check engine BMW 328i 1992 E36 Manual PDF

5
.
Remove
air
filter
housingcomplete
with
mass
air
flow
sensor
.
See113
Cylinder
HeadRemoval
and
Instal-
lation
.

6
.
Remove
oil
dipstick
guide
tube
mounting
bolt
.
Discon-
nect
oil
separator
hose
frombase
of
guide
tube
and
re-
move
tubefrom
oil
pan
(where
applicable)
.
See
Fig
.
10
.

NOTE-

The
guide
tube
is
sealed
in
the
blockusing
an
O-ring
.
Check
that
the
O-ring
comes
out
with
the
tube
.
Use
a
new
O-ring
when
installing
the
tube
.

Fig
.
10
.
Oil
dipstick
guide
tube
being
removed
.
Use
new
O-ring
(ar-
row)
during
installation
.

7
.
M50/S50US
engine
:
Using
a
clean
syringe,
remove
power
steering
fluid
from
fluid
reservoir
.
Disconnect
power
steering
fluid
lines
from
steering
rack
.
See
320
Steering
and
Wheel
Alignment
.

8
.
M52/S52US
engine
:
Unbolt
power
steering
reservoir
from
engíne,
then
tie
to
chassis
with
wire
.

9
.
Insta¡¡
engine
lifting
equipment
atfront
engine
lifting
point
and
raise
engine
approximately
5
mm
('/a
inch)
until
engineweight
is
supported
.
See
Fig
.
11
.

10
.
Workingbeneath
car,
separate
steering
column
shaft
from
steeringrack
at
universal
joint
.

"
Mark
steering
column
shaft
jointto
steering
rack
spin-

dle
.
Point
wheels
straight
ahead
before
disconnecting
shaft
from
rack
.
See
320
Steering
and
Wheel
Align-
ment
.

LUBRICATION
SYSTEM



119

Fig
.
11
.
Engine
lifting
equipment
shown
installed
acrossengíne
.

CA
UTION-

In
order
to
avoid
the
need
for
front-end
realign-
ment,
donot
unbolt
power
steering
rack
from
sus-
pension
crossmember
.

11
.
Support
suspension
crossmember
from
below
using
appropriate
jacking
equipment
.

12
.
Loosen
nuts
at
top
of
left
and
right
side
engine
mounts
.
Remove
nuts
from
bottom
of
left
and
right
side
engine
mounts
.

13
.
At
left
and
right
sides,
unbolt
control
arm
bushíng
carri-
ers
from
body
.
Disconnect
stabilizer
bar
links
fromcon-
trol
arms
.
Refer
to
Fig
.
3
.

14
.
Remove
bolts
from
left
and
right
sides
of
suspension
crossmember
and
lower
front
axle
as
far
as
possible
.

15
.
Remove
fuelline
clamping
brackets
from
oil
pan
.
On
cars
with
automatic
transmission,
remove
ATF
cooler
line
brackets
from
oil
pan
.

16
.
Remove
oil
pan
screws
.
Lower
and
remove
oil
pan
for-
ward
to
remove
.

CA
UTION-

If
the
oil
pan
does
not
separate
easily
from
the
en-
gine
cylinder
block,
a
few
taps
with
a
rubber
mallet
shouldbreak
it
free
.
Do
notpry
the
oil
pan
loose
.

OIL
PAN

119-
1
0



LUBRICATION
SYSTEM

Oil
pump,
removing
and
installing

(6-cylinder
engine)

Oil
pressure
on
the
6-cylinder
engines
is
generated
by
a
gear-type
pump
bolted
to
the
bottom
of
the
engine
block
.
The
oil
pump
is
chain
driven
off
the
front
of
the
crankshaft
.

NOTE-

Oil
pump
removal
requires
raising
the
engine
(cars
built
up
to
9-92)
or
lowering
the
front
suspension
crossmem-
ber
(cars
built
from
9-92)
to
remove
the
oil
pan
.

1.
Drain
oil
as
described
in
020
Maintenance
Program
.

2
.
Remove
oil
pan
as
described
earlier
.

3
.
Remove
oil
pump
sprocket
mounting
nut
(left-hand
thread)
.
See
Fig
.
16
.
Lift
sprocket
off
together
with
drive
chain
.

