1983-1989 BMW 635 Csi Service & Repair Manual

GroupNumber Description Maintenance and General Hints 02 Aftersales Development Professional Development Tools and Equipment CustomerRelations 11 12 Engine Electrical Systems 13 Fuel Systems 16 Fuel Supply Systems 17 CoolingSystems 18 Exhaust Svstems Manual Transmission Automatic Transmission GearShift Mechanism DriveShaft Intermediate and Special Transmission FrontAxle 32 Steering and Wheel Alignment Rear Axle Wheels and Tires 37 SpecialSuspension Systems 41 Body 51 Body Equipment Special Roofs 61 General Electrical Systems lnstruments 63 Lights Heating and Air Conditioning 65 SoundSystem, Cruise, Alarms,Monitors Remote ControlSystems 71 Vehicle Tools 72 Safety RestraintSystems Phone,Navigation Systems Corrosion Protection PaintWork 100 Visionwerke Information P/N 01 00 1 469 801

Repair Manual BMW 633 CSi - 635 CSi US (beginningwith 1983 Model) 121a5 00 Maintenance andGeneral Data I ntroduction Lifting the vehicle with a car hoist . , . . Lifting the vehicle with a garage jack. . . Towing. BMW Maintenance SYstem 0-3 00 00 009 210 220 230 240 249 259

o- 3 TOWING Please conform with lecal and national legislativemeasures concerning the towing of vehicles as applicable. Turn the ignition key to position "1" to unlock the steering wheel and be able to use the turn signals,horn and possibly windshield wipers. Since the brake booster only works with the engine running, greaterforce will be required on the brake pedal of cars with a brake booster when the "engine is stopped". The towing cable should be elastic to protect the towing and towed vehicles. Consequently only use plastic fiber cables or cables with elastic links. Cars with Automatic Ttansmission: Selector level in "N". Max. towing speed:50 km/h (30 mph). fuax. towing distance:40 to 50 kilometers (25 to 30 miles). l{ the car has to be towed further than 50 km (30 miles) add an extra liter (2 pints) of ATF than the specified oil volume for automatics or remove the propeller shaft. Atter repairingthe car it is absolutely essential to correct the ATF volume to the specitiedamount. Towing eyes front. ', W rowingeyerear.

00 -1 General I nformation 00 00 009 Pre'Delivery Inspection lnstructions! Check engine oil level (check for dilution ol lubricating oil), replacing oil and oil filter if necessary Check seal of filler cap Check coolant hoses tor leaks and correct routing Check tightness of hose clamps Check coolant level and anlilreeze protection correcting if necessarv Check battery acid level, addinq distilled water il necessary Check tightness ol battery terminals Check spark plugs and replace or clean and adiust electrode gaps Check fuel lines, tank, tank cap and filter for tight fit and leaks Check fuel injection parts for tight fit or leaks Check exhaust system for correct installation approved oil only! inspection antitr€sze corrosioninhibitor Gr.12 Gr.'12 Visual inspection Visual inspection

00- 2 00 00 009 Pre-Delivery Inspection Check nuts and bolts of steering box, coupling, tie rods, front axle for tightness, or presenceof cotter pins Ch€ck power steering for leaks Check fluid level in tank for hydraulic brake and clutch systems Check connections and lines of brake system for leaks, damage or wrong routing Check tire condition, tire size and tyPe as well as tire inflation pressure (also spare wheel) Check wheel bolts for specified tightening torque Check for correct size and type of rims Check function of lights: parking lights, turn signals, tail lights, stop lights, high and low beam headlights, side marker lights, fog lights, backup light(s). license plate lights, passenger compan- ment light and delay system, glove box light, trunk light and engine compartment light, sunvisor mirror illumination. map reading lights, front and rear. Check aiming of headlights (adjust if necessary) Check {unction of horns, headlight flasher and hazard light and control Adjust digital clock Program on board computer and check operation of lever and push button control Gr.32134 Gr.34 Gr.36 Gr.36 General I nformation Gr. 00 br. Jo I mportant lnstructionsl Check locks and coner plns Visual insp€ction Use approved btake fluids only; tightsning torque Visual inspection Gr. 63

00- 3 lront and rear, sun root in all positions, fog lights and aiming, electric radio antenna and speaker balance control. Check other equipmenr installed bv dealer Check outside mirrors Check operation of central locking system Check seat adiustment manual/electric Check seat belts General I nformation I mportant I nstructions! 00 00 009 Pre-Delivery Inspection I Repair Manuel Specifications Nominal Values Seruice lnformation Owner's Manual I Check instument and sign lights, and brightness control Check indicator and warning lamps, clock, buzzer and check control: i alternator. oil pressure,coolant temperature, turn signal indicator, brake lining / level control, tog light indicator, oxygen sensor,seat belt . lamps, ignition key warning buzzer, high beam indicator, fuel gauge, ABS and SRS light, Check control function. Transmission Range display Fill supply tank for windshield washing system, check antifreeze orotection Fill supply tank for intensivecleaning fluid Check function of windshield wipe/wash system and aiming of spray . jets, remove protective sleeves on wiper blades Check intensive cleaning function Check rear window defogger Check tunction of cigar lighter/s Check function of headlight cleaners Radio: check antenna, trimming, tune in station, check shieldingwith Gr.65 engine running whilo switching all electric equipment on and off check cassettetape player I Check function of other special equipment, e.g.: electric windows Gr.00 + + Fill with antifreeze additive if necessary

00-4 General I nformation 00 00 009 Pre.Delivery I nspection Check data plate, chassis and engine numbers Compare ordered car equipment against delivered car equipment lnstall wheel covers, if applicable ornamental rings and tailpipe extension Place car tools in toolbox, securejack and wheel bot wrench Mount label for BMW advice telephone number and annual brake fluid change Place owner's manual, list of BMW servicestations. spare keys and key case in glove box Battery and accessory warranty cards Badio operating maual (if equipped) Factory lnvoice (Monroney Label) Tape unit cleaning cassettekit

00-5 General Information 00 00 009 Pre-Delivery lnspection mportantInstructions! Test drlve: check acceleration, coasting, brake system (before and during road test) Check idle RPM Check function o{ Motronic Check car for rattling and squeaking noise On with Po- brake linings, braking Check handling and wheel balance Check function of engine, clutch, transmission, rear axle, steering (wheel in straight ahaed position), cars with rear disc brakes: bfeaking in parking brake Heater, fresh air ventilation/air condition Check function of all instruments Cruise control Gr.34

00- 6 BMWMAINTENANCE SYSTEM 00 00 009 Pre-Delivery Inspectton After Tesl Drive: Leak test on: engine, transmission, steering, final drive. dust covers on output shafts, luel system, clutch and brake hydraulic systems and Cooling system Check interrior of car and clean Car cleaned and polished No damage on underside Car without scratchesor damage Remove seat and orotective covers lmportant! The service indicator (Sl ) must be reset after completion of the pre- delivery inspection as follows, Switch oft all electrical equipment. Turn on ignition. Do not run engine. Plug Sl'R* in diagnosis socket. Push in and hold recessed, r€d INSPECTION button " green lamp (function control) comes on. Red famp also comes on alter approx 3 sec. and goes out after approx. 12 seconds. Releaseinspection button - green lamp goes out. Check Service lndicator (Sl): All f ive green diode lights must be on. Yellow and possibly red diodes as well as INSPECTION sign should go out. " Sl-R = Service indicator resetter. Order No- 62 1 100. General lnformation lmportantInstructionsl Visual inspection Visual inspection

1983-1989 BMW 635 Csi Service & Repair Manual

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