Hose BMW 328i 1998 E36 Repair Manual

160-
4



FUEL
TANK
AND
FUEL
PUMP

Fig
.
4
.



Pinch
off
supply
and
retum
fuel
hoses
(arrows)
before
dis-
connecting
from
rigid
metal
lines
.

0013143

Fig
.
5
.
After
removing
exhaustsystem,
remove
heat
shield
screws
(arrows)
and
heat
shield
.

9
.
Working
underneath
car,
loosen
hose
clamp
and
dis-

connect
filler
hose
.

10
.
Support
tank
from
below
.
Remove
tank
strap
mounting

bolts
.
Lower
and
remove
tank,
disconnecting
right
side



TheE36
model
uses
a
two-lobed
fuel
tank
and
each
lobeof
vent
and
other
hoses/electrical
connectors
as
neces-



the
tank
has
its
own
fuel
level
sending
unit
.
sary
.

11
.
Installation
is
reverse
of
removal
.

"
Always
use
new
seals,
gaskets,
O-rings,
and
hose
clamps
.

"
Inspect
hoses
and
replace
any
that
are
chafed,
dried

outor
cracked
.

"
Inspect
heat
shield
and
replace
if
corroded
.

"
Inspect
rubber
buffers
and
liners
on
fuel
tank,
support
straps
and
on
underside
of
body
.
Replace
rubber

parts
that
are
hardened
or
damaged
.

FUEL
LEVEL
SENDERS

CAUTION-

"
Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1.5
gallons
(5
liters)
of
fuel
to
prevent

damaging
a
dry
fuel
pump
.

"
If
the
filler
neck
has
been
removed
from
the
body,
be
sure
toreattach
theneck's
grounding
screw
(where
applicable)
.
Check
electrical
resistance
between
the
ground
tab
and
wheel
hub
.
The
re-
sistance
shouldbeno
higher
than
0
.6
ohms
.

Tightening
Torques

"
Fuel
tank
to
body
.............
...
23
Nm
(17
ft-Ib)

"
Hose
clamps
(10
mm-16
mm
día
.)
..
2
.0
Nm
(18
in-lb)

Fuel
Tank
Evaporative
Control
System

The
fuel
tank
evaporative
control
system
is
used
to
vent
the

fuel
tank
to
a
charcoal
canister,
which
is
then
purgedby
en-

gine
vacuum
during
normal
engine
operatíon
.
This
controls

emission
of
raw
hydrocarbons
(fuel)
to
the
atmosphere
.
See

Fig
.
1
.

A
fuel
expansion
tank,
located
under
the
right
rear
fender,

traps
overflow
fuel
and
incorporates
extra
fuel
tank
plumbing
.

Startingwith
1996
models,
OBD
II
standards
require
that

the
fuel
tank
evaporative
control
system
be
monitored
for

leaks
.
This
is
accomplished
usingthe
fuel
tankpressuresen-

sor,
the
ventshut
off
valve,
and
the
evaporative
purge
valve
.

NOTE-

On
most
early
cars(1992-1995),
the
charcoal
canister

is
in
the
engine
compartment
.
On
latercars,
the
char-
coal
canister
is
under
the
spare
tire
in
the
luggage
com-
partment
.

FUEL
LEVEL
SENDERS

The
right
side
fuel
leve¡
sender
is
integrated
with
the
fuel

pump
.
Each
senderhas
a
float
connected
to
a
variable
resis-

tance
for
fuel
leve¡
.
When
replacing
the
sender/pump
assem-

bly
always
replace
hose
clamps,gaskets
and
O-rings
.

WARNING
-

When
removing
the
fuel
level
sender
or
the
fuel
pump,
the
fuel
tank
should
be
emptied
.

Fuel
leve¡
senders,
testing



Fuel
leve¡
sender
(right
side)

The
left
and
right
fuelleve¡
sending
units
are
wired
in
series
.



and
fuel
pump,
removing
and
installing

The
fuel
gauge
receives
a
signal
that
is
the
average
of
the
two



1
.
Disconnect
negative
(-)
cable
from
battery
.

input
values
.