Fig
.
16
.
Oil
pump
sprocket
mounting
nut
(left-hand
thread)
on
6-cylin-
der
engine
(arrow)
.

4
.
Remove
mounting
bolts
from
oil
pump
and
oil
pump
pickup
tube
.
Withdraw
pump
.

NOTE-

Note
any
spacers
between
pump
and
engine
block
.
See
Fig
.
17
.

"
Note
position
of
locating
dowels
.

OIL
PUMP

811186

0011952

Fig
.
17
.
Oil
pump
mounting
points
(1)
and
pickup
tube
mountíng
points
(2)
.

5
.
Remove
coverfrom
oil
pump
and
check
for
wear
or
scoring
.
Spin
oil
pump
shaft
and
check
that
gears
turn
smoothly
.
Replace
pump
if
gears
spinwith
difficulty
or
any
wear
is
present
.

6
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Align
sprocket
splines
to
oil
pump
shaft
splines
before

tightening
sprocket
nut
.

Tightening
Torques

"
Oil
pump
to
engine
block
(M8)
......
22
Nm
(16
ft-Ib)

"
Oil
pan
to
engine
block
(M6
bolt)

8
.8
grade
..
...
.
...
...
.
.........
10
Nm
(89
in-lb)

10
.9
grade
.
...
.
..
....
.
........
12
Nm
(106
in-lb)

"
Oil
pump
sprocket
to
oil
pump
shaft
(M1
0x1
left-hand
thread)
..........
25
Nm
(18
ft-Ib)

GENERAL
.
........
.
...........
.
.
.
.
.
.
.
120-1



Camshaft
Position
(CMP)
Sensor
....
.
.
.
...
120-6

Disabling
Ignition
System
.
.
.
.
.....
.
.
.
.
.
.
.
120-2



Camshaft
position
(CMP)
sensor,
replacing

Warnings
and
Cautions
.
.
.
.
.
.
.....
.
.
.
.
.
.
.
120-2



(4-cylinder
engine)
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
120-6

Camshaft
position
(CMP)
sensor,
replacing

IGNITION
SYSTEM
DIAGNOSTICS
.
.
.
.
.
.
120-3



(6-cylinder
engine)
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
120-7
Basic
Troubleshooting
Principles
...
.
.
.
.
.
.
.
120-3



Knock
sensors,
replacing
.
.
...
.
.
.
.
.
.
.
.
.
.
.
.
120-7

Ignition
Firing
Order
.....
.
...
.
.
.
.....
.
.
.
.120-7

IGNITION
SYSTEM
SERVICE
.
.........
.
120-3

Checking
for
Spark
..
.
.
.
.
.
.
.
.
.
.......
.
.
.
120-3

Ignition
coil,
testing
and
replacing

(4-cylinder
engine)
.
.
.
.
.
.
.
.
.
.
.........
.
120-3

Ignition
coil,
testing
and
replacing

(6-cylinder
engine)
.........
.
..........
120-4

Crankshaft
Positionlrpm
Sensor
.......
.
...
120-5

Crankshaft
position/rpm
sensor,
testing
and

replacing
(front
mounted)
.........
.
.
.
.
.
.
120-6

Crankshaft
position/rpm
sensor,replacing

(rear
mounted)
.....
.
.....
.
.....
.
.
.
.
.
.
120-6

GENERAL



Troubleshooting
and
testing
of
the
engine
management

system
should
be
carried
out
using
the
BMW
specialized
ser

This
repair
group
covers
repair
andcomponent
replace-



vice
tester
(scan
tool)
.

ment
information
for
the
ignition
system
.
All
engines
use
a
distributorless
ignition
system
with
indívid-

ual
ignitioncoils
for
each
cylinder
.
There
is
no
distributor
cap

NOTE-



or
ignition
rotor
.
Each
coil
can
be
selectively
controlled
by
the

"
Spark
plug
replacement
is
covered
in
020
Mainte-



engine
control
module
on
a
cylinder-by-cylinder
basis
.
On
later

nance
Program
.



systems,
knock
sensors
are
used
to
monitor
and
control
igni-

"
For
fuel
related
troubleshooting
and
testing,
see
130



tion
knock
(ping)
and
adjusttiming
accordingly
.

