check engine light BMW M3 1995 E36 Repair Manual

NOTE-



NOTE-
"
The
Ole
speed
control
valve
signal
can
be
checked



The
intake
manifold
is
held
in
place
with
7
nuts
from
using
a
duty
cycle
meter
(or
dwellmeter)
.
Connect
the



above
and
2
support
bracket
bolts
from
undemeath
.
On
meter
to
the
valve
following
the
manufacturer's
in-



DME
3
.1
cars,
carefully
disconnect
the
idleair
hose
from
structions
.
Turn
on
the
WC
or
create
a
larga
air
leak



theintake
manifold
when
lifting
the
manifold
off
.
For
more
and
check
that
the
meter
reading
reacts
while
the
idle



information,
sea
113
Cylinder
HeadRemovaland
In-
speed
remainssteady
.



stallation
.

"
There
are
some
additional
inputs
to
the
control
mod-
ule
that
affect
idle
speed
(Le
.
throttle
position,
AIC-on



5
.
Disconnect
al¡
necessary
hoses
andremove
idle
speed
signals,
andAIT
Drive
position)
.
Check
these
signals



control
valve
.
if
idle
problems
persist
.
See
Tabla
i
orTable
j
.

Idle
speed
control
valva,
replacing

The
idle
speed
control
valve
is
mounted
beneath
the
intake
manifold
.
Accessing
the
valva
is
best
accomplishedby
first
re-
moving
the
intake
manifold
.

NOTE-

¡tis
recommended
that
the
intake
manifold
gaskets
be
replaced
whenever
the
intake
manifold
is
removed
.

1
.
Remove
top
enginecovers
from
engine
.
See
Fig
.
31
.

FUEL
INJECTION



130-21

6
.
Installation
is
reverse
of
Removal
.
Use
new
gaskets
when
installing
intake
manifold
.

NOTE-

Poor
driveability
may
be
noticed
afterinstalling
a
re-
placement
idle
speed
control
valve
.
After
about
10
min-
utes
of
driving,
the
system
will
adapt
the
base
setting
of
the
valva
and
the
idle
speed
should
retum
to
normal
.

Tightening
Torque

"
Intakemanifold
to

cylinder
head
(M7)
........
..
.
15±2
Nm
(11
ti
ft-Ib)

BOSCH
DME
M5
.2

COMPONENT
REPLACEMENT

On-Board
Diagnostics
11
(OBD
II)
is
incorporated
into
the

Bosch
DME
M5
.2
engine
management
systems
used
on
the

M44
engine
.
OBD
II
is
capable
of
detecting
a
full
range
of

faults
.
When
faults
are
detected,
a
Diagnostic
Trouble
Code
(DTC)
is
stored
in
the
system
ECM
.
The
Check
Engine
warn-
ing
light
will
also
come
on
if
an
emissions-relatad
fault
is
de-
tected
.

The
most
efficient
way
to
diagnose
the
Bosch
OBD
II
sys-

tem
is
by
using
a
specialized
scan
tool
.
The
OBD
II
system
is

capable
of
storing
hundreds
of
faults,
making
diagnostics
with

a
scan
tool
the
only
viable
method
.
Therefore,
system
diag-
nostics
is
not
covered
here
.

Fi



31
.
Remove
to
en
ine
covers
b



in
out
caPs
and
removin



NOTE-

nuts
(A)
9
.



P



g



y
Pry
g



g



"
The
OBD
11
fault
memory
(including
an
iiluminated
Note

14


L-te
at
cover
edge
(arrows)
.
Check
Engine
light)
can
only
be
reset
using
the
spe-
cial
scan
tool
.
Removing
the
connector
from
the
ECM
2
.
Remove
two
hold
down
nuts
from
fuel
injector
wiring



or
disconnecting
the
battery
will
not
arase
the
fault
duct
.
Pry
back
injector
connector
retainers
and
lift
off



memory
.

wiring
duct
.



