brake fluid BMW 328i 1994 E36 User Guide
[x] Cancel search | Manufacturer: BMW, Model Year: 1994, Model line: 328i, Model: BMW 328i 1994 E36Pages: 759
Page 29 of 759
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
"
NM
I
«)
al
aN
-
11
>
O
Ó
I
Ó
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Ó
d
Ny
.
0
°
_
VÑ
Ñ
Ñ
1
ZG
NN
MAÍNTENANCE
TABLES
Page 31 of 759
Final
Drive
Gear
Oil
BMW
recommends
using
only
a
specially
formulatedsyn-
thetic
gear
oil
that
is
available
through
an
authorized
BMW
dealer
parts
department
.
For
additional
information
on
this
¡u-
bricant
andany
other
lubricants
that
may
be
compatible,
con-
tact
an
authorized
BMW
dealer
senrice
department
.
See
331
Final
Drive
.
Brake
Fluid
Brake
fluid
absorbs
moisture
easily,
and
moisture
in
the
fluid
affects
brake
performance
and
reliability
.
This
is
why
brake
fluid
should
be
flushed
from
the
system
every
two
years
.
When
re-
placing
or
adding
brake
fluid,
use
only
new
(luid
from
previously
unopened
containers
.
Do
not
use
brake
fluid
that
has
been
bled
from
the
system,
even
ifit
is
brand
new
.
Use
only
DOT
4
brake
fluid
.
See340
Brakes
for
more
information
.
Engine
Coolant
(Anti-freeze)
BMW
recommends
coolant
that
is
a
50/50
mixture
of
distilled
water
and
phosphate/nítrate
freeanti-freeze
containing
ethyl-
ene
glycol
.
Anti-freezeraises
the
boiling
point
and
lowersthe
freezingpoint
of
the
coolant
.
It
alsocontains
additives
that
help
prevent
cooling
system
corrosion
.
Power
Steering
Fluid
The
power
steering
fluid
is
Dexron
II]®
ATF,
or
equivalent
.
The
system
is
permanently
filled
and
does
not
have
a
drain
.
Routinely
adding
ATF
is
not
required
unlessthe
system
is
leak-
i
n
g,
WARNING
-
Be
sure
to
check
the
fluid
specifications
on
the
pow-
er
steering
reservoir
to
confirm
the
fluid
type
in-
stalled
in
the
system
.
In
some
instances,
the
power
steering
system
may
be
filled
with
an
alternative
hy-
draulic
fluid
designated
CHF
7
.1
.
MAINTENANCE
PROGRAM
020-
ENGINE
OIL
SERVICE
Engine
oil
and
fiiter,
changing
Fig
.
3
.
Engine
oil
level
dipsticklocation
on
4-cylinder
engine
(arrow)
.
Dipsfck
is
marked
with
mínimum
and
maximum
level
marks
.
Fig
.
4
.
Oil
filler
cap
(arrow)
.
6-cylinder
engine
shown
.
0012202
Engine
oii,
checking
leve¡
A
complete
oil
change
requires
new
oil
(see
Table
e),
a
new
oil
filter
insert
kit,
and
a
new
drain
plug
sealing
washer
.
The
The
engine
oil
leve]
is
checked
with
a
dipstick
in
the
engine
tools
needed,
a
drain
plug
socket
or
box
wrench
(17
mm
or19
block
.
Check
the
oii
leve¡
with
the
canon
a
level
surface,
after
mm)
and
a
drain
pan
(8-10
US
qt
.
capacity),
are
described
in
the
engine
has
been
stopped
for
atleast
a
few
minutes
.
Check
010
Fundamentals
for
the
Do-It-Yourself
Owner
.
the
leve¡
by
pulling
outthe
dipstick
and
wiping
it
clean
.
Reinsert
it
all
the
way
and
withdraw
it
again
.
The
oil
leve¡
is
correct
if
it
is
NOTE-
between
the
two
marks
near
the
end
of
the
stick
.
See
Fig
.
3
.
