2009 BMW 3 Series (E90) Service & Repair Manual

Important Safety Notice .......................................................... ............................... ii Foreword .............................................................................................................. v Index ........... ... .................................................................................. rear of manual 0 General Data and 001 Warnings and Cautions 003 Symptoms and Field Observations ~ Maintenance 002 Vehicle Identification and VIN 010 Product Fami li arization Decoder 020 Maintenance 100 Engine-General 120 Ignition System ~ 1 110 Engine Removal and Installation 121 Battery, Starter, Alternator Engine 113 Cylinder Head Removal 130 Fuel Injection and Installation 160 Fuel Tank and Fuel Pump 117 Camshaft Timing Chain 170 Radiator and Cooli ng System 119 Lu brication System 180 Exhaust System 2 200 Transmission-General 250 Gearshift Linkage ~ Transmission 210 Clu tch 260 Driveshafts 230 Manual Transmission 270 Transfer Case 240 Automatic Transmission 3 Suspension, 300 Suspension, Steering and 320 Steering and Wheel Alignment ~ Steering and Brakes-General 330 Rear Suspension 310 Front Suspension 331 Rear Axle Differential Brakes 311 Front Axle Differential 340 Brakes 4 Body 400 Body-General 411 Doors ~ 410 Fenders, Engine Hood 412 Trunk Lid, Tailgate 5 Body Equipment 510 Exterior Trim, Bumpers 515 Central Locking and Anti-theft ~ 512 Door Windows 520 Seats 513 Interior Trim 541 Convertible Top 6 600 Electrical System-General 630 Lights ~ Electrical System 611 Wipers and Washers 640 Heating and Air-conditioning 612 Switches 650 Radio 620 Instruments 7 Equipment and 720 Seat Belts ~ Accessories 721 Airbag System (SRS) ECL ECL Electrical Component Locations ~ ELE ELE Electrical Wiring Diagrams 080 OBD On-Board Diagnostics BentleyPublishers Be <'tloyr>i.bl1sh rs.corr All I? gl>ts Ro ern;a

Foreword For the BMW owner with basic mechanical skills and for independent auto service professionals, this manual includes many of the specifications and procedures that were available in an authorized BMW dealer service department as this manual went to press. The BMW owner with no intention of working on his or her car will find that owning and referring to this manual will make it possible to be better informed and to more knowledgeably discuss repairs with a professional automotive technician. For those intending to do maintenance and repair on their BMW, it is essential that safety equipment be used and safety precautions observed when working on the vehicle. A minimum safety equipment list includes hand protection, eye protection and a fire extinguisher. A selection of good quality hand tools is also needed. This includes a torque wrench to ensure that fasteners are tightened in accordance with specifications. In some cases, the text refers to special tools that are recommended or required to accomplish adjustments or repairs. These tools are often identified by their BMW special tool number and illustrated. Disclaimer We have endeavored to ensure the accuracy of the information in this manual. 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. Please also read the WARNING- Importa nt Safety Notice on the copyright page at the beginning of this book. Prior to starting a repair procedure, read the procedure, 001 Warni n gs and Ca utions and the warnings and cautions that accompany the procedure. Reading a procedure before beginning work helps you determine in advance the need for specific skills, identify hazards, prepare for appropriate capture and handling of hazardous materials, and the need for particular tools and replacement parts such as gaskets. Bentley Publishers encourages comments from the readers of this manual with regard to errors, and suggestions for improvement of our product. These communications have been and will be carefully considered in the preparation of this and other manuals. If you identify inconsistencies in the manual, you may have found an error. Please contact the publisher and we will endeavor to post applicable corrections on our website. Posted updates and corrections should be reviewed before beginning work. Please see the following web address: http://www . BentleyPublishers.com/updates/ BMW will continue to issue service information and parts retrofits after the editorial closing of this manual. Some of this updated information may apply to procedures and specifications in this manual. For the latest information, please see the following web address: http://www.bmwtechinfo.com/ BMW offers extensive warranties, especially on components of the fuel delivery and emission control systems. Therefore, before deciding to repair a BMW that may be covered wholly or in part by any warranties issued by BMW of North America, LLC, consult your authorized BMW dealer. You may find that the dealer can make the repair either free or at minimum cost. Regardless of its age, or whether it is under warranty, your BMW is both an easy car to service and 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. Bentley Publishers v