"
The
16-pin
OBD
Il
diagnostic
connector
is
located
on
the
lower
left
dash
panel
.
Refer
to
Fig
.
1
.
3
.
Disconnect
intake
air
bootfrom
throttle
housing
.
Where

applicable
disconnect
accelerator
cable
and
cruise



"
BMW
special
scan
tool
ora
`generic"OBD
II
scan
tool

control
cable
from
their
brackets
.



must
be
used
to
access
DTCs
.

4
.
Unbolt
intake
manifold
and
move
it
out
of
way
enough

to
access
idle
speed
control
valva
.

"
Tablak
lists
engine
control
module
(ECM)
pinouts
for
the
DMEM5
.2
system

BOSCH
DME
M5
.
2
COMPONENT
REPLACEMENT

001ía4
i

Fig
.
34
.
Intake
air
temperature
(IAT)
sensor
in
top
section
of
air
filter
housing
.

¡die
speed
control
valve,
replacing

side
of
the
throttle
body
.
See
Fig
.
35
.

1
.
Disconnect
harness
connector
from
¡die
valve
.

0012725

Fig
.
35
.
M44
engine
:
Throttle
housing
showing
(A)
throttle
position
sensor
(fPS)
and
(B)
¡die
speed
control
valve
.

2
.
Remove
twomountingscrews
holding
sensor
to
throttle

housing
.

The
¡die
speed
valve
on
the
M44
engine
is
located
on
the

FUEL
INJECTION



130-23

2
.
Disconnect
vacuum
hose
and
retaining
screws
.

3
.
Pull
¡die
speed
control
valve
from
its
fittings
.

4
.
Installation
is
reverse
of
rémoval
.
Always
replace
0-

rings
and
seals
.

NOTE

Poor
driveability
may
be
notíced
after
installing
a
re-
placement
¡dio
control
valve
.
After
about10
minutes
of
driving,
the
idie
speed
should
retum
to
normal
.

SIEMENS
MS
41
.1

COMPONENT
REPLACEMENT

On-Board
Diagnostics
II
(OBD
II)
is
incorporated
into
the
Si-

emens
MS
41
.1
engine
management
systems
used
in
the

M52
and
S52US
engine
.
Refer
to
Fig
.
36
.

OBD
11
is
capable
of
detecting
a
fui¡
range
offaults
.
When

faults
are
detected,
a
Diagnostic
Trouble
Code
(DTC)
is

stored
in
the
system
ECM
.
The
Check
Engine
warning
light
will
also
come
on
if
an
emissions-related
fault
is
detected
.
The

most
efficient
way
to
diagnose
the
Siemens
OBD
II
system
is

by
using
a
specialized
scan
tool
.
The
OBD
II
system
is
capa-

ble
of
storing
hundreds
of
faults,
making
diagnostics
with
a
scan
tool
the
only
viable
method
.
Therefore,
system
diagnos-

tics
is
not
covered
here
.

NOTE
-

"
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
disconnecting
the
battery
will
not
erase
the
fault
memory
.

"
The
16-pin
OBD
11
diagnostic
connector
is
located
on

the
lower
left
dash
panel
.
Refer
to
Fig
.
1
.

"
BMW
special
scan
tool
ora
"generic"
OBD
11scan
tool

must
be
used
to
access
DTCs
.
3
.
Installation
is
reverse
of
removal
.
No
adjustment
is
nec
essary
.



"
Table
1
lists
engine
control
module
(ECM)
pinouts
forthe
MS
41
.1
systems
.

SIEMENS
MS
41
.
1
COMPONENT
REPLACEMENT

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

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

Brake
rotor,
removing
and
installing
.
.
.
.
.
.
.
.
340-7

MASTER
CYLINDER
............
.
.
.
.
.
.
.340-7

Master
cylinder,
removing
and
installing
.
...
.
340-7

GENERAL



TROUBLESHOOTING

WARNING
-

"
Although
semi-metallic
and
metallic
Brake
friction
materials
in
Brake
pads
or
shoes
no
longer
con-
tain
asbestos,
they
produce
dangerous
dust
.
"
Brake
fluid
is
poisonous,
highly
corrosive
and
dangerous
to
the
environment
Wear
safety
glasses
and
rubber
gloves
when
working
with
Brake
fluid
.
Do
not
siphonBrake
fluid
with
your
mouth
.
Immediately
clean
away
any
fluid
spilled
on
painted
surfaces
and
wash
with
water,
asBrake
fluid
will
remove
paint
.