If
using
a
"fast-lube"
service
facility
for
oil
changes,
make
sure
the
technician
hand-starts
and
torques
the
Add
oil
through
the
filler
cap
on
thetop
of
the
cylinder
head
.
engine
oil
drain
plug
using
hand-tools
.
Power
tools
can
See
Fig
.
4
.
Add
only
the
amount
needed
to
bring
the
oil
leve¡to
strip
the
threads
of
the
plug
and
the
oil
pan
.
the
MAX
mark
on
the
dipstick,
using
an
oil
of
the
correctviscos-
ity
andgrade
.
Too
much
oil
canbe
just
as
harmful
as
too
little
.
ENGINE
OIL
SERVICE
Page 39 of 759
Tires,
checking
inflation
pressure
Brake
pad/rotor
wear,
checking
Correct
tire
pressuresare
important
to
handling
and
stability,
Al¡
E36
cars
are
fitted
withdisc
brakes
at
al¡
four
wheels
.
See
fuel
economy,
and
tire
wear
.
Tire
pressures
change
with
temper-
Fig
.
24
.
Although
thebrakesare
equipped
with
a
brake
pad
ature
.
Pressures
should
be
checked
often
during
seasonal
tem-
warning
system,
the
system
only
monitors
one
wheel
per
axle
.
perature
changes
.
Correct
inflation
pressures
canbe
found
on
It
is
recommended
that
pad
thickness
should
be
checked
the
driver's
door
pillar
and
in
the
owner's
manual
.
Note
that
tire
whenever
the
wheels
are
off
or
brakework
is
beggg
done
.
pressuresshould
be
higher
when
thecar
is
more
heavily
loaded
.
WARNING
-
Do
not
inflate
any
tire
to
a
higher
pressure
than
the
tiress
maximum
ínflation
pressure
listed
on
the
side-
wall
.
Use
cara
when
addlng
air
to
warm
tires
.
Warm
tire
pressures
can
increase
as
much
as4
psi
(0.3
bar)
over
their
cold
pressures
.
Tires,
rotating
BMW
does
not
recommend
tire
rotation
.
Due
to
the
cars
sus-
pension
design,
the
fronttires
begin
to
wear
first
at
the
outer
shoulder
and
the
rear
tires
begin
to
wear
first
at
themiddle
of
the
tread
or
inner
shoulder
.
Rotating
the
tires
may
adversely
af-
fect
roadhandling
and
tire
grip
.
NOTE-
The
main
purpose
of
tire
rotation
isto
promote
even
wear
and
maximum
tire
life
.
Tire
life
may
be
decreased
slightly
if
the
tires
are
not
rotated
.
Wheels,
aligning
Routine
maintenance
of
the
brake
system
includes
maintain-
ing
the
brake
fluid
in
the
reservoir,
checking
brakepads
for
wear,
checking
hand
brake
functíon,
and
inspecting
the
system
for
fluid
leaks
or
other
damage
.
Check
that
brake
hoses
are
correctly
routed
to
avoidchafing
or
kinkíng
.
Inspect
unions
and
brake
calipers
for
signs
of
fluid
leaks
.
Inspect
rigid
fines
for
corrosion,
dents,
or
other
damage
.
Inspect
flexible
hoses
for
cracking
.
Replace
faulty
hoses
or
lines
as
described
in
340Brakes
.
WARNING
-
Incorrect
installation
or
overtightening
hoses,
fines,
and
unions
may
cause
chafing
or
leakage
.
This
can
lead
to
partíal
or
completebrake
system
failure
.
MAINTENANCE
PROGRAM
020-
1
7
B323
Fig
.
24
.
Disc
brake
pad
wear
can
checked
through
opening
in
caliper
.
The
brake
caliper
should
be
unbolted
from
the
suspension
strut
to
properly
inspect
the
brake
pads
and
the
rotors
.
See
Fig
.
25
.
Brake
caliper
removal
and
installation
procedures
are
given
in
340
Brakes
.
