catalytic converter BMW 325i 1994 E36 Workshop Manual

Fig
.
18
.
Fill
mark
on
coolant
expansion
tank
.
Coolant
level
should
be

at
mark
when
engine
ís
cold
.

.
..
e
..
.-
..



~
..
.-
.

Ozone
Damaged
Hose

0012476

Fig
.
19
.
Examples
of
damage
to
coolant
hoses
.
Any
of
conditions

shown
is
cause
for
replacement
.
Courtesy
of
Gates
Rubber
Company,
Inc
.

Specification

"
Power
steering
fluid
..........
.
...
Dexron
III®ATF

Oxygen
Sensors

1996
and
later
engines
are
equipped
withmultiple
oxygen

sensors
.
See
Fig
.
21
.
A
regulating
sensor
is
mounted
before

each
catalytic
converter
and
amonitoring
sensor
downstream

of
each
converter
.
The
regulating
sensor
monitors
engine
com-

bustion
efficiency
and
helps
to
control
the
fuel
injection
system

and
exhaust
emissions
.
The
monitoring
sensor
is
usedby
the

On-board
diagnostic
system
to
monitor
the
function
of
the
cata-

lytic
converter
.

MAINTENANCE
PROGRAM



020-
1
5

NOTE-

5pecialsockets
for
replacingthe
oxygen
sensor
are

available
from
most
automotive
parts
stores
.
The
sock-

et
has
agroove
cut
down
one
side
to
allow
the
sensor

to
be
installed
without
damaging
the
wire
hamess
.

Fig
.
20
.
Power
steering
fluid
dipstick
showing
MIN
and
MAX
marks
.

OBD
II
enhanced
emission
standards
require
the
engine

control
module
(ECM)
to
monitor
the
oxygen
content
in
theex-

haust
bothbefore
and
after
the
catalytic
converter
.
This
allows

for
tightercontrol
of
the
tail
pipe
emissions
and
also
allowsthe

ECM
to
diagnose
converter
problems
.
lf
the
DME
detects
that

catalytic
converter
or
oxygen
sensor
efficiency
has
degraded

past
a
certain
pre-programmed
limit,
it
will
turn
on
the
Check

Engine
light,
and
store
a
diagnostic
trouble
code
(DTC)
in
the

ECM
.

Replacement
of
oxygen
sensors
at
the
specified
intervals
en-

sures
that
the
engine
and
emission
control
system
wíll
continue

to
operate
as
designed
.
Extending
the
replacement
interval

may
void
the
emission
control
warranty
coverage
.
See
180
Ex-

haust
System
for
information
on
replacing
the
oxygen
sen-

sors
.

Tightening
Torque

"
Oxygen
sensor
to

exhaust
system
........
.
.
.
..
55±5
Nm
(40±4
ft-Ib)

ENGINE
COMPARTMENT
MAINTENANCE

100-
1
2
ENGINE-GENERAL

NOTE-

The
oxygen
sensor
signal
is
ignored
until
the
engine
reachesa
specified
minimum
temperature
.
Therefore,



The
primary
input
usedby
the
fuel
injection
system
to
deter-

when
troubleshooting
cold
engine
driveability
prob-



mine
how
much
fuel
should
be
delivered
is
the
signal
from
the

lems,
the
oxygensensor
canbe
ruled
out
asa
possible



mass
air
flow
sensor
in
the
intake
air
ductwork
.

cause
.

As
the
oxygen
sensor
ages,
its
ability
to
react
quickly
to

changing
conditions
deteriorates,
and
it
may
eventually
cease

to
produce
any
signal
at
all
.
To
check
the
operation
of
the
oxy-

gen
sensor,
see
130
Fuel
Injection
:

NOTE-

On
1996
and
latercars,
OBD
11
enhanced
emission
standards
require
the
engine
control
module
(ECM)
to
monitor
the
oxygen
content
in
the
exhaust
both
before
and
after
the
catalytic
converter
.
Thisallows
for
tighter
control
of
the
tail
pipe
emissions
and
also
allowsthe
ECM
to
diagnose
converter
problems
.
If
the
DME
de-
tects
that
catalytic
converter
or
oxygensensor
efficien-
cyhas
degraded
pasta
certain
pre-programmed
limit,
it
will
turn
on
the
Check
Engine
light,
and
store
a
diag-
nostic
trouble
code
(DTC)
in
the
ECM
.

DRIVEABILITY
TROUBLESHOOTING

Catalytic

B9506

Air
Flow
Measurement
and
Vacuum
Leaks

Because
proper
fuel
metering
depends
on
accurate
mea-

surement
of
the
incoming
air,
any
unmeasured
air
that
enters

the
engine
downstream
of
the
mass
air
flow
sensor
will
cause

a
lean
air-fuel
mixture
and
possibly
affectdriveability
.

