Transmission light BMW 328i 1997 E36 User Guide

117-
1
6



CAMSHAFT
TIMING
CHAIN

15
.
Remove
crankshaft
locking
tool
.
Remove
special
test

equipment
.
Insta¡¡
oil
supply
line
using
new
seals
and

reconnect
solenoid
connector
.
Remainder
of
installa-

tion
is
reverse
of
removal
.

Tightening
Torque

"
Cylinder
head
cover
to
cylinder
head
.
10
Nm
(89
in-lb)

"
VANOS
oil
supply
line
to
VANOS

control
unit
(banjo
bolt)



..
.........
32
Nm
(24
ft-Ib)

"
VANOS
solenoidlo
VANOS

control
unit
........
.
.
.
..
........
30
Nm
(22
ft-Ib)

VANOS
control
unit,
removing

Special
BMW
service
tools
are
required
lo
remove
and
in-

stall
the
VANOS
control
unit
.
Read
the
procedure
through
be-

forestarting
the
job
.

1
.
Remove
radiator
cooling
fan
shroud
and
cooling
fan
.

See
170
Radiator
and
Cooling
System
.

CAUTION-

Radiator
fan
has
left
hand
threads
.

2
.
Remove
top
plastic
engine
covers
.
Disconnect
ignition

coil
harness
connectors
from
coils
.
Remove
ignition

coils
.
Remove
cylinder
head
cover
.
Unclip
andremove

oil
baffle
cover
from
above
intake
camshaft
.See
113

Cylinder
Head
Removal
and
Installation
.

NOTE-

Make
note
of
the
mounting
bolt
insulator
arrangement
during
removal
of
the
cylinder
head
cover
.

3
.
Set
engine
lo
TDC
by
rotating
engine
in
normal
operat-

ing
direction
until
camshaft
lobes
at
cylinder
no
.
1
are

facing
each
other
and
"0/T"
mark
(0°TDC)
on
vibration

damper
lines
up
with
cast
boss
on
lower
timing
chain
cover
.
See
Fig
.
38
.

4
.
Lock
crankshaft
at
TDC
by
inserting
BMW
special
tool

no
.
11
2
300
through
transmission
bellhousing
and
finto

flywheel
or
drive
plate
.
Refer
to
Fig
.
36
given
earlier
.

NOTE-

Confirm
that
the
locking
tool
has
been
correctly
in-
stalled
by
trying
to
rotatethe
crankshaft
.

5
.
Remove
three
cylinder
head
cover
mounting
studs
from
rear
of
head
.
Lockcamshafts
at
TDC
bymounting

BMW
special
tool
no
.
11
3
240
at
ends
of
camshafts
.

Check
that
tool
is
squarely
seated
on
cylinder
head
gasket
surface
.
If
necessary,
rotate
camshafts
slightly
using
a24
mm
wrench
.
Refer
to
Fig
.
24
given
earlier
.

VANOS
(VARIABLE
VALVE
TIMING)

Fig
.
38
.
Camshafts
positioned
at
TDC-Cyl
.
No
.
1
cam
lobes
face
in
Note
0/T
mark
(0°TDC)
on
vibration
damper
alígned
with
boss
on
front
cover
.

CA
UTION-

Thecamshafts
mustbe
locked
in
the
TDC
position
using
the
specialservice
tool
or
an
equivalent
be-
fore
removing
the
timing
chain
.
Thearrows
on
the
sprockets
should
not
be
used
to
accurately
set
the
engine
to
TDC
The
special
tool
holds
the
cam-
shafts
parallel
to
each
other
and
perpendicular
to
the
valve
cover
gasket
surface
.

6
.
Disconnect
harness
connector
and
oil
line
fitting
from
bottom
of
VANOS
control
unit
.

NOTE-

Wrap
the
VANOS
oilfine
fitting
with
a
shop
rag
to
ab-
sorb
leaking
oil
.

7
.
Remove
two
access
plugs
from
VANOS
control
unit
in
frontof
exhaustcamshaft
sprocket
.
Loosen
4exhaustcamshaft
sprocket
mounting
bolts
but
do
not
remove

(Torx
El
0
socket)
.

NOTE-

Removal
of
the
access
plugs
allows
the
lower
exhaust
camshaft
sprocket
mounting
bolts
to
be
accessed
.

8
.
Depress
secondary
timing
chain
tensioner
and
lock
it
in
down
position
by
inserting
a
stiff
wire
into
rear
of
ten-
sioner
.
See
Fig
.
27
.