BMW
recommends
checking
the
front
and
rear
alignment
once
a
year
and
whenever
new
tires
are
installed
.
See320
Steering
and
Wheel
Alignment
for
a
more
detailed
discus-
sion
of
alignment
requirements
and
specifications
.
Brake
Pad
Lining
Minimum
Thickness
(Dimension
A)
Brake
system,
inspecting
"
Front
and
reardisc
brake
pads
....
3
.0
mm
(0
.12
in)
Brake
fluid,
replacing
BMW
strictly
recommends
replacing
the
brake
fluid
every
two
years
.
This
will
help
protect
against
corrosion
and
the
ef-
fects
of
moisture
in
the
(luid
.
See340
Brakes
for
brake
fluid
flushing
procedures
.
Parking
brake,
checking
The
parking
brakesystem
is
independent
of
the
main
braking
system
and
may
requireperiodic
adjustment
dependingon
use
.
Adjust
the
parking
brake
if
the
brake
lever
can
be
pulled
up
more
than
8
clicks
.
Check
that
the
cable
moves
freely
.
A
de-
scription
of
the
parking
brake
and
parking
brake
adjustment
can
be
found
in
340Brakes
.
UNDER-CARMAINTENANCE
Page 40 of 759
020-
1
8
MAINTENANCE
PROGRAM
Fig
.
25
.
Inspect
brake
pads
with
the
caliper
removed
.
Minimum
brake
pad
thickness
shown
by
dimension
(A)
.
NOTE-
The
parking
brake
may
lose
some
of
its
effectiveness
if
it
is
not
used
frequently
.
This
is
due
to
corrosion
build-
up
on
the
parking
brake
drum
.
To
remove
corrosion,
ap-
plythe
parking
brake
just
until
it
begins
togrip,
then
pulí
the
lever
up
one
more
stop
(click)
.
Drive
thecar
approx-
imately
400
meters
(1,300
ft
.)
and
release
the
brake
.
To
recheck
the
adjustment
of
the
parking
brake
see340
Brakes
.
UNDER-CAR
MAINTENANCE
0011920
Manual
transmission
fluid,
checking
and
filling
The
manual
transmission
fluid
leve¡
should
be
checked
at
specified
intervals
.
Check
and
fill
the
transmission
with
the
car
ona
leve¡
surface
.
Transmission
(luid
leve¡
checking
and
re-
placement
procedures
are
covered
in
230
Manual
Transmis-
sion
.
Automatic
Transmission
Service
The
automatic
transmission
is
not
equipped
with
a
dipstíck
.
Therefore,
checking
the
ATF
level
is
an
ínvolved
procedure,
which
includes
measuring
and
maintaining
a
specified
ATF
temperature
during
the
checking
procedure
.
For
more
complete
ATF
service,
including
checking
ATF
lev-
e¡
and
ATF
filter
replacement
procedures,
see
240
Automatic
Transmission
.
Front
suspension
and
steering
linkages,
inspecting
Inspection
of
the
front
suspension'and
steering
includes
a
check
of
all
moving
parts
for
wear
and
excessive
play
.
Also
in-
spect
the
rubber
seals
and
boots
for
cracks
or
tears
that
could
allow
the
entry
of
dirt,
water,
and
other
contaminants
.
See
310
Front
Suspension
.
Exhaust
system,
inspecting
Rear
suspension,
inspecting
Exhaust
system
life
varies
widely
according
to
driving
habits
Final
drive
and
rear
drive
axle
service
consists
of
checking
and
environmental
conditions
.
If
short-distance
driving
pre-
and
changing
the
gear
oil,
inspecting
for
leaks,
and
checking
dominates,
the
moisture
and
condensation
in
the
system
will
the
rear
drive
axle
rubber
boots
for
damage
.
not
fully
dryout
.
This
will
lead
to
early
corrosion
damage
and
more
frequent
replacement
.
The
areas
where
leaks
are
most
likely
to
occur
are
around
the
driveshaft
and
drive
axle
mounting
flanges
.