NOTE-

Fig
.
10
.
Regulating
oxygen
sensor
measures
oxygen
content
of
ex-



gattery
Voltage
hausY
gas
as
indicator
of
.¡_fi
.1
ratio
and
"-k,
.

E-
effi-
ciency
.
Monitoríng
oxygen
sensor
(not
shown)
monitors

If
a
large
air
leak
is
causing
driveability
problems,
the
Check
Engine
light
will
usually
be
illuminated
and
a
fault
will
be
stored
in
the
fault
code
memory
.
See
On
Board
Diagnostics
(OBD)
.

There
are
many
places
for
unmeasured
air
to
enter
theen-

gine
.
First,
inspect
all
hoses,
fittings,
ducts,
seals,
and
gaskets

in
the
intake
air
tract
for
cracks
or
looseness
.
It
may
be
neces-

sary
to
remove
parts
that
cannot
be
fully
checked
in
their
in-

stalled
positions
.
Also
make
sure
all
of
the
intake
manifold
and

throttle
body
mounting
nuts
are
tight
.

In
addition
to
air
leaks,
air
restrictions
can
also
cause
drive-

ability
problems
.
Remove
the
air
filter
and
hold
it
up
to
a
strong

light
source
.
If
the
filter
does
not
pass
light,
it
is
restricted
and

should
be
replaced
.
Also,
remove
the
intake
air
ductwork
and

check
for
oily
deposits
at
the
throttle
plate
.
Buildup
in
this
area

can
cause
an
erratic
idle
.
Clean
away
any
deposits
using
a

cloth
wetted
withcarburetor
cleaner
and
reinstall
the
ductwork
.

CAUTION-

Do
not
spray
carburetor
cleaner
directly
in
the
throt-
tle
anea
.
Spraying
cleaner
may
force
it
into
the
throt-
tle
position
switch
or
sensor
and
cause
damage
.

catalytic
converter
operation
.



All
of
the
electrical
components
in
the
fuelinjection
and
igni-
tion
systems
require
a
minimum
voltage
to
operate
properly
.

When
troubleshooting
engine
driveability
problems,
one
of
Replacement
of
oxygensensors
at
the
specified
intenrals
en-



the
first
checks
should
be
to
make
sure
the
battery
is
fully
sures
that
the
engine
and
emission
control
system
wili
continue



charged
and
capable
of
delivering
allits
power
to
the
electricalto
operate
as
designed
.
As
the
oxygen
sensor
ages,
its
ability
to



system
.
react
quickly
to
changing
conditions
deteriorates,
and
it
may
eventually
cease
to
produceany
signal
at
all
.



To
make
a
quick
check
of
battery
charge,
measure
the
volt-
age
across
the
battery
terminals
with
all
cables
attached
and
As
the
oxygen
sensor
ages,
its
ability
to
react
quickly
to



the
ignition
off
.
A
fully
charged
battery
will
measure
12
.6
volts
changing
conditions
deteriorates,
and
it
may
eventually
cease



or
slightly
more,
compared
to
12
.15
volts
for
a
battery
with
a
to
produce
any
signal
at
all
.
To
check
theoperation
of
the
oxy-



25%
charge
.
gen
sensor,
see130
Fuel
Injection
.

Even
a
fully
charged
battery
cannot
deliver
power
unless
it

is
properly
connected
to
the
electrical
system
.
Check
the
bat-
tery
terminals
for
corrosion
and
loosecableconnections
.
If
the
battery
does
not
maintain
the
proper
voltage,
the
charging
system
may
be
atfault
.
See
121
Battery,
Starter,
Alternator
.

100-
1
4
ENGINE-GENERAL

0013131

Fig
.
13
.
Main
chassis
ground
(arrow)
inleft
front
of
engine
compart-
ment
.

Fuel
Supply

For
the
engine
tostart
and
run
properly,
the
injection
sys-

tem
must
deliver
fuel
in
precise
proportion
to
the
amount
of
air

entering
the
engine
.
Todo
this,
the
injection
system
requires

an
unrestricted
supply
of
fuel
from
the
fuel
pump
.

If
the
fuel
pump
is
not
working,
the
engine
will
notrun
.
If
the
fuel
filter
or
a
fuel
line
is
restricted,
the
engine
may
run
poorly
.
If
the
restriction
is
severe
enough
the
engine
will
not
start
.
lf

fuel
delivery
problemsare
suspected,
perform
the
tests
de-

scribed
in
160
Fuel
Tank
and
Fuel
Pump
.