001-1 001 Warnings and Cautions PLEASE READ THESE WARNINGS AND CAUTIONS BEFORE PROCEEDING WITH MAINTENANCE AND REPAIR WORK. WARNINGS- See also CAUTIONS • Read the important safety notice on the copyright page at the beginning of the book. • Some repairs may be beyond your capability. If you lack the skills, tools and equipment or a suitable workplace for any procedure described in this manual, we suggest you leave such repairs to an authorized BMW dealer service department or other qualified shop. • Thoroughly read each procedure and the WARNINGS and CAUTIONS that accompany the procedure. Also review posted corrections atwww.BentleyPublishers.com/updates/ before beginning work. • If any procedure, tightening torque, wear limit, specification or data presented in this manual does not appear to be appropriate for a specific application, contact the publisher or the vehicle manufacturer for clarification before using the information in question. • Do not reuse any fasteners that are worn or deformed. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips and cotter pins. Replace these fasteners with new parts. • Do not work under a lifted car unless it is solidly supported on stands designed for the purpose. Do not support a car on cinder blocks, hollow tiles or other props that may crumble under continuous load. Do not work under a car that is supported solely by a jack. Do not work under the car while the engine is running. • If you are going to work under a car on the ground, make sure that the ground is level. Block the wheels to keep the car from rolling. Disconnect the battery negative ( -) terminal to prevent others from starting the car while you are under it. • Do not run the engine unless the work area is well ventilated. Carbon monoxide kills. • Remove rings, bracelets and other jewelry so that they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts. • Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result. • Do not attempt to work on your car if you do not feel well. You increase the danger of injury to yourself and others if you are tired, upset or have taken medication or any other substance that may keep you from being fully alert. • illuminate your work area adequately but safely. 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, vapors or oil. • Catch draining fuel, oil, or brake fluid in suitable containers. Do not use food or beverage containers that might mislead someone into drinking 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. • Observe good workshop practices. Wear goggles when you operate machine tools or work with battery acid. Wear gloves or other protective clothing whenever the job requires working with harmful substances. • Greases, lubricants and other automotive chemi cals 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. • Disconnect the battery negative (-) terminal whenever you work on the fuel system or the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy. • Friction materials (such as brake pads and shoes or clutch discs) contain asbestos fibers or other friction materials. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing dust. Breathing any friction material dust can lead to serious diseases and may result in death. • Batteries give off explosive hydrogen gas during charging. Keep sparks, lighted matches and open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it may ignite gas trapped in the cells and cause the battery to explode. • The air-conditiorning system is filled with chemical refrigerant, which is hazardous. Make sure the system is serviced only by a trained technician using approved refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with regul ations governing the discharge and disposal of automotive chemical refrigerants. Continued on next page

001-2 Warnings and Cautions WARNINGS (continued) • Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat increases system pressure and may cause the system to burst. • Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflater. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair. • Cars covered by this manual are equipped with a supplemental restraint system (SAS) that automatically deploys airbags and pyrotechnic seat belt tensioners in case of a frontal or side impact. These are explosive devices. Handled improperly or without adequate safeguards, they 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 ignition switched ON. • Place jack stands only at locations specified by the manufacturer. The vehicle lifting jack supplied with the vehicle is intended for tire changes only. Use a heavy duty floor jack to li ft vehicle before installing jack stands. See 020 Maintenance. • Battery acid (electrolyte) can cause severe burns. Flush contact area with water, then seek medical attention. • Aerosol cleaners and solvents may contain hazardous or deadly vapors and are highly flammabl e. Use only in a well ventilated area. Do not use on hot surfaces (engines, brakes, etc.). • Due to risk of personal injury, be sure the engine is cold before beginning work on the cooling system. CAUTIONS- See also WARNINGS • If you lack the skill s, tools and equipment, or a suitable workshop for any procedure described in this manual, leave such repairs to an authorized BMW dealer or other qualifi ed shop. • BMW is constantly improving its cars and sometimes these changes, both in parts and specifications, are made applicable to earlier models. Any part numbers listed in this manual are for reference only. Check with your authorized BMW dealer parts department for the latest information. • Before starting a job, make certain that you have the necessary tools and parts on hand. Read all the instructions thoroughly, and do not attempt shortcuts. Use tools appropriate to the work and use only replacement parts meeting BMW specifications. • Use pneumatic and electric tools only to loosen threaded parts and fasteners. Do not use these tools to tighten fasteners, especially on light alloy parts. Use a torque wrench to tighten fasteners to the tightening torque specification listed. • Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond or lake. Dispose of waste in accordance with federal, state and local laws. • The control module for the anti-lock brake system (ABS) cannot withstand temperatures from a paint-drying booth or a heat l amp in excess of 203°F (95°C). Do not subject to temperatures in excess of 185 °F (85°C) for more than two hours. • Before doing any electrical welding on cars equipped with ABS, disconnect the battery negative (-) terminal (ground strap) and the ABS control module connector. • Make sure ignition is switched OFF before disconnecting battery. • Label battery cables before disconnecting. On some models, battery cables are not color coded. • Disconnecting the battery may erase fault code(s) stored in control module memory. Using special BMW diagnostic equipment, check for fault codes prior to disconnecting the battery cables. If the malfunction indicator light (MIL) is illuminated, see OBD On-Boa rd Diagnostics at the back of this manual. (This light may be identified as the Check Engine light or the Service Engine Soon light.) If any other system faults are detected (indicated by an illuminated warning light), see an authorized BMW deal er. • If a normal or rapid charger is used to charge battery, disconnect lhe battery remove it from lhe vehicle in order to avoid damaging the vehicle. • Do not quick-charge the battery (for boost starting) for longer than one minute. Wait at least one minute before boosting the battery a second time. • Connect and disconnect a battery charger only with the battery charger switched OFF. • 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. • Do not use steel fasteners on engine components made of aluminum-magnesium alloy. Use aluminum fasteners only. Test fasteners for aluminum composition with magnet. • Replace aluminum bolts each time they are loosened. Follow torque instructions, including angle of rotation specifications, when installing aluminum fasteners.

