Drive fluid BMW 325i 1994 E36 User Guide

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)

NOTE-

Use
a14
mm
or17
mm
alíen
bit
socket
to
remove
the
drain
plug
.

"
If
thecar
is
raised
in
the
air,
it
shouldbe
leve¡
.

Fuel
tank
and
fuel
fines,
inspecting

0012474

Inspect
the
fuel
tank,
fuel
lines,
and
fuel
system
for
damage

or
leaks
.
Check
for
fuel
leaks
in
the
engine
compartment
or

fuel
odors
in
the
passenger
compartment
.
Check
for
faultyfuel

lines
bybending
them
.
If
any
leaks
are
present,
fuel
should
be

expelled
.
Check
for
any
evaporative
emissions
hoses
that

may
have
become
disconnected,
checking
carefully
at
the

charcoal
canister
and
evaporative
emissionspurge
system
.

See130
Fuel
Injection
and
160
Fuel
Tank
and
Fuel
Pump

for
component
locations
and
additional
information
.

WARNING
-

When
checking
for
fuel
leaks,
the
engine
must
be
cold
.
A
hot
exhaust
manifold
or
exhaust
system
could
cause
the
fuel
to
ignite
or
explode
causing
se-
rious
personal
injury
.
Uentilate
the
workarea
and
clean
up
spilled
fuel
immediately
.

Clutch
fluid,
checking

The
hydraulic
clutch
and
the
brake
system
share
the
same

reservoir
and
the
same
brake
fluid
.
Clutch
fluid
leve¡
and
brake

fluid
level
are
checked
at
the
same
time
.
See340
Brakes
for

more
information
.
See210
Clutch
for
information
on
the
clutch

and
the
hydraulic
clutch
operating
system
.

MAINTENANCE
PROGRAM



020-19

Drive
axie
joint
boots,
inspecting

100
Engine-General

The
protective
boots
must
be
closely
inspected
for
cracks
andany
other
damage
that
will
allow
contaminants
to
get
ínto
the
joint
.
If
the
rubber
boots
faf
,
the
water
and
dirt
that
enter
the
joint
will
quickly
damage
¡t
.
Replacement
of
the
drive
axle
joint
boots
and
inspection
of
the
joints
are
described
in
330
Rear
Suspension
.

BODY
AND
INTERIOR
MAINTENANCE

Windshield
Wiper
Biade
Maintenance

Common
problems
with
the
windshield
wipers
include

streaking
or
sheeting,
water
drops
after
wiping,
and
blade
chat-

ter
.
Streaking
is
usually
caused
when
wiper
blades
are
coated

with
road
film
or
car
wash
wax
.
Clean
the
blades
using
soapy
water
.
If
cleaning
theblades
does
not
cure
the
problem
then

they
should
be
replaced
.
BMW
recommends
replacing
the
wip-
er
blades
twice
a
year,
before
and
after
the
cold
season
.
Onold-

er
cars,
check
the
tension
spring
that
holds
the
wiper
to
the

glass
.
Replace
the
wiper
arm
if
the
springs
are
weak
.

Drops
that
remainbehind
after
wipingare
caused
by
oil,
road

film,
or
diesel
exhaust
coating
the
windshield
.
Use
an
alcohol
or

ammonia
solution,
or
a
non-abrasive
cleanser
to
clean
the

windshield
.

Wiper
blade
chatter
may
be
caused
by
dirty
or
worn
blades,

bya
dirty
windshield,
or
by
bentor
twisted
wiper
arms
.
Clean

the
blades
and
windshield
as
described
above
.
Adjust
the
wiper

arm
so
that
there
is
even
pressure
along
the
blade,
and
so
that

the
blade
is
perpendicular
to
the
windshield
atrest
.
Lubricate

the
wiper
linkage
with
a
light
oil
.
The
linkage
is
located
under

the
hood
on
the
drivers
side
.
If
the
problem
persists,
theblades
are
excessively
aged
or
worn
and
should
be
replaced
.
See
611
Wipers
and
Washers
.

Body
and
hinges,
lubricating

The
door
locks
and
lock
cylinders
canbe
lubricated
with
an

oil
that
contains
graphite
.

The
body
and
door
hinges,
the
hood
latch,
and
the
door

check
rods
should
be
lubricated
with
SAE
30
or
SAE
40
engine

oil
.
Lubricate
the
seat
runners
with
multipurpose
grease
.
Do
not

apply
any
oil
to
rubber
parts
.
If
door
weatherstrips
are
sticking,

lubricate
them
with
silicone
spray
or
talcum
powder
.
The
hood

release
cable
should
be
lubricated
as
well
.