Fuel
lnjection
.
Ignition
timing
is
electronically
controlled
and
not
adjust-

All
engines
covered
by
this
manual
use
an
advanced
en-



able
.
The
engine
control
module
(ECM)
usesengine
load,
en-

gine
management
system
.
The
engine
management
system



gine
speed,
coolant
temperature,
and
intake
air
temperature

incorporates
on-board
diagnostics,
fuel
injection,
ignition
and



as
the
basic
inputs
for
timing
control
.
Knock
detection
is
also

other
advanced
engine
control
functions
.



an
input
to
the
control
module,
where
applicable
.

Table
a
.
Engine
Management
System
Variants

Engine
code



1
System

4-cylinder
M42
(1.8
I)



Bosch
DME
Ml
.7
M44
(1
.9
I)



Bosch
DME
M5
.2
(OBD
II)

6-cylinder
M50
1992
(2.5
I)



Bosch
DME
M8
.1
1993-1995
(2
.5
I)



Bosch
DME
M33
.1
M52
1996-1998
(2.8
I)



Siemens
MS
41
.1
(OBD
II)

1998
(2
.5
I)



Siemens
MS
41
.1
(013D
11)
S50US
(3.0
I)



Bosch
DME
M3
.3.1
S52US
(3.2
I)



Siemens
MS
41
.1
(OBD
II)

120
Ignition
System

IGNITION
SYSTEM



120-1

IGNITION
SYSTEM
SCHEMATICS
...
.
.
.
.120-7

TABLES

a
.
Engine
Management
System
Variants
......
120-1

b
.
Ignition
Coil
Resistance
(M42
engine)
......
120-4

c
.
Ignition
Coil
Resistance
(M44
engine)
......
120-4

d
.
Ignition
Coil
Resistance

(6-cylinder
engine)
..
.
.
.
.
.
.
.
.
.
.
.
.....
.
..
120-5

NOTE-

All
engines
coveredby
this
manual,
with
theexception

of
the
1992
M50,
incorporate
knocksensors
as
part
of

the
engine
management
system
.

The
initial
ignition
point
is
determined
by
the
crankshaft
po-

sition/rpm
sensor
during
cranking
.
Once
the
engine
is
run-

ning,
timing
is
continually
adjusted
based
on
operating

conditions
.
A
characteristic
ignition
map
is
shown
in
Fig
.
1
.
A

map
similar
to
the
one
shown
is
digitally
stored
in
the
engine

control
module
.

GENERAL

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

120-
4



IGNITION
SYSTEM

2
.
Check
for
battery
voltage
o
cofs
.
If
voltage
is
not



Table
b
.
Ignition
Coil
Resistance

present,
check
wire
between
terminal
15
and
ignition



(M42
Engine)
switch
.
See
Electrical
Wiring
Diagrams
.

"
On
M42
engine,
connect
digital
multimeter
between
ter-

minal
15(+)
in
each
harness
connector
and
ground
.
See

Fig
.
4
.

"
On
M44
engine,
connect
voltmeter
between
terminal
2

(15+)
in
connector
and
ground
.
Turn
ignition
on
and

check
for
voltage
.
See
Fig
.
5
.

3
.
Turn
ignition
off
.

0
4a15

Fig
.
4
.



Ignition
coil
harness
connector
terminal
identification
for
M42

engine
.

Fig
.
5
.



Ignition
coil
harness
connector
terminal
identification
for
M44
engine
.

CAUTION-

The
wiring
to
the
coil(via
the
ignition
switch
15+)
is
not
fuse
protected
.
Use
care
when
testing
thiscircuit
.

4
.
Use
a
digital
multimeter
totest
coil
primary
resistance
.

"
On
M42
engine,
use
Table
b
asa
guide
to
check
coil

resistance
.
Make
checks
at
each
harness
connector
.

"
On
M44
engine,
use
Table,c
as
a
guide
to
check
coil
primary
resistance
.

5
.
Inspect
coil
housing
for
hairline
cracks
or
leaking
cast-
ing
material
.
See
Fig
.
7
.
A
leaky
ignition
coil
may
indi-



11502

cate
a
faulty
ECM
(engine
control
module)
.
Check
the
ECM
before
installing
a
new
coil
.



Fig
.
6
.



Ignition
coil
harnessconnector
terminal
identification
for
6-
cylinder
engine
.

IGNITION
SYSTEM
SERVICE

11502

Terminals
Resistance
(refer
to
Fig
.
4
.)