The
fuel
pressure
created
by
the
fuel
pump
is
controlled
by
a
pressure
regulator
thatreturns
excess
fuelto
the
tank
.
Any
change
in
fuel
pressure
will
cause
a
change
in
the
base
air-fuel

mixture
delivered
to
the
engine
.
If
the
fuel
pressure
is
too
low,
the

base
air-fuel
mixture
will
be
lean
.
lf
the
fuel
pressure
is
too
high,
the
base
mixture
will
be
rich
.
Fuel
pressure
tests
aredescribed
in
160
Fuel
Tank
and
Fuel
Pump
and130
Fuel
Injection
.

NOTE-

Fuel
pressure
tests
require
a
pressure
gauge
.
If
thistoolís
not
avaílable,
the
tests
can
be
performed
byan
authorized
BMW
dealer
or
other
qualified
shop
.

DRIVEABILITY
TROUBLESHOOTING

Properly
operating
fuel
injectors
play
amajor
role
in
fuel
de-

livery
.
The
DMEECM
switches
the
injectors
on
and
off
at
the

negative
(-)
or
ground
side
of
the
connectors
.
Posítíve
(+)
bat-

tery
voltage
is
always
present
at
the
connectors
when
theen-

gine
is
running
.
An
injector
that
fails
or
loses
power
will
not

open,
creating
a
lean
air-fuel
mixture
and
causing
the
engine
to

run
poorly
when
coldor
stumble
on
acceleration
.
An
injector

that
shorts
to
ground
will
remain
open
constantly
when
the
en-

gine
is
running,
creating
a
richair-fuel
mixture
that
can
dilute

engine
oil,
foul
the
spark
plugs,
cause
a
rough
idle,
and
damage

the
catalytic
converter
.

Table
e
lists
additional
symptoms
of
common
engine
drive-

ability
problems,
their
probable
causes,
and
the
suggested

corrective
actions
.
The
entries
in
boldtype
in
the
corrective

action
column
indicate
the
repair
groups
where
applicable
test

and
repair
procedures
can
befound
.

NOTE-

Most
of
the
symptoms
fisted
in
Table
e
will
also
cause
the
Check
Engine
light
to
come
on
.
If
the
light
is
on,

check
for
any
stored
faults
as
the
first
step
ín
trouble-
shooting
driveability
complaints
.

IGNITION
SYSTEM
DIAGNOSTICS



IGNITION
SYSTEM
SERVICE

Poor
driveability
may
have
a
variety
of
causes
.
The
fault



On
4-cylinder
engines,
an
ignition
coil
pack
is
mounted
to

may
lie
with
the
ignition
system,
the
fuel
system,
parts
of
the



the
passenger
side
strut
tower
in
the
engine
compartment
.

emission
control
system,
or
a
combination
of
the
three
.
Be-



The
coil
pack
integrates
4
individual
coils
.

cause
of
these
interrelated
functions
and
their
effects
oneach

other,
it
is
often
difficult
to
know
where
to
begin
looking
for



On
6-cylinder
engines,
an
ignition
coil
is
located
directly

problems
.



above
each
spark
plug
.

For
this
reason,
effective
troubleshooting
should
alwaysbe-

gin
with
an
interrogation
of
the
On-Board
Diagnostic
(OBD)

system
.
The
OBD
system
detects
certain
emissions-related

engine
management
malfunctions
.
When
faults
are
detected,

the
OBD
system
stores
a
Diagnostic
Trouble
Code
(DTC)
in

the
system
ECM
.
In
addition,
the
Check
Enginewarning
light

will
come
on
if
an
emissions-related
fault
is
detected
.

Two
generations
of
OBD
areusedon
the
cars
coveredby

this
manual
.
See
100
Engine-General
for
OBD
information
.

On-Board
Diagnostics

"
1992-1995
models
............
...
.
..
...



OBD
I

"
1996
and
later
models
.........
.......
..
OBD
II

NOTE-

"
On
carswith
OBD
ti,
specialized
OBD
11
scan
tool

equipment
mustbeused
to
access
DTCs,
either
using

the
BMW
special
tool
or
a
`generic"
OBD
11
scan
tool
.

"
The
OBD
11
fault
memory
(including
an
illuminated

Check
Engine
light)
can
only
be
reset
using
the
spe-

cial
scan
tool
.
Removing
the
connector
from
the
ECM

or
dísconnecting
the
battery
will
not
erase
the
fault

memory
.

Basic
Troubleshooting
Principies

An
engine
that
starts
and
runs
indicates
the
ignition
system

is
fundamentally
working-delivering
voltage
toat
least
some

of
the
sparkplugs
.
A
hard-starting
or
poor-running
engine,

however,
may
indicate
ignition
coil
problems,
cracked
or
dete-

riorated
spark
plug
wires
(4-cylinder
engines
only),
and
worn

or
fouled
spark
plugs
.

WARNING
-

Inefficient
combustion
(richair/fuel
mixture)
can

cause
the
catalytic
converter
to
overheat
and
plug
.