1
.
Remove
rear
seat
cushion,
lift
up
insulation
mats,
andremove
both
fuel
tank
access
covers
.

2
.
Disconnect
white
plug
on
each
sending
unit
.
See
Fig
.
6
.

3
.
Check
resistance
value
of
eachsending
unit
.
Values
should
be
the
same
.

5
.
If
valuesare
different,
remove
sending
units
as
described

below,
and
check
resistance
valuésacross
terminals
.
Table
a

lists
resistance
values
for
senders
at
various
float
positions
.

Table
a
.
Fuel
Leve¡
Sender
Resistances

Float
position



Test
result
(ohms)

Right
side
empty



10
ohm
t2

Right
side
full



250
ohm
±
5
Left
side
empty



10
ohm
t
2

Left
side
fui¡



250
ohm
±
5

FUEL
TANK
AND
FUEL
PUMP



160-
5

CAUTION
-

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

2
.
Drain
fuel
from
tank
as
described
earlier
.

WARNING
-

Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
fines
.

3
.
Remove
rear
seat
cushion
and
pull
back
insulation
pad
under
right
side
.

4
.
Remove
screws
holding
rightfuel
tank
accesscover
.

Remove
cover
.

5
.
Label
fuel
hoses
.
Disconnect
hoses
and
harness
con-

nectors
from
fuel
sending
unit
and
fuel
pump
.

6
.
Unscrew
threaded
collar
from
fuel
pumplfuel
leve¡
sender
.
Slowly
withdraw
assembly
from
tank,allowing

fuelto
drain
off
.
See
Fig
.
7
.
0013187
&
0013194

Fig
.
6
.



Fuel
pump/leve¡
sender
terminal
identification
.
Check
resis-
tance
at
terminals
of
white
connectors
(arrows)
.



"
If
necessary,
push
leve¡
sender
arm
toward
fuel
pump

assembly
to
facilitate
removal
.

NOTE
-

BMW
special
tool
no
.
16
1
020
should
beused
to
re-
move
and
install
the
threaded
collar
.
Damage
to
the
collar
may
result
if
the
special
tool
is
not
used

WARNING
-

NOTE-



Fuel
may
be
spilled
.
Do
not
smoke
or
work
near

The
compensating
siphon
pump
(Fig
.
1)
maintains
the



heaters
or
other
fire
hazards
.

fuel
leve¡
between
the
right
and
left
tank
lobes
.
If
the
re-
sistances
are
different
between
the
left
and
right
send-
ers,
remove
the
senders
and
visually
inspect
the
leve)
in



7
.
Using
a
new
sealing
ring,
install
pump
and
sending
each
lobe
.
If
the
leve¡
is
different,
check
the
siphon
com-



unit,
being
sure
that
fuel
line
connections
point
in
same

pensating
pump
.



direction
as
they
carne
out
.

8
.
Reconnect
harnessconnector
and
hoses
.
Fill
tank
and

check
for
leaks
by
running
engine
.
Insta¡¡
access
cover

and
its
mountingscrews
.
Reconnect
negative
(-)
cable

to
battery
.

CAUTION
-

Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1
.5
gallons
(5liters)
of
fuel
.
The
pump
will
be
damaged
if
you
run
it
without
fuel
.

FUEL
LEVEL
SENDERS

160-
8



FUEL
TANK
AND
FUEL
PUMP

UU131
tst5

Fig
.
11
.
Voltage
supply
to
fuel
pump
harness
(black)
connector
being
checked
(arrow)
.

00131ts7

Fig
.
12
.
Test
fuel
pump
for
current
draw
by
attadhing
ammeter
andjumper
wire
as
shown
.

CAUTION-

Do
not
allow
the
test
leads
to
short
to
ground
.

NOTE-

See
600
Electrical
System-General
for
information
on
electricaltests
using
a
digital
multimeter
(DMM)
.

4
.
Run
pump
as
described
in
Operating
fuel
pump
for
tests
.

FUEL
PUMP

5
.
Compare
ammeter
reading
with
specification
listed
in

Table
b
.