Coil
primary



1
(-)
and
15
(+)



10
.4-0
.8
ohms

Coil
secondary



N
.A
.



N
.A
.

Table
c
.
Ignition
Coil
Resistance

(M44
Engine)

Terminais
Resistance
(referto
Fig
.
5
.)

Coil
#1
primary



1
(-)
and
2
(+)



0
.4-0
.8
ohms

Coil
#2
primary



6
(-)
and2
(+)



0
.4-0
.8
ohms

Coil
#3
primary



7
(-)
and
2
(+)



0
.4-0
.8
ohms

Coil
#4
primary



5
(-)
and2
(+)



0
.4-0
.8
ohms

Coil
secondary



N
.A
.



N
.A
.

NOTE-

If
a
single
coilís
faulty
on
M44
engines,
the
complete
coil
pack
will
have
to
be
replaced
.

Ignition
coil,
testing
and
replacing

(6-cylinder
engine)

CAUTION-

Use
a
digital
multimeter
for
the
following
tests
.

1.
Remove
plastic
enginecovers
from
top
of
engine
by

prying
off
nut
covers
and
removingcover
mounting

nuts
.
See
113
Cylinder
HeadRemoval
and
Installa-

tion
.

2
.
Disconnect
harnessconnectorfromcof
.
Connect
mul-
timeter
between
terminal
15
(+)
in
connector
and

ground
.
See
Fig
.
6
.

3
.
Turn
ignition
on
and
check
for
batteryvoltage
.

"
If
batteryvoltage
is
not
present,
check
wire
between

terminal
15
and
ignition
switch
.
See
Electrical
Wiring

Diagrams
.

"mozo

CAUTION
-

The
wiring
to
termina¡
15
(+)
of
the
coil(vía
the
ig-

nition
switch)
is
not
fuse
protected
.
Use
care
when
testíng
thiscircuit
.

4
.
Turn
ignition
off
.

5
.
Use
a
multimeter
to
test
coil
primary
resistanceat
coil

terminals
.
See
Table
d
.

Table
d
.
Ignition
Coil
Resistance

(6-cylinder
Engine)

Terminals
Resistance

(referto
Fig
.
4
.)

Coil
primary



1
1
(-)
and
15
(+)



X
0
.4-0
.8
ohms

Coil
secondary



l
N
.A
.



N
.A
.

6
.
Remove
coil
and
inspect
coil
housing
for
hairline
cracks

or
leaking
casting
material
.
See
Fig
.
7
.
A
leaky
ignition

coil
may
indícate
a
faulty
engine
control
module
(ECM)
.

Check
ECM
before
installing
a
new
coil
.

811004

Fig
.
7
.



Ignition
coil
being
removed
on
6-cylinder
engine
(M52
engine

shown)
.

CA
UTION-

"
Note
location
of
coil
ground
straps
before
coilre-

moval
;
reinstallin
the
same
location
.

"
When
replacing
ignition
coils,
ensure
that
the
re-

placement
coil(s)
are
from
the
same
manufactur-

er
containing
the
same
partlcode
numbers
.
If

individual
coils
with
the
correct
specifications
are
not
available,
all
coils
should
be
replaced
.

IGNITION
SYSTEM



120-
5

Crankshaft
Position/rpm
Sensor

If
the
engine
control
module
(ECM)
does
not
receive
a

crankshaft
position
signal
during
cranking,
the
engine
will
not

start
.

On
1992-1995(pre-OBD
II)
cars,
the
crankshaft
posi-
tion/rpm
sensor
is
mounted
on
the
front
engine
cover
and

reads
the
toothed
vibration
dampener
wheel
.
See
Fig
.
8
.

Fig
.
8
.



Crankshaft
position/rpm
sensor
mounted
at
front
of
engine
on
1992-1995
cars
.
(arrow)
.

On
1996
and
latee
cars
(OBD
II
compliant),
the
crankshaft
position/rpm
sensor
is
mounted
in
the
left
rear
side
of
the
cyl-

inderblock
.
The
sensor
reads
a
toothed
wheel
mounted
to
the

end
of
the
crankshaft
.
See
Fig
.
9
.

Fig
.
9
.