The
use
of
winter
lock
de-icer
spraysshould
be
kept
to
an
ab-

solute
minimum,
as
the
alcohol
in
the
de-icer
will
wash
the

grease
out
of
the
lock
assemblies,
and
may
cause
the
locks
to

corrode
internally,
or
become
difficult
to
operate
.

ENGINE-GENERAL
100-1

14
.
Unbolt
power
steering
fluid
reservoir
from
íts
mounting
bracket
.
Use
stiff
wire
to
hang
reservoir
to
one
side
.
Do
not
disconnect
fluid
lines
.

15
.
Remove
power
steering
pump
drive
belt
and
remove
pump
from
its
mounting
bracket
.
Use
stiff
wire
to
hang
pump
from
body
.

16
.
On
cars
with
automatic
transmission
remove
front
and
rear
brackets
holding
automatic
transmission
cooler
linesto
engine
.

17
.
Remove
A/C
compressor
from
its
mounting
bracket
without
disconnecting
any
refrigerantlines
.
See
Fig
.
5
.

ENGINE
REMOVAL
AND
INSTALLATION



110-
3

21
.
Remove
front
exhaust
pipefrom
exhaust
manifold
.
See

Fig
.
6
.

22
.
Install
an
engine
lifting
device
and
raise
engine
until
its

weight
is
supported
.
Remove
nuts
and
ground
strap

from
left
and
right
engine
mounts
.

0011967

Fig
.
6
.



Front
exhaustpipe
to
exhaust
mounting
nuts
(arrows),
as
viewed
from
below
on
4-cylinder
engine
.

23
.
Carefully
raíse
engine
out
of
car,
checking
for
any
wir-
ing
harnesses,
fuel
lines,
or
mechanical
parts
that
might
become
snagged
as
engine
is
removed
.

24
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Replace
all
gaskets,
O-rings
and
seals
.

"
Change
engine
oil
and
filter
and
check
al¡
other
fluid
levels
.
See020
Maintenance
Program
.
"
Refill
and
bleed
cooling
system
.
See
170
Radiator
and
Cooling
System
.

"
Insta¡¡
the
front
exhaust
pipes
using
new
gaskets
and

self-locking
nuts
.
Use
copper
pasteon
threads
.
See

180
Exhaust
System
.

Tightening
Torques

"
Coolant
drain
plug
to
cylinder
block
.
25
Nm
(18
ft-Ib)

Fig
.
5
.
A/
C
compressor
mounting
bolts
(arrows)
.



"
Engine
mount
to
subframe

M8
......:...
..
..
..
......,:..
22
Nm
(17
ft
-
1b)
,

18
.
Move
A/C
compressor
out
of
way
without
distorting
or



M10
.
...
.



..
...
.
.
...........
45
Nm
(33
ft'-Ib)

damaging
any
lines
.
Support
compressor
by
hanging
it



"
Intake
manifold
to
cylinder
head

from
chassis
using
stiff
wire
.



M7
.....
.
..
...
..
..
...........
15
Nm
(11
ft-Ib)
M8
...
.
.
.
..
..
...
..
...........
22
Nm
(16
ft-Ib)

19
.
Disconnect
wiring
from
starter
and
alternator
.
Move



`
"
Radiator
cooling
fan
to
coolant
pump40
Nm
(30
ft-Ib)

wiring
harness
out
of
way
.
See
121
Battery,
Starter,



"
Radiator
drain
screw
to
radiator
...
2
.5
Nm
(22
in-lb)

Alternator
.



"
Wiring
to
alternator
(M8
nut)
........
12
Nm
(9
ft-1b)

"
Wiring
to
starter

20
.
Remove
oil
dipstick
guide
tube
.
Note
O-ring
at
base
of



M6
nut
..
.
..
..
...
..
...........
.
:5
Nm
(44
in-lb)

tube
when
removing
.



M8
nut
..
.
..
..
...
..
............
12
Nm
(9
ft-Ib)

ENGINE
REMOVAL
AND
INSTALLATION

22
.
Move
A/C
compressor
out
of
the
way
without
distorting



26
.
Carefully
raise
engine
out
ofcar,
checking
for
any
wir-
or
damaging
any
lines
.
Support
compressor
by
hanging



ing,fuel
lines,
or
mechanical
parts
that
might
become
it
from
chassis
using
stiff
wire
.



snagged
as
engine
is
removed
.