002-1 002 Vehicle Identification and VIN Decoder n ._____._ ____ • Some of the information in this manual applies only to cars of a particular model year or range of years. For example, 2006 refers to the 2006 model year but does not necessarily match the calendar year in which the car was manufactured or sold. To be sure of the model year of a particular car, check the vehicle identification number (VIN) on the car. The VIN is a unique sequence of 17 characters assigned by BMW to identify each individual car. When decoded, the VIN tells the country and year of manufacture; make, model and seri al number; assembly plant and even some equipment specifications. The BMW VIN is on a plate mounted on the top of the dashboard, on the driver's side where the number can be seen through the windshield. The 10th character is the model year code: 6 for 2006, 7 for 2007, 8 for 2008, 9 for 2009, and A for 2010. The table below explains some of the codes in the VIN for 2006 through 201 OBMW E90, E91, E92, and E93 3 Series covered by this manual. Sample VIN: lWBA ll PK53ll5lXl9lAI 9 9 9 9 9 9 I position 1 2 3 4 5 6 7 8 9 10 I 12 -17 VIN Description Decoding information position 1 - 3 Country of WBA BMW, AG. Munich, Germany manufacture 4 Line p 3281 xDrive Sedan (2009 - 2010) u 328i, xDrive Sports Wagon (2009 - 2010) v 325i, 325xi, 330i. 330xi (2006), 328i Sedan, 328xi Sedan and Sports Wagon, 335i, 335xl (2007-2009) w 328i Coupe and Convertible, 328xi Coupe, 335i Convertible (2007-2010) 5 Series A 328i Sedan (2007-2008) B 325i, 3301, Sedan (2006) 328i Coupe (2007-2009), 335i Sedan and Coupe (2007-2008) c 328i Sedan (2007), 328xi Sedan and Coupe (2007-2009) D 325xi Sedan,330xi Sedan (2006),335xiSedan (2007- 2008) H 328i Sedan (2009 - 201 O) K 328i xDrive Sedan (2009 - 2010) L 328i Convertible, 3351 Convertible (2007-201 O) R 328i Convertible (2007-2010) T 328xi Sports Wagon (2008), 328i Sports Wagon (2009 - 2010) u 328xi Sports Wagon (2009 - 2010) v 3281 xDrlve Coupe (2009 - 2010) 6 Engine type 1 3.0 liter 6-cylinder 3 5 7 9 7 Vehicle type 3, 7 Passenger vehicle {2006·2009) A,G Passenger vehicle (2010) 8 Restraint system 5 Multiple restraint system 9 Check digit o - 9 or X, calculated by NHTSA 10 Model year 6 2006 7 2007 8 2008 9 2009 A 2010 11 Assembly plant A,F,K Munich, Germany N, V Leipzig, Germany E,J,P Regensburg, Germany 12-17 Serial number Sequential production number for specific vehicle leyPub ,;entleyPu 11 Ii rs om- Al Right Re