Maximum
current



5
.0
amps
consumption

FuelDelivery
Tests

Table
b
.
Fuel
Pump
Current

Checking
fuel
delivery
is
a
fundamental
part
of
trouble-

shooting
and
diagnosing
the
DME
system
.
Fuelpressure
di-

rectly
influences
fuel
delivery
.
An
accurate
fuel
pressure

gauge
will
be
needed
to
make
the
tests
.

There
arethree
significant
fuel
delivery
values
to
bemea-

sured
:

"
System
pressure-created
by
the
fuel
pump
and
main-

tained
by
the
pressure
regulator
.

"
Fuel
delivery
volume-created
by
the
fuel
pump
and
af-

fected
by
restrictions,
suchas
clogged
fuel
filter
.

"
Residual
pressure-the
pressure
maintained
in
the

closed
system
after
the
engine
and
fuel
pump
areshut

off
.

Procedures
for
measuring
the
first
two
quantities
arede-

scribed
here
.

Residual
fuel
pressure
is
checked
using
the
procedurede-

tailed
in
130
Fuel
Injection
.

Relieving
fuel
pressure
and
connecting

fuel
pressure
gauge

WARNING
-

"
Gasoline
is
highly
flammable
and
its
vaporsare
explosive
.
Do
not
smoke
or
work
ona
car
near
heaters
or
other
fire
hazards
when
diagnosing
and
repairing
fuel
system
problems
.
Have
a
fire
extinguisher
available
in
case
of
an
emergency
.

"
When
working
onan
open
fuel
system,
wear
suit-
able
hand
protection
.
Prolonged
contact
with
fuel
can
cause
iflnesses
and
skin
disorders
.

CA
UTION-

Cleanliness
is
essential
when
working
withfuel
circuit
components
.
Thoroughly
clean
the
unionsbefore
disconnecting
fuel
fines

To
prevent
fuel
from
spraying
on
a
hotengine,
system
fuel

pressure
should
be
relieved
before
disconnecting
fuel
lines
.

One
method
is
to
tightly
wrap
a
shop
towel
around
a
fuel
line
fit-
ting
and
loosen
or
disconnect
the
fitting
.

Measuring
fuel
pressure
requires
special
tools
.
Earlier
cars
use
pressure
hose
with
clamps
for
fuel
delivery
.
These
can
be
attached
to
a
fuel
pressure
gauge
below
the
intake
manifold
.

NOTE-



NOTE
-

On
1996
and
later
4-cylinder
cars,
use
BMW
special



"
Use
BMW
pressure
gauge
Part
No
.
133
060,or
an
tool
13
6051
(hose
with
quick
release
coupling)
toat-



equivalent
.
The
fuel
pressure
gauge
should
have
a
tach
pressure
gauge
to
Shraeder
valve
fitting
on
top
of



rangeof
0
to
5bar
(0
to
75
psi)
and
mustbe
securely
the
M44
fuel
rail
.
See
Fig
.
13
.



connected
to
prevent
it
from
coming
loose
under
pres-
sure
.

u012503a

Fig
.
13
.
Fuel
rail
showing
location
of
Shrader
valve
fitting
on
M44
en-
gine
(arrow)
.

Later
model
6-cylinder
fuel
systems
require
BMW
specíal

tool
16
1
050
to
release
fittings
and
connect
the
fuel
gauge
.
See
Fig
.
14
.

0012699

Fig
.
14
.
Fuel
lines
at
rear
of
íntake
manifold
on
M52
engine
.
Use
BMW

special
tool
16
1
050
to
release
fittings
.

If
the
special
tools
arenot
available,
a
length
offuel
line
and

a
T-fitting
can
be
installed
tothe
inlet
fuel
line
and
connected

to
a
fuel
gauge
.

FUEL
TANK
AND
FUEL
PUMP



160-
9

"
On
cars
with
6-cylinder
engine,
thetop
left-side
en-
Bine
cover
will
have
to
be
removed
to
access
the
fuel
rail
.