23
.
Disconnect
wiring
from
starter
and
alternator
.
Move



27
.
Installation
is
reverse
of
removal,
noting
the
following
:
wiring
harness
out
of
the
way
.
See
121
Battery,
Start-
Replace
al¡
gaskets,
O-rings
and
seals
.
er,
Alternator
.



"
Change
engine
oil
and
filter
and
check
all
other
fluid

24
.
Remove
Fontexhaust
pipe
fromexhaust
manifold
.
See



levels
.
See
020
Maintenance
Program
.
"
Refill
and
bleed
cooling
system
.
See
170
Radiator
Fig
.
16
.



and
Cooling
System
.

"
Check
that
engine
drivebelts
properly
engage
the
pul-

ley
grooves
.

"
Install
the
Font
exhaust
pipesusing
new
gaskets
and
seif-locking
nuts
.
Use
copper
paste
on
threads
.
See
180
Exhaust
System
.

0012525

Fig
.
16
.
Front
exhaust
pipeto
exhaust
manifolds
mounting
nuts
on
6-

cylinder
engine
(arrows)
.

25
.
Install
an
engine
lifting
device
and
raise
engine
until
its

weight
is
supported
.
Remove
nuts
and
ground
strap

from
left
and
right
engine
mounts
.

ENGINE
REMOVAL
AND
INSTALLATION



110-
7

Tightening
Torques

"
Coolant
drain
plug
to
cylinder
block
.
25
Nm
(18
ft-Ib)
"
Engine
mount
to
subframe
M10
..
.
.
.
...
..............
..
.
45
Nm
(33
ft-Ib)

M8
..
..
.
..
................
...
22
Nm
(16
ft-Ib)

"
Intake
manifold
to
cylinder
head

M7
..
..
..
...
................
.
15
Nm
(11
ft-Ib)

M8
...
.
..
...
................
.
22
Nm
(16
ft-Ib)
"
Radiator
cooling
fan
to
coolant
pump40
Nm
(30
ft-Ib)

"
Radiator
drain
screw
to
radíator
...
2
.5
Nm
(22
in-lb)
"
Wiring
to
alternator
(M8
nut)
........
12
Nm
(9
ft-Ib)

"
Wiring
to
starter

M6
nut



.
..
...
..................
5
Nm
(44
in-lb)

M8
nut
.....
..
.
.
.
.
.............
12
Nm
(9
ft-Ib)

ENGINE
REMOVAL
AND
INSTALLATION

8
.
Remove
air
plenum
from
rear
of
engine
compartment
.
See
640
Heating
and
Air
Conditioning
.

9
.
Release
drive
belt
tension
and
remove
alternator
drive
belt
.
Remove
A/C
compressor
drive
belt
.
See
Fig
.
6
.

B11143
Fig
.
6
.



To
remove
poly-ribbed
drive
belt,
pry
cover
from
front
of
ten-
sioner
.
Then
using
8
mm
hex
key,
turntensioner
clockwise
(arrow)
torelease
tension
and
slip
belt
off
pulleys
.

10
.
Unbolt
power
steering
reservoir
and
pull
reservoir
off
engine
mount
bracket
.

11
.
Without
disconnecting
fluid
lines,
remove
power
steer-
ing
bracket
(with
pump)
from
oil
panand
engine
block
.
See
Fig
.
7
.
Disconnect
fluid
lines
from
bracket
on
en-
gine
mount
.
Hang
pump
from
chassis
using
wire
.

12
.
Without
disconnecting
refrigerant
lines,
remove
A/C
compressor
from
engine
block
.
Hang
compressor
from
chassis
using
wire
.
See
640
Heating
and
Air
Condi-
tioning
.

13
.
Remove
oil
dipstick
guide
tube
mounting
bolt
and
re-
move
tube
.
See
Fig
.
8
.

NOTE-

The
guide
tube
is
sealed
in
the
oil
pan
with
an
O-ring
.
Check
that
the
O-ring
comes
out
with
the
tube
.
Use
anew
O-ring
when
installing
the
tube
.

14
.
On
cars
with
automatic
transmission,
remove
brackets
holding
ATF
cooler
linesto
oil
pan
and
cylinder
block
.

LUBRICATION
SYSTEM



119-
5

Fig
.
7
.



Power
steering
pump
mounting
bolts
(arrows)
.

Fig
.
8
.