For
more
infor
Scheduled
maintenance
of
the
exhaust
system
is
limitedlo
mation
on
ídentifying
oil
leaks
and
their
causes,
see330
Rear
inspection
.
Check
for
restrictions
due
to
dents
or
kinks
.
Check
Suspension
.
for
weakness
or
perforation
due
to
rust
.
Check
lo
see
that
all
the
hangers
are
in
place
and
properly
supporting
the
system
and
that
the
system
does
not
strike
the
body
.
Alignment
of
the
sys-
Final
drive
oil
leve¡,
checking
temand
the
location
of
the
hangers
aredescribed
in
180
Ex-
haust
System
.
Check
the
lubricant
leve¡
with
thecar
level
.
Remove
the
oil
filler
plug
.
The
leve¡
is
correct
when
the
fluidjust
reaches
the
edge
of
the
filler
hole
.
Install
and
tighten
the
oil
filler
plug
when
Manual
Transmission
Service
the
oil
level
is
correct
.
See
Fig
.
26
.
Manual
transmissionservice
consists
of
inspectingfor
leaks
The
final
drive
should
be
filled
with
a
special
BMW
lubricant
and
checking
and
changing
the
fluid
.
available
through
an
authorized
BMW
dealer
.
In
addition,
the
lubricant
type
varies
depending
onwhether
or
nota
limited-slip
Evidence
of
transmissionleaks
is
fkely
to
beseenaround
the
differential
is
fitted
.
driveshaft
mounting
flange
and
at
the
bottom
of
the
bellhousing
.
For
more
information
on
identifying
oil
leaks
and
their
causes,
see230ManualTransmissionand210
Clutch
.
Tightening
Torque
"
Finaldrive
filler
plug
to
final
drive
housing
..................
70
Nm
(52
ft-Ib)
Page 41 of 759
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
Page 215 of 759
GENERAL
..
.
.
.
.
.
.
.
.
.
.
.
.
.
......
.
......
210-1
CLUTCH
MECHANICAL
.
.
.
.
.
...
.
.....
.
.
210-3
CLUTCH
HYDRAULICS
.
.
.
.............
210-1
Clutch,
removing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
210-4
Clutch,inspecting
and
installing
.
.
.
.
.
.
.
.
.
.
.
.210-5Clutch
hydraulic
system,
Transmission
pilot
bearing,replacing
.
.
.
.
...
210-6
bleeding
and
flushing
.
.
.
.
.
.......
.
.....
210-2
Clutch
master
cylinder,
replacing
..
.
.
.
.
.
...
210-2
Table
Clutch
slave
cylinder,
replacing
...
.
.
.
.
.
.
.
.
210-3
a
.
Clutch
Disc
Diameter
.............
..
..
.
......
210-3
GENERAL
CLUTCH
HYDRAULICS
This
repair
group
covers
replacement
of
the
clutch
mechan-
The
Clutch
is
hydraulically
actuated
by
the
master
and
slave
¡cal
and
hydraulic
components
.
Special
tools
may
be
required
cylinders
.
Clutch
disc
wear
is
automatically
taken
upby
the
for
some
of
the
procedures
.
Read
the
procedure
through
be-
pushrod
travelof
the
slave
cylinder,
making
periodic
adjust-fore
beginning
a
job
.
ments
unnecessary
.
NOTE-
See200
Transmission-General
for
transmission
applicatíon
information
.
The
major
components
of
the
clutch
system
are
shown
in
Fig
.
1
.
Engine
Pressure
plate
flywheel,,
assembly
Clutch
Flywheel
bolt
Pressure
plate
release
lever
Release
lever
Fig
.
1
.
Clutch
assembly
and
hydraufcs
.
210
Clutch
Release
bearing
Pushrod
A
soft
or
spongy
feel
to
the
clutchpedal,
long
pedal
free-
play,
or
grinding
noises
from
thegears
while
shifting
can
all
in-
dicate
problems
with
the
Clutch
hydraulics
.
