1991-1999 BMW 3 Series E36 Service & Repair Manual

B mw 3 Series M3, 3181, 3231, 3251, 3281 Sedan, Coupe and Convertible 1992, 1993, 1994, 1995, 1996,1997, 1998 Bentley, Publishers Cambridge, Massachusetts

B -1 ROBERT BENTLEY, INC. I AUTOMOTIVE PUBLISHERS Information that makes 1734 Massachusetts Avenue the differenceo Cambridge,MA 02138 USA 800-423-45951617-547-4170 www.rb .com e-mail : sales@rb.com WARNING-Important Safety Notice Technical Contact Information We value your feedback . Technical comments and suggestions are helpful to us . Please send your comments and thoughts to Bentley Publishers e-mail : tech .bmw@rb .co m From time to time, updates may be made to this manual . A listing of updates can be found on the web Iat www .rb .com/update s Do not use this manual unless you are familiar with basic automotive repair procedures and safe workshop practices. This manual illustrates the workshop procedures required for most service work . It is not a substitute for fui¡ and up-to-date information from the vehicie manufacturer or for proper training as an automotive technician . Note that it is not possible for us to anticipate al¡ of the ways or conditions under which vehicles may be serviced or to provide cautions as to all of the possible hazards that may result. The vehicie manufacturer will continue to issue service information updates and parts retrofits after the editorial closing of this manual . Some of those updates and retrofits will apply to procedures and specifications in this manual . We regret that we cannot supply updates to purchasers of this manual . We have endeavored to ensure the accuracy of the information in this manual . Please note, however, that considering the vast quantity and the complexity of the service information involved, we cannot warrant the accuracy or completeness of the information contained in this manual . FORTHESE REASONS,NEITHERTHE PUBLISHER NORTHE AUTHOR MAKES ANY WARRANTIES, EXPRESS OR IMPLIED,THATTHE INFORMATION IN THIS BOOK IS FREE OF ERRORS OR OMISSIONS, AND WE EXPRESSLY DISCLAIMTHEIMPLIED WARRANTIES OF MERCHANTABILITYANDOF FITNESS FOR A PARTICULAR PURPOSE, EVEN IF THE PUBLISHER OR AUTHOR NAVE BEEN ADVISED OF A PARTICULAR PURPOSE, AND EVEN IF A PARTICULAR PURPOSE IS INDICATED IN THE MANUAL . THE PUBLISHER AND AUTHOR ALSO DISCLAIM ALL LIABILITY FOR DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGESTHAT RESULT FROM ANYUSE OF THE EXAMPLES, INSTRUCTIONS OR OTHER INFORMATION IN THIS BOOK.I N NO EVENTSHALL OUR LIABILITYWHETHER INTORT, CONTRACT OR OTHERWISE EXCEEDTHECOST OFTHIS MANUAL. Your common sense and good judgment are crucial to safe and successful service work. Read procedures through before starting them . Think about whether the condition of your car, your leve¡ of mechanical skill, or your leve¡ of reading comprehension might result in or contribute in some way to an occurrence which might cause you injury, damage your car, or result in an unsafe repair. lf you have doubts for these or other reasons about your ability to perform safe repair work on your car, have the work done at an authorized BMW dealer or other qualified shop . Part numbers listed in this manual are for identification purposes only, not for ordering . Always check with your authorized BMW dealer to verify part numbers and availability before beginning service work that may requíre new parts . Before attempting any work on your BMW, read the wamings and cautions on pages vi¡ and vi¡¡, and any waming or caution that accompanies a procedure in the service manual . Review the warnings and cautions on pages vi¡ and viü each time you prepare to work on your BMW . Special tools required to perform certain service operations are