"
Always
use
new
Brake
fluid
froma
fresh,
un-
opened
container
.
Brake
fluid
will
absorb
mois-
ture
from
the
air
.
This
canlead
to
corrosion
problems
in
the
brakingsystem,
and
will
also
low-
er
the
Brake
fluid's
boiling
point
.
Dispose
of
Brake
fluid
properly
.

"
Do
notreuse
self-locking
nuts,bolts
or
fasteners
.
They
are
designed
to
be
used
only
once
and
may
failif
reused
.
Always
replace
them
with
new
self-
locking
fasteners
.

BMW
E36
models
areequipped
with
vacuum
power-assist-

ed
four-wheel
disc
brakes
with
an
integral
Antilock
Brake
Sys-

tem
(ABS)
.
Single-pistoncalipers
act
on
solid
or
vented
front
rotors
and
solid
rear
rotors
.
A
brake
pad
wear
sensor
for
each

axle
indicates
when
brake
padsneed
replacement
.
The
dual

drum-type
parking
brakesystem
is
integrated
with
the
rear
brake
rotors
.

NOTE-

M3
models
havevented
directional
Brake
rotors
on
the
rearaxle
as
well
ason
the
front
.

340
Brakes

BRAKES
340-1

GENERAL
.
.
.
.
.
.
.........
.
.
.
..........
340-1



BRAKE
BOOSTER
.........
.
.
.
.
.
...
.
.
.
.
340-8

TROUBLESHOOTING
.......
.
......
.
...
340-1



Brake
booster,
removing
and
installing
....
.
.
340-8

PARKING
BRAKE
.
.....
.
...
.
.
.
.....
.
.
.
340-10
BLEEDING
BRAKES
.
.
.
.
.
.
.
.
..........
340-3



Parking
brake,adjusting
.
.
.
.
.
.
.
.
.
.
.....
.
340-10
Pressure
bleeding
brakes



Parking
brake
shoes,
removing
and
installing
.
340-11(except
cars
with
AST)
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.340-3



Parking
Brake
cable,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
340-11

BRAKE
PADS,
CALIPERS,



ANTILOCK
BRAKE
SYSTEM
(ABS)
.
.
.
.340-11
AND
ROTORS
..........
.
.......
.
.
.
.
.
.
.
340-3



ABS
System
Inspection
.
...
.
.......
.
.
.
..
340-12
Brake
pads,
replacing
............
.
.
.
.
.
.
.
340-4
ABS
wheel
speed
sensors,
replacing
.
.
.
.
..
340-12
Brake
caliper,
removing
and
installing
.
..
..
.
340-6

TABLES

a
.
Brake
System
Troubleshooting
.....
...
.
.
.....
.340-2
b
.
Brake
Rotor
Reconditioning
Specifications
.
.....
.340-7

Brakeperformance
is
mainly
affected
by
three
things
:
the
leve¡
and
condition
of
the
brake
fluid,
the
system's
abilíty
to
create
and
maintain
hydraulic
pressure,
and
the
condition
of
the
friction
components
.

Air
in
the
Brake
fluid
will
make
the
Brake
pedal
feel
spongy

during
braking
or
will
increase
the
Brake
pedalforce
required

to
stop
.
Fluid
contaminated
by
moisture
or
dirt
can
corrode
the

system
.
Inspect
the
Brake
fluid
inside
the
reservoir
.
Ifit
is
dirty
or
murky,
or
is
over
a
year
old,
the
fluid
should
be
replaced
.

Visually
check
the
hydraulic
system
startingat
the
master

cylinder
.
To
check
the
function
of
the
master
cylinder
hold
the

brake
pedal
down
hard
with
the
engine
running
.
The
pedal

should
feelsolid
and
stay
solid
.
If
the
pedal
slowly
falls
to
the

floor,
either
the
master
cylinder
is
leaking
internally,
or
fluid
is
leaking
externally
.
If
no
leaks
canbe
found,
the
master
cylin-
der
is
faulty
and
should
be
replaced
.
Check
all
Brake
fluid
lines

and
couplings
for
leaks,
kinks,
chafing
and
corrosion
.