In
these
circum-
stances
it
is
best
to
start
with
a
clutch
fluid
flush,
followed,
if
necessary,
byreplacement
of
the
hydraulic
parts
.
From
brake
fluid
reservoir
CLUTCH
210-1
0
0
Transmission
inputshaft
Clutch
master
cylinder
Bulkhead
Slave
cylinder
6535
CLUTCH
HYDRAULICS
Page 216 of 759
210-2
CLUTCH
Clutch
hydraulic
system,
bleeding
and
flushing
If
the
clutch/brake
fluid
is
murky
or
muddy,
or
has
not
been
changed
within
the
last
two
years,
the
system
should
be
flushed
.
Flushing
the
old
fluid
from
the
clutch
lines
is
done
us-
ing
a
brake
system
pressure
bleeder
.
1
.
Remove
brake
fluíd
reservoir
cap
.
Usinga
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
Refill
reservoir
with
clean
fluid
.
2
.
Attach
pressure
brake
bleeder
to
fluid
reservoír
.
CA
UTION-
Do
not
exceed
2
bar
(29
psi)
pressure
at
the
fluid
reservoir
when
bleeding
or
flushing
the
hydraulic
system
.
3
.
Connect
a
length
of
hose
from
clutch
slave
cylinder
bleeder
valve
lo
a
container
.
See
Fig
.
2
.
0012003
Fig
.
2
.
Clutch
slave
cylinder
bleeder
valve
on
left
side
of
transmission
(arrow)
.
4
.
Open
bleeder
valve
and
allow
brake
fluid
to
expel
until
clean
fluid
comes
out
free
of
air
bubbles
.
5
.
Close
bleeder
valve
and
disconnect
pressure
bleeding
equipment
from
fluid
reservoir
.
Hose
on
bleeder
valve
remainsconnected
.
6
.
Slowly
operate
clutch
pedal
about10
times
.
Fill
reser-
voir
with
clean
fluid
asnecessary
.
7
.
Unbolt
slavecylinder
from
transmission
.
8
.
Position
slave
cylinder
so
that
bleeder
valve
is
facing
up
(highest
point)
.
CLUTCH
HYDRAULICS
9
.
Open
bleeder
valve
and
slowly
push
slave
cylinder
pushrod
al¡
the
way
in
.
Close
bleeder
valve
and
slowly
release
pushrod
.
Repeat
procedure
until
fluid
runs
out
clear
and
without
bubbles
.
10
.
Disconnect
bleeder
hose
.
Instan
slavecylinder
lo
trans-
mission
.
Add
cleanbrake
fluid
to
reservoir
as
neces-
sary
.
Check
clutch
operation
.
Tightening
Torques
"
Clutch
slave
cylinder
to
transmission
................
..
22
Nm
(17
ft
lb)
Clutch
master
cylinder,
replacing
The
clutch
master
cylinder
is
mounted
to
the
pedal
assem-
bly,
directly
above
the
clutch
pedal
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautionsgiven
at
the
front
of
this
manual
on
page
viii
.
2
.
Remove
brake
fluid
reservoir
cap
.
Usinga
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
CA
UTION-
Brake
fluid
is
poisonous,
highly
corrosive
and
dan-gerous
to
the
environment
.
Wear
safety
glasses
and
rubbergloves
when
working
with
brake
fluid
.
Do
notsiphonbrake
fluid
with
your
mouth
.
Imme-
diately
clean
away
any
fluid
spilled
on
painted
sur-
faces
and
wash
with
water,
asbrake
fluid
will
remove
point
.
3
.
Disconnect
fluid
supply
hose
from
master
cylinder
.
Placea
pan
under
hose
to
catch
any
excess
fluid
.
4
.
Working
in
engine
compartment,
disconnect
fluid
line
fitting
frommaster
cylinder
.
5
.
Working
in
passenger
compartment,
remove
lower
in-
strument
panel
trim
above
pedal
cluster
.
6
.
Disconnect
clutch
pedal
from
clutch
master
cylinder
push
rod
by
removing
clevis
pin
locking
clip
and
slide
out
clevis
pin
.