Oil
dipstick
guide
tube
being
removed
.
Usea
new
O-ring
(arrow)
during
installation
.

15
.
Insta¡¡
engine
lifting
equipment
at
front
engine
lifting
point
and
raise
engine
just
until
its
weight
is
supported
.

16
.
Remove
nuts
at
bottom
of
left
and
right
engine
mounts
.
Remove
ground
wire
from
right
engine
mount
.
1-oosen
nuts
at
top
of
left
and
right
engine
mounts
(do
not
re-
move)
.

OIL
PAN

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
.

170-
4



RADIATOR
AND
COOLING
SYSTEM
A
quick
testat
the
coolant
temperature
gauge
sender
can



The
auxiliary
cooling
fan
comes
on
when
coolant
tempera

determine
if
the
gauge
is
functioning
correctly
.



ture
exceeds
a
predetermined
leve¡
or
whenever
the
air
condi-

tioning
is
on
.
A
dual-range
temperature
switch
for
cooling
fan
lf
the
gauge
needie
remains
at
the
rest
position
with
theen-



control
is
mounted
on
the
right
side
of
the
radiator
.
See
Fig
.
3
.
gine
warm,
remove
the
harness
connector
from
the
sender
and
jumper
the
correct
terminals
in
the
connector
to
simulate
a
high
engine
temperature
.
See
Table
a
.
Turn
the
ignition
on
.

If
the
gauge
needle
moves
upward,
the
sender
is
faulty
.
If
the

gauge
does
not
respond,
the
wiring
to
the
gauge
is
broken
(open
circuit)
or
the
gauge
itselfis
faulty
.

WARNING
-

1996
and
laten
models
are
OBD
11
compliant
.
Dis-
connecting
electrical
connectors
wíth
the
ignition
turned
on
may
set
fault
codes
in
the
ECM
.
It
is
rec-
ommended
that
you
leave
the
diagnosis
of
faults
in
the
coolant
temperature
sensorsystem
to
the
BMW
dealer
service
department
which
has
specialized
OBD
11
scan
tool
equipment
.

If
the
gauge
needle
reads
too
high
when
the
engine
is
cold,
remove
the
harness
connector
from
the
sender
.
Turn
the
igni-

tion
on
.
lf
the
gauge
needle
position
does
not
change,
the
wir-

ing
or
the
gauge
is
shorted
to
ground
.
If
the
gauge
needle

drops,
the
sender
is
faulty
and
should
be
replaced
.
When
re-

placing
a
faulty
coolant
temperature
sender,
the
gasket
ring
on
the
sender
should
also
be
replaced
.

Tightening
Torque

"
Temperature
gauge
sender
to
engine
18
Nm
(13
ft-Ib)

Cooling
fan,
testing

NOTE-

OnM44
engines
with
manual
transmission,
the
primary
electric
cooling
fan
is
mounted
on
the
engine
side
of
the
radiator
and
is
controlled
by
the
engine
control
module
(ECM)
.
Troubleshooting
thiscircuit
should
be
left
to
an
authorized
BMW
dealer
with
the
proper
diagnostic
equipment

An
otherwise
sound
cooling
system
may
still
overheat,
par-
ticularly
with
prolonged
idling,
due
to
a
failure
of
the
coolíng

fan(s)
.

The
belt-driven
cooling
fan
is
controlled
by
a
temperature
dependent
viscous
clutch
.
A
failed
fan
clutch
may
affect
air
flow
through
the
radiator
resulting
in
overheating
orpossibly
overcooling
.
Speed

Low
sp
High
s

With
the
engine
off,
check
thefan
clutch
by
spinning
thefan
.



eed
The
fan
should
spin
on
the
clutch
with
some
resistance
.



peed
Check
for
signs
of
leaking
fluid
from
the
clutch
.
If
thefan
free-
wheels
with
no
resistance,
cannot
be
tu
rned
by
hand,
or
there
are
signs
of
oil
leakage,
the
clutch
should
be
replaced
.

TROUBLESHOOTING

Fig
.
3
.



Radiatorcooling
fan
temperature
switch
(arrow)
.

WARNING
-

"
Use
caution
when
testing
the
electric
cooling
fan(s)
and
coolant
temperature
switch
.
Keep
hands
and
wires
clear
of
thefan
blades
.
The
cool-
ing
fan(s)
can
run
any
time
the
ignition
is
ON
.