Check
the
Brake
booster
by
pumping
the
Brake
pedal
ap-

proximately
10
times
with
the
engine
off
.
Hold
the
pedal
down
and
start
the
engine
.
The
pedal
should
fa¡¡
slightly
.
If
not,
check

for
any
visiblefaults
before
suspecting
a
faulty
brake
booster
.

Check
for
strong
vacuum
at
the
vacuum
hose
fitting
at
the

booster,
and
check
the
non-retum
valve
for
one-way
flow
.

Worn
or
contaminated
brake
pads
will
cause
poor
braking

performance
.
Oil-contaminated
or
glazed
pads
will
cause

stopping
distances
to
increase
.
Inspect
the
rotors
for
glazing,

discoloration
and
scoring
.
Steering
wheel
vibration
while

braking
at
speed
is
often
caused
by
warped
rotors,
but
can
also
be
caused
byworn
suspension
components
.

TROUBLESHOOTING

6
.
Disconnect
ABS
electrical
connectors
.
Label
and
then

disconnect
brake
lines
from
hydraulic
brake
unit
.
Plug

openíngs
.
See
Fig
.
12
.

~
~
A
1/
B
'1v
C
~
F

lu
11
-ri
J
.

0013244
A
.
Right
front



F



Front
from
master
cylinder
B
.
Leftfront



R
.
Rear
from
master
cylinder
C
.
Rear

Fig
.
12
.
Brake
fluid
linesat
ABS
hydraulic
unit
.

WARNING
-

"
On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
required
to
properly
bleed
the
Antilock
Brake
System
(ABS)
.
Removal
of
the
ABS
hydraulic
unit
is
not
recommended
un-
less
this
equipment
is
available
.
For
safetyrea-
sons,
the
brake
system
on
cars
with
ABS
must

not
be
bled
using
the
procedures
described
inthis
repair
group
.

"
Do
not
mix
up
the
fluid
fines
at
the
ABS
hydraulic
unit
Label
all
connections
before
disconnecting
.

7
.
Remove
ABS
hydraulic
unit
from
engine
compartment
.

8
.
Working
inside
car,
remove
panel(s)
frombeneath

steering
column
to
access
pedal
assembly
.
See513
In-

terior
Trim
.

12
.
Make
sure
al¡
nuts,
fluid
couplings,
thread
bores
and

mating
surfaces
are
clean
.

BRAKES
340-
9

0011261

Fig
.
13
.
Brake
pedal
clevispin
and
retaining
clip
(A)
.
Brake
booster
mounting
nuts
shown
at
arrows
.

13
.
If
necessary,
mount
master
cylinder
to
vacuum
booster

using
a
new
O-ríng
and
newself-locking
nuts
.

CAUTION-

Do
not
over-torque
the
master
cylinder
mounting
bolts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

14
.
Installation
is
reverse
of
Rmoval
.

"
Bleed
brakes
as
described
earlier
.

"
Check
and,
if
necessary,
adjust
brake
light
switch

above
brake
pedal
.

Tightening
Torques

"
Brakemaster
cylinder
to

brake
booster
...........
.
..
..
...
26
Nm
(18
ft-Ib)

"
Brake
booster
to
bulkhead
.
.
..
..
...
22
Nm
(16
ft-Ib)

"
Brake
fluidline
to
master
cylinder
or

ABS
hydraulic
unit
.......
.
..
17-19
Nm
(13-14
ft-lb)
9
.
Remove
clip
and
clevis
pin
from
brake
booster
pushrod

and
disconnect
it
from
brakepedal
.
Remove
brake

booster
mounting
nuts
.
See
Fig
.
13
.
NOTE-

10
.
Working
in
engine
compartment,
remove
brake
booster



When
replacing
the
brake
booster
one-way
valve
or
together
with
master
cylinder
.



vacuum
hose,
install
the
valve
so
that
the
molded
arrow

is
pointing
toward
the
intake
manifold
.
Use
new
hose

11
.
If
booster
or
master
cylinder
O-ring
is
being
replaced,



clamps
.

disconnect
master
cylinder
from
brake
booster
.