An
overheated
catalytic
converter
can
also
bea
tire

hazard
.

Checking
for
Spark

IGNITION
SYSTEM



120-
3

WARNING
-

If
a
spark
test
is
done
incorrectly,
damage
to
theen-
gine
control
module
(ECM)
or
the
ignitioncoil(s)
may
result
.

Checking
for
spark
is
difficult
onengines
with
distributorless

ignition
systems
.

Try
Rmovng
the
plugs
and
inspecting
for
differences
be-

tween
them
.
A
poor-firing
plug
may
be
wet
with
fuel
and/or

black
and
sooty,
butnot
always
.
If
a
coil
is
not
operating,
the

engine
management
system
will
electrically
disable
the
fuel
injectorto
that
cylinder
.
The
key
is
to
look
for
differences
be-

tween
cylinders
.

Ignition
coil,
testing
and
replacing

(4-cylinder
engine)

1.
Disconnect
mainharness
connector
from
coils
:

"
On
M42
engine,
remove
plastic
covering
from
coils
and

disconnect
individual
harness
connectors
.

"
On
M44
engine,
disconnect
main
harness
connectorat

end
of
coil
pack
.
See
Fig
.
3
.

Fig
.
3
.



Ignition
coil
pack
for
M44
engine
(arrow)
.
Coil
harness
con-

nector
shown
at1
.

IGNITION
SYSTEM
SERVICE

FUEL
INJECTION



130-
3

Fuel
metering
.
The
ECM
meters
fuel
bychanging
the



The
engine
management
system
compensates
automatical-
opening
time
(pulsewidth)
of
the
fuel
injectors
.
To
ensure
that



ly
for
changes
in
the
engine
due
to
age,
minor
wear
or
small
injector
pulsewídth
is
the
only
factor
that
determines
fuel
me-



problems,
such
as
a
disconnected
vacuum
hose
.
Asa
result,
tering,fuel
pressure
is
maintained
bya
fuel
pressure
regula-



idle
speed
and
mixture
do
not
need
lo
be
adjustedas
partof
tor
.
The
injectors
are
mounted
lo
a
common
fuel
supply
called



routine
maintenance
.
the
fuel
rail
.

The
ECM
monitors
engine
speed
to
determine
the
duration



NOTE-

ofinjector
openings
.
Other
signals
to
the
ECM
help
determine



Poordriveabilitymaybe
encountered
when
the
batteryis

injector
pulse
time
for
different
operating
conditions
.
A
tem-



disconnected
and
reconnected
.
when
the
battery
is
dis-
connected,
the
adaptive
memory
is
lost
The
system
will
perature
sensor
signals
engine
temperature
for
mixture
adap-



readaptafterabout
ten
minutes
of
drfving
.
tion
.
A
throttle
position
sensor
signals
throttle
position
.
The
exhaust
oxygen
sensor(s)
signal
information
about
combus-
tion
efficiency
for
control
of
the
air-fuel
mixture
.
1992
to
1995



DISA
(Dual
Resonance
Intake
System)
engines
are
equipped
with
a
single
sensor
.
1996
and
later
(OBD
II)
engines
are
equipped
with
an
oxygen
sensor
before



TheE36
4-cylinder
engine
is
equipped
with
a
dual
intake
andone
after
each
catalytic
converter
.
Forexample,the
M52



runner
system,
termed
DISA
.
DISA
offers
the
advantages
of
engine
is
equipped
withfour
oxygen
sensors
.



both
short
and
long
intake
pipes
.
Long
intake
runners
are
most
useful
at
low
to
medium
engine
rpm
for
producing
good
Idle
speed
control
.
ldle
speed
is
electronically
controlled



torque
characteristics
.
Short
intake
runners
produce
hígherviathe
idle
speed
control
valve,
which
maintains
idle
speed
by



horsepower
at
hígher
engine
speeds
.
bypassing
varying
amounts
of
air
around
theclosed
throttle
valve
.
Idle
speed
is
not
adjustable
.



NOTE-

Knock
(detonation)
control
.
Knock
sensors
monitor
and



The
term
DISA
comes
from
the
German
words
Differen-

control
ignition
knock
through
the
ECM
.
The
knock
sensors



zierte
Sauganlage,
and
can
roughlybe
translated
as
"dif-
fering
intake
manifold
configuration
."
See
100
Engine-
function
like
microphones
and
are
able
to
convert
mechanical



General
foradditional
information
on
DISA
operation
.
vibration
(knock)
into
electrical
signals
.
The
ECM
is
pro-

grammed
to
react
to
frequencies
that
are
characteristic
of
en-



Manifold
construction
:
The
intake
manifold
is
a
two-piece
gine
knock
and
adapt
the
ignition
timing
point
accordingly
.



metal
construction,
with
a
pair
of
runners
in
thetop
section
See120
Ignition
System
for
further
details
.



and
four
runners
in
the
lower
section
.
A
butterfly
valve
is
in-
stalled
in
the
lower
section,
enabling
the
DISA
solenoid
toiso-

NOTE-



late
one
pair
of
runners
from
the
other
pair
.
See
Fig
.
2
.