System
pressure,
testing

System
pressure
is
the
pressure
created
by
the
fuel
pump
and
maintained
by
the
pressure
regulator
.
See
Fig
.
15
.
Sys-
tem
pressure
is
not
adjustable
.

1
.
Remove
fuel
tank
filler
cap
.

Fig
.
15
.
Fuel
pressure
regulator
.
Fuel
pressure
deflects
diaphragm
to
retum
fuel
to
tank
when
pressure
reaches
desired
limit
.

CA
UTION-

The
fuel
pump
is
capable
of
developing
a
higher
pressure
than
that
regulated
by
the
pressure
reg-
ulator
.
In
the
event
the
fuel
pump
check
valve
is
faulty
(stuck
closed),
make
sure
the
fuel
pressure
does
not
rise
aboye
6
.0
bar(87
psi)
.
Damage
to
the
fuel
fines
or
fuel
system
components
could
re-
sult
.

2
.
Connect
in-fine
a
Tfitting
and
fuel
pressure
gauge
to

outlet
hose
atfuel
pump
.

FUEL
PUMP

160-
1
0



FUEL
TANK
AND
FUEL
PUMP

3
.
Operate
fuel
pump
as
described
earlier
under
Operat-

ing
fuel
pump
for
tests
.
Check
that
fuel
pressure
cor-

responds
to
specifications
listed
in
Table
c
.

"
If
system
pressure
is
low,
repeat
test
whilegradually

pinching
off
return
hose
.
Pressure
should
rise
rapidly
.

If
not,fuel
pump
is
most
likely
faulty
.

"
If
system
pressure
is
too
high,
check
return
line
from
pressure
regulator
to
tank
.
Check
for
kinks
in
hose
.
Blow
compressed
air
through
line
to
check
for
block-

ages
.
If
no
faulty
canbe
found,
pressure
regulator
is

most
likely
faulty
.
See
130
Fuel
Injection
for
testing

and
replacementprocedures
.

Table
c
.
Fuel
Pressure
Specifications

Engine



1
Fuel
pressure

4-cylinder
M42/M44



3
.0
:e
0
.06
bar(43
.5
±0
.9
psi)

6-cylinder
M50/S50US



3
.0
:j-
0
.06bar(43
.5
t0
.9
psi)
M52/S52US



3
.5
t
0
.06
bar
(51
t0
.9psi)

CA
UTION-

Do
not
use
compressed
air
above
40
psi
to
blow
out
fines
or
components
.
Interna¡
damage
to
com-
ponents
may
result
.

4
.
When
finished,
disconnect
pressure
gauge
.

FUEL
PUMP

Fuel
delivery
volume,
testing

1
.
Disconnect
return
line
from
fuel
rail
in
engine
compart-

ment
.

2
.
Connect
a
length
of
hose
to
fitting
on
fuel
rail
and
place

open
end
of
hose
in
a
suitable
container
for
catching

fuel
(2-quart
capacity)
.

3
.
Run
fuel
pump
for
exactly
30
seconds
as
described

earlier
under
Operating
fuel
pump
for
tests
and
mea-

sure
fuel
collected
.
Refer
to
Table
d
.

WARNING-



Table
d
.
Fuel
Pump
Delivery
Specifications

Fuel
under
pressure
is
present
duringthe
test
.
Use
I



Engine



Delivery
rate
(30
seconds
@
12V)
hose
clamps
at
all
connections
.
4-cylinder
M42/M44



0
.875
fter
(0
.93
qt)

6-cylinder
M50/S50US



0
.875
fter(0
.93
qt)
M52/S52US



~



1
.12
liter
(1
.16
qt)

4
.
When
finished
testing,
reconnect
fuel
line
.
Tighten
all
hose
clamps
.

NOTE-

It
is
common
practice
to
replace
the
fuel
filter
any
time
the
fuel
pump
unit
is
replaced
.