9
.
Remove
VANOS
control
unít
mounting
nuts
and
boltat

front
of
cylinder
head
.

Alternator
brushes,



STARTER
SERVICE
inspecting
and
replacing

Regulator
brushesarenot
available
as
replacement
parts
from
BMW
.
Replacement
brushes
may
be
available
from
af-

termarket
sources,
however
.

1
.
Remove
voltage
regulator
as
described
above
.

2
.
Clean
brush
contact
sürfaces
and
measure
brush
pro-trusion
.
See
Fig
.
7
.

Check
for
battery
voltage
at
terminal
50
of
the
starter
motor
Fig
.
7
.



Regulator
brush
protrusion
(A)
.



with
the
key
in
the
start
position
.
See
Fig
.
8
.
If
voltage
is
not
present,
check
the
wiring
between
the
ignition
switch
and
the
starter
terminal
.
If
voltage
is
present
and
no
other
visible
wir
Voltage
Regulator



ing
faults
can
be
found,
the
problem
is
most
likely
interna¡in

"
Brush
protrusion
(minimum)
.......
.
..
5
mm
(
1
/4
in
.)



the
starter
motor
.

3
.
To
replace
brushes,
carefully
and
as
quickly
as
possi-

ble,
unsolder
brush
lead
from
brush
holder
termina¡,

withdrawing
brush
from
holder
at
same
time
.

4
.
Remove
any
traces
of
solder
frombrush
holder
termi-
nal
using
solder
wick
.

5
.
Fit
spring
into
brush
holder
and
inserí
new
brush
.

6
.
Guide
brush
lead
into
terminal
and
solder
into
place
.

Check
for
free
movement
of
brushes
when
solder

cools
.

7
.
Check
brush
slip
rings
in
alternator
for
wear
.
Lightly
clean
slip
rings
using
fine
abrasive
cloth
.

BATTERY,
STARTER,
ALTERNATOR



121-
7

Starter
Troubleshooting

If
the
starter
tucos
the
engine
slowlyor
fails
to
operate
when
the
ignition
isin
the
start
position,
check
the
battery
first
.
In-
spect
the
starter
wires,
terminals,
and
ground
connections
for
good
contact
.
In
particular,
make
sure
the
ground
connections
between
the
battery,
the
body
and
the
engine
are
completely
clean
and
tight
.
If
no
faults
can
be
found,
the
starter
may
be
faulty
and
should
be
replaced
.

NOTE
-

"
Starting
in1194,
a
factory-installed
drive-away
protec-
tion
system,
alsoreferred
to
as
EWS
or
EWS
11,
was
used
on
all
E36
cars
.
This
system
prevenís
operation
of
the
starter
when
the
system
is
engaged
.
See
515
Central
Locking
and
Anti-theft
.

"
On
cars
with
automatic
transmission,
a
starter
relay
and
a
neutral
safetyswitchare
used
to
present
theen-
ginefrom
starting
in
gear
positions
other
than
park
or
neutral
.
ff
voltage
is
not
present
atterminal
50
with
the
key
in
the
startposition,
check
these
components

To
make
the
most
accurate
check
of
the
battery
cables
and
starterwiring,
make
a
voltage
drop
test
on
the
cables
and
wir-

ing
as
described
in
600
Electrical
System-General
.

Terminal
30
'
\



/
Terminal
30h

0012518

8
.
Reinstall
regulator
and
alternator
.



Fig
.
8
.



Typical
starterwiring
terminal
identification
.
Large
wireat
ter-
minal
30
is
direct
battery
voltage
.
Smaller
wire
at
terminal
50
operates
starter
solenoid
via
ignition
switch
.

STARTER
SERVICE

121-
8



BATTERY,
STARTER,
ALTERNATOR

1f
the
solenoid
audibly
cliicks
but
the
motor
does
not
turn,



Starter,
removing
and
installing
switch
on
the
lights
andtum
the
key
to
the
start
position
.
lf
the



(6-cylinder
engine
with
lights
go
out
while
attempting
to
start,
the
battery
cable
may
be



manual
transmission)
loose
or
the
starter
may
have
a
short
circuit
.
If
the
lights
stay

on,the
solenoid
is
most
likely
atfault
.
The
starter
on
a
6-cylinder
car
with
manual
transmission
is

Starter,
removing
and
installing

(4-cylinder
engine)



1
.
Disconnect
negative
(-)
battery
cable
.