identified in the manual and are recommended for use. Use of tools other than those recommended in this service manual may be detrimental to the car's safe operation as well as the safety of the person servicing the car . Copies of this manual may be purchased from most automotive accessories and parts dealers specializing in BMW automobiles, from selected booksellers, or directly from the publisher by mail . The publisher encourages comments from the reader of this manual . These communications have been and will be carefully considered in the preparation of this and other manuals . Please write to Robert Bentley, Inc ., Publishers at the address listed on the top of this page . This manual was published by Robert Bentley, Inc ., Publishers . BMW has not reviewed and does not vouch forthe accuracy of the technical specifications and procedures described in this manual. Library of Congress Cataloging-in-Publication Data BMW 3 Series Service Manual M3, 318i, 323i, 3251, 328i, Sedan, Coupe and Convertible: 1992, 1993, 1994, 1995, 1996, 1997, 1998 . p . c m . Includes index . ISBN 0-8376-0326-9 1 . BMW 3 Series automobile--Maintenance and repair--Handbooks, manuals, etc . I . Robert Bentley, inc . TL215 .13251356 1999 629 .28' 722--cic21 99-17179 CIP Bentley Stock No . B398 Editorial closing 01/99 0302010099 1098765432 The paper used in this publication is acid free and meets the requirements of the National Standard for Information Sciences- Permanence of Paper for Printed Library Materials . O ©Copyright 1999 Robert Bentley, Inc . All rights reserved . All information contained in this manual is based on the information available to the publisher at the time of editorial closing . The right is reserved to make changes at any time without notice . No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written consent of the publisher . This includes text, figures, and tables . All rights reserved under Berne and Pan-American Copyright conventions . Manufactured in the United States of America

General Data and 010 FundamentalsfortheDo-lt-YourselfOwner Maintenance 020 Maintenance Program Engine Transmission Suspension, Steering and Brakes 4 Body 100 Engine-General 110 Engine Removal and Installation 113 Cylinder Head Removal and Installation 116 Cylinder Head and Valvetrain 117 Camshaft Timing Chain 119 Lubrication System 200 Transmission-General 210 Clutch 230 Manual Transmission 510 Exterior Trim, Bumpers 520 Seats Bo y Equipment 512 DoorWTdws 540 nrt 513 InteriorTrim 541 Convertible Top 515 Central Locking and Anti-Theft 600 Electrical System-General 620 Instruments Electrical S stem 610 Electrical Component Locations 630 Exterior Lighting 611 Wipers and Washers 640 Heating and Air Conditioning 6 612 Switches and Electrical Accessories 650 Radio Equipment and 720 SeatBelts Accessories 721 Airbag System (SRS) Electrical Wiring Diagrams Foreword . ... . . . .................. . . . ..... . ............ . ... . . . . . ................ . . . ..... . ...... . ... . . ... . ....... . . . ..... v Warnings and Cautions ..... . ... . . . . . .......... . ... . . . . . ...... . ......... . . . ... . . . ...... . . . . . ............ . . . . . . .vii Index .............. . . . ..... . ............ . ... . . . . . ........ . ... . . . . . ....... . ... . .. . . .. . . . . . . . ........ . . . .. back of book 300 Suspension, Steering and 330 Rear Suspension Brakes-General 331 Final Drive 310 Front Suspension 340 Brakes 320 Steering and Wheel Alignment 400 Body-General 411 Doors 410 Fenders, Engine Hood 412 Trunk Lid 120 Ignition System 121 Battery, Starter, Alternator 130 Fue¡ Injection 160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System 180 Exhaust System 240 Automatic Transmission 250 Gearshift Linkage 260 Driveshaft