170-2



RADIATOR
AND
COOLING
SYSTEM

Cooling
Fans



TROUBLESHOOTING

Belt-driven
coolingfan
.
The
primary
cooling
fan
is
belt-

driven
.
It
is
mounted
to
the
frontof
the
coolant
pump
through
a

fan
clutch
.
The
fan
clutch
is
a
viscous
fluid
coupling
that
con-

trols
the
speed
of
thefan
based
on
engine
compartment
tem-

perature
.

Electric
cooling
fan
.
Models
with
M44
engine
and
stan-

dard
transmission
substitute
an
electric
fan
for
the
belt-driven

viscous
fan
.
This
is
attached
to
the
rear
of
the
radiator
and

controlledvia
the
DME
5
.2
engine
management
system
.

NOTE-

The
electric
cooling
fan
in
these
models
is
activated
by
the
engine
control
module
(ECM)
.

Auxiliary
coolingfan
.
In
al¡
models
a
two-speed
electric

auxiliary
cooling
fan
is
mounted
behind
the
front
grill
and
in

front
of
the
radiator
.
This
fan
is
primarily
used
for
the
A/C
sys-

tem,
but
also
operates
when
the
coolant
temperature
ex-

ceeds
a
predetermined
leve¡
.

Warnings
and
Cautions

The
following
warnings
and
Cautions
should
beobserved

when
working
on
the
cooling
system
.

WARNING
-

"
Atnormal
operating
temperature
the
cooling
sys-
tem
is
pressurized
.
Allow
the
system
to
cool
as
long
as
possible
before
opening-a
minimum
of
an
hour-then
release
the
cap
slowly
to
allow
sale
release
of
pressure
.

"
Releasing
the
cooling
system
pressure
lowers
the
coolants
boiling
point
and
the
coolant
may
boíl
suddenly
.
Use
heavy
gloves
and
wear
eye
and
laceprotection
to
guard
against
scalding
.

"
Use
extreme
care
when
draining
and
disposing
of
engine
coolant
.
Coolant
is
poisonous
and
lethal
to
humans
and
pets
.
Pets
are
attracted
to
coolant
because
of
its
sweet
smell
and
taste
.
Consult
a
veterinarian
immediately
if
coolant
is
ingested
byan
animal
.

CAUTION-

"
Avoidadding
cold
water
to
the
coolant
while
the
engine
is
hot
or
overheated
.
If
it
is
necessary
to
add
coolant
to
ahot
system,
do
so
only
with
the
engine
running
and
coolant
pump
tuming
.

"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.

TROUBLESHOOTING

Most
cooling
system
faults
can
be
grouped
into
one
of
three

categories
:

"
Cooling
system
leaks

"
Poor
coolant
circulation

"
Radiator
cooling
fan
faults

When
investigating
the
cause
of
overheating
or
coolant

loss,
begin
with
a
visual
inspection
.
Be
sure
to
check
the
con-

dition
and
tension
of
the
coolant
pump
drive
belt
.
Check
hoses

for
cracks
or
softness
.
Check
clamps
for
looseness
.
Check

the
coolant
leve¡
and
check
for
evidence
of
coolantleaks
from

the
engine
.

Check
that
the
radiator
fins
are
not
blocked
with
dirt
or
de-

bris
.
Clean
the
radiator
using
low-pressure
water
or
com-

pressed
air
.
Blow
outward,
fromthe
engine
side
out
.

Inspect
the
coolant
pump
by
first
removing
the
drive
belt

from
the
pump
.
Firmly
grasp
opposite
sídes
of
the
pulley
and

check
for
play
in
all
directions
.
Spin
the
pulley
and
check
that

the
shaft
runs
smoothly
.

NOTE-

The
coolant
provides
lubrication
for
the
pump
shaft,
soan
occasional
drop
of
coolant
leaking
from
the
pump
is
acceptable
.
If
coolant
drips
steadily
from
the
vent
hole,
the
pump
should
be
replaced
.

The
cooling
system
becomes
pressurized
at
normal
operat-

ing
temperature,
which
raises
the
boiling
point
of
the
coolant
.

Leaks
may
prevent
the
system
from
becoming
pressurized,

allowing
the
coolant
to
boil
at
a
lower
temperature
.
If
visual
ev-

idence
is
inconclusive,
a
cooling
system
pressure
test
can

help
to
pinpointhard-to-find
leaks
.