BRAKE
BOOSTER

600-2



ELECTRICAL
SYSTEM-GENERAL

CAUTION
-

"
Always
turn
off
the
engine
and
disconnect
the

negative
()
cable
from
the
batterybefore
remov-

ing
any
electrical
components
.
Disconnecting
the

battery
may
erase
fault
code(s)
stored
in
control

module
memory
.
Check
for
fault
codes
using
spe-
cial
BMW
diagnostic
equipment
.

"
Prior
to
disconnecting
the
battery,
read
the
bat-

tery
disconnection
cautions
given
at
the
front
of

this
manual
onpage
viii
.

"
Connect
and
disconnect
ignition
system
wires,
multiple
connectors,
and
ignition
test
equipment
leads
only
while
the
ignition
is
off
.

"
Do
not
disconnect
the
battery
with
engine
run-

ning
.

"
Do
not
quick-charge
the
battery
(for
boost
start-
ing)
for
longer
than
one
minute,
and
do
not
ex-
ceed
16
.5
volts
at
the
battery
with
the
boosting
cables
attached
.
Wait
at
feast
one
minute
before
boosting
the
battery
a
second
time
.

"
Do
not
usea
test
famp
that
has
a
normal
incan-

descent
bulb
to
test
circuits
contafning
electronic
components
.
The
high
electrical
consumptionof
these
test
lamps
may
damage
the
components
.

"
Do
not
use
an
analog
meter
.
Use
onfy
a
digital
multimeter
.

"
Many
of
the
solid-state
modules
are
static
sensi-
tive
.
Static
discharge
will
permanently
damage
them
.
Always
handle
the
modules
using
proper
static
prevention
equipment
and
techniques
.

"
To
avoid
damaging
harness
connectors
or
relay
panel
sockets,
use
jumper
wires
with
flat-blade
connectors
that
are
the
same
size
as
the
connec-
tor
or
relay
terminals
.

"
Always
switch
a
digital
multimeter
to
the
appropri-
ate
function
and
range
before
making
test
con-
nections
.

"
Do
not
tryto
start
the
engine
of
a
carwhich
has
been
heated
above176°F
(80°C),
(for
example,
in
a
paint
dryingbooth)
.
Allow
it
to
cool
to
normal
temperature
.

"
Disconnect
the
battery
before
dolng
any
electric
welding
on
the
car
.

"
Do
not
wash
the
engine
while
it
is
runnfng,
or
any-
time
the
ignition
is
switched
on
.

WIRING
DIAGRAMS

Electrical
Test
Equipment

Many
of
the
electrical
tests
described
in
this
manual
call
for

measuring
voltage,
currentorresistanceusing
a
digital
multi-

meter
(DMM)
.
Digital
meters
are
preferred
for
precise
mea-

surements
and
for
electronics
work
because
they
are
generally
more
accuratethan
analog
meters
.
The
numerical

display
is
alsoless
likely
to
be
misread,
since
there
is
no
nee-

dle
position
to
be
misinterpreted
by
reading
at
an
angle
.

An
LED
test
light
is
a
safe,
inexpensive
tool
that
can
be
used

to
perform
many
simple
electrical
tests
that
would
otherwise

require
a
digital
multimeter
.
The
LED
indicates
when
voltage

is
present
between
anytwo
test-points
in
a
circuit
.

CA
UTION-

"
Choose
test
equipment
carefully
.
Use
a
digital

multimeter
with
at
leadt
10
megaohm
input
im-

pedance,or
an
LED
test
light
.
An
analog
meter
(swing-need1e)
ora
test
light
with
a
normal
incan-
descent
bulb
may
draw
enough
current
to
dam-
age
sensitive
electronic
components
.

"
An
ohmmeter
must
not
beused
to
measure
resis-
tance
on
solidstate
components
suchas
controlunits
or
time
delay
relays
.