1
.
Disconnect
negative
(-)
cable
from
battery
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery

disconnection
cautions
given
at
the
front
of
this

manual
on
page
viii
.

2
.
Remove
guide
tube
for
oil
dipstick
.

3
.
Raise
vehicle
.

WARNING
-

Make
sure
the
car
ís
stable
and
wefl
supported
at
all
times
.
Use
a
professional
automotive
lift
or
jack
stands
designed
forthe
purpose
.
A
floor
jack
is
not
adequate
support
.

4
.
Disconnect
wiring
from
starter
.

5
.
Remove
top
and
bottom
starter
bolts
.
Bottom
bolt
must

be
removed
from
below
car
.
Remove
starter
support

bracket,
if
applicable
.

removed
from
below
.

2
.
Raise
vehicle
.

3
.
Remove
reinforcing
cross
bracefromunder
transmís-

sion,
if
applicable
.

4
.
Remove
cover
from
fuel
filter
and
fuel
lines
on
left
side

underneath
car,
if
applicable
.
Detach
fuel
lines
and
har-

ness
connectors
from
retainingbrackets,
as
necessary

5
.
Disconnect
wiring
from
starter
.

6
.
Loosen
andremove
bolts
and
nuts
fastening
starter
to

transmission
bell
housing
and/or
engine
block
.
Remove

starter
supportbracket
.

7
.
Remove
starter
from
below
.

8
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-

age
.

9
.
Installation
is
reverse
of
removal
.

6
.
Pull
starter
downward
and
turn
until
solenoid
is
at
top,



Tightening
Torques

then
remove
from
car
.



"
Re¡
nforcing
cross
brace

to
chassis
(M10)
..
...............
42
Nm
(31
ft-Ib)

7
.
>Check
starter
pinion
gear
and
flywheel
teeth
for
dam-



"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)

age
.



"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)

"
Support
bracket

8
.
Installation
is
reverse
of
removal
.



to
engine
block
(M10
bolt)
.........
47
Nm
(35
ft-Ib)

"
Wire
to
terminal
50
(M6
nut)
.........
6
Nm
(53
ín-Ib)

"
Wire
to
terminal
30
(M8
nut)
.........
12
Nm
(9
ft-lb)

Tightening
Torques

"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-lb)

Wire
to
terminal
50
(M6
nut)
........
6
Nm
(53
in-lb)

"
Wire
toterminal
30
(M8
nut)
...
,
..:.
12
Nm
(9
ft-Ib)

STARTER
SERVICE

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

Clutch,
inspecting
and
installing

1
.
Inspect
clutch
disc
for
wear,
cracks,
loose
rivets,
con-

tamination
or
excessive
runout
(warping)
.
Replace
if

necessary
.

2
.
Inspect
flywheel
for
scoring,
hot
spots,
cracks
or
loose

or
worn
guide
pins
.
Replace
flywheel
if
any
faults
are

found
.

WARNING
-

If
flywheel
is
removed
from
vehicle,
use
new
bolts
duríng
installation
.
The
old
stretch-typebolts
should
not
be
reused
.

3
.
Inspecttransmission
pilot
bearing
in
end
of
crankshaft
.

The
bearing
should
rotate
smoothly
without
play
.
If
nec-

essary,
replace
as
described
later
.

4
.
Inspect
and
clean
releasebearing
lever
.
Apply
a
thin

coat
of
grease
to
releasebearíng
lever
contact
points
.

See
Fig
.
9
.
Also,
lightly
lubricate
clutch
disc
splines
and

transmission
inputshaft
splínes
.

5
.
Install
pressure
plate
and
clutch
disc
.
Do
not
fully
tight-

en
bolts
.

6
.
Center
clutch
disc
on
flywheel
using
centering
tool

(BMW
special
tool
no
.
21
2
130
or
equivalent)
.
Refer
to

Fig
.
7
.

NOTE-

Be
sure
clutchdísc
is
facing
the
correct
way
.
The
new

disc
should
bemarked
engine
sfde
or
transmission
side
.
See
Fig
.
10
.

7
.
Tighten
each
bolt
one
turn
at
a
time
until
pressure
plate

is
fully
seated,
and
then
torque
to
specification
.

8
.
Remove
clutch
disc
centering
tool
.
Remove
flywheel

locking
tool
.

Fig
.
9
.