If
the
cooling
system
is
full
of
coolant
and
holds
pressure,

the
next
most
probable
cause
of
overheating
are
:

"
Faulty
radiator
fan

"
Loose
or
worn
drive
belt

"
Failed
thermostat
or
coolant
pump

"
Clogged/plugged
radiator
or
coolant
passages
.

NOTE
-

"
Some
early
style
coolant
pumps
were
fitted
wíth
fi-
berlplastic
type
impellers
.
Over
time,
this
impeller
can
wear
away
and
result
in
overheating
.
The
plastic
im-
peller
can
also
slip
or
free-wheel
on
the
pump
shaft
.
If
the
engine
overheats
and
no
other
faults
canbe
found,
theold
style
impeller
may
be
the
cause
of
the
problem
.

"
Only
pumps
with
the
updated
metal
impeller
should
be
used
for
replacement
.

Cooling
System
Pressure
Test



If
the
engine
overheats
and
no
other
cooling
system
testsindicate
trouble,
the
radiator
may
have
some
pluggedpassag-

A
cooling
system
pressure
test
is
used
to
check
for
internal



es
that
are
restricting
coolant
flow
.

leaks
.
Some
of
the
common
sources
ofinternal
leaks
are
a
faulty
cylinder
head
gasket,
a
cracked
cylinder
head,
or
a



Temperature
Gauge
Quick
Check
cracked
cylinder
block
.

The
coolant
temperature
sensor
is
located
on
the
intake
To
doa
cooling
system
pressure
test,
a
special
pressure



manifold
(left)
side
of
the
cylinder
head,
under
the
intake
man-
tester
is
needed
.



ifold
runners
.
See
Fig
.
2
.

WARNING
-

At
normal
operating
temperature
-
the
cooling
sys-
tem
is
pressurized
.
Allow
the
system
to
cool
before
opening
.
Release
the
cap
slowly
to
allow
sale
re-
tease
of
pressure
.

With
the
engine
cold,instan
a
pressure
tester
to
the
expan-

sion
tank
.
Pressurize
thesystem
to
the
specification
listed
be-

low
.
Pressure
should
not
drop
more
than
0
.1
bar
(1
.45
psi)
for

at
leakt
two
minutes
.
If
the
pressure
drops
rapidly
and
there
is
no
sign
of
an
externa¡
leak,
the
cylinder
head
gasket
may
be
faulty
.
Considera
compression
test
as
described
in
100
En-

gine-General
.

The
screw-on
type
expansion
tank
cap
should
also
be
test-

ed
using
a
pressure
tester
and
the
correct
adapter
.

Cooling
System
Test
Pressure

"
Radiator
test
pressure
.........
.
1
.5
bar
(21
.75
psi)

"
Radiator
cap
test
pressure
..
.
........
2
bar
(29
psi)

CA
UTION-

Exceeding
the
speclfied
test
pressure
could
dam-
age
the
radiatoror
other
system
components
.

Carefully
inspect
the
radiator
cap
for
damage
.
Replace
a

faulty
cap
or
a
damaged
cap
gasket
.

Thermostat
Quick
Check



In
later
models,
the
ECT
sensor
and
the
gauge
sender
are
combined
into
one
sender
unit
.
For
wire
colors
refer
to
Table
a
.
To
check
if
the
thermostat
is
opening
and
coolant
is
circulat-

ing
through
the
radiator,
allow
a
cold
engine
to
reach
operat-

ing
temperature
(temperature
gauge
needieapproximately

centered)
.
Shut
off
engine
.
Feel
the
top
radiator
hose
.
If
the

hose
is
hot
to
the
touch,
the
coolant
is
probably
circulating
cor-
rectly
.
If
there
are
any
cool
areas
in
the
hose
or
radiator,
cool-

ant
flow
to
the
radiator
is
probably
restricted
.
Check
for
a
faulty

thermostat
or
aplugged
radiator
.