BMW SERVICE MANUUAS BMW 7 Series Service Manual: 1988-1994 7351, 735iL, 740i, 740iL, 750iL Robert Bentley ISBN 0-8376-0328-5 BMW 3 Series Service Manual : 1992-1998 M3, 3181,323i,325i, 328i, Sedan, Coupe and Convertible Robert Bentley ISBN 0-8376-0326-9 Glory Days : When Horsepower and BMW Z3 Service Manual : 1996-1998 Passion Ruled Detroit 4-cylinder and 6-cylinder models Jim Wangers ISBN 0-8376-0208-4 Robert Bentley ISBN 0-8376-0327-7 Alfa Romeo Owner's BibleTM BMW 3-Series Service Manual: 1984-1990 Pat Braden with foreword by Don Black 3181, 325, 325e(es), 325i(is), and 325i ISBN 0-8376-0707-9 Convertible Robert Bentley ISBN 0-8376-0325-0 Ford F-Series Pickup Owner's BibleTM Moses Ludel ISBN 0-8376-0152-5 BMW5-Series Service Manual: 1989-1995 5251, 530i, 535i, 540i including Touring Robert Bentley ISBN 0-8376-0319-6 BMW 5-Series Service Manual: 1982-1988 528e, 5331, 535i, 535is Robert Bentley ISBN 0-8376-0318-8 ENTHUSIAST TITLES Complete Roundel 1969-1998 :30 Years of the Magazine of the BMW Car Club of America (CD-ROM) ISBN 0-8376-0322-6 A French Kiss With Death: Steve McQueen and the Making of Le Mans Michael Keyser ISBN 0-8376-0234-3 The Speed Merchants : AJourney Through The World of Motor Racing,1969-72 Michael Keyser ISBN 0-8376-0232-7 Mustang 5.0 Technical Reference & Performance Handbook Al Kirschenbaum ISBN 0-8376-0210-6 Maximum Boost: Designing, Testing, and Installing Turbocharger Systems Corky Bell ISBN 0-8376-0160-6 Volkswagen Sport Tuning for Street and Competition Per SchroederISBN 0-8376-0161-4 Sports Carand Competition Driving Paul Frére with foreword by Phil Hill ISBN 0-8376-0202-5 Automotive Books From Robert Bentley GTI, Golf, and Jetta Service Manual: 1985- The Design and Tuning of Competition 1992 Gasoline, Diesel, and Turbo Diesel, Engines PhilipH. Smith, 6th edition revised by including 16V Robert Bentley David N . Wenner ISBN 0-8376-0140-1 ISBN 0-8376-0342-0 Going Faster: The Skip Barber Racing Corrado Official Factory Repair Manual: School Carl Lopez ISBN 0-8376-0227-0 1990-1994 Volkswagen United States 9M-f, Ir- Win n on Alexander with foreword ISBN 0-8376-0387-0 by Mark Martín ISBN 0-8376-0070-7 Passat Service Manual : 1990-1993, The Technique of Motor Racing Piero including Wagon Volkswagen United States Taruf fi with foreword by Juan Manuel Fangio ISBN 0-8376-0378-1 ISBN 0-8376-0228-9 Cabriolet and Scirocco Service Manual : Race Car Aerodynamics 1985-1993, including 16V Joseph Katz ISBN 0-8376-0142-8 Robert Bentley ISBN 0-8376-0362-5 The Scientific Design of Exhaust and Volkswagen Fox Service Manual: 1987- Intake Systems Philip H . Smith and John C . 1993, including GL, GL Sport and Wagon Morrison ISBN 0-8376-0309-9 Robert Bentley ISBN 0-8376-0363-3 Volkswagen Model Documentation Rabbit, Scirocco, Jetta Service Manual : Joachim Kuch ISBN 0-8376-0078-2 1980-1984 Gasoline Models, including Volkswagen Beetle: Portrait of a Legend Pickup Truck, Convertible, and GTIRobert Edwin Baaske ISBN 0-8376-0162-2 Bentley ISBN 0-8376-0183-5 Jeep Owner's BibleTM Moses Ludel ISBN 0-8376-0154-1 Eurovan Official Factory Repair Manual : MANUUAS Volkswagen Inspection/Maintenance (I/M) Emission Test Handbook :1980-1997 Volkswagen of America ISBN 0-8376-0394-3 Rabbit, Jetta Service Manual: 1977-1984 Diesel Models, including Pickup Truck and Turbo Diesel Robert Bentley ISBN 0-8376-0184-3 Super Beetle, Beetle and Karmann Ghia Official Service Manual Type 1:1970-1979 Volkswagen United States ISBN 0-8376-0096-0 Beetle and Karmann Ghia Official Service Manual Type 1:1966-1969 Volkswagen United States ISBN 0-8376-0416-8 Harley-Davidson Evolution V Twin Owner's BibleTM Moses Ludel ISBN 0-8376-0146-0 