"
For
greatest
safety,
coolíng
fan
and
coolant
tem-perature
switch
tests
shouldbe
performed
on
acoldengine
with
the
air
conditioning
off
.

Table
b
.
Auxiliary
Cooling
Fan
Switching

Temperatures

Switching
temperature
196°F(91°C)
210°F(99°C)

0012506

If
a
faulty
thermostat,
trapped
air,
or
a
restriction
in
the
sys-
tem
is
not
allowing
the
coolant
to
circulate
through
the
radia-
tor,
the
temperature
switch
will
not
close
and
the
auxiliary
cooling
fan
will
not
run
.
Before
making
the
tests
described
be-
low,
make
sure
the
thermostat
is
operating
correctly
as
de-
scribed
earlier
.
The
normal
switching
temperatures
for
the

dual
-speed
switch
are
listed
in
Table
b
.

5
.
Slowly
add
coolant
until
it
spills
from
bleed
screws
.

When
coolant
spillíng
from
bleed
screws
is
free
of
air

bubbies,
tighten
screws
.

6
.
Run
engine
until
it
reaches
operatíng
temperature
.
Af-

ter
engine
has
cooled,
recheck
coolant
level
and
top
up
as
necessary
.

CAUTION-

Always
use
genuine
BMW
coolant
or
its
equiva-

lent
to
avoid
the
formation
of
harmful,
clogging
de-

posits
in
the
cooling
system
.
Use
of
other
antifreeze
solutions
may
be
harmful
to
the
cooling
system
.

Tightening
Torque

"
Radiator
bleed
screw

to
thermostat
housing
...
.
.
........
8
Nm
(71
in-lb)

Belt-driven
cooling
fan,
replacing

1
.
Usinga32
mm
wrench
on
fan
clutch
nut,
turn
wrench

quickly
in
a
clockwise
direction
(working
from
front
of

car)
to
loosen
.
Spin
fan
off
pump
.
See
Fig
.
8
.

NOTE-

"
The
radiator
cooling
fan
nut(32
mm
wrench)
has
left-
hand
threads
.

"
The
nut
may
be
difficult
to
loosen
.
Use
a
tool
to
hold
the
coolant
pump
pulleystationary
.
BMW
hasa
spe-
cial
tool
forthis
purpose
(BMW
special
tool
no
.
115
030)
.

2
.
Remove
expansion
rivets
holding
shroud
to
radiator
.

See
Fig
.
9
.
Remove
fan
and
shroud
together
.

NOTE-

Store
the
removed
fan
clutch
assembly
in
an
upright
(installed)
positionto
prevent
lossof
clutch
fluid
.

RADIATOR
AND
COOLING
SYSTEM



170-
7

Fig
.
8
.



Radiatorcooling
fannut
(arrow)
.
Nuthas
left-hand
threads
.

3
.
To
replace
fan
clutch,
remove
fan
mounting
bolts
and

separate
clutch
from
fan
.
Fig
.
9
.



Fan
shroud
retaining
rivet
(arrow)
.
Pryout
center
pin
and
re

4
.
Installation
is
reverse
of
rernoval
.



move
rivet
.
Rivet
design
may
vary
depending
on
model
and

model
year
.

Tightening
Torques

"
Clutchnut
to
coolant
pump
(left-hand
threads)

Wíthout
BMW
tool
no
.
11
5
040
.....
40
Nm
(29
ft-lb)

With
BMW
tool
no
.
11
5
040
.
......
30
Nm
(22
ft-Ib)

"
Fan
to
viscous
clutch
...
.
..
.
......
10
Nm
(89
in-lb)

0013203

COOLING
SYSTEM
SERVICE

Fig
.
19
.
Coolant
pump
being
removed
.
Thread
two
M6
bolts
(arrows)
in
evenly
to
withdraw
pump
.
(Thermostat
and
hoseshavebeen
removed
tor
visual
access
.)

8
.
Installation
is
reverse
of
removal
.

"
Be
sure
to
replace
O-ring
and
gaskets
.

"
Coat
O-ring
with
lubricant
during
installation
.

Tightening
Torque

"
Coolant
pump
to
timing
chaincover

M6
...
.
...................
..
.
.
10
Nm
(89
in-lb)

M8
.
..
.
....................
.
.
.
22
Nm
(17
ft-Ib)

"
Coolant
pump
pulley

to
coolant
pump
.................
10
Nm
(89
in-lb)

RADIATOR
SERVICE

Radiator,
removing
and
installing

1
.
Drain
radiator
as
described
earlier
.