The
1992
M50
engine
is
not
equipped
with
knock
sen-



Operation
.
With
the
DISA
butterfly
valve
closed,
the
pipes
sors
.
All
other
engines
are
equipped
with
two
knock



in
thetop
half
of
the
manifold
act
together
with
the
ram
air
sensors
.



pipes
in
the
lower
halfto
producea
single,
long
air
intake
pipe
for
each
cylinder
.
See
Fig
.
3
.
The
column
of
aír
oscíllating
in

Basic
Engine
Settings



this
combined
pipe
significantly
increases
engine
torque
in
the

medium
rpm
range
.

Idle
speed,
idle
mixture
(%CO),
and
ignition
timing
arenot

adjustable
.
The
adaptive
engine
management
system
is
de-

signed
to
automatically
compensate
for
changes
in
engine
op-

eratingconditions,
although
the
adaptive
range
is
limited
.
Once

these
limits
are
exceeded,
driveability
problems
usually
be-

come
noticeable
.

Above
approximately
4,800
rpm,
the
butterfly
valve
between
the
intake
air
pipes
for
the
two
cylinder
groups
is
opened
.
The
shorter
pipes
in
the
lower
manifold
section
now
become
the

main
suppliers
of
ram
air
to
the
cylinders,yielding
greater
pow-

er
at
the
upper
end
of
the
engine
rpm
range
.
See
Fig
.
4
.

Control
components
.
The
DISA
butterfly
valve
is
actuated

NOTE-



electro-pneumatically
via
the
engine
control
module
(ECM)
.

lf
the
system
adaptive
limits
are
exceeded,
the
Check



The
valve
begins
to
open
as
engine
speed
rises
aboye
4,840

Engine
light
will
most
likely
come
on,
indicating
an



rpmand
closes
below
4,760
rpm
.
The
action
of
the
valve
is
de-
emissions-
related
fault
For
Check
Engine
light
diag-



liberately
delayed
to
prevent
it
from
opening
and
closing
repeat-
nostics,
see100
Engine-General
.



edly
within
a
short
time
.

GENERAL

The
fuel
injection
systems
used
on
the
1996
and
later
cars
covered
bythis
manual
are
OBD
II
compliant
.
This
system
is
in-
corporated
into
both
the
Bosch
M5
.2
(M44
engine)
and
the
Si-
emens
MS
41
.1
(M52/S52US
engine)
engine
management
systems
.
OBD
II
systems
use
sophisticateddiagnostic
soft-
ware
capable
of
recognizing
and
electronically
storing
hun-
dreds
of
DTCs
in
the
system
ECM
.
DTCs
can
only
be
accessed
using
special
scan
tooltest
equipment
.
The
BMW
dealer
is
equipped
with
the
specialized
OBD
II
scan
toolto
quickly
and
efficiently
locate
engine
management
problems
.
Alternately,
a
"generic"
scan
tool
can
be
used
to
access
OBD
II
fault
informa-
tion
.

NOTE-

"
At
the
time
this
manual
went
to
press,
generic
scan
tools
were
notwidely
available
for
BMW
vehicles
.
The
generic
sean
tool
is
a
specialized
toolthat
plugs
into
a
standardized
OBD
11
connector
on
1996
and
later
pas-senger
vehícles
built
for
sale
in
the
US
.

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

"
The
16-pin
OBD
11
diagnostic
connector
is
located
on
the
lower
left
dash
panel
.
Refer
to
Fig
.
1
.

6

1
.
Secondary
air
pump
2
.
Electric
solenoid
valve
3
.
One-way
check
valve
4
.
Intake
manifold
5
.
Exhaust
manifolds
6
.
Secondary
air
check-valve

®
G~



i

o
o



0
0
G
0000
o



,-
00

~

1111111
in

,,
0
1--

a

Fig
.
5
.



Components
of
6-cylinder
secondary
air
injection
system
.
4-
cylinder
system
is
similar
.

Secondary
AirInjection

FUEL
INJECTION



130-
5

All
OBD
II
6-cylinder
engines
are
equípped
with
asecond-
ary
air
injection
system
.
In
addition,
beginning
in
January
1997,
the
M44
engine
was
classified
as
a
TLEV
(Transitional
Low
Emission
Vehicle)
engine
and
is
also
equipped
with
sec-
ondary
air
injection
.