7
.
Remove
master
cylinder
mounting
bolts
.
See
Fig
.
3
.
8
.
Installation
is
reverse
of
removal
.
Fill
fluid
reservoir
with
clean
fluid
.
Bleed
clutch
hydraulics
as
described
earlier
.
Connect
negative
cable
to
battery
last
.
Page 217 of 759
Fig
.
3
.
Clutch
master
cylinder
mounting
bolts
.
Clutch
slave
cylinder,
replacing
0012589
Tightening
Torques
"
Clutch
master
cylinder
to
bulkhead
..
22
Nm
(17
ft-Ib)
"
Fluid
line
to
master
cylinder
orslave
cylinder
.................
16
Nm
(12
ft-1b)
The
clutch
slave
cylinder
is
mounted
on
the
left
side
of
the
transmission
.
CLUTCH
MECHANICAL
1
.
Remove
brake
fluid
reservoir
cap
.
Using
a
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
2
.
Disconnect
fluid
hose
from
slave
cylinder
.
Place
a
pan
under
hose
to
catch
any
excess
fluid
.
3
.
Unbolt
slave
cylinder
from
transmission
.
See
Fig
.
4
.
4
.
Installation
is
reverse
of
removal,
noting
the
following
:
"
Check
for
wear
on
pushrod
.
Any
other
wear
except
on
tipis
caused
by
misalignment
of
clutch
components
.
"
Lightly
coat
pushrod
tip
with
molybdenum
disulfide
grease
(Molykote
0
Longterm
2
or
equivalent)
.
"
During
installation
be
sure
pushrod
tip
engages
recess
in
clutch
release
lever
.
"
Fill
fluid
reservoir
with
clean
fluid
.
"
Bleed
clutch
hydraulics
as
described
earlier
.
CLUTCH
210-
3
Fig
.
4
.
Clutch
slave
cylinder
mounting
bolts
(arrows)
.
Tablea
.
ClutchDisc
Diameter
Model
Diameter
3181/is/iC
215
mm
(8
.46
in)
325i/is/iC
228
mm
(8
.98
in)
323is/iC
328i/is/iC
240
mm
(9
.45
in)
M3
0012715
Tightening
Torques
"
Clutch
slave
cylinder
to
transmission
.
.
................
22
Nm
(17
ft
lb)
"
Fluid
line
to
slave
cylinder
......
.17
Nm
(10-12
ft
lb)
The
transmission
must
be
removed
from
the
engine
to
ac-
cess
the
clutch
mechanical
components
.
It
is
recommended
that
the
clutch
disc,
pressure
plate
and
release
bearing
be
re-
placed
duringa
clutch
overhaul
.
Be
sure
to
check
the
bottom
of
the
bellhousing
for
oil
.
If
engine
oil
is
found,
check
for
a
faulty
rear
crankshaft
oil
seal
.
CLUTCH
MECHANICAL
Page 223 of 759
Selector
shaft
seal,
replacing
(transmission
instalied)
1
.
Raise
and
safely
support
vehicle
to
access
drain
plug
.
2
.
Support
transmission
with
transmission
jack
.
3
.
Remove
driveshaft
.
See
260
Driveshaft
.
4
.
Remove
transmission
crossmember
and
tilt
down
rear
of
transmission
.
CA
UTION--
Tilting
the
engine
to
lower
the
transmission
can
lead
to
damage
to
various
cgmponents
due
to
lack
of
clearance
.
-On
cars
with
AST
(traction
control)
remove
throt-
tle
body
before
tiltlng
engine
.
-Remove
brake
fluid
reservoir
lf
necessary
.
Locking
pin
á
Locking
clip
8
.
Reinstall
shift
linkage
to
selectorshaft
.
7
.
Coat
new
seal
with
transmission
fluid
.
Drive
new
seal
in
flush
with
housing
.
Use
BMW
special
seal
installation
tool
no
.
23
2
260
orequivalent
and
a
soft-faced
(plastic)
hammer
.