Clutch
release
lever
lubrication
points
(arrows)
.

CLUTCH
210-
5

Clutch
Clutch

pressure
disc
plate

0012026

Fig
.
10
.
Clutch
assembly
Note
clutch
disc
hub
position
during
instal-
lation
.

CLUTCH
MECHANICAL

230
Manual
Transmission

MANUAL
TRANSMISSION



230-1

GENERAL
...
.
............
.
.......
.
.
.
.
230-1



Output
shaft
sea¡,
replacing

(transmission
installed)
....
.
.....
.
.....
.230-4

TRANSMISSION
FLUID
SERVICE
.
.
.
.
.
.
.230-1



Inputshaft
sea¡,
replacing

Transmission
fluid
leve¡,
checking
...
.
...
.
.
230-2



(transmission
removed)
.
.
.
.
...
.
.
.
.....
.
230-5
Transmission
fluid,
replacing
.........
.
.
.
.
230-2



TRANSMISSION
REMOVAL
AND

TRANSMISSION
SERVICE
.
.
.....
.
.
.
.
.
.
230-2



INSTALLATION
.
.
.
.
.
.
.....
.
.
.
.
.
.
.
.....
.
230-5

Back-up
light
switch,
replacing
.
.
.
...
.
.
.
.
.
.
230-2



Transmission,
removing
and
installing
...
.
.
.
.
230-6



_

Selector
shaft
sea¡,
replacing

(transmission
installed)
.
.
.
.
.
.
.
.
.
.
.
...
.
.
230-3



TAB

a
.
Manual
Transmission
Gear
Ratios
.
.
.
.........
.230-1

GENERAL



TRANSMISSION
FLUID
SERVICE

This
repair
group
covers
external
transmission
service,
in-



The
manual
transmissions
installed
in
the
E36
models
are

cluding
removal
and
installation
of
thetransmission
unit
.
Inter-



normally
filled
with
automatic
transmission
fluid
(ATF),
al-

nal
transmission
repair
is
not
covered
.
Special
press
tools
and



though
alternative
lubricants
may
have
beenused
from
the

procedures
are
required
to
disassemble
and
service
the
inter-



factory,
depending
on
transmission
type
and
model
year
.
For

nal
geartrain
.



example,
transmissions
fitted
to
the
M3
models
are
normally

filled
with
a
"lifetime"
manual
transmission
fluid
(BMW
MTF

Manual
transmissions
used
are
based
on
engine
applica-



LT-1)
and
do
not
require
periodic
fluid
changes
.

tion
.
Consult
200
Transmission-General
for
transmission

application
information
.
Table
a
lists
gear
ratio
specifications
.



NOTE-

The
transmission
lubricant
type
can
be
found
ona
label

NOTE-



on
the
sideof
the
transmission
.
Consult
an
authorized

Do
not
rely
on
forged
casting
numbers
for
transmission



BMW
dealer
for
altemate
fluid
use
and
the
most-up-to-

code
identification
.



date
information
regarding
transmission
operating
fluids
.

Tablea
.
Manual
Transmission
Gear
Ratios

Transmission



1



Getrag
S5D
200
G



1



Getrag
SSD
250
G



1



ZF
S5D
310
Z



1



ZF
S5D
320
Z

Gear
Ratios
:
1st



4
.23



4
.23



4
.20



4
.20
2nd



2
.52



2
.52



2
.49



2
.49
3rd



1
.66



1
.66



1
.66



1
.664th



1
.22



1
.22



1
.24



1
.24
5th



1
.00



1
.00



1
.00



1
.00

reverse



4
.04



4
.04



3
.89



3
.89

TRANSMISSION
FLUID
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
.

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
.

230-
6



MANUAL
TRANSMISSION

Transmission,
removing
and
installing

1
.
Disconnect
negative
(-)
cable
from
battery
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.

2
.
Insta¡¡
enginesupportacrossengine
bay
.
Raise
engine

so
that
weight
of
engine
ís
supported
.
See
Fig
.
10
.

Fig
.
10
.
Engine
support
equipment
used
to
support
engine
from
above
before
removing
transmission
.

3
.
Raise
vehicle
to
gain
access
to
underside
of
car
.

4
.
Support
transmission
with
transmission
jack
.
lf
applica-
ble,
remove
reinforcing
cross
brace
from
belowen-
gine/transmission
.

5
.
Disconnect
harnesscon
nector
from
reverse
light
switch
on
transmission
.