Typical
components
of
the
secondary
air
injection
system

are
depicted
in
Fig
.
5
.

Secondary
air
injection
usesan
electric
pump
to
pump
fresh
air
finto
the
exhaust
systemupstream
of
the
catalytic
converter
during
engine
warm-up
.
By
providing
extra
oxygen
to
the
un-
burned
fuel
in
the
exhaust,
hydrocarbons
oxidize
and
carbon

monoxide
combines
with
oxygen
to
form
carbon
dioxide
andwa-
ter
.
The
air
injection
pump
stops
within
a
specified
timed
intenral
.

4

0013120

GENERAL

130-
6



FUEL
INJECTION

Warnings
and
Cautions

For
personal
safety,
as
well
as
the
protection
of
sensitive

electronic
components,
the
following
warnings
and
cautions

should
be
adhered
to
when
working
on
the
engine
manage-

ment
system
.

GENERAL
WARNING
-

"
The
ignition
system
produces
high
voltages
that

can
be
fatal
.
Avoid
contact
with
exposed
termi-

nals
.
Use
extreme
caution
when
working
onacar
with
the
ignition
switched
on
or
the
engine
run-
ning
.

"
Do
not
touch
or
disconnect
any
high
voltage
ca-

bles
from
the
coils
or
spark
plugs
while
the
engine

is
running
or
beingcranked
by
the
starter
.

"
Connect
and
disconnect
the
DME
system
wiring
and
test
equipment
leads
only
when
the
ignition
is
switched
off
.

"
Gasoline
is
highly
flammable
and
fts
vaporsare

explosive
.
Do
not
smoke
or
work
on
a
car
near
heaters
or
other
fire
hazards
when
diagnosing
and
repalring
fuel
system
problems
.
Have
a
tire
extinguisher
avaílable
in
case
of
an
emergency
.

"
When
working
onan
open
fuel
system,
wear
suit-
able
hand
protection,
asprolonged
contact
wfth
fuel
can
cause
illnesses
and
skin
disorders
.

"
Renew
fuel
system
hoses,
clamps
and
O-rings
any
timethey
are
removed
.

"
Before
makingany
electrical
tests
that
require
the
engine
to
be
cranked
using
the
starter,
disable
the
ignition
system
as
described
in
120
Ignition
System
.

CAUTION-

"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnectinn
cautions
given
at
the
front
of
this
manual
onpage
vifi
.

"
Do
not
connect
any
test
equipment
that
delivers

a
12-volt
power
supply
to
terminal
15
(+)
of
the
ig-

nitioncoil
.
The
current
flow
may
damage
the

ECM
.
In
general,
connect
test
equipment
only
as

speclfied
by
BMW,
this
manual,
or
the
equipment

maker
.

"
Only
use
a
digital
multlmeter
for
electrical
test
.

"
Only
use
an
LED
test
light
for
quick
tests
.

"
Disconnecting
the
battery
may
erase
fault

code(s)
stored
in
memory
.
Check
for
fault
codes

prior
to
disconnecting
the
battery
cables
.
ff
the

Check
Engine
light
ís
illuminated,
see100En-
gine-General
for
DME
fault
code
information
.
ff
any
other
system
faults
have
been
detected
(indi-
catedbyan
illuminated
warning
light),
see
an
au-
thorized
BMW
dealer
.
Additional
systems
with
self-diagnostic
capabilities
include,
ABS
(Anti-
lock
brakes),
SRS
(Airbags),
EML
and
ASC+T
and
AST
(Traction
Control)
.

"
Do
not
run
the
engine
wfth
any
of
the
spark
plug
wires
dlsconnected
.
Catalytic
converter
damage
may
result
.

"
Always
waitat
least
40
seconds
afterturning
off
the
ignition
before
removing
the
engine
control
module
(ECM)
connector
.
ff
the
connector
isre-
moved
before
this
time,
residual
power
in
the
sys-
tem
relay
may
damage
the
control
module
.

"
Cleanliness
is
essential
when
working
onan
open
fuel
system
.
Thoroughly
clean
fuel
line
con-
nections
and
surroundlng
areas
before
loosen-
ing
.
Avoid
moving
the
car
.
Only
fnstall
cleanparts
.

"
Fuel
system
cleaners
and
other
chemical
addi-
tives
other
than
those
specifically
recommended
by
BMW
may
damage
the
catalytic
converter,
the
oxygensensor
or
other
fuel
supply
components
.

130-
8



FUEL
INJECTION

Fig
.
8
.



Fuel
pump
relayterminal
identification
.
1.
Peel
back
rubber
boot
on
oxygen
sensor
electrical
har-
ness
connector
(car
wiring
side)
.
With
connector
at-
Oxygen
sensor,
testing



tached
to
sensor,
connect
digital
voltmeter
to
pins
1
(BOSch
systems
only)



and
2
in
rear
of
connector
.
See
Fig
.
10
.