See
Fig
.
4
.
9
.
Fiaise
transmission
and
reinstall
crossmember
.
MANUAL
TRANSMISSION
230-
3
Seal
Selector
_
shaft
5
.
Working
at
rear
of
selector
shaft,
disconnect
shift
link-
Fig
.
3
.
Selector
shaft
oil
sea¡
being
pried
out
with
screwdriver
.
age
from
selectorshaft
.
See
Fig
.
2
.
Fig
.
4
.
Selector
shaftseal
being
installed
.
6542
0012020
Fig
.
2
.
Disconnect
shift
linkage
from
transmission
selector
shaft
by
prying
back
locking
clip
and
pushing
locking
pin
out
.
10
.
Install
driveshaft
using
new
nuts
.
See260
Driveshaft
.
6
.
Carefully
pry
sea¡
out
with
a
narrow
seal
remover
or
11
.
Check
transmission
oil
level,
topping
upas
necessary
.
small
screwdriver
.
See
Fig
.
3
.
Tightening
Torques
"
Driveshaftto
flex
disc/
final
drive
flange
..............
See
260
Driveshaft
"
Transmission
crossmember
to
chassis
M8
........
..
.
...
........
22-24
Nm
(16-17
ft-1b)
M10
........
.
.
...
...
.
.........
42
Nm
(31
ft-Ib)
TRANSMISSIONSERVICE
Page 224 of 759
230-
4
MANUAL
TRANSMISSION
Output
shaft
sea¡,
replacing
(transmission
installed)
1
.
Raise
and
safely
support
vehicle
.
Support
transmission
with
transmission
jack
.
WARNING
-
"
When
raising
thecar
using
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
shift
or
tilt
.
As
the
car
is
raised,
the
car
may
roll
slightly
and
the
jack
may
shift
.
2
.
Remove
driveshaft
.
See
260
Driveshaft
.
3
.
Remove
transmission
crossmember
and
lower
trans-
mission
at
rear
.
CAUTION-
Tilting
the
engine
to
lower
thetransmissíon
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
.
-On
cars
with
AST
(traction
control)
remove
throt-
tle
body
before
tilting
engine
.
-Remove
brake
fluid
reservoir
if
necessary
.
4
.
Bend
back
and
remove
collar
nut
lockplate
.
5
.
Hold
flange
steady
andremove
collar
lock
nut
(use
30mm
thin-walled
deep
socket
.)
See
Fig
.
5
.
Fig
.
5
.
Use
holding
tool
when
loosening
output
shaft
collar
nut
.
6
.
Remove
flange
.
If
necessary,
use
a
puller
.
7
.
Use
a
sea¡
puller
to
remove
seal
from
transmission
housing
.
See
Fig
.
6
.
8
.
Coat
new
sea¡
wíth
transmission
fluid
and
drive
into
po-
sition
until
it
is
flush
with
housing
.
See
Fig
.
7
.
TRANSMISSIONSERVICE
Fig
.
6
.
Puller
used
to
remove
transmission
seal
.
Fig
.
7
.
Output
shaftseal
being
installed
using
seal
driver
(BMW
spe-
cial
tool
no
.
232
300)
.
9
.
Reinstall
output
flange
(and
shims,
if
applicable)
to
out-
put
shaft
.
NOTE-
On
Getrag
S5D200G
and
S5D
250G
transmissions
BMW
recommends
heating
theoutputflange
to
about
176°F
(80°C)
to
aid
in
installation
.
This
canbe
done
by
placing
the
flange
in
hot
water
.
10
.
Coat
bearingsurface
ofcollar
nut
withsealer
and
install
nut
.
Tighten
collar
nut
in
two
stages
.
Insta¡¡
new
lock-
plate
.
Bend
tabs
into
flange
grooves
.
NOTE-
BMW
recommends
the
use
of
a
sealer
such
as
Loctite
®
242
when
installing
the
flange
collar
nut
to
prevent
oil
from
leaking
past
the
threads
.