6
.
Remove
completeexhaustsystem
and
heat
shield
.
See
180
Exhaust
System
.

NOTE-

Disconnect
oxygensensor
hamess
connector(s)be-
fore
lowering
exhaust
system
.

7
.
Remove
driveshaft
.
See260
Driveshaft
.

8
.
Disconnect
shift
rod
from
transmission
selectorshaft
.
See
Fig
.
11
.

9
.
Disconnect
shift
console
fromtop
of
transmission
.
See
250
Gearshift
Linkage
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

Washers

Shift



Shift
rod

rod



retaining
clip

0
0
,

Fig
.
11
.
Shift
lever
to
transmission
connection
.

Shift
console

0012024

10
.
Unbolt
clutch
slave
cylinder
from
sideof
transmission
.

Do
not
disconnect
fluid
hose
.
Suspend
slavecylinder

from
chassis
using
stiff
wire
.

CAUTION-

Do
not
operate
clutch
pedal
with
slave
cylinder
re-
moved
from
transmission
.

11
.
Support
transmission
from
below
with
jack
.
Remove
rear

support
crossmember
from
transmission
.
See
Fig
.
12
.

Fig
.
12
.
Rear
transmission
crossmember
(arrow)
.

12
.
Lower
transmission/engine
assembly
until
it
rests
on
front
suspension
crossmember
.

CAUTION-

Tilting
the
engine
to
lower
thetransmission
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
at
rear
of
engine
-On
cars
with
AST
remove
throttle
body
before
tilt-
ing
engine
.
-Remove
brace
fluid
reservoir
if
necessary
.

0013135

13
.
Remove
transmission
mounting
bolts
(Torx-head)
.

Note
length
and
location
of
bolts
.
See
Fig
.
13
.

Fig
.
13
.
Transmission
mounting
bolts
.

0611642

CA
UTION-

Atno
time
should
the
weight
of
thetransmission
be
supported
by
the
transmission
inputshaft
.

NOTE
-

Washers
should
always
be
used
with
Torx-head
bolts
.

Installing
bolts
without
washers
will
make
them
difficult

to
loosen
.

MANUAL
TRANSMISSION



230-
7

Fig
.
14
.
Bellhousing
alignment
dowels
(arrows)
.

16
.
Install
driveshaft
and
preload
center
bearing
bracket
.

Usenew
nuts
when
mounting
driveshaft
to
transmis-

síon/flex
disc
and
final
drive
.
See
260
Driveshaft
.

17
.
Refill
transmission
with
appropriate
lubricant
before

starting
or
towingthe
car
.
See
Transmission
Fluid

Service
earlier
in
this
repair
group
.

14
.
Remove
transmission
by
pulling
backward
until
the
trans-



Tightening
Torques

mission
inputshaft
clears
the
clutch
disc
splines,
then



"
Reinforcing
cross
brace

pulí
downwards
.
Lower
jack
andremove
transmission
.



to
chassis
(M10)
.
...
.............
42
Nm
(31
ft-Ib)

"
Rubber
mount
to
transmission

15
.
Installation
is
reverse
of
removal,
keeping
in
mind
the



or
bracket
nut
(M8)
.
...
.
...
.......
21
Nm
(16
ft-Ib)

following
:



"
Slave
cylinder
to
transmission
......
22
Nm
(16
ft-Ib)

"
When
installing
exchange
transmission,
transfer
parts



"
Transmission
crossmember
to
chassis

from
old
unit
to
exchange
unit



M8
...............
.
.
...
..
22-24
Nm
(16-17
ft-Ib)

"
Thoroughly
clean
inputshaft
and
clutch
disc
splines
.



M10
..............
.
..
..
.......
42
Nm
(31
ft-Ib)

Lightly
lubrícate
transmission
inputshaft
before
in-



"
Transmission
to
engine
(Torx-head)

stalling
.-



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

"
Be
sure
bellhousing
dowels
are
correctly
located
.
See



M10
.
.................
...
.
..
..
43
Nm
(32
ft-Ib)

Fig
.
14
.



M12
.
..................
..
.
..
..
72
Nm
(53
ft-Ib)

"
Center
rear
of
transmission
in
driveshaft
tunnel
before



"
Transmission
drain/fill
plugs
.
..
.
..
..
50
Nm
(37
ft-Ib)

tightening
transmission
support
bracket
.

TRANSMISSION
REMOVAL
AND
INSTALLATION