CAUTION-

"
The
information
inthis
sectionapplies
to
Bosch
engine
management
systems
only
.

"
The
Siemens
MS
41
.1
system
uses
resistive-type
oxygen
sensors
.
This
sensor
uses
a
5-volt
refer-
ence
signal
input
and
the
output
to
the
ECM
var-
ees
from
1-5
volts,
in
stepped
increments
based
on
oxygen
content
in
the
exhaust
.

NOTE-

"
On
pre-08D
11(1992-1995)
cars,
there
is
one
oxygen
sensor
mounted
upstream
of
the
catalytic
convert-
er(s)
in
the
exhaust
pipe
.
See
Fig
.
9
.
"
On
OBD
11
cars
(1996-1998)
cars,
there
is
one
oxygen
sensor
before
andone
after
each
catalytic
converter
.

"
OnM52
and
S52US
engines,
the
front
pairof
oxygen
sensors
are
installed
in
the
exhaust
manifolds
.

The
oxygen
sensor
providesan
input
voltage
signal
(0-1
VDC)
to
the
ECM
based
on
the
oxygen
content
in
the
exhaust
gas
.
TO
generate
voltage,
the
sensor
temperature
must
exceed
575°F
(300°C)
.
Therefore
it
ís
electrically
heated
.

NOTE-

"
The
test
given
below
is
not
a
conclusive
test
of
oxygen
sensor
efficiency
and
does
not
test
how
quickly
the
oxygensensor
can
react
to
changing
conditions
.

"
Pin
numbers
and
wirecolors
can
vary
.
Always
check
the
wiring
diagrams
to
conflrm
wire
color
and
pinas-
signment
.

ELECTRICAL
CHECKS
AND
COMPONENT
TESTING

0013135

Fig
.
9
.



Oxygen
sensor
location
(arrow)
ahead
of
catalytic
converter
.
3181
model
with
M42
engine
shown
.

1
.
Black
(ground)
2
.
Grey
(signal)



4
.
White
(heater
circuit)
3
.
White
(heater
circuit)

0013189
Fig
.
10
.
Oxygen
sensor
connector
terminal
identification
(sensor
sede)
.
Terminals
numbers
are
molded
into
connector
.

2
.
Start
engine
.
Oxygen
sensorshould
start
to
output
a
fluctuating
voltage
within
a
short
period
.
If
voltage
is
in-
correct,
turn
engine
off
and
check
preheater
circuit
as
described
below
.

WARNING
-

Exhaust
manifolds
and
pipes
can
be
hot
enough
to
cause
serious
burns
.
Wear
suitable
heavy
gloves
and
other
appropriate
protection
.

GENERAL
.
.
.......
.
......
.
...
.
.
.
.
.
...
180-1



Exhaust
system,
removing
and
installing
.
...
.180-3

EXHAUST
SYSTEM
REPLACEMENT
.
...
180-1



Exhaust
manifolds,
removing
and
installing
.
.
.180-5

GENERAL

The
exhaust
system
is
designed
to
be
maintenance
free,
al-
though
regular
inspection
is
warranted
due
to
the
harsh
oper-
atingconditions
.
Under
normal
conditions,
the
catalytic

converter
does
not
require
replacement
unless
it
is
damaged
.

On
1996
and
later
cars,
a
pre-
and
post-catalytic
converter

oxygen
sensor
is
used
at
each
catalytic
converter
.
Be
sure
to

take
care
when
removingthe
system
not
to
damage
the
sen-



EXHAUST
SYSTEMREPLACEMENT
sors
.

See
130
Fuel
Injection
for
information
on
testing
oxygen

sensors
.

NOTE-

OnM52
engines,
two
resonator
pípes
(short
and
long)
are
incorporated
into
the
rear
muffler
assembly
.
See
Fíg
.
1
.
An
exhaust
flap
is
integrated
into
the
outlet
side
of
the
short
pipe
.
The
flap
is
operated
by
a
vacuum
ac-
tuator
via
the
Siemens
MS
41
.1
engine
control
mod-
ule)
.
The
flap
is
closed
at
engine
speeds
below
2,500
rpm
.
This
allows
exhaust
gasses
to
flow
through
the
long
resonator
pipe
and
reduce
noise
.
Above
2,500rpm,
the
exhaust
flap
is
open
(no
vacuum
applied
to
the
actuator)
and
allows
exhaust
gasses
to
flow
through
the
short
pipe
for
maximum
performance
.

180
Exhaust
System

0013101

Fig
.
1
.



Rear
muffler
(active
silencer
usedon
M52
engines)
.
Vacuum

operated
flap
(A)
changesbetween
short
and
long
pipes,
de-

pending
on
engine
speed
.