Crankshaft
position/rpm
sensor
toothed
wheel
mounted
to

rear
of
crankshaft
OBD
II
compliant
cars
.
The
sensor
is

mounted
in
the
left
rear
side
of
the
cylinder
block
.

IGNITION
SYSTEM
SERVICE

120-
6



IGNITION
SYSTEM

Crankshaft
position/rpm
sensor,

testing
and
replacing
(front
mounted)

1
.
Disconnect
sensor
harness
connector
.

2
.
Using
a
digital
multimeter,
check
resistance
between
terminals
1
and
2
in
connector
.
See
Fig
.
10
.

n1
n2n3

Fig
.
10
.
Crankshaft
position/rpm
sensorconnector
.

Crankshaft
positionlrpm
sensor
specifications

"
Coil
resistance
(approx
.)
terminais
1
and
2
....
.
..
...
....
1280
±
10%
ohms

"
Air
gap
(sensor
distance
from
toothed
wheel)
..
.
.
........
.1
.0
±
0
.3
mm
(0
.04
±
0
.01
in
.)

3
.
If
the
resistance
is
not
correct,
the
sensor
is
faulty
and
should
be
replaced
.

NOTE
-

When
installing
the
new
sensor,
be
sure
thewiring
Is
rerouted
in
the
same
orientation
.
Secure
the
sensor
us-
ing
new
wire
ties
.

Tightening
Torque

"
Crankshaft
position/rpm
sensor
to
mounting
bracket
.........
.
.
5
t
1
Nm
(62
t
9
in-lb)

Crankshaft
position/rpm
sensor,



4
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring
replacing
(rear
mounted)



when
installing
sensor
.
Be
sure
wiring
is
rerouted
in
same
orientation
.
1
.
Disconnect
sensor
harness
connector
.

6502AGN56

2
.
Locatesensor
on
rear
left
sideof
cylinder
block
.
Re-
move
sensormounting
bolt
and
remove
sensorfrom
cylinder
block
.

IGNITION
SYSTEM
SERVICE

3
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring

when
installing
sensor
.
Be
sure
wiring
is
rerouted
in
same
orientation
.
Secure
sensor
using
new
wire
ties
.

NOTE-

It
may
be
easier
to
remove
the
sensor
working
from
the
underside
of
the
vehicle
.

Camshaft
Position
(CMP)
Sensor

The
camshaft
position
(CMP)
sensor
is
usedby
the
engine
management
system
for
sequential
fuel
injection
and
knock
control
.

Camshaft
position
(CMP)
sensor,

replacing
(4-cylinder
engine)

1
.
Remove
CMP
sensorfromtop
timing
cover,
just
above
coolantthermostat
housing
.
See
Fig
.
11
.

Fig
.
11
.
Camshaft
position
sensor
mounting
bolt
(arrow)
.
M42
engine
shown
.

2
.
On
M42
engines
to
9/93
:
Disconnect
CMP
harness
plug
just
above
oil
filter
housing
.

3
.
On
M42
from9/93
and
all
M44
engines
:
Remove
upper
intake
manifold
as
described
in
113
Cylinder
Head
Re-
moval
and
Installation
.
Then
unplug
CMP
sensor
har-
ness
connector
below
manifold
.

CHARGING
SYSTEM

TROUBLESHOOTING
.............
.
.
.
.
.121-2

Charging
System
Quick-Check
...
.
..
.
...
.
121-2

Static
current
draw,
checking
........
.
...
.
121-2

BATTERY
SERVICE
....................
121-3

Battery
Testing
.
.
.
.
.
.........
.
........
.
121-3

Hydrometer
Testing
.
...
.
.
.
...
.
.........
121-3

Battery
Open-Circuit
Voltage
Test
....
.
....
121-4

Battery
Load
Voltage
Test
.
.
.
.
.
.
.........
121-4

Battery
Charging
.
.
.
.
...
.
.
.
.
.
.
.
.........
121-4

ALTERNATOR
SERVICE
.
.
.
.
.
.
.....
.
...
121-4

Chargingsystem,checking
.
.
.
.
.
.........
121-4

Alternator,
removingand
installing

(4-cylinder
engine)
....
.
.
.
.
.
.
.
.........
121-5

Alternator,
removingand
installing

(6-cylinder
engine)
..
.
.
.
.
.
.
.
.
.
.........
121-6

GENERAL

The
charging
system
consists
of
a
belt-driven
alternator

with
integral
voltage
regulator
and
a
battery
mounted
in
the

luggage
compartment
.