Audi 100, A6 Official Factory Repair Manual: 1992-1997, including S4, S6, quattro and Wagon models . Toyota Truck & Land Cruiser Owner's Audi of America . ISBN 0-8376-0374-9 BibleTM Moses Ludel ISBN 0-8376-0159-2 Audi 80, 90, Coupe Quattro Official AUDI SERVICE MANUUAS The Racing Driver Denis Jenkinson Factory Repair Manual: 1988-1992 ISBN 0-8376-0201-7 including 80 Quattro, 90 Quattro and 20-valve models Audi of America Unbeatable BMW : Eighty Years of FUEL INJECTION ISBN 0-8376-0367-6 Engineering and Motorsport Success Ford Fuel Injection and Electronic Engine Audi 100, 200 Official Factory Repair Jeremy Walton ISBN 0-8376-0206-8 Charles O Probst, SAE Manua1 :1988-1991 Audi of America Control: 1788-1993 . BMW 6 Series Enthusiast's CompanionTM ISBN 0-8376-0301-3 ISBN 0-8376-0372-2 Jeremy W .11 ISBN 0-8376-0149-5 Ford Fuel Injection and Electronic Engine Audi 50005 5000CS Official Fa ,ctory BMW Enthusiast's CompanionTM BMW Control: 1980-1987 Charles O. Probst, SAE Repair Manual : 1984-1988 Gasoline, Car Club of America ISBN 0-8376-0321-8 ISBN 0-8376-0302-1 Turbo, and Turbo Diesel, including Wagon BMW Notecards Series 1 Photography by Bosch Fuel In1ection and Engne and Quattro Audi of America ISBN 0-8376- i Klaus Schnitzer ISBN 0-8376-0211-4 Management Charles O. 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Foreword This service manual covers 1992 through 1998 BMW 3 Series models, and is specifically designed to cover only those models built for sale in the United States . BMW, and most accessories and parts sellers specializing in BMWs, refer to the 3 Series cars coveredby this manual as the E36 model . The code "E36" is BMW's internal code for the basic plat- form shared by al¡ of the cars covered by this manual . Except for the engine and afew other components, the models covered by this manual share many of same components such as suspension parts, body panels, and the interior pieces . When ordering parts, especially body parts, knowing the E36 code may be helpful . BMW also uses an interna¡ code for the engines used in the 3 Series models . Consult the text in the 100 Engine-General repair group of this manual for a complete listing of engine codes . Engine - code information is primarily used internally by BMW, but may be helpful if you have access to BMW technical information . Forthe BMW ownerwith basic mechanical skills, this manual gives detailed maintenance and repair information . In addition, the BMW owner who has no intention of working on his or her own car will find that owning and reading this manual will make it possible to be better informed and to dis- cuss repairs more intelligently with a professional technician . This manual has been prepared from the repair information that BMW provides to its factory-trained technicians and has been developed primarily with the do-it-yourself BMW owner in mind . The aim throughout has been clarity and un- derstanding with practical descriptions, step-by-step procedures, and accurate specifications. The BMW owner intending to do maintenance and repair should have a set of tools including a set of metric wrenches and sockets, screwdrivers, a torque wrench, and feeler gauges, since these basic tools will be used to do the majority of the maintenance and repair procedures described in this manual . This manual includes detailed information on these basic tools and other tips for the beginner in the first section of the manual, entitled 010 Fundamentals for the Do-It-Yourself Owner . For some of the repairs described in this manual, BMW technicians use special tools . The text will note when a repair requires these special tools and, where possible, will recommend practica¡ alter- natives .