"
Always
disconnect
the
battery
before
making
re-

sístance
(ohm)
measurements
on
the
circuit
.

WIRING
DIAGRAMS

The
wiring
diagrams
shown
in
Electrical
Wiring
Diagrams

have
been
specially
designed
to
enable
quick
and
efficientdi-

agnosis
and
troubleshooting
of
electrical
malfunctions
.

Wiring
Codes
and
Abbreviations

A
lot
of
information
is
included
in
each
wiring
diagram
if
you
know
how
to
read
them
.
Wire
colors
in
the
diagrams
are
ab-

breviated
.
Combined
color
codes
indicate
a
multi-colored
wire
.
For
example
the
code
BLU/RED
indicates
a
Blue
wire

with
a
Red
stripe
.

Many
electrical
components,
connectors,
fuses,
and

ground
locations
are
identified
using
a
unique
number
.
Each

of
there
numbers
corresponds
to
a
particular
part
in
the
circuit
commonly
found
in
Electrical
Wiring
Diagrams
.

600-
4



ELECTRICAL
SYSTEM-GENERAL

Voltage
and
Voltage
Drops

The
wires,
connectors,
and
switches
that
carry
current
are

designed
with
very
low
resistance
so
that
current
flows
with
a

minimum
loss
of
voltage
.
A
voltage
drop
is
caused
by
higher
than
normal
resistance
in
a
circuit
.
This
additional
resistance

actually
decreases
or
stops
the
flow
of
current
.
A
voltage
drop

can
be
noticed
byproblems
ranging
fromdim
headlights
to
sluggish
wipers
.
Some
common
sources
of
voltage
drops
are
corroded
or
dirty
switches,
dirty
or
corroded
connections
or

contacts,
and
loose
or
corroded
ground
wires
and
ground
con-

nections
.

A
voltage
drop
test
is
a
good
test
to
make
if
current
is
flowing
through
the
circuit,
butthe
circuit
is
not
operating
correctly
.
A
voltage
drop
test
will
help
to
pinpoint
a
corroded
ground
strap
or
a
faulty
switch
.
Normally,
there
should
be
less
than
1
volt

drop
across
most
wires
or
closed
switches
.
A
voltage
drop
across
a
connector
or
short
cable
shouldnot
exceed
0
.5
volts
.

Voltage,
measuring

1
.
Connect
digital
multimeternegative
lead
to
a
reliable
ground
point
oncar
.

NOTE-

The
negative
(-)
battery
terminal
is
alwaysa
good
ground
point
.

2
.
Connect
digital
multimeter
positive
lead
to
point
incir-
cuit
you
wish
to
measure
.
See
Fig
.
1
.
If
a
reading
is
ob-
tained,
current
is
flowing
through
circuit
.

NOTE-

The
voltage
reading
shouldnot
deviate
more
than
1
volt
from
the
voltage
at
the
battery
.
If
the
voltage
drop
is
more
than
this,
check
for
acorroded
connector
or
cose
ground
wire
.

ELECTRICAL
TROLIBLESHOOTING

from
Battery

Fig
.
1
.



Digital
multimeterbeing
used
to
test
voltage
.

No
voltage
r_l

-1
Load

LJ

Switch

NOTE-

The
maximum
voltage
drop
in
an
automotive
circuit,
as
recommended
by
the
Society
of
AutomotiveEngineers
(SAE),
is
as
follows
:
0
voltsfor
small
vire
connections
;
0
.1
Volts
for
high
current
connections
;
0
.2
volts
for
high
current
cables
;
and
0
.3volts
for
switch
or
solenoidcon-
tacts
.
On
longer
wires
or
cables,
the
drop
may
be
slight-ly
higher
.
In
any
case,
a
voltage
drop
of
more
than
1.0volt
usually
indicates
a
problem
.