EXHAUST
SYSTEM



180-1

WARNING
-

Exhaust
gases
are
colorless,
odorless,
and
very
toxic
.
Run
the
engine
only
ín
a
well-ventilated
area
.
Immediately
repair
any
leaks
in
the
exhaust
system
or
structural
damage
to
the
car
body
that
might
al-
lowexhaust
gases
to
enter
the
passenger
compart-
ment
.

Exhaustsystem
components
are
detailed
in
Fig
.
2
through

Fig
.
4
.

New
fasteners,
clamps,rubber
mounts,
and
gaskets
should

be
used
when
replacing
exhaust
components
.
A
liberal
appli-
cationof
penetrating
oil
to
the
exhaustsystem
nuts
and
bolts
in
advance
may
make
removal
easier
.

WARNING
-

"
The
exhaust
system
and
catalytic
converter
op-
erate
at
high
temperatures
.
Allow
components
to
cool
before
servicing
.
Wear
protectíve
clothíng
to
prevent
bums
.
Do
not
use
flammable
chemicals
near
a
hot
catalytic
converter
.

"
Old,
corroded
exhaust
system
components
crumble
easíly
and
often
have
exposed
sharp
edges
.
To
avoid
injury,
wear
eye
protection
and
heavy
gloves
when
working
with
old
exhaust
parts
.

EXHAUST
SYSTEM
REPLACEMENT

T

610-16



ELECTRICAL
COMPONENT
LOCATIONS

Component



Model
Year



Location



Refer
to

MixingSwitch



1992-1994



Center
console

Multi-Function
Clock



1992-1998



Center
console

Multi-information
Display
(MDI)



1992-1998



Center
console

Normal
Speed
Cooling
Fan
Relay



1992-1998



Power
distribution
box



Fig
.
2
.

Neutral
SafetySwitch
(Automatic



1992-1998



Next
to
gear
shift
lever
in
center
console



Fig
.
29
.

Transmission
Range
Switch)

Oil
Pressure
Switch



1992-1998



Left
front
of
engine
below
intake
manifold
at
oil
filter
housing

On-Board
Computer



1992-1998



Center
console

On-BoardComputerHorn
Relay



1992-1998



Behind
glove
compartment



Fig
.
8
.
Fig
.
9
.

On-Board
Computer
Temperature



11992-1998



I
Right
front
of
engine
compartment

Sensor

Outside
Temperature
Sensor



1992-1997



Inright
front
brake
cooling
duct

Outside
Temperature
Sensor



1998



Right
rear
of
engine
compartment
behind
fresh
air
cowl

Oxygen
Sensor
HeaterRelay



1992-1998



Power
distribution
box



Fig
.
2
.

Oxygen
Sensor(s)



1992-1998



On
exhaust
pipe
ahead/behind
catalytic
converter
(M42/M44
engine)

Oxygen
Sensor
(x2)



1992-1995



On
exhaust
pipe
ahead
of
catalytic
converter
(M50/S50US
engine)

Oxygen
Sensors
(x4)



1996-1998



On
exhaust
manifold/exhaust
pípe
behind
catalytic
converter
(M52/S52US
engine)

Parking
Brake
Switch



1
1992-1998



I
On
rear
of
parking
brake
lever

Power
Distribution
Box



11992-1998



I
Rear
left
of
engine
compartment



I



Fig
.
2
.
Fig
.
7
.
Fig
.
10
.

Radio
Microswitch



1992
-
1996



Center
console
behind
radio

Radio
Receíver



1
1997-1998



1
Right
rear
luggage
compartment

Relay
And
Fuse
Box
(Power



1992-1998



I
Left
side
of
engine
compartment



I



Fig
.
2
.

Distribution
Box)



Fig
.
7
.
Fig
.
10
.

Rear
Window
Blower



1994-1998



Behind
rear
seat
(convertible)

Rear
Window
Blower
Microswitch



1994-1994



At
convertible
top
linkage

Rear
Window
Blower
Microswitch



1995-1998



Behind
rear
seat
(convertible)

Rear
Window
BlowerRelay



11994-1998



Behind
glove
compartment



Fig
.
8
.
Fig
.
9
.

Fig
.
2
.

Fig
.
30
.

Fig
.
8
.

Rear
Window
DefoggerRelay

Reversing
(Back-up)
Light
Switch

SplicePanel,
Right
Rollover
Protection
Actuator



11994-1998

COMPONENT
LOCATIONS

Table
a
.
E36
Component
Locations

1992-1998
1992-1998

1992-1998

Power
distribution
box

Right
or
left
side
top
of
transmission

Behind
glove
compartment

Behind
rear
seat
(convertible)

Fig
.
9
.

Continued