Various
versions
of
alternators,
voltage
regulators,
starters,

and
batteries
are
used
in
the
E36
cars
.
It
is
important
to
re-

place
components
according
tothe
original
equipment
speci-

fication
.
Check
with
an
authorized
BMW
dealer
for
specific

application
and
parts
information
.

WARNING
-

"
Weargoggles,
rubbergloves,
and
a
rubberapron
when
working
around
batteries
and
battery
acid
(electrolyte)
.

"
Battery
acid
contains
sulfuric
acid
and
can
cause
skin
irritation
and
burning
.
ff
acid
is
spilled
onyour
skin
or
clothing,
flush
the
area
at
once
with
large
quantities
of
water
.
lf
electrolyte
gets
into
your
eyes,flush
them
with
largequantities
of
clean
wa-
terfor
several
minutes
and
call
a
physician
.

"
Batteries
that
are
being
charged
or
are
fully
charged
give
off
explosive
hydrogen
gas
.
Keep
sparks
and
open
flames
away
.
Do
not
smoke
.

BATTERY,
STARTER,
ALTERNATOR



121-1

121
Battery,
Starter,
Alternator

GENERAL
..
.
...
.
........
.
...
.
.
.
.
.
.
.
.
.
121-1



Voltage
regulator,
removing
and
ínstalling
.
.
.
121-6

Alternator
brushes,
inspecting
and
replacing
.121-7

STARTER
SERVICE
....
.
.
.
.
.
..........
.121-7

Starter
Troubleshootíng



121-7



15
..
.
.
.
.
.
........
.
.
.

Starter,
removing
and
installing

(4-cylinder
engine)
....
.
.
.
............
.
121-8

Starter,
removing
and
installing

(6-cylinder
engine
with
manual
transmission)
..
.
...........
.
...
121-8

Starter,
removing
and
installing

(6-cylinder
engine
with

automatic
transmission)
................
121-9

Solenoid
switch,
removingand
installing
....
121-10

TABLES

a
.
Battery,
Starter
and
Charging
System

Troubleshooting
............
.
.
.
.
:...
........
121-2

b
.
Specific
Gravity
of
Battery
Electrolyte
at
80°F
(27°C)
...............
.
.
..
..........
121-3

c
.
Open-Circuit
Voltage
and
Battery
Charge
........
121-4

d
.
Battery
Load
Test-Minimum
Voltage
.
..........
121-4

CAUTION
-

"
Prior
to
disconnectiog
the
battery,
read
the
bat-tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.
"
Disconnecting
the
battery
cables
may
erase
fault
codes
stored
in
control
unit
memory
.

"
Always
disconnect
the
negative
()
battery
cable
first
and
reconnect
it
last
.
Cover
the
battery
post
with
an
insulating
material
whenever
the
cable
is
removed
.

"
After
reconnecting
the
battery,
the
power
window
motors
must
be
reinitialized
.
See
511
Door
Win-
dows
.

"
Never
reverse
the
battery
cables
.
Even
a
momen-
tary
wrong
connection
can
damage
the
alternatoror
other
electrical
components
.

"
Battery
cables
may
be
the
same
color
.
Label
ca-blebefore
removing
.

GENERAL

121-2



BATTERY,
STARTER,
ALTERNATOR

CHARGING
SYSTEM
TROUBLESHOOTING



Static
currentdraw,
checking

Charging
system
diagnostics
requires
special
test
equip-

ment
.
If
the
test
equipment
is
not
available,
charging
system

fault
diagnosis
can
be
performedby
an
authorized
BMW
deal-

eror
other
qualified
repair
shop
.
A
general
troubleshooting

guide
is
given
in
Table
a
.

Charging
System
Quick-Check

As
a
quick-check,
use
a
digital
multimeter
lo
measure
volt-



2
.
Disconnect
battery
negative
(-)
cable
.

age
across
the
battery
terminals
with
the
key
off
and
then

again
with
the
engine
running
.
The
battery
voltage
should
be



CAUTION-
about12
.6
volts
with
key
off
and
approximately
14
.0
volts
with



Prior
to
disconnecting
the
battery,
read
the
battery
the
engine
running
.
If
the
voltage
does
not
increase
when
the



disconnection
cautions
given
at
the
front
of
this
engine
is
running,there
is
a
fault
in
the
charging
system
.



manual
onpaga
viii
.