We have endeavored to ensure the highest degree of accuracy possible . When the vast array of data presented in the manual is taken into account, however, no claim to infallibility can be made . We therefore cannot be responsible for the result of any errors that may have crept into the text. The publisher encourages comments from the readers of this manual with regard to any errors and, also, suggestíons for improvement in the presentation of technical material. These communications have been and will be carefully considered in the preparation of future printings of this and other manuals . Please contact Robert Bentley, Inc . using the contact information on the copyright page at the beginning of this manual . BMW offers extensive warranties, especially on components of the fuel delivery and emissions control systems . Therefore, before deciding to repair a BMW that may still be covered wholly or in part by any warranties issued by BMW of North America, consult your authorized BMW dealer . You may find that he can make the repair either free or at minimum cost . Regardless of its age and whether or not it is still protected by warranty, your BMW is an easy car to get serviced . So if at any time a repair is needed that you feel is too difficult to do yourself, a trained BMW technician is ready to do the job for you . Each authorized BMW dealer senrice department has made a significant investment in service and diagnostic test equipment, specials tools, and BMW original parts . It is also the best source of the most up-to-date repair and service tech- niques, which includes factory training and technical literature . Servicing your BMW through an authorized BMW dealer will insure that your investment will be protected while maintaining the highest degree of service standards . Robert Bentley

Please read these warnings and cautions before proceeding with maintenance and repair work . WARNING- " Friction materials (such as brake pads or shorts or clutch discs) contain asbestos fibers or other friction materials. Do not create " See also Cautions on page viü dust by grinding, sanding, or by cleaning with compressed air. " Some repairs may be beyond your capability . If you lack the Avoid breathing dust. Breathing any friction material dust can lead skills, tools and equipment, or a suitable workplace for any proce- to serious diseases and may result in death . dure described in this manual, we suggest you leave such repairs " Batteries give off explosive hydrogen gas during charging . to an authorized BMW dealer service department or other quali- Keep sparks, lighted matches and open flame away from the top fied shop . of the battery If hydrogen gas escaping from the cap vents is " Do not re-use any fasteners that are worn or deformed in normal ignited, it will ignite gas trapped in the cells and cause the battery use . Many fasteners are designed to be used only once and to explode . become unreliable and may fail when used a second time. This " Connect and disconnect battery cables, jumper cables or a bat- includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips and cotter pins . Always replace these fasteners with new parts. " Do not quick-charge the battery (for boost starting) for longer " Never work under a lifted car unless it is solidly supported on than one minute . Wait at least one minute before boosting the bat- stands designed for the purpose . Do not support a car on cinder tery a second time . blocks, hollow tiles or other props that may crumble under contin- uous load . Never work under a car that is supported solely by a " Do not allow battery charging voltage to exceed 16 .5 volts. If the jack. Never work under the car while the engine is running . battery begins producing gas or boiling violently, reduce the charging rate . Boosting a sulfated battery at a high charging rate can " If you are going to work under a car on the ground, make sure cause an explosion . that the ground is level . Block the wheels to keep the car from roll- ing . Disconnect the battery negative (-) terminal (ground strap) to " The air-conditioning system is filled with chemical refrigerant, prevent others from starting the car while you are under it. which is hazardous . The A/C system should be serviced only by trained technicians using approved refrigerant recovery/recycling " Never run the engine unless the work area is well ventilated . equipment, trained in related safety precautions, and familiar with Carbon monoxide kills . regulations governing the discharging and disposal of automotive " Finger rings, bracelets and other jewelry should be removed so chemical refrigerants. tery charger only with the ignition switched off, to prevent sparks. Do not disconnect the battery while the engine is running . that they cannot cause electrical shorts, get caught in running " Do not expose any part of the A/C system to high temperatures machinery, or be crushed by heavy parts . such as open flame. Excessive heat will increase system pressure " Tie long hair behind your head . Do not wear a necktie, a scarf, and may cause the system to burst . loose clothing, or a necklace when you work near machine tools or " Some aerosol tire inflators are highly flammable . Be extremely running engines . If your hair, clothing, or jewelry were to get caught cautious when repairing a tire that may have been inflated using in the machinery, severe injury could result . an aerosol tire inflator. Keep sparks, open flame or other sources " Do not attempt to work on your car if you do not feel well . You of ignition away from the tire repair area . Inflate and deflate the tire increase the danger of injury to yourself and others if you are tired, at least four times before breaking the bead from the rim . Com- upset or have taken medication or any other substance that may Pletely remove the tire from the rim before attempting any repair. keep you from being fully alert . " Illuminate your work area adequately but safety. Use a portable safety light for working inside or under the car. Make sure the bulb is enclosed by a wire cage . The hot filament of an accidentally broken bulb can ignite spilled fuel or oil . " Catch draining fuel, oil, or brake fluid in suitable containers. Do not use food or beverage containers that might mislead someone into drínking from them . Store flammable fluids away from fire hazards . Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously . " Always observe good workshop practices. Wear goggles when you operate machine tools or work with battery acid . Gloves or other protectioe clothing should be worn whenever the job requires working with harmful substances . " Greases, lubricants and other automotive chemicals contain toxic substances, many of which are absorbed directly through the skin . Read the manufacturer's instructions and warnings carefully . Use hand and eye protection . Avoid direct skin contact " Cars covered by this manual are equipped with a supplemental restraint system (SRS), that automatically deploys an airbag(s) in the event of a frontal ímpact . The airbag(s) is inflated by an explosive device. Handled improperly or without adequate safeguards, can be accidently activated and cause serious injury. " The ignition system produces high voltages that can be fatal . Avoid contact with exposed terminals and use extreme care when working on a car with the engine running or the ígnition switched on . " Place jack stands only at locations specified by manufacturer. The vehicle lifting jack supplied with the vehicle is intended for tire changes only . A heavy duty floor jack should be used to lift vehicle before installing jack stands. See 010 Fundamentals for the Do- . it-Yourself Owner. " Battery acid (electrolyte) can cause severe burns . Flush contact area with water, seek medical attention . " Aerosol cleaners and solvents may contain hazardous ordeadly vapors and are highly flammable . Use only in a well ventilated area . Do not use on hot surfaces (engines, brakes, etc .) . " Disconnect the battery negative (-) terminal (Ground strap) " Do not remove coolant reservoir or radiator cap with the engine whenever you work on the fuel system orthe electrical system . Do hot . Danger of bums and engine damage . not smoke or work near heaters or other fire hazards . Keep an approved fire extinguisher handy. continued on next page vii

Please read these warnings and cautions before proceeding with maintenance and repair work . CAUTION- " See also Warnings on page vi¡ " Before doing any electrical welding on cars equipped with ABS, disconnect the battery negative (-) terminal (ground strap) and the " If you lack the skills, tools and equipment, or a suitable work- ABS control unit connector. shop for any procedure described in this manual, we suggest you leave such repairs to an authorized BMW dealer or other qualified " On cars equipped with anti-theft radios, make sure you know the shop. correct radio activation code before disconnecting the battery or removing the radio. lf the wrong code is entered into the radio " BMW is constantly improving its cars and sometimes these when power is restored, that radio may lock up and be rendered changes, both in parts and specifications, are made applicable to inoperable, even if the correct code is then entered . earlier models. Therefore, part numbers listed in this manual are for reference only . Always check with your authorized BMW dealer " Always make sure ignition is off before disconnecting battery . parts department for the latest information . " Label battery cables before disconnecting . On some models, " Before starting a job, make certain that you have all the neces- battery cables are not color coded . sary tools and parts on hand . Read al¡ the instructions thoroughly, do not attempt shortcuts . Use tools appropriate to the work and " Disconnecting the battery may erase fault code(s) stored in con- use only replacement parts meeting BMW specifications . Make- trol module memory Using special BMW diagnostíc equipment, shift tools, parts and procedures will not make good repairs . check for fault codes prior to disconnecting the battery cables. If the Check Engine light is illuminated, see 100 Engine-General for " Use pneumatic and electric tools only to loosen threaded parts On-Board Diagnostics (OBD) fault code information . lf any other and fasteners . Never use these tools to tighten fasteners, espe- system faults have been detected (indicated by an ílluminated cially on light alloy parts. Always use a torque wrench to tighten warning light), see an authorized BMW dealer. fasteners to the tightening torque specification listed . " If a normal or rapid charger is used to charge battery, the battery " Be mindful of the environment and ecology . Before you drain the must be disconnected and removed from the vehicle in order to crankcase, find out the proper way to dispose of the oil . Do not avoid damaging paint and upholstery pour oil onto the ground, down a drain, or into a stream, pond or lake . Dispose of in accordance with Federal, State and Local laws. " Do not quick-charge the battery (for boost starting) for longer than one minute . Wait at least one minute before boosting the bat- e If battery power is lost or the battery has been disconnected, the tery a second time . power windows must be re-initialized . Both one touch up/down and pinch-protection will be inactive until windows are re-initial- " Connect and disconnect a battery charger only with the battery ized . See 512 Door Windows . charger switched off. " The control module for the anti-lock brake system (ABS) cannot withstand temperatures from a paint-drying booth or a heat lamp in excess of 203°F (95°C) and should not be subjected to temperatures in excess of 185°F (85°C) for more than two hours . " Sealed or "maintenance free" batteries should be slow-charged only, at an amperage rate that is approximately 10% of the battery's ampere-hour (Ah) rating . " Do not allow battery charging voltage to exceed 16 .5 volts. If the battery begins producing gas or boiling violently, reduce the charging rate . Boosting a sulfated battery at a high charging rate can cause an explosion .