NOTE-

A
thermostat
that
is
stuck
open
will
cause
the
engine
to
warmup
slowly
and
run
belownormal
temperature
at
highway
speed
.
A
thermostat
that
is
stuck
closed
will
re-

strict
coolant
flow
to
the
radiator
and
cause
overheating
.

RADIATOR
AND
COOLING
SYSTEM



170-
3

U
.¡ig
.v

Fig
.
2
.
Temperature
gauge
sender
on
M44
engine
.
Temperature
gauge
sender
location
is
similar
on
al]
engines
.

In
early
models,
the
engine
coolant
temperature
(ECT)
sen-

sor
for
the
fuel
injection
and
the
coolant
temperature
gauge

sender
are
located
side
by
side
.

Table
a
.
Coolant
Temperature
Sensor
Wire
Colors

Function



Sensor



Terminal



Wire
colors
location
number

Two
sensors
:
Temperature
Rear
1
Brown/violet
gauge
sender



2



Brown/yellow
ECT
sensor



Front



1



Brown/red
2



Brown
or
Brown/black

One
sensor
:
Temperature
Dual
1
Brown/yellow
gauge
sender



sensor



2



Brown/violet
ECT
sensor



3



Brown/red
4
Brown/black
or
Grey/black

TROUBLESHOOTING

170-6



RADIATOR
AND
COOLING
SYSTEM

Fig
.
6
.



Radiator
drain
plug
(arrow)
.

WARNING
-

Coolant
is
poisonous
.
Itis
especially
lethal
to
pets
.

Cleanup
spills
immediately
and
rinse
the
area
with

water
.

NOTE
-

The
block
drain
plug
is
located
on
the
exhaust
side
of
the
engine,
near
the
reas
of
the
engine
.

4
.
Reinstall
radiator
and
engine
block
drain
plugsusing

new
sealing
washers
.
Leave
heater
controis
on
full

warm
.

5
.
Using
a
coolantmixture
of
50%
antifreeze
and
50%
dis-

tilled
water,
fill
system
slowly
On
radiator
with
integral

expansion
tank,
bleed
cooling
system
as
described
be-

low
.

NOTE-

"
Tap
water
may
cause
corrosion
of
radiator,
engine
and
coolant
hoses
.

"
Coolant
can
often
be
reused
provided
itis
clean
and
less
than
twoyears
old
.
Do
not
reuse
coolant
when
re-
placing
damaged
engine
parts
.
Contaminated
coolant
may
damage
the
engine
or
cooling
system
.

Tabled
.
Cooling
System
Capacities

Engine



j
Capacity

4-cylinder



1
6
.5
liters
(6.9
qt)

6-cylinder
M50/M52



10
liters
(10
.6
qt)
S50US/S52US



10
.5
liters
(11
.1
qt)

COOLING
SYSTEM
SERVICE

Tightehing
Torques

"
Radiator
drain
plug
to
radiator
...
2-3
Nm
(18-27
in-lb)

"
Engine
block
drain
plug
to
block



.
.
..
25
Nm
(18
ft-Ib)

Cooling
system,
bleeding

(radiator
with
integral
expansion
tank)

NOTE
-

On
radiators
with
a
separate
expansion
tank,
ableed

screw
is
not
provided
.
The
cooling
system
with
sepa-

rate
expansion
tank
is
self
bleeding
via
the
vent
hose

on
the
expansion
tank
.

Air
maybecome
trapped
in
the
system
during
filling
.

Trapped
air
can
prevent
proper
coolant
circulation
.
Whenever

the
coolant
is
drained
and
filled,
the
system
should
be
bled
of

trapped
air
.

1
.
With
engine
cold,
add
coolant
to
expansion
tank
until

level
reaches
COLD
(KALT)
mark
on
tank
.

2
.
Loosen
bleed
screw
on
radiator
expansion
tank
.
See

Fig
.
7
.

0011976

Fig
.
7
.



Cooling
system
bleed
screwon
radiator
(arrow)
.
Note
cold
level
mark
on
expansion
tank
.