0013238

NOTE-

"
A
voltage
drop
test
is
generally
more
accuratethan
a



Voltage
drop,
testing

simple
resistance
check
because
the
resistances
in-
volvedare
often
too
small
to
measure
with
most
ohm-



Voltage
drop
can
only
be
checked
when
current
is
running
meters
.
For
example,
a
resistance
as
small
as0
.02



through
the
circuit,
suchasby
operating
the
starter
motor
or
ohms
would
results
in
a
3
volt
drop
in
a
typical
150



turning
onthe
headlights
.
A
digital
multimeter
should
beused
amp
starter
circuit
.
(150
amps
x
0
.02
ohms
=3
volts)
.



lo
ensure
accurate
readings
.

"
Keep
in
mind
that
voltage
with
the
key
on
and
voltage
with
the
engine
running
arenotthe
same
.
With
the
ig-



1
.
Connect
digital
multimeter
positive
lead
to
positive
(+)
nition
on
and
the
engine
off
(battery
voltage),
voltage



battery
terminalor
a
positive
power
supply
close
lo
bat
should
be
approximately
12
.6volts
.
With
the
engine



tery
source
.
running
(charging
voltage),
voltage
should
be
approx-
imately
14
.0
volts
.
Measure
voltage
at
the
battery
with



2
.
Connect
digital
multimeter
negativelead
to
other
end
of
the
ignition
on
and
then
with
the
engine
running
to
get



cable
orswitch
being
tested
.
See
Fig
.
2
.
exact
measurements
.

3
.
With
power
on
and
circuit
working,
meter
shows
volt-
age
drop
(difference
between
two
points)
.
This
value
should
not
exceed
1
volt
.

Continuity,
checking
Short
Circuits

from
Battery

CAUTION-

Use
only
a
high
quality
digital
ohmmeter
having
high
input
impedance
when
checking
electronic
componente
.
The
internal
power
source
used
in
most
analog
(swing-need1e)
meterscan
damage
solidstate
components
.

0013239

Fig
.
2
.



Digital
multimeter
being
used
to
check
for
voltage
drop
across
a
switch
.

The
continuity
test
can
beused
to
check
a
circuit
or
switch
.
Because
most
automotive
circuits
are
designed
to
have
little

or
no
resistance,
a
circuit
or
part
of
a
circuit
canbe
easily

checked
for
faults
using
an
ohmmeter
.
An
open
circuit
or
a
cir-

cuit
withhigh
resistance
will
not
allow
current
to
flow
.
A
círcuit
with
little
or
no
resistanceallows
current
to
flow
easily
.

When
checking
continuity,
the
ignition
should
be
off
.
On
cir-
cuits
that
are
powered
at
all
times,
the
battery
should
be
dis-
connected
.
Using
the
appropriate
wiring
diagram,
a
circuit
can
be
easily
tested
for
faulty
connections,
wires,
switches,
relays,
and
engine
sensorsby
checking
forcontinuity
.
For
a
continu-
ity
check
on
a
brake
light
switch,
see
Fig
.
3
..

A
short
circuit
is
exactly
what
the
narre
implies
.
The
circuit
takes
a
shorter
paththan
it
was
designed
to
take
.
The
most

common
short
that
causes
problems
is
a
short
to
ground

where
the
insulation
on
a
positive
(+)
wire
wears
away
and
the

metal
wire
is
exposed
.
When
the
wire
rubs
against
a
metal

partof
thecar
or
other
ground
source,
the
circuit
is
shorted
to
ground
.
If
the
exposed
wire
is
live
(positive
battery
voltage),
a

Puse
will
blow
and
the
circuit
may
possibly
be
damaged
.

ELECTRICAL
SYSTEM
-
GENERAL
600-
5

Brake
light
switch

Brake
pedal
in
rest
position

Q

Brake
pedal
depressed
Brake
light
switch

Fig
.
3
.



Brake
light
switchbeing
tested
for
continuity
.
With
brake
ped-
alin
rest
position
(switch
open)
there
is
no
continuity
(infinite
ohms)
.
With
pedal
depressed
(switch
closed)
there
is
continu-
ity
(zero
ohms)
.

Shorts
to
groundcanbe
located
with
a
digital
multimeter
.
Short
circuits
are
often
difficult
to
locate
and
may
vary
in
na-
ture
.
Short
circuits
can
befound
using
a
logical
approach
based
onthe
current
path
.