003-1 003 Symptoms and Field Observations ,_____ _ __ ____. I GENERAL .............................. 003-1 0 GENERAL DATA AND MAINTENANCE ..... 003-2 1 ENGINE .............................. 003-6 2 TRANSMISSION . ................. . .... 003-12 3 SUSPENSION, STEERING AND BRAKES .. 003-14 4 BODY ..... . .......................... 003-18 5 BODY EQUIPMENT. . . . . . . . . . . . . . . . . . . . 003-19 6 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . 003-22 7 EQUIPMENT AND A CCESSORIES. . . . . . . . 003-28 GENERAL This repair group includes a list of symptoms, field observations, and suggested fixes for common problems and issues found on 3 Series (E90, E91, E92, and E93) cars. The information is organized by sections that correspond to the layout of the repair manual. Additional information (when avail able) can be found in the repair group associated with the specific issue: • O General Data and Maintenance • 1 Engine • 2 Transmission • 3 Suspension, Steering and Brakes • 4 Body • 5 Body Equipment • 6 Electrical System • 7 Equipment and Accessories This information was developed from varied sources, ranging from professional BMW technician feedback to manufacturer-issued technical service bulletins (TSBs). The content is intended to complement the repair information found in this repair manual. CAUTION- • The information contained in this section is inherently dated material. It was applicable and relevant at the time this manual went to press. Always check BMW factory repair information at www.bmwtechinfo.com or the publisher's website at www.bentleypublishers.com for information that may supersede any information included in this section. Be tleyPublishersc 8 rtl y 'Lb t 1'1!.C'OIT' All RlgMs R rv d

003-2 Symptoms and Field Observations 0 GENERAL DATA AND MAINTENANCE T opic Not es Exit ing a vehicle that is double-l ocked Do not lock a vehicle from outside the car wi th someone inside the from the outsi de car. Service Engine Soon or Check Gas Cap warning Is illuminated: faulty gas cap or software error (t o 09/2008) Cabin filters, changing In the unlikely event that someone gets double-locked inside the car, the person inside the car can exit the vehicle using the following 2- step procedure: •Press central unlock button to disable "double-lock". • Pull door handle twice to open door. NOTE- • For vehicles with factory alarm, opening door activates alarm. DME has stored faults for a small leak, microleak, super fine leak, or large leak in the tank ventilation or evaporative system. • Remove the fuel cap and inspect cap seal for damage (torn, worn or curling seal). If any damage is detected, replace cap. Be sure cap is properly tightened down. • If no cap faults can be found and fault returns, additional DMTL system diagnosis is required (e.g. run DMTL test plan using the BMW diagnostic scan tool). NOTE- • On vehicles produced from July 1st, 2006 up to September 30th, 2008 with the following stored faults: 2A 15 - DMTL minor leak, leak greater than 1. O mm or 2A 16 - DMTL microleak, leak greater than 0.5 mm, there may be a software error for the tank leak diagnostic system. If these faults are present, be sure the software level (/-level vehicle data status) is up to date. When servicing fresh air (cabin) micro filter, be sure to reinstall the filter lid correctly. Incorrect installation can result in premature blower motor failure due to water intrusion. • Check that gap (A) between upper microfilter housing and cowl is no more than 1 cm (0.40 in). Remove and reposition housing as necessary to reduce gap. Additional Information (when available) 08 0 020 Bentley Publishers com Bn 1 llayPubl t>ors com-All Righi~ R e111ed

Symptoms and Field Observations 003-3 0 GENERAL DATA AND MAINTENANCE (CONTINUED) Additional I Topic Engine o il , topping up Replacing spark plugs , service tip (N52 / N51 engines) Special tool for spark plug removal (N54 engine) Notes Oil residue may collect on the cyli nder head cover near the oil filler cap a few days after topping up or refilling the engine oil. When oil is added, the filler cap is laid partially upside down. In this position, engine oil seeps into the area of the oil cap that is not sealed by the gasket. When the cap is reinstalled, the oil leaks from the unsealed area onto the cylinder head cover surface. If investigating an oil leak in this area, confirm that it is not oil from the cap. When servicing spark plugs, a standard socket may fit too tightly into the spark pl ug bore in the cyli nder head. If this is the case, remove the heat shield insi de plug hole (arrow) before servicing spark plugs. A 12-point Bosch spark plug with 12 mm threads is used in the N54 (turbocharged) engine. Removal and installation requires a t hi n- wall socket (BMW special tool part no. 83 30 O 495 560), owing to the confin ed area of the N54 cylinder head. lnfonnatlon - (when available) - 020 020 020 Bentley Publishers coM BentleyPublishcrs com-All Rights Rosorved

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2009 BMW 3 Series (E90) Service & Repair Manual

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