WARNING
-

Allow
cooling
system
to
cool
before
opening
ordraining
system
.

2
.
Remove
primary
cooling
fan
(belt-driven
or
electric)
as

described
earlier
.

3
.
Disconnect
coolingfan
and
leve¡
sensor
harness
con-

nectors
from
bottom
of
radiator,
where
applicable

4
.
Disconnect
harness
connector
from
auxiliary
fandual

temperature
switch
.
See
Fig
.
20
.

5
.
Disconnect
all
coolant
hoses
from
radiator
.

RADIATOR
AND
COOLING
SYSTEM



170-11

0012500

Fig
.
20
.
Cooling
fan
dual
temperatura
switch
(arrow)
on
right
sido
of
radiator
.

6
.
Where
applicable,
disconnectautomatic
transmission
fluid
(ATF)
cooler
lines
from
radiator
.
See
Fig
.
21
.

Fig
.
21
.
Automatic
transmission
fluid
(ATF)
linos
at
radiator
.

7
.
Carefully
pryout
radiator
retaining
clips
from
top
of
ra-

diator
.
See
Fig
.
22
.

8
.
Pul¡
radiator
up
and
out
of
car
.

NOTE-

The
radiator
rests
ontwo
rubber
mounts
.
Check
that

the
mounts
do
not
stick
to
the
bottomof
the
radiator
.

RADIATOR
SERVICE

230-2



MANUAL
TRANSMISSION

Transmission
fluidleve¡,
checking

Checking
thetransmission
oil
level
involves
simply
remov-
ing
the
side
drain
plug
and
inserting
a
finger
into
the
holeto
check
the
fluid
leve¡
.
lf
the
fluid
leve¡
is
up
to
the
bottom
of
the
drain
hole
(finger
is
wetted
by
transmission
fluid),
the
leve¡
is

correct
.

Transmission
fluid,
replacing

NOTE-

Manual
transmission
fluid
type
should
be
printed
ona
label
on
the
side
of
the
transmission
.
If
in
doubt,
consult
an
authorized
BMW
dealer
for
the
up-to-dateinforma-
tion
on
operating
fluids
.

1
.
Drive
vehicle
for
afew
miles
to
warm
transmission
.

2
.
Raise
and
safely
support
vehicle
to
access
drain
plug
.

WARNING
-

"
When
raising
the
car
uslng
a
floor
jack
or
a
hy-
draulic
lift,
carefully
position
the
jack
pad
to
pre-
vent
damaging
the
car
body
.
A
suitable
liner
(wood,
rubber,
etc
.)
should
be
placed
between
the
jack
and
the
car
to
prevent
body
damage
.

"
Watch
the
jack
closely
.
Make
sure
it
stays
stable
and
does
not
shíít
or
tilt
.
As
the
car
is
raised,
the
car
may
roll
slightly
and
the
jack
may
shift
.

3
.
Place
a
drain
pan
under
transmission
andremove
drain
plug
at
bottom
of
transmission
.
See
Fig
.
1
.

Fig
.
1
.



Manual
transmission
fill
(1)
and
drain
plugs
(2)
.

TRANSMISSION
SERVICE

4
.
Install
and
torque
drain
plug
.

5
.
Remove
fill
plug
from
side
of
transmission
.
Slowly
fill

transmission
with
fluiduntilfluid
overflows
fill
hole
.

6
.
Install
and
torque
fluid
fill
plug
.

Fluid
Capacity

"
Getrag
transmission
...........
1
.0
liter
(1.1
US
qts)

"
ZF
transmission
.............
1
.2
liters(1
.3
US
qts)

Tightening
Torque

"
Transmission
drain
or
fill
plug
.......
50
Nm
(37
ft-Ib)

TRANSMISSION
SERVICE

Back-up
light
switch,
replacing

1
.
Raise
and
safely
support
vehicle
to
accessback-up

light
switch
.

NOTE-

"
The
back-up
light
switch
on
Getrag
transmissions
is
in
the
left
rearof
the
transmission
.

"
Theback-up
light
switch
on
ZF
transmission
isin
the
rightfront
of
thetransmission
.

2
.
Unscrew
switch
from
transmission
.

3
.
Install
new
switch
.

Tightening
Torque

"
Back-up
light
switch

to
transmission
..
..
.
.....
.
..
.....
20
Nm
(15
ft-ib)

4
.
Check
transmission
fluid
leve¡
before
lowering
vehicle
.