CAUTION
-

"
On
circuits
protected
with
high
rating
fuses
(25
amp
and
greater),
the
wires
or
circuit
compo-
nents
may
be
damaged
before
the
fuse
blows
.
Always
check
for
damage
before
replacing
fuses
of
this
rating
.

"
When
replacing
blown
fuses,
use
only
fuses
hav-
ingthe
correct
rating
.
Always
confirm
the
correct
fuse
rating
printed
on
the
fuselrelay
panelcover

DC

ELECTRICAL
TROUBLESHOOTING

Table
a
.
E36
Component
Locations

Component



Model
Year



Location



Refer
to

Anti-theft
Control
Module



1992-1998



Behind
glove
compartment



Fig
.
8
.
Fig
.
9
.

Anti-theft
Horn



1
1992-1998



1
Right
rear
engine
compartment

Anti-slip
(Traction)
Control
Module



1994-1998



Power
distribution
box



Fig
.
8
.
(AST/ASC+T)



Fig
.
9
.

Anti-slip
(Traction)
Control
Switch



1994-1998



In
center
console

Automatic
Climate
(A/C)
Control



1992-1998



Behind
center
console
Module

AutomaticTransmission
Range



1992-1998



~
Next
to
gear
shift
lever
in
center
console



Fig
.
29
.
Switch
(Gear
Position/Neutral
Safety
Switch)

Auxiliary
Cooling
Fan
Dual
Switch



1992-1998



Right
side
radiator



1



Fig
.
18
.

Auxiliary
Cooling
Fan
Motor



1992-1998



Behind
front
grill

Auxiliary
Fuse
Box
(Left
Splice



1992-1998



I
Behind
left
front
footwell
kick-panel
Panel)

Auxiliary
RelayPanel



1
1992-1998



1
Left
side
of
dash
under
steering
column

Auxiliary
Fuse
Box
In
Trunk



1



1997-1998



1
Right
sideof
trunk
behind
trim
panel

AuADSry
ThrottlePosition
Motor



11994-1998



Front
of
engine
compartment

B+
Jump
Start
Junction
Point



1992-1998



Right
rear
of
engine
compartment



Fig
.
7
.

Back-Up
Light
Switch
(Manual)



1992-1998



Right
or
left
side
top
of
transmission



Fig
.
30
.

Body
Electronics
Control
Module



1994-1998



Behindglove
compartment



Fig
.
8
.
(ZKE
IV)



Fig
.
9
.

Brake
Fluid
Level
Sensor



1992-1998



Top
of
brake
fluid
reservoir
at
master
cylinder



Fig
.
15
.

Brake
Light
Switch



1
1992-1998



1
On
brake
pedal
supportbracket

Brake
Pad
Sensor,
Left
Front



1
1992-1998



1
Left
front
brake
caliper

Brake
Pad
Sensor,
Right
Rear



1992-1998



Right
rear
brake
caliper

Camshaft
Actuator
(VANOS)



1993-1998



Front
of
cylinder
head
Camshaft
Position
Sensor
(Cylinder



1992-1998



Front
of
engine
Identification)

Carbon
Canister
Valve
(TLEV)



1
1997-1998



1
In
sparewheel
well
in
trunk

ELECTRICAL
COMPONENT
LOCATIONS



610-11

Fig
.
5
.

Fig
.
4
.

Fig
.
24
.

Fig
.
7
.

Central
Locking
Module
(ZVM)



11992-1993



1
Behindglove
compartment



I



Fig
.
8
.
Fig
.
9
.

Check
Control
Module
(if
applicable)
1
1992
-
1998



1
Below
left
side
of
dash

Child
Protection
Window
Control



1992-1998



Center
console
(console)

Chime
Module



1992-1998



Below
left
side
of
dash
inleft
dash
trim
panel

Clock
(Multi-Function)



1993-1998



Center
console

Clutch
Pedal
Switch



1992-1998



On
clutch
pedal
support
bracket

Continued

COMPONENT
LOCATIONS