low
oil
pressure/worn
or
faulty
oil
pump
.
Oil
pump
pickup
restricted/clogged
.
Check
oil
pressure
.
Repair
Group
119

The
OBD
system
detects
emissions-related
engine
manage-
ment
malfunctions
and
tucos
on
the
Check
Engíne
lightin
the
in-
strument
cluster
.
TheCheck
Engine
light
will
stay
on
until
the
code(s)are
called
up
and
the
memory
is
erased
.
When
faulty
are
detected,
the
OBD
system
stores
a
Diagnostic
Trouble
Code
(DTC)
in
the
system
ECM
.
In
addition,
the
Check
Engine
warn-
ing
light
will
come
on
if
an
emissions-related
fault
is
detected
.

NOTE-

"
On
carswith
OBD
ti,
specialized
OBD
11
scan
tool
equipment
must
be
used
to
access
the
DTCs,
either
using
the
BMW
special
tool
ora
`generic"
OBD
11
scan
tool
.
See
130
Fuel
Injection
.

"
The
08D
11
fault
memory
(including
an
iiluminated
Check
Engine
light)
can
only
be
reset
using
the
spe-
cial
scan
tool
.
Removing
the
connector
from
the
ECM
or
disconnecting
the
battery
will
not
erase
the
fault
memory
.

Table
d
.
OBD
1
Fault
(Blink)
Codes

(1992-1995
modeis
only)

Graphic
representation
of
flashing
Check
Engine
light
fault
code
:
1221
5
Seconds
.
:-



2
.5~-

--05--

Fault
code
and
meaning



1
Corrective
action

Code
1216
:
Throttle
potentiometer

Code
1218
:
Output
stage,
group#1
(DME
3
.3
.ionly)

Code
1219
:
Output
stage,
group
#2
(DME
3
.3.1
only)

Code
1221
:
Oxygen
sensor
#1

Code
1224
:
Air
temperature
sensor
(NTC)

Code
1226
:
Knock
sensor
#2
(DME
3
.3
.1
only)

130

ENGINE-GENERAL
100-
9

2
.5
seconds,
then
go
off
for
2
.5
seconds
.
At
thispoint,
the
fault
codes
will
begin
to
flash
.
See
Table
d
.

If
more
than
one
fault
has
been
detected,
eachcode
will
be
separated
by
a2
.5
second
pause
.
When
al¡
fault
codes
havebeen
displayed,
there
will
be0
.5
second
flash
and
thenthe
light
will
remain
off
.
To
read
the
codes
again,
turn
the
key
off
and
then
on
again
.
Depress
theaccelerator
pedal
to
the
floor
five
times
quickly
(within
5
seconds)
.
The
codes
will
begin
to
repeat
.

On
cars
with
OBD
I,
fault
codes
can
be
read
by
turning
the



To
erase
the
fault
code
memory,
first
make
sure
the
fault

ignition
key
on
and
fully
depressing
theaccelerator
pedal
to



code
1000
(short
blink
and
then
light
goes
out
for
long
period)

the
floor
five
times
within
five
seconds
.
TheCheck
Engine



is
present,
then
depress
the
throttle
fully
for
at
least
10
sec-

light
will
then
remain
on
for
five
seconds,
blink
off,
come
on
for



onds
.
Read
the
fault
codes
as
described
earlier
and
check
for
the
1444
code
(no
faults
stored)
.

-,--------------
Check
Engine
light
on

Check
Engine
light
off

Code
1211
:
DM
E
Control
Module



DME
control
module
may
be
faulty
.
This
code
appears
if
the
control
module
fails
the
self
test
.
Check
inputsto
control
module
.
Repair
Group
130

Code
1215
:
Mass
air
flow
sensor



Check
air
flow
or
mass
air
flow
sensor
and
wiring
to
sensor
.
Repair
Group
130

Test
throttle
potentiometer
resistance
and
wiring
.
Repair
Group
130

Test
DME
control
module
input/outputs
.
Repair
Group
130

Test
DME
control
module
input/outputs
.
Repair
Group
130

Check
sensor
output
signal
to
DME
control
module
.
Repair
Group

Code
1222
:
Oxygen
sensor
lean/rich
control
stop



Check
for
intake
air
leaks
or
reasons
forrich
míxture
.
See
Driveabil-
ity
Troubleshooting
given
earlier
in
this
repair
group

Code
1223
:
Coolant
temperaturesensor
(NTC)



1
Test
coolant
temperature
sensor
.
Repair
Group
130

Test
intake
air
temperature
sensor
.
Repair
Group
130

Code
1225
:
Knock
sensor#1
(DME
3
.3
.1
only)



1
Check
knocksensorand
sensor
wiring
.
Repair
Group
120

Check
knocksensor
and
sensor
wiring
.
Repair
Group
120

Code
1231
:
Batteryvoltage
monitor



Test
battery
voltage
and
battery
check
charging
system
and
starter
.
Repair
Group
121

Code
1234
:
Speedometer
"A"signal
(DME
3
.3
.1
only)



Check
wiring
between
instrument
cluster
and
DME
control
module
.
Electrical
Wiring
Diagrams

Code
1237
:
A/C
compressor
cutoff
(DME
3
.3
.1
only)



Test
DME
control
module
inputs/outputs
from
A/C
system
.
Repair
Group
130

Code
1242
:
A/C
compressor
signal
(DME
3
.3.1
only)



Test
DME
control
module
inputs/outputs
from
A/C
system
.
Repair
Group
130

DRIVEABILITY
TROLIBLESHOOTING