NOTE
-

The
regulated
voltage
(engine
running)
should
be
be-
tween
13
.5
and
14
.5,
depending
on
temperatura
and
operating
conditions
.
If
the
voltage
is
higher
than
14
.8,
the
voltage
regulator
is
most
Mely
faulty
.

Check
for
clean
and
tight
battery
cables
.
Check
the
ground

cable
running
from
the
negative
(-)
battery
terminal
lo
the

chassis
and
the
ground
cable
running
from
the
engine
lo
the

chassis
.
Check
the
alternator
drive
belt
condition
and
tension
.

If
the
battery
discharges
over
time,
there
may
be
a
constant

drain
or
current
draw
on
the
battery
.
A
small
static
drain
on
the

battery
is
normal,
but
a
largedrain
will
cause
the
battery
lo

quickly
discharge
.
Make
a
static
current
draw
test
asthe
first

step
when
experiencing
battery
discharge
.

1
.
Make
sure
ignition
and
al¡
electrical
accessories
are

switched
off
.

3
.
Connect
a
digital
ammeter
between
negative
battery

post
and
negative
battery
cable
lo
measure
current
.

See
Fig
.
1
.
Wait
at
least
one
minuta
lo
get
an
accurate

reading
.

A
range
of
about
0
lo
100
milliamps
is
normal,
dependingon

the
number
of
accessories
that
need
constant
power
.
A
current

of
400
milliamps
(0.4
amp)
or
more
may
indicate
a
problem
.

Table
a
.
Battery,
Starter
and
Charging
System
Troubleshooting

Symptom



1



Probable
Cause



1



Correctiva
Action

1
.
Engine
cranks
slowlyor
not



a
.
Battery
cables
loose,
dirty
orcor-



a
.
Clean
or
replace
cables
.
See020
Maintenance
Program
.
a
tall,
solenoíd
clicks
when



roded
.
starter
is
operated
.



b
.
Battery
discharged
.



b
.
Charge
battery,
test
and
replace
if
necessary
.
c
.
Body
ground
straploose,
dirty
or



c
.
Inspect
ground
strap,
clean,
tighten
or
replace
if
necessary
.
corroded
.
d
.
Poor
connection
at
starter
motor



d
.
Check
connections,
test
for
voltage
at
starter
.
Test
for
voltage
at
terminal
30
.



neutral
safety
or
clutch
interlock
switch
.
e
.
Starter
motor
or
solenoid
faulty
.



e
.
Test
starter
.

2
.
Battery
will
not
stay



a
.
Short
circuit
draining
the
battery
.



a
.
Test
for
excessive
current
drainwith
everything
electrical
in
the
charged
more
than
a
few



vehicle
off
.
days
.



b
.
Short
driving
trips
and
high
elec-



b
.
Evaluate
driving
style
.
Where
possible,
reduce
electrical
con
trical
drain
on
charging
system



sumption
when
making
short
trips
.
does
not
allow
battery
to
re-
charge
.
c
.
Drive
belt(s)
worn
or
damaged
.



c
.
Inspect
or
replace
multi-ribbed
belt(s)
.
See
020
Maintenance
Program
.
d
.
Battery
faulty
.



d
.
Test
battery
and
replace
íf
necessary
.
e
.
Battery
cables
loose,
dirty
orcor-



e
.
Clean
or
replace
cables
.
See
020
Maintenance
Program
.
rodad
.
f
.
Alternatoror
voltage
regulator



f
.
Test
alternator
and
voltage
regulator
.
faulty
.

3
.
Battery
losing
water
.



1
a
.
Battery
overcharging
.



1
a
.
Test
voltage
regulator
for
proper
operation
.

4
.
Lights
dim,
light
intensity



a
.
Drive
belt(s)
worn
or
damaged
.



a
.
Inspect
or
replace
multi-ribbed
belt(s)
.
See
020
Maintenance
varies
with
engine
speed
.



Program
.
b
.
Alternatoror
voltage
regulator



b
.
Test
alternator
and
voltage
regulator
.
faulty
.
c
.
Body
ground
straps
loose,
dirty
or



c
.
Inspect
ground
straps,
clean,
tighten
or
replace
as
necessary
.
corroded
.