GENERAL FUNDAMENTALS FORTHE DO-ITYOURSELF OWNER 010-1 010 Fundamentals for the Do-lt-Yourself Owner GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010-1 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-8 Basic Tool Requirements . . . . . . . . . . . . . . . . 010-8 HOW TO USE THIS MANUAL . . . . . . . . . . . 010-2 Jack Stands . . . . . . . . . . . . . . . . . . . . . . . . . 010-9 Warnings, Cautions and Notes . . . . . . . . . . . . 010-2 Oil Change Equipment . . . . . . . . . . . . . . . . . . 010-9 GETTING STARTED . . . . . . . . . . . . . . . . . . . .010-2 Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . 010-10 Feeler Gauges . . . . . . . . . . . . . . . . . . . . . . . 010-10 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-2 Digital Multimeter . . . . . . . . . . . . . . . . . . . . . 010-10 Lífting the Car . . . . . . . . . . . . . . . . . . . . . . . . . . 010-3 gMW Special Tools . . . . . . . . .. . . . . . . . . . . 010-11 Raising car safely . . . .. . . . . . . . . . . . . . . . . . 010-3 Working under car safely . . . .. . . . . . . . . . . . . . . 010-4 EMERGENCIES . . . . . . . . . . . . . . . . . . . . . . 010-11 ADVICE FOR THE BEGINNER . . . . . . . . . . 010-4 Changing a Tire . . . . . . . . . . .. . . . . . . . . . .010-11 Car Will Not Start . . . . . . . . . . . . . . . . . . . . .010-11 Planning Ahead . . . . . . . . . . . . . . . . . . . . . . . . 010-4 Jump Starting Car . . . . . . . . . . . . . . . . . . . . . 010-12 Cleanliness . . . . . . . .. . . . . . . . . . . . . . . . . . . . 010-4 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . 010-12 Non-reusable Fasteners . . . . . . . . . . . . . . . . . . 010-5 Low Oil Pressure . . . ... . . . . . . . . . . . .. . . . . 010-13 Tightening Fasteners . . . . . . . . . . . . . . . . . . . . 010-5 Brake Fluid Level . . . . . . . . . . . . . . . . . . . . . 010-13 Gaskets and Seals . . . . . . . . . . . . . . . . . . . . . . 010-5 Check Engine Warning Light . . . . . . . . . . . . 010-13 Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . 010-6 pim Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-13 Wire Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 010-6 Towíng . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010-13 BUYING PARTS . . . . . . . . . . . . . . . . . . . . . . . 010-6 Spare Parts Kit . . . . . . . . . . . . . . . . . . . . . . . 010-14 Genuine BMW Parts . . . . . . . . . . . . . . . . . . . . 010-6 Non-returnable Parts . . . . . . . . . . . . . . . . . . . . 010-7 TABLES Information You Need to Know . . . . . . . . . . . . 010-7 a. General Bolt Tightening Torques SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-7 Although the BMW is a sophisticated and complex machine, basic maintenance can be accomplished by an interested owner with mechanical skills and the right information . Most of the preventive maintenance that is required in the lifetime of the av- erage BMW is weil within the capabilities of the do-it-yourseifer. WARNING - Do not use this manual unless you are familiar with basic automotive repair procedures and sale workshop practices . This manual illustrates the workshop procedures required for most service work ; it is not a substitute for full and up-to-date information from the vehicle manufacturer or for proper training as an automotive technician . Note that it is not possible for us to anticipate al¡ of the ways or conditions under which vehicles may be serviced or to provide cautions as to all of the possible hazards that may result ' in Nm (max . permissible) . .. . ... . . . . . . . . . . . . . 010-5 WARNING - Your common sense and good judgment are crucial to sale and successful service work. Read procedures through before starting them. Think about whether the condition ofyour car, your leve¡ of mechanical skill, or your leve¡ of reading comprehension might result in or contribute in some way to an occurrence that might cause you injury damage your car, or result in an unsafe repair . lf you have doubts for these or other reasons about your abilíty to perform sale repair work on your car, have the work done at an authorized BMW dealer or other qualified shop. This section of the manual is intended to help the beginner get started . To begin with there is a discussion on How To Use This Manual . Tips on mechanicas skills and workshop practices that can help the beginner do a faster and more thorough job can be found under Getting Started. The basic tools needed to do most of the procedures in this manual are found under Tools . The section ends with a quick reference guide to Emer- gencies, including basic troubleshooting and information on how to gauge the seriousness of a problem . GENERAL