3
.
M3
models
:
Loosen
bleed
screw
on
thermostathous-

ing
.

4
.
Set
temperature
controls
in
passenger
compartment
to

fui¡
warm
and
turn
ignition
on
position
(do
not
start
en-

gine)
.

170-10



RADIATOR
AND
COOLING
SYSTEM

Coolant
pump,
replacing

The
engine
coolant
pump
is
mounted
in
the
frontof
the
en-

gine
on
the
timing
cover
.
See
Fig
.
16
.

Fig
.
16
.
Coolant
pump
mounted
on
timing
cover
.

NOTE-

Onlyreplacement
coolant
pumps
with
metal
¡mpellers
should
be
installed
.
Pumps
with
plastic
impellers
should
not
be
used
.

1.
Drain
cooling
system
as
described
earlier
.

0013197

WARNING
-

Allow
cool¡ng
system
to
cool
before
open¡ngor
drain¡ng
system
.

2
.
Remove
primary
cooling
fan
shroud
and
cooling
fan
(belt-driven
or
electric)
as
described
earlier
.

Fig
.
17
.
Engine
drive
belt
tensioner
being
released
on
M44
engine
.
Pry
off
tensioner
cover
and
then
lever
tensioner
in
counterciock-
wise
direction
(as
facing
engine)
and
slip
belt
off
pulleys
.

Fig
.
18
.
Drive
belt
tensioner
being
released
on
M52
engine
.
Pry
off
3
.
Disconnect
hoses
from
thermostat
housing
.
Unbolt



tensioner
cover
and
then
lever
tensioner
clockwise
(as
facing
thermostat
housing
from
front
of
cylinder
head
.



engine)torelease
belt
tension
.

4
.
Remove
coolant
pump
drive
belt
.
See
Fig
.
17
or
Fig
.
18
.

NOTE-

-
Mark
direction
of
drive
belt
rotation
if
reusing
belt
.



"
The
6-cylinder
coolant
pump
¡s
mounted
on
studs
and
retained
by
nuts
.
"
Severa¡
drive
belt
and
tensioner
configurations
havebeenused
in
E36
models
.
Refer
to
020
Maintenance
Program
and
640
Heating
and
Air
Conditioning
.

5
.
Remove
coolant
pump
pulley
from
pump
.

6
.
Remove
mounting
fasteners
from
pump
.

COOLING
SYSTEM
SERVICE

NOTE-

"
The
4-cylinder
coolant
pump
¡s
mounted
us¡ng
two
dif-
terent
length
bolts
.
Note
where
thelonger
bolt
fits
dur-
ing
disassembly
.

0011989

7
.
Insert
twoscrews
(M6)
in
tapped
bores
and
tighten
uni-
formly
until
pump
is
free
from
timing
chain
cover
.
See
Fig
.
19
.

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

8
.
Installation
is
reverse
of
removal
.

"
Be
sure
to
replace
O-ring
and
gaskets
.

"
Coat
O-ring
with
lubricant
during
installation
.

Tightening
Torque

"
Coolant
pump
to
timing
chaincover

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

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

"
Coolant
pump
pulley

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

RADIATOR
SERVICE

Radiator,
removing
and
installing

1
.
Drain
radiator
as
described
earlier
.

WARNING
-

Allow
cooling
system
to
cool
before
opening
ordraining
system
.

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

described
earlier
.

3
.
Disconnect
coolingfan
and
leve¡
sensor
harness
con-

nectors
from
bottom
of
radiator,
where
applicable

4
.
Disconnect
harness
connector
from
auxiliary
fandual

temperature
switch
.
See
Fig
.
20
.

5
.
Disconnect
all
coolant
hoses
from
radiator
.

RADIATOR
AND
COOLING
SYSTEM



170-11

0012500

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

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

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

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

diator
.
See
Fig
.
22
.

8
.
Pul¡
radiator
up
and
out
of
car
.

NOTE-

The
radiator
rests
ontwo
rubber
mounts
.
Check
that

the
mounts
do
not
stick
to
the
bottomof
the
radiator
.

RADIATOR
SERVICE