CHARGING
SYSTEM
TROUBLESHOOTING

Fig
.1.



Electrical
system
static
current
draw
being
measured
.

To
determine
the
circuit
or
component
causing
the
problem,

remove
one
Puse
at
a
time
until
the
current
drops
to
a
normal
range
.

BATTERY
SERVICE

The
E36
uses
a
six-cell,
12-volt
leadacid
battery
mounted

in
the
luggage
compartment
.
See
Fig
.
2
.

NOTE-

E36
convertible
models
require
a
specialbattery
which
is
designed
for
constant
vibratfon
.
A
battery
not
de-signed
for
this
will
fail
much
earlier
.

Battery
capacity
is
determined
by
the
amount
of
current

needed
tostart
the
vehicle,
and
by
the
amount
of
current
con-
sumed
by
the
electrical
system
.

BMW
batteries
are
rated
by
ampere/hours
(Ah)
and
cold

cranking
amps
(CCA)
rating
.
The
Ah
rating
is
determined
by

the
average
amount
of
current
the
battery
can
deliver
over
time
without
dropping
below
a
specified
voltage
.
The
CCA
is

determined
by
the
battery's
ability
to
deliver
starting
current
at

0°
F
(-18°
C)
without
dropping
below
a
specified
voltage
.

Battery
Testing

noN~A

B9517

Battery
testing
determines
the
state
of
battery
charge
.
On

conventional
or
low-maintenance
batteries
the
most
common

method
of
testing
the
battery
is
that
of
checking
the
specific

gravity
of
the
electrolyte
using
a
hydrometer
.
Before
testing

the
battery,
check
that
the
cables
are
tight
and
free
of
corro-

sion
.
See
Fig
.
2
.

Hydrometer
Testing

The
hydrometer
consists
of
a
glass
cylinder
with
a
freely

moving
float
inside
.
When
electrolyte
is
drawn
into
the
cylin-

der,
the
levelto
which
the
float
sinks
indicates
the
specific

BATTERY,
STARTER,
ALTERNATOR



121-
3

Fig
.
2
.



Battery
in
right
sideof
luggage
compartment
.

gravity
of
the
electrolyte
.
The
more
dense
the
concentration
of
sulfuric
acid
in
the
electrolyte,
the
less
the
float
will
sink,
result-

ing
in
a
higher
reading
and
indicating
a
higher
state
of
charge)
.

NOTE-

Electrolyte
temperature
affects
hydrometer
reading
.
Check
the
electrolyte
temperaturewith
a
thermometer
.
Add
0
.004
to
the
hydrometer
reading
for
every
10°F
(6°C)
that
the
electrolyte
is
above
80°F
(27°C)
.
Sub-
tract
0
.004
from
the
reading
for
every
10°F
(6°C)
that
the
electrolyte
is
below
80°F
(27°C)
.

Before
checking
the
specificgravity
of
a
battery,
load
the
battery
with
15
amperes
for
one
minute
.
lf
the
battery
is
in-

stalled
in
the
vehicle,
this
can
be
done
by
turning
on
the
head-

lights
without
the
engine
running
.
Table
b
lists
the
percentage

of
charge
based
on
specific
gravity
values
.

Table
b
.
Specific
Gravity
of
Battery
Electrolyteat

80
°
F
(27°C)

Specific
gravity



1



Stateof
charge

1
.265



Fully
charged
1
.225



75%
charged
1
.190



50%
charged
1
.155



25%
charged
1
.120



Fully
discharged

The
battery
isin
satisfactory
condition
if
theaverage
specif-

ic
gravity
of
the
six
cells
is
at
least
1
.225
.
If
the
specific
gravity

is
above
this
leve¡,
butthe
battery
lacks
power
for
starting,
de-

termine
the
battery's
senrice
condition
with
a
load
voltage
test,

as
described
below
.
If
the
average
specific
gravity
of
the
six

cells
is
below
1
.225,
remove
the
battery
from
the
luggage

compartment
and
recharge
.
If,
after
recharging,
the
specific
gravity
varies
by
more
than
0
.005
between
any
two
celis,
re-

place
the
battery
.

CHARGING
SYSTEM
TROUBLESHOOTING