010-2 FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER HOW TO USE THIS MANUAL A note contains helpful information, tips that will hefp in The manual is divided into nine sections : doing a better job and completing !t more easíly . 0 GENERAL DATA AND MAINTENANCE 1 ENGINE 2 TRANSMISSION 3 SUSPENSION, STEERING AND BRAKES 4 BODY 5 BODY EQUIPMENT 6 ELECTRICAL SYSTEM 7 EQUIPMENTANDACCESSORIES ELECTRICAL WIRING DIAGRAMS 0 GENERAL DATA AND MAINTENANCE covers the recommended maintenance schedules and service procedures needed to perform BMW scheduled maintenance work. Also within this section is the 010 Fundamentals for the Do-It- Yourself Owner section, which contains basic instructions, tips and helpful hints for do-it-yourself maintenance and repair . The next seven sections (1 through 7) are repair based and are further broken down into three digit repair groups . Each major section begins with a General repair group, e.g . 100 En- gine-General . These "00" (double zero) groups are mostly descriptive in nature, covering topics such as theory of operation and troubleshooting . The remainder of the repair groups contain the more involved repair information. The last major section contains detailed electrical wiring diagram schematics . A master listing of the 9 major sections and the correspond- ing individual repair groups can be found on the inside front cover . Each repair group begins with a Table of Contents listing the majos subject headings within the group . Page numbers throughout the manual are organized according to the repair groupsystem . For example, youcan expect to find repair information on brakes (Repair Group 340) beginning on page 340- 1 . A comprehensive index can be found at the back of the manual . Warnings, Cautions and Notes Throughout this manual are many passages with the headings WARNING, CAUTION, or NOTE . These very important headings have diflerent meanings . WARNING - The text under this heading warns of unsafe practices thatare very likelyto cause ínjury, eitherby dírect threat to the person(s) pertorming the work or by in- creased risk of accident or mechanfcal fallure whíle driving. CAUTION- A caution calls attention to important precautions to be observed during the repair work that will helo prevent accidentally damaging the car or its parts. GETTING STARTED Safety NOTE- Please read every WARNING, CAUTION, and NOTE at the front of the manual and as they appear in repair procedures . They are very important . Read them before you begin any maintenance or repair job. Some WARNINGs and CAUTIONs are repeated wherever they apply . Read them all . Do not skip any. These messages are important, even to the owner who never intends to work on the car . GETTING STARTED Most of the necessary maintenance and minor repair that an automobile will need can be done with ordinary tools, even by owners with little or no experience in car repair . Below is some important information on how to work safely, a discussion of what tools will be needed and how to use them . Although an automobile presents many hazards, common sense and good equipment can helo ensure safety. Many acci- dents happen because of carelessness . Pay attention and stick to these few important safety rules . WARNING - " Never run the engine in the work area unless it is well-ventflated. Theexhaustshouldbe vented to the outside. Carbon monoxide (CO) in the exhaust kilts. " Remove all neckties, scarts, loose clothing, or jewelry when working near running engines or power tools. Tuck in shirts . Tie long haír and se- cure it under a cap. Severe injury can result from these things beíng caught in rotating parts. " Remove ríngs, watches, and bracelets. Asíde from the dangers of moving parts, metallic jewelry conducts electricity and may cause shorts, sparks, bums, or damage to the electrical system when accidentally contacting the battery or other electrical terminals . " Disconnect the battery negative () cable whenever working on or near the fuel system or any- thlng that is electrically powered. Accidental electrícal contact may damage the electrical system or cause a fire.

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1991-1999 BMW 3 Series E36 Service & Repair Manual

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